Page Comparison

Designed by: Ethan Sobkowich, Yanshen Zhou, Winnie Lin

...

Needs statement: There exists a need to create a fixture that can hold specimens a stationary position for adhesive curing while being adjustable to different specimen sizes. adjustability?

Constraints:

• All three adhesive joints curing at the same time

• Constrained movement in three axis

...

• Steel to steel

• Composite to composite

• Steel to composite

go thru reasoning to do this design. decision making matrix

show dimensions and material

...

Fig. 1: An image of the base tray for the testing jig

...

Figure 3, seen below, is a side view of one test specimen. This is how they will be aligned in the jig. The rectangular jigs will be placed in the gap spaces.

*jig can be spring with boards on either side (will remove tolerance error)

Fig. 3: Side view of specimen in tray

Figure 4 is an example of how the jig will clamp the test specimen. The green planks are aligned as seen in Figure 3. The main edges will be placed on a flat board or table. Then, another flat board (like a piece of plywood for example) will be placed on top of the specimens and weights will be placed on top of the board to apply downwards pressure on the z axis (purple). When the tray is full of specimens and brown rectangular jigs, seen in Figure 4, y-axis movement will be restricted due to the packing of specimens an jigs. A sliding board will be on the edge and a pipe clamp will apply inwards pressure on the x-axis. The idea is that the blue square-shaped pieces will ensure that the test pieces line up properly under this clamping force. It is possible that more thin brown square pieces may need to be added in the middle section to ensure adequate restriction on movement. Nine of these specimens must be lined up at once inside of this tray for proper usage.

put ALL specimen. show board above

...

Fig. 4: Example of how specimen will be placed in tray

...

Table 1: Anti-stick Solution Comparison Chart

color code this

...

Source: https://www.youtube.com/watch?v=uLH1MsaHnX4  

add some figs

one design matrix per step

Assembly Procedure 

Step 1: Printing

...

1. Use PrusaSlicer to print an array of support pieces on the tray. Two of the longer spacing supports are required per specimen and 3 of the spacing supports are required between two specimens.

   1. You may need to change the dimensioning of the support beams to customize it to your specimen.

   2. Print according to the number of specimens that are cured.

2. Remove the printed pieces.

...

Step 2: Machining Cover

This component is placed on top of all the specimens after they are placed correctly. The purpose of this cover is to restrain joints with epoxy from lifting.

1. Measure and mark the area to be cut on the 3mm birch plywood. Ideally, each length and width should be 0.5cm less than the inner dimensions of the tray. For example, if the inner dimensions of the tray are 19cm by 24cm, then the dimensions of the tray are 18.5cm by 23.5cm.

2. Use a band saw in the design center machine shop to cut out measured dimensions.

...

Step 3: Laser Cut Tray

Laser cutting was chosen as the manufacturing method as it provides more cut precision when compared to manufacturing by hand. It is also faster.

1. Use AutoCAD to create layout of pieces that need to be laser cut. In total, this needs to include 4 copies of each component of the tray.

   1. The idea behind this is to stack four 1/8 inch thick pieces of fiberboard to create a 1/2 inch tall tray.

   2. Minimize the area occupied by the pieces. This is because the 3D Print Centre charges per square foot.

   3. All vector cut lines should be 0.00 units line thickness and all raster/engraving lines should be set to a minimum of 0.25 units.

2. Submit a laser cutting request: https://uwaterloo.ca/3d-print-centre/laser-cutting-request-form

   1. Turnaround time is 2-3 days.

3. Use wood glue to bond two copies of the same part.

   1. Apply a thin strip of wood glue along the entire piece.

   2. Clamp down both pairs of fiberboard pieces for curing. This takes 24 hours according to the glue manufacturer instructions.

   3. After the pairs of fiber board have fully cured, repeat steps a-b to bond the two pairs of fiberboard. This creates four stacked layers of fiberboard.

   4. After curing, use sand paper to sand off any excess glue.

   5. Note: it is important to cure the layers as aligned as possible to create a flat edge.

...

Step 4: Anti-stick Solution

...

generally less walls of text. pictures explain for you, just use the right pictures.