DESIGN PROBLEMBoeing is one of the leading companies for the design and

manufacturing of the highest quality aircraft. Many of the parts have to be created out of titanium, and must be crafted to a low tolerance. Large end mills with many tungsten carbide inserts are used to cut the metal. Machinists are responsible for the upkeep of these end mills, which includes the removal and inspection of each insert, and then replacing certified inserts back into the mill. This process takes a great deal of time and effort, and Boeing is seeking to automate this process. The members of the 416 group set out to solve this problem.

CAROUSELThe carousel subsystem handles the removal, replacement and storage of cutter inserts and screws.

● 85 insert carousel, 10 3D printed parts

● Programmed stepper motor and one-off 3D printed gear drives carousel, cycling through inserts

● Designed suction head, contoured to insert geometry

● Top-mounted components and hinging vertical columns

● Stand created to seamlessly integrate systems

● 5/3 valves handle suction and linear pneumatic actuator to control insert motion into place

A pneumatic linear actuator will extend, and suction will be applied to grasp the insert as soon as it is unscrewed from the mill. The pneumatic arm then brings the insert and its screw back into the carousel ring, where it is deposited until it is inspected. A stepper motor then turns the ring one slot increment, and repeats the process.

SCREWDRIVEROnce the end mill is in place, the

screwdriver goes to work.

● Small Festo servo motor lowers and raises the screwdriver using a ball screw linear actuator

● Big Festo servo motor provides necessary torque to tighten/loosen screws to/from the required 35 in-lbs

● Flexible shaft allows transmission of torque without cantilevering heavy load

To loosen the inserts, the screwdriver will lower into position once the tool is in

the correct alignment. The two servo motors will simultaneously raise and

rotate counterclockwise. To tighten the inserts, the screwdriver will again allign

itself in the correct position. The two servo motors will simultaneously lower

and rotate in the clockwise direction.

LINEAR ACTUATORThe linear actuator subsystem is responsible for moving the end mill into

place. A stepper motor turns a belt, which acts as a linear actuator, driving the end mill toward the carousel. A stepper motor turns a worm gear which rotates the end mill slightly, allowing the next insert to be level with the

suction head. The belt then drives the mill slightly, to bring the insert in line with the suction head.

PROGRAMMING AND INTEGRATION

This system is operated using two progammable logic controllers (PLC) and a touch screen human-machine

interface (HMI). The user can control the operation using the HMI to start, pause, reset, or stop the program.

Ladder logic code programmed onto the PLCs controls the sequence, timing, and movement of the 3 stepper motors,

2 servo motors, and 2 pneumatic valves on the machine. The ladder logic is written in Totally Integrated

Automation (TIA) Portal, and the FESTO motors each require additional configuring via the software Festo

Configuration Tool (FCT).

AUTOMATED END MILL INSERT REPLACEMENT SYSTEMMEMBERS: KISA BROSTROM, ANDREW CLEMENTS, JOSEPH MCKENNA, CONNOR MCBRIDE, CONOR MOLONEY, TREVOR DOUGLAS,

AARON THONNEY, JOSIAH WAI, SCOTT OLIVARES, NICHOLAS WOOD