ME 324: Manufacturing

TERM PAPER PROJECT Final Presentation Ice Hockey Stick

ME 324_S4_G2
05/04/13 xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

Outline

Problem Statement Literature Survey Common Materials Material Selection and Assessment Matrix Advantages and Disadvantages of Chosen Material Proposed Manufacturing Process Machining Equipment Cost Estimation
Group Member Contribution

References

Problem Statement

To analyze the current process and materials involved in ice hockey stick manufacturing Develop a best design of the chosen material and manufacturing processes of ice hockey stick based on our detailed researched and engineering knowledge

Literature survey

Traditionally, wood is used as the primary material to manufacture ice hockey stick. Wood can be considered as cheap material, yet durable and flexible at that time. However, after being used for a number of times, it losses some stiffness and affects the accuracy. As time changed, new technology has come out with a better material called aluminum. Aluminum is very durable compared to wood. It is also much cheaper and last for a longer time. Even though it looks better than the wooden stick, yet the player claimed that the cant really feel the puck on the stick due to less stability. In the late 1990s, full composite fibers stick were introduced. These sticks were made from carbon fibers (graphite) bound together by polymer resin, which made them extremely light. Composite fibers also it combines the flexibility of wood to generate hard shots, the stiffness and stability of aluminum for control and a lightness that is unmatched by wood or aluminum. Thus, it becomes the most popular choice among the hockey player until now.

Literature survey

The blade is positioned at roughly a 135 angle from the axis of the shaft The length will be approximately 150200 cm Consist of 2 parts: -long slender shaft -blade (usually 25 40 cm long) The common material used for the shaft will be aluminum while the blade will be made from wood.

Literature survey
Common Manufacturing Process for Aluminum Shaft with Wood Blade

SHAFT

- Aluminum shaft is molded into a block

- Required heating and finishing process

Finishing
- The shaft will be finished off by colored or anodized

Literature survey
Common Manufacturing Process for Aluminum Shaft with Wood Blade

Blade
-The wood would be cut according to the desired shape -Treated to heat and hydraulic pressure process

Finishing
- The blade undergo coating or laminate it with ABS plastic

Common Materials
Different materials have their own specific techniques for the shaft and the blade manufacturing. Choosing a right material is important to achieve the flexibility criteria that the players seek. Current Common materials:

Wood

o o o
o

Inexpensive

Easily machined
Widely used Lightweight Easily shaped Lightweight Durable

Aluminum

o o
o

Carbon fiber (graphite)

o o

Detailed Assessment of Materials

Material
Flexibility Durability Lightweight Cost per stick

Aluminum
56-105 Flex 483MPa 525 g 20 60$

Carbon Fiber
85-126 Flex 600MPa 455 g 80 150 $

Wood
43-85 Flex 20.5MPa 675 g 15 50 $

Assessment Matrix of Materials

Material/ Features Flexibility Durability Aluminum 3 4 Carbon Fibers 5 5 Wood 2 2

Lightweight
Cost

4
3

5
1

3
5

Total Score

14

16

12

Notes: Scale are given from 1 to 5 where 1 is least favorable criteria and 5 is the most favorable criteria that a material acquired The highest score from the assessment matrix is the material of choice

Justification on Material of choice

We are agree to choose the Carbon fiber to manufacture the shaft and the blade based on the assessment matrix evaluated. The first advantage of this material is its lightweight characteristic. It is not just less weight to carry, but it also a lot less weight to swing when taking a shot. Moreover, composite material has high durability compared to aluminum and wood. This means that it is hardly to break.

Justification on Material of choice

Besides, it also has a very high flexibility. This is really important to produce a bigger torque. Thus, it will exert more power to hit the puck. On the other hand, composite material is quite expensive as to compare with aluminum and wood. Nevertheless, it has a longer dependency and not easily to break. Therefore, people will just have to spend a little bit more money once to get a life long stick. In conclusion, carbon fiber would be the best material for the ice hockey stick

Advantages and Disadvantages of Carbon fiber

o

Advantages:
Very high flexibility that will exerts more torque
Extremely light that is easy to handle Easy to manufacture Very hard to break

Disadvantages:
More expensive

Proposed Manufacturing Process for Carbon Fiber Shaft

Cut the carbon fiber sheet into pieces and attached together to form a layer

The carbon fiber layer undergo rolling process following a shaft mold
Heat up and wrapped into compression tubes As it harden, the final carbon fiber shaft is pulled out from the mold The shaft is ready to be attached with the blade.

Detailed Process
Cut the carbon fiber sheet into pieces with a slight angle. The carbon pieces attached together face to face in opposite direction using warm iron 2. The carbon fiber pieces is rolled through hot roller
1. 3.

After the pieces cool, cut it to right length of the shafts

Detailed Process
The carbon fiber piece is rolled around to follow a mold model shaft shape. 5. Place and heat up the model shafts wrapped with carbon fiber sheets into compression tubes. 6. After shaft get cool, pull out the harden carbon fiber shaft from the model shaft leaving a hollow carbon fiber shaft. 7. The shaft is ready to be attached with the blade
4.

Proposed Manufacturing Process for Carbon Fiber Blade

Plastic core blade is clamped together with the shaft Laminate the core blade with graphite socks attached the strips Compress the blade using wooden mold

Sanding process of final product

Coating and paint spraying Finished product of ice hockey stick

Detailed Process
1.

Start with plastic core of as a center of a blade Glue and clamp the blade to the shaft together Cover the core with graphite socks (give stiffness to blade)

2.

3.

4.

Two graphite strips are stick to the blade using hot glue

Detailed Process

5.

High compression to the graphite blade layers using wooden mold to get a final blade shape. Finished up the shaft and the blade with sanding process and coating it with urethane and silver spray paint

5.

Machining Equipment

CUTTING

Advantages: Excellent beam quality: smaller focus diameter and high work efficiency, high quality High cutting speed: cutting speed is more than 20m/min Low cost: saves energy and protects environment, Easy operations: fiber line transmission, no adjustment of optical path Disadvantages: Limited for material below 6mm thick Big size, hard to move

Fiber Laser Cutting Machine

Machining Equipment

Rolling

Advantages: Produce a high pressure between two roller High efficiency power-saving design( 18.7 kW); Control working temperature automatically High adhesive effect ( temperature from 150-300 c) Disadvantage: Slow process between 0-5 m/min

Hot Roller Press Machine

Machining Equipment

Sanding

Advantages: Suitable for Composite material High efficient comes from the combination of planning drum, roller sanding unit, and combinatory sanding unit high quality conveyor belt make transmission smooth and stable equipped with four-edge cutter blades (14 x 14 x 12mm), which are non-resharpen, super stiff, and convenient for replacing Multiple speed sanding between 4-20 m/min feed speed

Sanding Machine Manufacturer

Disadvantage: the sanding belt may deflect or bow during a sanding operation

Cost Estimation

Different material selection will affect the final cost.

Carbon Fibers is more expensive than aluminum and wood. Machining cost would also a little bit higher However, the machining process is simpler than the rest In large production, the cost would be justified.

Labor cost

Less number of labor is needed.

Most process run by the machine.

The high cost of the machine is balanced with less number or labor.

Actual production cost per unit.

Depends quantity, material and labor cost. It could be lowered in large scale production.

References
Anderson, Rosanna. Experimental Characterization of Ice Hockey Sticks and Pucks. Web. May 2008. <http://www.dissertations.wsu.edu/Thesis/Spring2008/R_Anderson_042308.pdf> Bennett, Michael T., and David E. Calapp. Composite Hockey Stick Shaft and Process for Making Same. Christian Brothers, Inc., assignee. Patent US5865696 A. 2 Feb. 1999. Web.<http://www.google.com/patents?hl=en&lr=&vid=USPAT586569 6&id=ResWAAAAEBAJ&oi=fnd&dq=ice+hockey+stick+costs+&printsec=abstract#v=onepage&q=ice%20hockey%20stick%20costs&f=false> Chitale, A. K., and R. C. Gupta. Product Design and Manufacturing. New Delhi:Prentice-Hall of India, 2005. Web. <http://books.google.com/books?id =CFlyglsIINYC&pg=PA438&lpg=PA438&dq=assessment+matrix+in+manufac turing&source=bl&ots=SFoZ7ggm4P&sig=dlmh1wPd9WcHSMN-nsne8LM6wqE&hl=en&sa=X&ei=Pq1cUceTNaTL2 QXlgoG4Ag&ved=0CEQQ6 AEwAw#v=onepage&q=assessment%20matrix%20in%20manufacturing&f=false> Deleris, Claude. Hockey Stick Made of Composite Materials and Its Manufacturing Process. Destra S.A., assignee. Patent Sept. 1991.Web.<http://www.google.com/patents/US5050878?printsec=description&dq=ice+ hockey+stick+manufacturing#v=onepage&q=ice%20hockey%20stick%20manufacturing&f=false> Factory Made - Ice Hockey Sticks. Prod. Factory Made. YouTube. 06 Mar. 2010. YouTube. 02 May 2013 <http://www.youtube.com/watch?v=vDNDXQrLXxU> Hockey Stick Sizing Guide | Hockey Stick Length | Pure Hockey. Hockey Stick Sizing Guide | Hockey Stick Length | Pure N.p., n.d. Web. 02 May 2013.<http://www.purehockey.com/guidance-info/hockey-stick-sizing-guide-hockeypure-hockey> How Hockey Sticks are Made. Prod. The Science Channel. YouTube. 18 Feb. 2006. YouTube. 02 May 2013 <http://www.youtube.com/watch?v=dKkk7RuAG48> Hockey Stick. Enotes.com. Enotes.com, n.d. Web. 02 May 2013. <http://www.enotes.com/hockey-stick-reference/hockey-stick> Hockey. stick- sizesUS5050878 A. 24

Ice Hockey Sticks. Prod. Discovery channel. YouTube. 23 Aug. 2009. YouTube. 02 May 2013 <http://www.youtube.com/watch?v=27uZ2s0TsKs>
LeGault, Michael. "Advanced Hockey Stick Design Delivers Optimal Performance : CompositesWorld." Advanced Hockey Stick Delivers Optimal Performance : CompositesWorld. N.p., 1 July 2012. Web. 02 May 2013. <http://www.compositesworld.com/articles/advanced-hockey-stick-design-delivers-optimal-performance> Design

Thank You Any Questions?