Feasibility Analysis P14415
Thermoforming Quote- CJK
DIY Vacuum Forming Use kitchen oven to heat plastic Use shop-vac with vacuum box shown Build vacuum box for under $100 Shop-vac costs $69-$299 External Heat source possibility Quote for New and Used Machines
Purchasing Vacuum Forming Mach. Cost: $12,900
ABS vs. Polycarbonate P olycarbonate Pros: Outstanding toughness Good optical clarity Strong and stiff Easy to fabricate Easy to solvent bond Cons: Expensive compared to ABS Good resistance to UV with stabilizers Thermoforms well after drying ABS Pros: Outstanding impact resistance Good machinability Easy to thermoform Easy to bond with adhesives Strong and stiff Low cost Cons: Poor UV resistance Becomes brittle with UV stabilizers
Material Eliminations: Acrylic: Brittle Polyethylene (HDPE/LDPE): Poor material strength properties compared to ABS Polycarbonate: Expensive relative to ABS (2x the cost for most sheets) Curbellplastics.com
Material Research References:
Design 1 Models
Ansys Analysis - Design 1 Summary Max Stress: ~1.5x Ultimate Strength Values Too high of stress values for fairly conservative model of worst case Design is insufficient as is to move forward with Needs redesign with added strength from additional supports: metal
Ansys Analysis - Modeling Summary Worst Case and Normal Usage Multiple Discussions with Dr. Boedo and Dr. Debartolo Worst Case: Load (270lbs) around hole Normal Usage: Load (270lbs) across two locations at normal stance width Only base modeled, without material thinning Iterative solution modeling
Ansys Analysis - Results Summary
Design 1 - Stresses: Normal Loading Circles denote peak stress locations.
Design 1 - Deflection: Normal Loading
Design 1 - Meshing: Normal Loading
Design 1 - Stresses: Normal Loading Circles denote peak stress locations.
Design 1 - Deflection: Normal Loading
Design 1 - Meshing: Normal Loading
Design 1 Feedback
Ansys Analysis - Conclusions Stresses too high for a fairly conservative model Redesign required with additional supports, such as rebar Debartolo believed analysis and conclusions seemed valid
Design 2 - Analysis Assumptions Rigid supports for deflection between ribs Cantilevered rib bending
Design 2 - Analysis Deflection between rigid supports
Design 2 - Analysis Deflection of Ribs
Design 2 - Analysis
Design 2 - Feedback Dr. Debartolo Assumptions inappropriate Need to assume ribs pinned, not cantilevered Need to assume deflection between ribs is cantilevered Distributed load will reduce deflection between ribs
Design 2 - Moving Forward Redo calculations with new boundary condition assumptions Possibly change material based on new analysis
Shipping Costs- Miami To Haiti (Preliminary Analysis) -Analysis of per unit cost if container is filled to capacity -Assumptions: - One day storage before loading and after unloading (2 days total) - Weight does not affect cost - Cost per part is determined by volume
Shipping Costs- Data
Shipping Costs- Calculations
New Risks Risk Chart Entry: