Black and Decker Grinder

Figure 1: Fully dissected product

Description

This product is a produced by Black and Decker. The product is used to grind down metal.

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.

Because of constant friction and the forces acting on each component there is a certain life expency. This varries for individual parts based on the force acting on the part and the design of the part.

For the bearing, an assumed torque of 0.315 Nm was applied to the shaft. Assuming the grinder is being used constantly the bearing would last 1.83 years before failure. If the grinder was being used six hours every day, 365 days a year then the bearing would last 7.33 years. If the grinder was being used six hours a day, five days a week, the bearing would last 10.26 years.

For the force requirement on the gears to rotate the grind wheel at 10,000 RPM, the power consumption of the grinder was looked up. 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.

To calculate the stress in the gears, a stress equation was used from the Fundamentals of Machine Compoents 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 disposable camera:

Table 3.1: Disposable Camera Bill of Materials
Part # Part Name # Req'd Mat'l Manufacturing Process Image
1 Back Interior 1 ABS Plastic Injection Molding
2 Back Plastic Cover 1 ABS Plastic Injection Molding
3 Camshaft 1 ABS Plastic Injection Molding
4 Eyehole for Shutter 1 ABS Plastic Injection Molding
5 Film Advance Gear 1 ABS Plastic Injection Molding
6 Film Advance Lock 1 ABS Plastic Injection Molding
7 Film Canister 1 Varied Varied
8 Film Spindle 1 ABS Plastic Injection Molding
9 Frame Counter 1 ABS Plastic Injection Molding
10 Front Interior 1 ABS Plastic Injection Molding
11 Front Plastic Cover 1 ABS Plastic and Rubber Injection Molding and Molding
12 Inner Lens 1 ABS Plastic Injection Molding
13 Interior Body 1 ABS Plastic Injection Molding
14 Lens Holder 1 ABS Plastic Injection Molding
15 Outer Lens 1 ABS Plastic Injection Molding
16 Outside Film Advance 1 ABS Plastic Injection Molding
17 Shutter 1 1040 Steel Stamping
18 Shutter Lever 1 ABS Plastic Injection Molding
19 Shutter Spring 1 1040 Steel Forming
20 Spring for Shutter Lever 1 1040 Steel Forming
21 Sprocket 1 ABS Plastic Injection Molding
22 Viewfinder 1 ABS Plastic Injection Molding
23 Washer 1 Rubber Molding

Disassembly

The ease of disassembly (ranked on a scale of 1 - 5 with five being the most difficult) is ranked at 2. No tools are required for disassembly but a flathead screwdriver or knife helps.

The following table lists the steps and procedures for disassembly:

Table 4.1: Disassembly of a Disposable Camera
Step Procedure Image
1 Pop film advance wheel up and
out from body; separate covers
Figure 5.1: Exterior Disassembly
2 Remove film canister and film spindle
Figure 5.2: Large Component Removal
3 Remove lens holder, outer lens, shutter cap,
shutter spring, shutter, eyehole, and inner lens
Figure 5.3: Lens Assembly Dissection
Figure 5.4: Lens Assembly Dissection View 2
4 Remove viewfinder, frame counter, internal film
lever spring, and sprocket
Figure 5.5: Final Component Removal

Files

Camera Assembly

(Zipped ACIS, IGS, STL, STP, AD_PRT Files)
Part # Part Name Image 3D Models 2D Drawings
1 Back Interior
3D Package 2D Package
2 Back Plastic Cover
3D Package 2D Package
3 Camshaft
3D Package 2D Package
4 Eyehole for Shutter
3D Package 2D Package
3D Package 2D Package
3D Package 2D Package
7 Film Canister
3D Package 2D Package
8 Film Spindle
3D Package 2D Package
9 Frame Counter
3D Package 2D Package
10 Front Interior
3D Package 2D Package
11 Front Plastic Cover
3D Package 2D Package
12 Inner Lens
3D Package 2D Package
13 Interior Body
3D Package 2D Package
14 Lens Holder
3D Package 2D Package
15 Outer Lens
3D Package 2D Package
3D Package 2D Package
17 Shutter
3D Package 2D Package
18 Shutter Lever
3D Package 2D Package
19 Shutter Spring
3D Package 2D Package
20 Spring for Shutter Lever
3D Package 2D Package
21 Sprocket
3D Package 2D Package
22 Viewfinder
3D Package 2D Package
23 Washer
3D Package 2D Package

(Zipped .wrp format)
Figure 5.1 Front Exterior Scan
Gave to Dave
Figure 5.2 Front Interior Scan
Gave to Dave
Figure 5.3 Rear Exterior Scan (Front View)
Figure 5.4 Rear Exterior Scan (Back View)
Gave to Dave
Figure 5.4 Rear Interior Scan
WRP Scan Files