1. PASCOR Group Progress Report Industry Advisor: Craig Smit Academic Advisor: Dr. Chien Wern Presenters: Jeremie Bilisari Matt Smith Group Members: Steve Greene Joe Hartley Robby Hoff

2. Overview Background & Objective Cutting & Forming Devices Design Concepts Decision Matrix Testing & Analysis Conclusion

3. Background PASCOR – Pacific Air Switch Corporation PASCOR – Pacific Air Switch Corporation

4. Strip Data 2”, 3”, 5” & 6.5” R=1/4” 1/4” Tolerance ( +/- 1/16” ) The strips are cut from spools of 85%:15% Silver/Nickel. Strip width is ¼ inch and thickness is 1/100 of an inch. Strips will be cut in 2”, 3”, 5”, and 6.5” lengths. A ¼ inch radius formed running along strip length.

5. Background Current Strip Forming System Current Strip Forming System

6. Strip Cutters No forming devices High rate of speed Adjustable width and length Capable of cutting metals © Sheffield Cutting Equipment, Inc.

7. Continuous Forming Variable width Nearly infinite shapes Low volume Higher maintenance Examples include seamless gutters and metal roof sheeting © Roller Die Inc. © New Tech Machinery Corp.

8. Design Concepts IdeasProCon Press-Cut One action to cut/form, Few moving parts Timing and alignment issues, Limited to cutting methods Roll Forming + Cutting Multiple methods of cutting Shape only as accurate as rollers, Timing and alignment issues Roll Forming w/Cutter High speed, Accuracy, Simplicity, Small size, Few moving parts, No complex PLC Separate wheels for lengths, *Difficult to manufacture, Cost of wheels, Alignment issues

9. Decision Matrix Design SpecificationsWeightRoll FormingRoll Forming w/ CutterPress Forming Tolerance 0.2444 Adjustability 0.2424 Radius Curvature 0.1444 Parts/Time 0.1452 Length Curvature 0.05554 Safety 0.05333 Overall Complexity 0.1322 Maintenance Complex Parts0.05423 Number of Parts0.05453 Cost 0.1333 Total13.83.35 1 - Unsatisfactory, 2 - Not Good, 3 - Acceptable, 4 - Good, 5 - Excellent

10. Testing Cutting Forces Test silver shear strength Test silver shear strength (load cell and LabView) (load cell and LabView) Find maximum cutting force Find maximum cutting force Compare cutting blade shapes Compare cutting blade shapes (flat VS 15° angle) (flat VS 15° angle)

11. Testing Cutting Forces Cutter TypeAverage Force (lbf)Std. Dev. (lbf) Flat87.98.1 Angled (15°)34.13.5 Experimental Cutting Force Theoretical Cutting Force σ = 0.7 * 50000 = 35000 lb/in²(Shear Strength) A = thickness * width = 0.01 * 0.25 = 0.0025 in²(Cut Area) F = σ * A = 35000 * 0.0025 = 87.5 lbf(Theoretical Shear Force) F = 87.5 lbf

12. Testing Forming Roll Forming Roll Forming Press Forming Press Forming

13. Conclusion Roll forming is best option according to matrix Roll forming is best option according to matrix Decision on final design is pending Decision on final design is pending More analysis and research is required More analysis and research is required Deadlines are expected to be met

14. Questions?