Eagle Secondary Operation Prototype

Overview

The team was tasked with the objective of reducing Eagle Manufacturing’s secondary operation cutting time by 10 to 20% (9 to 18 seconds) for their “lab pack”, chemical-certified barrels. After preliminary research, testing efforts were focused on three potential solutions: plasma cutting, hot-wire cutting, and an In-mold blade insert. By utilizing an in-house plasma cutter, hand-held hot wire cutter, and the plastic lab’s extrusion blow molder, quantifiable results were obtained for analysis. Based on these results, plasma cutting, and hot wire cutting were deemed to be inefficient due to the inability to maintain Eagle Manufacturing’s quality parameters. However, with the addition of an in-mold blade insert, an efficient cutting groove was formed within the cutting region.

Objectives

The objective for this project is to reduce the secondary operation cut time by 10-20% (9-18 seconds). The students will simulate and test potential avenues of change, within the capabilities of PSB.

Approach

• After preliminary research, testing was conducted with a plasma cutter, hot-wire cutter, and an in-mold blade insert.
• Plasma cutting produced charring on the surface of the barrel as well as inefficient cuts, differing in cut depth and rounded edges.
• Hot-wire cutting resulted in long cut times and the possibility of material welding back together
• Two designs were produced for the in-mold blade insert.
• The first design aimed to reduce the wall thickness at the cutting region of the geometry, but was deemed a failure, as it did not reduce the wall enough due to geometry restrictions.
• The second design was produced to create a cutting groove at the cut region, and was successful during molding.
• After testing indicated that a cutting groove reduced the cut time by up to 30%, the current molds at Eagle Manufacturing were redesigned to incorporate the geometry of the in-mold blade insert.

Outcomes

The group believes that through the utilization of an In-Mold Blade Insert, the secondary operation cut time may be reduced beyond 20%.
• Establishes a cutting groove for the existing hot-knife to cut within, ensuring complete linearity of the cut.
• Thins cross-sectional area at cutting groove, reducing overall volume of material needed to be cut.
• Geometry can be changed to account for different barrel volumes.