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MATE 222: Final Project

Complete Design

Quarter Blend

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Brecken DeOilers

Shaina Jung

Neri Lupian

Calvin Noetzel

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Identification of Design Constraints

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Product Identification

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The product we have chosen to design is the shaft of a golf club for a driver.

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The Driver

  • The driver is a golf club meant for hitting long distances at high speeds, and preferably, with accuracy

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Stakeholder Analysis

  • Clients: professional golfers
  • Want lightweight shaft that supports the club head in order to maintain performance and lower their handicap
  • Cost reduction isn’t crucial because the clients can generally afford high quality golf clubs
  • Higher quality=higher price
  • Benchmark analysis: steel and graphite

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Objectives

  • Need: A shaft that supports the golf club head while hitting golf balls at high speeds and for long distances
  • Want: lightweight, durable shaft
  • Functions: support club head and reduce force user applies to the club
  • Objectives: minimize costs and be more environmentally friendly
  • Constraints: maximize yield strength and minimize cost, but the shaft should also be able to have some flex (40-45 GPa)

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Life Cycle Assessment

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SLCA

  • The traditional material and process of a golf club shaft for a driver is graphite and pultrusion
  • The shaft is made of layers of carbon fiber and epoxy resin that holds it together

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SLCA in Excel

Life Stages

Materials Choice

Energy Use

Solid Residues

Liquid Residues

Gaseous Residues

Total

Premanufacture

3

2

2

3

3

13/20

Product Manufacture

3

3

3

3

3

13/20

Product Delivery

3

2

3

3

2

13/20

Product Use

2

3

3

3

3

14/20

Recycling, Disposal

2

3

2

3

3

13/20

Total

13/20

13/20

13/20

15/20

14/20

67/100

Impactful environmental stressors: bolded numbers

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How Carbon Fiber Affects Life Stages

  • Premanufacture: carbon fiber is manufactured with gases and liquids. Does not utilize recycled materials
  • Product Manufacture: resins are easily recyclable so it is not that impactful
  • Product Delivery: most effect is based on transportation so the weight of the material is impactful
  • Recycling/Disposal: carbon fiber is difficult to recycle because it cannot be melted down like other metals

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Eco-Audit

Energy

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  • CF- Epoxy/ Carbon Fiber, Woven Fiber

Composite, Quasi-Isotropic Laminate

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  • Glass- Epoxy/ S-Glass Fiber, UD Composite,

Quasi-Isotropic Laminate

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  • Currently the only disposal option is the Landfill or Combustion

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  • Glass- Material: 1.5E +13 (J)

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Batch of 2.4 million Golf Shafts

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​

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  • FST (FEMCO Steel Technology)-

Currently the largest Golf Shaft

Manufacturer, Located in Colorado

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  • Glass- Material: 8E +5 (Kg)

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  • Combustion as disposal should be

avoided

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  • Transport is negligible

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Batch of 2.4 million Golf Shafts

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CO2

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Material Selection

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Trade-Off Curve

  • Multi-objective optimization
  • Wanted material to have a range of 40-45 GPa for the elastic modulus

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Materials Based on Trade-Off Curve

  • BMI/ Carbon fiber, UD composite, quasi-isotropic laminate
  • Epoxy/ HS Carbon fiber, woven fabric composite, QI laminate
  • Glass/Epoxy unidirectional composite
  • Magnesium, EQ21A, cast
  • Magnesium, QE22A, cast, T6
  • Metal impregnated carbon

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Selection Criteria

  • Cost
  • Yield Strength (permanent deformation)
  • Toughness (energy required to break at impact toughness)
  • Water Resistance
  • Young’s Modulus (measure of stiffness)

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Saaty’s Scale

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Normalized Saaty’s Scale

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Material W.P.I.

  • Based on the spreadsheet, the material with the highest WPI is Epoxy/HS Carbon fiber.
  • Sensitivity analysis proves Glass/Epoxy as best material.

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Process Selection

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Grinding

  • Secondary Shaping process

after Compression Molding

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  • Smooth outer surface

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  • Can be done by machinery for

an increase in production rate

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Filament Winding

  • For hollow parts

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  • Spun until desired thickness

is achieved

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  • Component is removed after

it hardens

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Centrifugal Molding

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  • Two smooth surfaces from

one tool face

  • High capital cost due to

machinery

  • Resin is sprayed, then hot

air is introduced to cure

while rotating

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Cost Modeling

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Material Data

  • Mass: 0.080 kg/shaft
  • Cost of Material

Epoxy/HS Carbon Fiber: $39.4/kg

Glass/Epoxy Unidirectional Composite: $28.9/kg

  • Batch Size: 2,400,000 shafts/year

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Process Specifics

  • Filament Winding
    • Um= 0.872, Ct= $1890, Batch Rate = 1.1units/hr

Cc= $13300

  • Grinding
    • Um = 0.5, Ct = $10000, Batch Rate = 1.0units/hr

Cc = $1,000,000

  • Centrifugal Molding
    • Um = 0.872, Ct = $7890, Batch Rate = 1.22units/hr

Cc = $231,000

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Cost Analysis

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Alterations in Batch Size

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Industry Standards

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The Final Product

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Recommendations

Material: Glass/Epoxy

Process: Filament Winding (Glass/Epoxy)

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In conclusion, using glass/epoxy with filament winding is the most cost effective and is more environmentally-friendly.

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