Novel Material and Mechanical Design for Shipping Pallets

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1 Novel Material and Mechanical Design for Shipping Pallets Justin Gallagher, Taylor Hopkins, Craig Leslie, Niko McMurray, Kevin Rebellino Advisor: Dr. Daehn Partner: Alcoa Foundation

2 Background Global packaging market Over $459 billion* Wooden pallets Cost $20 each** *** Weigh 50 lbs.** Not environmentally resistant *** Non-recyclable Potential for invasive species *:"Pallet Trends." Solutions For Wood. FP Innovations. Web. 1 Dec < **: Pallet Sizes and Dimensions. ***: "Aluminum pallets." Aluminum pallets. N.p., n.d. Web. 4 Dec <

100% Corrugated Pallet. Web. 01 Dec. 2011. <http://www.loadek.com/index.htm>.

3 ** Background Wooden pallets Occupy 4% solid waste in landfills* Deforest up 100 million acres of forest each year* Short life span- generally single use* ** *: Loadek - the First 100% Corrugated Pallet. Web. 01 Dec < **: "Aluminum pallets." Aluminum pallets. N.p., n.d. Web. 4 Dec <

Background ** Plastic pallets Cost $60-100 each* Weighs between 30-50 lbs.

4 Background ** Plastic pallets Cost $ each* Weighs between lbs.* Lack rigidity Low creep resistance at high loads Recyclable *: Premier Pallets FAQ. **:"Aluminum pallets." Aluminum pallets. N.p., n.d. Web. 4 Dec <

5 Background ** Aluminum pallet Cost at least $200 each* Weigh ~35 lbs.* Longer life span More visual appealing *: National Wooden Pallet and Container Association **:"Aluminum pallets." Aluminum pallets. N.p., n.d. Web. 4 Dec <

6 Background Aluminum pallet Recyclable/.97 cents per lb.* Environmentally resistant Do not carry insects/bacteria ** *: National Wooden Pallet and Container Association **:"Aluminum pallets." Aluminum pallets. N.p., n.d. Web. 4 Dec <

7 Motivation of Project Design an sustainable shipping pallet to fulfill a market need Produce at a lower lifetime cost than currently available options Use manufacturing processes that can be highly automated, and therefore, cost will be close to that of raw material at high volume.

8 Design Criteria Aluminum pallet Dimensions*: 48 x42 x6 Minimize weight/increase strength Decrease cost (under $100) Possess a load bearing capacity of 2000 lbs (Dynamic) & 6000 lbs (Static)** May be transported by standard forklifts* 100% recyclable *: ISO 6780, Flat pallets for intercontinental materials handling-principal dimensions and tolerances **: ISO , Pallets for materials handling-flat pallets-part 2: Performance requirements and selection of tests

9 Technical Approach Widely available material Al alloy 6061-T6 Each group member contribute designs Use various manufacturing methods maximize automation Determine at least two viable designs CAD meet weight and design standards FEM meet ISO standards Prototype viability of manufacturing

*: Industrial Origami. Design and Technology Overview.

10 Industrial Origami Rapid, simple manufacturing process Perforations made along fold lines Shapes folded in sequence * * *: Industrial Origami. Design and Technology Overview. Middleburg Heights, Ohio technology/science.cfm.

11 Joining Methods-Welding Welding Aluminum Heat input ages material rapidly Leads to overcoarsening of precipitates, massive grains* IWSL process uses water cooled electrode Focuses current at weld site * *Mathers, Gene. The Welding of aluminum and its Alloys. Woodhead Publishing London.

and shear strength, corrosion resistance * * *Lotus Exige, body and bare

12 Joining Methods- Adhesive High strength adhesives for structural applications Example: Lotus Elise/ Exige chassis Important properties Peel and shear strength, corrosion resistance * * *Lotus Exige, body and bare chassis _ec_2006_lotus_exige/photo_04.html

13 Industrial Origami Design 6061-T6, 48 x42 x4, under 29 lbs.

14 Industrial Origami Stress Analysis Basic finite element analysis High stress regions where top is bonded to middle sections

15 Industrial Origami Fabrication Shapes formed with hydraulic shear, manual bend press Pieces were bonded using Loctite E-120HP Substituted U-channels for expansion formed channels

16 U-Channel Design 6061-T6, 48 x42 x5, 21.9 lbs Requires only two distinct pieces channel thickness tube thickness

17 U-Channel FEM Modeled in Solid Works 0.14 cm deflection at max. loading 107 MPa VonMises stress at max. loading 6061-T6 yields at 276 Mpa at room temp.* *

18 U-Channel Fabrication Water Jet holes in sheets Bend cut out patterns Use electromagnetic expansive forming

19 U-Channel Fabrication Some issues in conformal joining, adhesives also used in prototype

20 Interference Fit Extrusions Background This design relies on two types of pieces Very similar to U-Channel design produced Number of required parts reduced for decreased costs

21 Interference Fit Extrusions Design 6061-T6, 48 x42 x5, 23.4 lbs Holes cut in T-beams to reduce weight Varied wall thickness to reduce weight

22 Interference Fit Extrusions FEM Stress concentrations are a limiting factor VonMises stress of 196 MPa at max. loading Max. displacement 0.15 cm in dynamic loading

23 Design Comparison Design Industrial Origami Weight Material Cost 28.8 lbs $ Way T-Beam 23.4 lbs $ Way U-Channel 21.9 lbs $ Way Entry Deflection (6000lb Static Load) (2000lb Dynamic Load) (2000lb Dynamic Load) U-channel is the lightest and cheapest design The origami design allows 4-way entry T-Beam has deflects more than U-channel Equivalent FEM was not run for both, however loads are roughly comparable

24 Testing ISO Standard Static and Dynamic Load Deflection A large test frame must be found or designed to allow the maximum load to be determined both statically and dynamically Nominal load is defined as the load at which the maximum deflection is less than 20mm, or 0.787

25 Results 3 viable options All weigh < 30lb Estimated cost < $75 3 different manufacturing methods All manufacturing methods commercially viable FEM analysis Passed Requirements 2000lb Dynamic and 6000lb Static Loads

26 Design Conclusions U-Channel is lightest at 21.9 lbs All components are easily manufactured Can be available in larger quantities Simple Construction Expansive forming must be optimized for large scale production Spot welding is also an option

27 Future Recommendations Testing Based on ISO standards Develop a process for fabrication Automatable, as much so as possible Address other design aspects Aesthetics, Stackability, Design optimization

28 Acknowledgements Advisor: Dr. Glenn Daehn Department of Mechanical Engineering Advisors: Dr. Tony Luscher and Dr. Leo Rusli Industrial Partners Bill Shepard from Die Matic, Dr. Dr. Anthony Ananthanarayanana from Innovative Welding Solutions Ltd. The Aluminum Company of America (ALCOA) Dr. Daehn s Lab: Geoffrey Tabor and Ryan Brune Dept. of Mechanical Engineering machine shop: Chad Bivens and Matt Little

complete with pallet support bars, column guards, safety barriers, pallet back stopper painting

complete with pallet support bars, column guards, safety barriers, pallet back stopper painting DESCRIPTION / SPECIFICATIONS OF GOODS The Goods to be supplied by the Supplier include the following: The scope of works including:- 1. Supply, delivery and installation of pallet racking system as follow:-