Adwait

Sunday 10/14/12 8:30 - 11pm SolidWorks for gears - submitted prints to RPL

Sunday 10/7/12 5-10 pm & Monday 10/8/12 10am-3pm Solution to scaling problem - dimension options while exporting to .stl Tried creating new gear profile in Inventor - LOTS OF PROBLEMS! Design Accelerator doesn't have option to create new profile

Tuesday 10/2/12 10:30 - 11pm Gear_new profile_12T.stl X 5 | Kapton on perf | Nozzle height **132 mm** (leaves considerable gap) (Use Windex and water to remove paint)

Friday 9/21/12 2:30pm - 7pm, 10pm - 2am Printed 2 Gear_11F_modified.stl X10 (calc error - stick to X5) on Kapton film without raft | Nozzle height **131mm** (leaves considerable gap) Was having problems with extrusion (thought the nozzle was being blocked) - adjusted flatness Good results with 15T 1:1, but may have problems with higher gear ratios Excel sheet - fixed and driven parameters Print 4:1 gears with increased nozzle gap; might solve problem - create .stl from .ipt //Changed spool - Weight 700g//

Works fine with new Kapton tape (old one had a thin layer of ABS, which is why it didn't stick) New profile print - froze up mid print | Action: pause, withdraw, extrude, resume - didn't solve problem // Use Kapton+perf : gets rid of air bubbles //

Thursday 9/20/12 9:30 - 11 am Printed Gear_11F_modified.stl X10 (nozzle height 132.9 mm) - doesn't print on perf board without raft Complete gears with larger teeth

Tuesday 9/18/12 10:30 - 11:30 am Ben Finio meeting

Friday 9/14/12 11am - 2pm Inventor gears - new teeth profile | also used Design Accelerator to design ACME gears with more spacing Tried SolidWorks (easier user interface) - produce different tooth profile from Inventor

Thursday 9/13/12 10am - 11am, 4-5pm ​Morning meeting with Dr. Bull, Peter about plans for working with Ben Finio Evening conference call with Ben Finio

Tuesday 9/11/12 9am - 11am Tried print on new UP | **Nozzle height = 132.6 mm with perf board** | // Use small clip on back // Didn't extrude at first | worked fine after reinsertion of filament However, stopped extruding halfway through the print (phantom extrusion)

Thursday 9/6/12 9am - 11am Printer froze again on old UP! before the first layer was completed, maybe it's a software issue (reinstall?) Really hard to remove material from painted platform, ask Eric for tips

Set up the new UP! to try raftless print, but ran out of time

Tuesday 9/4/12 9:30am - 11:30am Optimal nozzle height = **139.8 mm** with paint Modified Graham's Gear_11F to reduce teeth from 20 to 15. Scaled 15T gear 5X, but it was still pretty small (~26 mm OD). The teeth look good, but I wasn't able to get the raft off easily (there might be a trick to it, ask Eric) Printed 5X scale without raft - BUT, print aborted when I disconnected my laptop

To do: Ask Eric for Kapton film Print without raft

Friday 8/31/12 11:30pm - 2:30pm, 3:30-4:30 pm Used the UP after a 3 week gap, so spent relearning the UP. 1. Installed the XML converter for Office on the Mac (the one that's used for the UP) 2. Initialization, Calibration of the UP, painting the platform (got help from Eric), read user manual 3. Tried a sample print, but ran out of time

Monday 8/13/12 9:30pm - 1:30am Tasks completed: Issues:
 * Focus: Familiarization with UP printer**
 * 1) Installed software v1.15 from [|http://www.up3dusa.com/support#!__support/vstc23=software]
 * 2) Read user manual (says 201109-v2.0 on cover page) [|complete v1.1 user manual]
 * 3) Printed sample part (on the one with the painted platform)
 * 1) Nozzle height option not available in Setup menu, platform was too far from nozzle
 * 2) Nozzle height adjustment only in Print menu - inconvenient
 * 3) Which model of UP printer is this? Do I have the correct software version and user manuals?
 * 4) Inventor not available on the Hive - couldn't generate .stl file from .ipt file of gear

Sunday 8/12/12 7pm - 11pm Tasks completed: Action items for next session:
 * Focus: Meshing of gears on wind turbine**
 * 1) Understanding design considerations for meshing of gears (Shigley's Mechanical Engineering Design - 9th edition)
 * 2) Literature search on potential design issues leading to improper meshing of gears
 * 1) Get familiar with Up printer - observe problem with "flattening" of material at base
 * If Up printer has support material, use it to solve "flattening" problem
 * 1) Print larger gear teeth
 * Keep in mind that minimum 13T needed for 1:1 ratio (Shigley Eq 13-10)

Other ideas: Create assembly of all parts - helps calculate center distance for gears

Friday 8/3/12 1pm - 3pm Tasks completed:
 * Focus: Meshing of gears on wind turbine**
 * 1) Spur gear tutorial on Inventor
 * 2) Organizing current Inventor files obtained from Dropbox

Action items for next session:
 * 1) Read gear design theory from Shigley

Friday 7/27/12 1pm - 5pm
 * Focus: Meshing of gears on wind turbine**

Tasks completed:
 * 1) Talked to Daniel Wicklund about design recommendations
 * He suggested that we increase the gear teeth size, but it also depends on the capabilities of Up printer
 * 1) Attempted to create complete Inventor assembly of separate parts

Actions items for next session:
 * 1) Learn how to use Inventor for creating gears