Black and Decker Grinder

Revision as of 19:24, 24 March 2007

Figure 1: Fully dissected product

Description

This product is a produced by Black and Decker. The product is used to grind down metal. The purpose of this Wiki is to give the reader insight as to why this grinder works, through the use engineering specifications.

How It Works

Inside the grinder there is an electric motor that spins a shaft connected to a bevel gear. The bevel gear is then attached to another driving shaft. A grinding wheel is clamped onto the driving shaft, causing the grinding wheel to spin.

Why It Works

Every component in the assembly has a life expectancy due wear generated by constant friction and other forces acting on the parts. This expectency varies between individual parts based on the location, direction and magnitude of the forces acting on the part and also the geometery and material compositon of the part.

For the force requirement on the gears to rotate the grind wheel at 10,000 RPM, the power consumption of the grinder was researched. From the power consumption the torque was calculated to be 0.315 Nm, which equates to about 2.61 lbs of force on the workpeice from the grind wheel. This calculates to 12.4626 N of force at the gears to rotate the grind wheel at 10,000 RPM.

The torque calculated in the gear analysis, 0.315 Nm, was also used to calculate the life expectancy of the bearing. Assuming the grinder will be used constantly the bearing will last 1.83 years before failure. If the grinder will be used six hours every day, 365 days a year then the bearing will last 7.33 years. Under the more realisitic assumption that the grinder will be used six hours a day, five days a week, the bearing will last 10.26 years.

To calculate the stress in the gears, a stress equation was used from the Fundamentals of Machine Components Design by Robert C. Juvinall. The velocity factor was caluated with the assumption that the gears were precision shaved and ground. The overload factor was calculated with the assumption that the source of power is uniform and the driven machinery is assumed to have moderate shock. Both gears were overhung, which gave a mounting factor of 1.25. The calculated stress in the smaller gear was 613.601 PSI and the stress in the larger gear was 442.438 PSI.

Parts

The table belows lists the Bill of Materials for the Black and Decker Grinder:

Table 1: Black and Decker Grinder Bill of Materials

Part #	Part Name	# Category	Function	Material	Picture
1	Bottom Disk Holder	Support Element	Attaches to bottom disk holder to lock grinding disk in place	Metal
2	Screws	Support Elements	Attach various components to one another	Metal
3	Top disk holder	Support Element	Attaches to disk holder to lock grinding disk in place	Metal
4	Washer	Support Elements	Attacjes grinding shield to the grinder	Metal
5	Handle	Structural Components	Provides grip and stability for the grinder	Plastic with metal screw on end
6	Griding Shield	Structural Components	Protects operator from any parts that may get grinded off from work material	Metal with greese lubricant
7	Transmission	Transmission	Transfers energy from horizontal plane into vertical plane for grinding wheel	Metal with grease lubricant
8	Internal Motor Assembly	Output	Converts the electrical energy into the horizontal mechanical energy	Metal, plastic, and ball bearings
9	Outer Motor Assembly	Input	Creates the electromagnetic field that provides the power for the tool	Metal, wires and plastic
10	Transmission Casing	Structural Components	Attaches the transmission to the motor and allows the shaft and transmission to run smoothly	Metal Composite with grease lubricant
11	Washer	Support elements	Attaches the motor to the gears.	Metal
12	Hypoid Gear	Motion Conversion Elements	Transfers power from shaft to transmission.	Metal
13	Drill handle and electrical circuits	Input and support elements	Provides the electrical power to the motor and turns the grinder on and off.	Plastic and Electrical Circuits

Engineering Specifications

The table belows explains the life expectancy of the bearing:

Table 2.1: Bearing Life Expenctancy

1	Engineering Specification (description, target value, direction of improvement) and related User requirement.	Life expectancy of a ball bearing, 10 years,↑, durability, customer satisfaction
2	Design decisions/parameters affected	The major design decisions are the size of the bearing to be used and the material composition of the bearing. These decisions are interrelated in that the increasing the size of the bearing increases the durability of the bearing while increasing the strength of the material also performs the same task; so, an optimization needs to be done to maximize the performance of the bearing under the constraints of the given situation. The parameter affected by these decisions is the Dynamic load which in turn affects the acceptable load felt by the shaft.
3	Top disk holder	Support Element	Attaches to disk holder to lock grinding disk in place	Metal
4	Washer	Support Elements	Attacjes grinding shield to the grinder	Metal
5	Handle	Structural Components	Provides grip and stability for the grinder	Plastic with metal screw on end
6	Griding Shield	Structural Components	Protects operator from any parts that may get grinded off from work material	Metal with greese lubricant
7	Transmission	Transmission	Transfers energy from horizontal plane into vertical plane for grinding wheel	Metal with grease lubricant
8	Internal Motor Assembly	Output	Converts the electrical energy into the horizontal mechanical energy	Metal, plastic, and ball bearings
9	Outer Motor Assembly	Input	Creates the electromagnetic field that provides the power for the tool	Metal, wires and plastic
10	Transmission Casing	Structural Components	Attaches the transmission to the motor and allows the shaft and transmission to run smoothly	Metal Composite with grease lubricant
11	Washer	Support elements	Attaches the motor to the gears.	Metal
12	Hypoid Gear	Motion Conversion Elements	Transfers power from shaft to transmission.	Metal
13	Drill handle and electrical circuits	Input and support elements	Provides the electrical power to the motor and turns the grinder on and off.	Plastic and Electrical Circuits

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