Assisted Pool Float for Children and Young Adults with Physical Limitations

A Baccalaureate thesis submitted to the Department of Mechanical and Materials Engineering College of Engineering and Applied Science University of Cincinnati

in partial fulfillment of the requirements for the degree of

Bachelor of Science

in Mechanical Engineering Technology

Austin Sillies

April 2014

Thesis Advisor: Professor Laura Caldwell

ACKNOWLEDGEMENTS

Throughout this project there have been many individuals and companies that made it possible. I first like to offer my special thanks and appreciation to May We Help for all the work and services they provide to those who truly need help. May We Help assisted in the funding, research, and design of this device. Next, I would like to express my great appreciation to D.S. Design Company LLC., and President/Owner David Sillies and Design Engineer Devin Sillies for their assistance in conceptual design, detailed design, and manufacture. Their willingness to give their time, talents, and monetary assistance is greatly appreciated. I also wish to acknowledge the assistance provided by Professor Laura Caldwell. Professor Caldwell was my advisor throughout the duration of this project offering input, assistance, and guidance for whatever the project called for. All of which is greatly appreciated. I would like to offer my special thanks to Mrs. Janet Garner, Smith Electrochemical, and Professor Dave Conrad. Mrs. Garner provided her time and knowledge of sewing to assist in the manufacture of the device. Smith Electrochemical donated their services to anodize all the aluminum material required in this project. Professor Conrad, College of Engineering and Applied Science’s Machine Shop Advisor, for his countless hours spent in the lab assisting students, myself included, on their projects. Mrs. Janet Garner, Smith Electrochemical, and Professor Dave Conrad’s services and time are very much appreciated. Finally, I wish to express my deepest gratitude to my parents and family for their support and encouragement throughout my college career.

TABLE OF CONTENTS

ACKNOWLEDGEMENTS ...... II TABLE OF CONTENTS ...... III LIST OF FIGURES ...... IV LIST OF TABLES ...... VI ABSTRACT ...... II INTRODUCTION ...... 3 BACKGROUND ...... 3 INTERVIEWS ...... 4 EXISTING PRODUCTS ...... 5 THE LITTLE MERMAID...... 5 STABILIZING BAR ...... 6 OTHER FLOATATION DEVICES ON THE MARKET...... 7 GAIT WALKER ...... 8 OVERVIEW - CUSTOMER FEEDBACK AND OBJECTIVES ...... 9 SURVEY RESULTS AND ANALYSIS ...... 9 OBJECTIVES AND ENGINEERING CHARACTERISTICS ...... 10 CONCEPT GENERATION AND SELECTION ...... 12

CALCULATIONS ...... 17 BUOYANCY FORCE ...... 17 TIPPING/MOMENT ...... 19 OVERALL DESIGN DETAILS...... 23

DRAWINGS ...... 30 BILL OF MATERIALS ...... 30 SPECIAL TREATMENT OF PARTS...... 30 FABRICATION / ASSEMBLY ...... 31 MANUFACTURING ...... 31 ASSEMBLY ...... 36 TESTING ...... 40

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SCHEDULE AND BUDGET ...... 45 SCHEDULE ...... 45 BUDGET ...... 46 RECOMMENDATIONS ...... 47 WORKS CITED ...... 48 APPENDIX A - RESEARCH ...... 49 APPENDIX B - SURVEY WITH RESULTS ...... 54 APPENDIX C - QUALITY FUNCTION DEPLOYMENT (QFD) ...... 55 APPENDIX D – OBJECTIVES ...... 56 APPENDIX E: PART DETAILS ...... 57 APPENDIX F: MATERIAL DETAILS ...... 66 APPENDIX G: BILL OF MATERIALS ...... 69 APPENDIX H: SCHEDULE ...... 70 APPENDIX I – ACCURACY/QUALITY ...... 71

LIST OF FIGURES Figure 1: Savannah's Current Pool Float ...... 4 Figure 2: The Little Mermaid Inflatable Pool Float...... 5 Figure 3: Jet Propulsion System ...... 5 Figure 4: Stabilizing Bar ...... 6 Figure 5: Stabilizing Bar with Neck Jacket (left), holding onto Bar (right) ...... 6 Figure 6: Floatation Mat ...... 7 Figure 7: Modified Lifejacket ...... 7 Figure 8: Child in Gait Walker ...... 8 Figure 9: Gait Walker Seat ...... 8

Figure 26: Waist Support ...... 26 Figure 27: Front View ...... 26 Figure 28: Top View ...... 27

Figure 38: Drilling Setup ...... 33 Figure 39: Plasma Cutting ...... 34 Figure 40: Plasma Cutting ...... 34 Figure 41: Piece after Plasma Cutting ...... 34 Figure 42: Press Break Process ...... 35

LIST OF TABLES Table 1: Survey Results ...... 9 Table 2: Survey Results Price Selection ...... 10

ABSTRACT

Contained in this report is the research, design, fabrication and testing for a Flotation Device for Children and Young Adults with Physical Limitations. This work was completed in the final year to fulfill requirements for the degree of Bachelors of Science of Mechanical Engineering Technologies. The need for this project arose when Mr. and Mrs. Johnson contacted May We Help in regards to the design and build of a personal flotation device for their daughter Savannah. Miss Johnson was diagnosed with Cerebral Palsy at birth and has physical limitations thus limiting her ability to enjoy activities in their pool. This concept was thought of by Designer Austin Sillies, Dave Sillies, Devin Sillies, and May We Help as a way for Miss Johnson and many others like her to experience the joys of playing in a pool.

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INTRODUCTION

BACKGROUND

Children with Handicaps are presented with many challenges in life. Some of these challenges prevent them from fully participating in many activities. One such activity is swimming. For some, swimming comes with ease, for others it doesn’t. This project was chosen in order to truly benefit and help someone; someone like my little brother who has Trisomy 21. May We Help is a non-profit engineering group that works with handicapped and disabled persons and their families. People send in requests to the organization to help facilitate activities of daily living for people with all sorts of handicaps. May We Help was contacted and a project was chosen to design and build an independent pool float, which has been requested by four different families.

The Johnson family is one of these families; they have a 13 year old daughter Savannah. Miss Johnson has Cerebral Palsy (CP)1. Although she has good control of her movements she still is limited in many ways.

1 CP is a condition marked by impaired muscle coordination (spastic paralysis) and/or other disabilities, typically caused by damage to the brain before or at birth. (2) It is the most common disability during childhood.

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INTERVIEWS

The second interview conducted was with the Johnson family themselves. Going into the interview the current means of floatation for Miss Johnson was already made clear. The goal of the interview then became to figure out what Miss Johnson and her family were really looking for in the pool float. The features that were ultimately decided on and discussed are described in the objectives which can be found in Appendix D.

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EXISTING PRODUCTS

THE LITTLE MERMAID

The Little Mermaid Inflatable Pool float below shown in Figure 2 is a prototype that addresses some of the issues regarding Miss Johnson’s current flotation method.(see Appendix A) It is a compact inflatable float that incorporates a jet propulsion unit. (3) The hand crank shown in Figure 2, sucks in water as it is cranked. This water is then directed to the back of the float where it is discharged similar to a jet of water. The flow of the jet system is shown in Figure 3. This prototype addresses some of the issues that Miss Johnson is having with her current set up but it does not address some of the most important ones. This prototype provides stability and some independence, but it is still restrictive when it comes to swimming assistance. It is also inflatable; this is very problematic to Miss Johnson because the device could pop and if no one is in the water to help her, there could be serious problems.

Hand Crank

Figure 2: The Little Mermaid Inflatable Pool Float

Figure 3: Jet Propulsion System

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STABILIZING BAR

There are several different devices that keep people afloat in the water. One that people might not be too familiar with is the Stabilizing Bar, shown in Figure 4. The Stabilizing bar is a standard 1in diameter PVC pipe that is caped at each end. This pipe holds flotation rings on either end of it leaving a space in the middle for someone to strap a neck jacket to or just hold on to, see Figures 5 & 6 (4) The stabilizing bar has some good features in it because it provides a lot of stability for someone who requires stability in the water. The flotation rings are a good form of floatation that provide versatility in their use and can be applied to many different applications. They can be removed and added as different amounts of flotation are needed.

Figure 4: Stabilizing Bar

The neck jacket with stabilizing bar in Figure 5, left, is good for someone that needs to have full body submersion in order to move their muscles. It can be very uncomfortable at times for the user, and does not allow them to swim. This is not ideal for Miss Johnson as she would like to swim and still remain partially out of the water. Just holding onto the bar as shown below in Figure 5, right, can be an effective way to stay stable in the water for someone that has trouble walking. People with walking disabilities on land can have a much easier time trying to walk in the water. So to focus on walking they obtain the use of the bar to keep their body that is out of the water stable.

Neck Jacket

Figure 5: Stabilizing Bar with Neck Jacket (left), holding onto Bar (right)

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OTHER FLOATATION DEVICES ON THE MARKET

Some other common floatation devices that people with disabilities use can be found on websites such as AbleData. (4) Some of these floatation devices are shown in Figures 6 & 7. These floats such as the ones described in the Stabilizing Bar portion of the report are constructed of moisture proof, vinyl covered foam, making them resistant to damages of chlorine water and soft and safe for the user. (4)

The Floatation Mat shown below in Figure 6 allows a person that is ultimately confined to a wheelchair, or has almost no physical control of their body, to get in the water. The mat is useful because it relieves the day to day pressures that their body faces on land. It can also be used at the pools edge to get people in and out of the water easily.

Figure 6: Floatation Mat

Another basic example of a floatation device is one that most people are familiar with, the lifejacket. An example of a modified lifejacket for people with Handicaps is shown in Figure 7. (4) This modified life jacket wraps around the neck, at the hips and between the legs, maximizing the support that a lifejacket can have in the water. Like most lifejackets on the market if a person was to become unconscious in the water the lifejacket is designed to float the person on their back so there head is exposed to air. In this version of a lifejacket the neck floats assist in achieving this goal.

Figure 7: Modified Lifejacket

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GAIT WALKER

The Gait Walker (Appendix A) is not a floatation device but is a device that serves a similar purpose on land, see Figure 8. The walker provides support and stability to the upper portion of a person’s body while their legs dangle down in between the supports of the device. This device is ultimately to assist a person with a walking disability. When the person is in the device they are supported by a seat Figure 9. The seat is a cushioned pad with four straps attached to it. These straps reach up to the frame of the seat and allow the seat to be free floating in the middle of the device. This ultimately gives the user complete movement of their legs when strapped into the walker. (5) The four wheels incorporated into the frame of the device allow the user to move in any direction that a free walking person with no disability would be able to walk.

Figure 8: Child in Gait Walker

Figure 9: Gait Walker Seat

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OVERVIEW - CUSTOMER FEEDBACK AND OBJECTIVES SURVEY RESULTS AND ANALYSIS

Customer feedback is a large part of the success of a product. The features of the pool float that were found to be most favorable based on the research and interviews were placed into a survey. This survey was sent out to all of the May We Help community which consists of hundreds of families that have children and adults with disabilities, or have disabilities of their own. It also consists of Doctors, Nurses and Physical Therapists that assist people with disabilities on a day to day basis. All in all 51 surveys were obtained, resulting in good data.

Based on the 10 customer features that were identified the participants were asked to rank the importance of each on a scale of 1-5, 1 being the least important and 5 being the most important. In the same survey they were asked to evaluate, on a scale of 1-5, their satisfaction with current with flotation devices on the market today, 1 being the least satisfied and 5 being very satisfied. Table 1 shows the weighted results of the survey with overall importance displayed in a percentage. It also includes the designer multiplier. This multiplier is determined by the designer to increase the importance of a certain feature. The designer chose to increase the importance of safety and stability. This is because when the devices operate in the water there can be increased consequences if something goes wrong, as it is not as easy to address issues of safety and stability in a pool environment.

For this survey the customer satisfaction portion had to be eliminated due to invalid data. Out of the 51 surveys that were received over half of them, 26, came back with not applicable (N/A) results. This means that most of the surveyors were not familiar with current handicap assisted pool floats. This is because, per the research in Appendix A, there are no products that are currently on the market and address the problem that the flotation device will solve With this in mind safety was determined as the most important feature with an astounding rating of 5 and a relative weight of 14% over 51 surveys. The least important feature was determined to be Non-Inflatable. Although the customer surveys show that non-inflatable is unimportant, the Johnson family surveyed this at a rating of 5. The complete survey results can be found in Appendix B.

1: Survey Results Customer Designer Relative Relative Importance Multiplier Weight Weight % 5 1.1 0.14 14% 4.8 1.1 0.13 13% 4.4 1 0.11 11% 4.1 1 0.10 10% 3.9 1 0.10 10% 3.7 1 0.09 9% 3.4 1 0.09 9% 3.4 1 0.09 9% 3 1 0.08 8% 2.9 1 0.07 7%

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The participants were also asked how much they would be willing to pay for a flotation device. They were given a set of five different ranges, ranging from $0 to $400+. The average price range that participants are willing to pay is $100-$200. See Table 2 below.

Table 2: Survey Results Price Selection

With these specific customer features defined, a list of project objectives were defined as a way to obtain measurable data.

OBJECTIVES AND ENGINEERING CHARACTERISTICS

With the most important product features identified product feature objectives were chosen to achieve the proper design of said features. The objectives with their relative weights based on the customer survey can be found in Table 3 below with the specified product feature objectives.

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requirement. After the objectives were completed relative importance weights for each of the engineering characteristics were calculated and determined by the designer from greatest to least.

Table 4: Engineering Characteristics Weighted Importance

Relative Importance Weights %

13% 12% 11% 11% 10% 8% 8% 7% 7% 5% 4% 3% 2%

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CONCEPT GENERATION AND SELECTION

CONCEPT 1

The first concept show below in Figure 10 is a

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CONCEPT 2

The concept shown in Figure 12 is referred to as the

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CONCEPT 1

The first concept for the

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CONCEPT 2

The second concept for the

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PUGH’S WEIGHTED RATING METHOD

Table 5: Pugh's Weight Rating Method

Importance Weighted Weighted Weighted Weighted Rating Rating Rating Rating Weights % Rating Rating Rating Rating 14% 2 0.28 4 0.56 4 0.56 4 0.56 11% 2 0.22 3 0.33 3 0.33 4 0.44 13% 1 0.13 4 0.53 4 0.53 4 0.53 10% 2 0.20 3 0.30 3 0.30 3 0.30 7% 4 0.29 4 0.29 4 0.29 4 0.29 9% 3 0.26 2 0.17 3 0.26 3 0.26 10% 2 0.21 3 0.31 0 0.00 4 0.41 9% 2 0.19 3 0.28 3 0.28 3 0.28 9% 3 0.26 3 0.26 2 0.17 3 0.26 8% 2 0.15 2 0.15 2 0.15 3 0.23 100% 2.18 3.18 2.87 3.56

Rating Value Very Good 4 Good 3 Adequate 2 Just Tolerable 1 Unsatisfactory 0

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CALCULATIONS

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푉

퐹

= 62. 2.15

2 퐹

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= cos = 50 cos 60 푥′ 퐹 =푊25 .휃 푥′ 퐹 푥′ 퐹 = sin푙푏 = 50 sin 60 푦′ 퐹 = 43푊.3 휃. 푦′ 퐹 푦′ 퐹 푙푏

= cos = 3 cos 60 푥′ 퐹 =푊 1.5 .휃 푥′ 퐹 푥′ 퐹 = sin푙푏 n= 3 si 60 푦′ 퐹 = 2.푊59 휃. 퐹 퐹 푙푏

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Using the same equations as above the results are as follows:

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OVERALL DESIGN DETAILS OVERALL ASSEMBLY The components of this flotation device were designed to operate in a swimming pool environment. The main concern

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DRAWINGS

BILL OF MATERIALS

A completed Bill of Materials is located in Appendix G.

SPECIAL TREATMENT OF PARTS

As mention earlier all aluminum parts will be anodized with a heavy clear coat. The benefits to anodizing aluminum are listed below. (8)

• Durability. Most anodized products have an extremely long life span and offer significant economic advantages through maintenance and operating savings. Anodizing is a reacted finish that is integrated with the underlying aluminum for total bonding and unmatched adhesion. • Color Stability. Exterior anodic coatings provide good stability to ultraviolet rays, do not chip or peel, and are easily repeatable. • Ease of Maintenance. Scars and wear from fabrication, handling, installation, frequent surface dirt cleaning and usage are virtually non-existent. Rinsing or mild soap and water cleaning usually will restore an anodized surface to its original appearance. Mild abrasive cleaners can be used for more difficult deposits. • Aesthetics. Anodizing offers a large increasing number of gloss and color alternatives and minimizes or eliminates color variations. Unlike other finishes, anodizing allows the aluminum to maintain its metallic appearance. • Cost. A lower initial finishing cost combines with lower maintenance costs for greater long-term value. • Health and Safety. Anodizing is a safe process that is not harmful to human health. An anodized finish is chemically stable, will not decompose; is non-toxic; and is heat-resistant to the melting point of aluminum (1,221 degrees F.) • Since the anodizing process is a reinforcement of a naturally occurring oxide process, it is non-hazardous and produces no harmful or dangerous by-products.

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FABRICATION / ASSEMBLY

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n ee

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SCHEDULE AND BUDGET

SCHEDULE

The complete project schedule can be found in Appendix H. Table 7 below outlines all the deadlines for the project including design, fabrication, testing/modifications, and Tech Expo. It also shows, in green (on time) and orange (past due), the completion of the tasks as the actually happened.

Table 7: Planned Schedule vs. Actual Schedule Austin Sillie s Pool Float Oct 27 - Nov 2 - Nov 27 Oct Nov 3 - Nov 9 - 16 10 Nov - 23 17 Nov - 30 24 Nov - 7 1 Dec - 14 8 Dec - 21 15 Dec - 28 22 Dec 4 - Jan 29 Dec 11 Jan 5- Jan - 18 Jan12 - 25 19 Jan 1 - Feb 26 Jan - 8 2 Feb - 15 9 Feb - 22 16 Feb 1 - Mar 23 Feb - 8 2 Mar - 15 9 Mar - 22 16 Mar - 29 23 Mar 5 - Apr 30 Mar 6

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BUDGET

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RECOMMENDATIONS

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WORKS CITED 1. Kubik, Chris. Project Director. April 23, 2012. 2. Johnson, James, Johnson, Melanie and Johnson, Savannah. 10 1, 2013. 3. Seth, Radhika. Disadvantaged Little Tyke Can Swim! Yanko Design. [Online] 11 2, 2010. [Cited: 8 30, 2013.] http://www.yankodesign.com/2010/11/05/disadvantaged-little-tyke-can- swim/. 4. AbleData. Float Swimming Aid. AbleData. [Online] AbleData. [Cited: 9 5, 2013.] http://www.abledata.com/abledata.cfm?pageid=19327&top=12965&deep=1&trail=0&ksecti onid=0&startpage=1&orgid=0&discontinued=0. 5. Equiptment, Rifton. Rifton Pacer Gait Trainers. rifton. [Online] Rifton Equiptment, 2013. [Cited: 10 15, 2013.] http://www.rifton.com/products/mobility/pacergaittrainers/. 6. What does "Pounds of Buoyancy" Mean. Savvy Boater. [Online] http://www.savvyboater.com/s-92-what-does-pounds-of-buoyancy-mean.aspx. 7. Weight to Volume Conversion. aqua-calc. [Online] 2005. http://www.aqua- calc.com/calculate/weight-to-volume. 8. Council, Aluminum Anodizers. Aluminum Anodizers Council. Aluminum Anodizers Council. [Online] [Cited: October 30, 2014.] http://www.anodizing.org/Anodizing/benefits.html. 9. MatWeb. . ASM Aerospace Specification Metals INC. [Online] [Cited: October 15, 2014.] http://asm.matweb.com/search/GetReference.asp?bassnum=MA6061t6. 10. PRODUCTS, METRO FOAM. EVA FOAM. METRO FOAM. [Online] [Cited: OCTOBER 20, 2014.] http://metrofoam.com.au/eva-foam.html.

APPENDIX A - RESEARCH

Interview: Chris Kubik May We Help Project Director [email protected] 513.275.9975

I contacted May We Help about possible projects for my senior design project. I spoke with Chris Kubik project director at May We Help and

ucted by Chris.

Non Restrictive Interview: Johnson Family (James, Melanie and Savannah) Hands free 6637 Ambar Ave. Cincinnati, Ohio 45230 Stable Body Mass (513)272-3635 Ability to Swim I met with the Johnson family on Oct. 1st 2013. We discussed the features of the pool float for Savannah. Savannah is a 13 year old girl Non inflatable, but not with Cerebral Palsy (CP) she has pretty good function of her body completely rigid. and can speak clear as day. She really enjoys playing in the pool but is limited due to Nontherapeutic, it is a fun device.

Keep afloat

Flexible

the entire conversation so I have record of what was said.

Definition of Cerebral Palsy: a condition marked by impaired muscle coordination (spastic paralysis) and/or other disabilities, typically caused by damage to the brain before or at birth.

Move around The Little Mermaid Inflatable Pool Float - Prototype. Independently

Pedaled propulsion ------PROTOTYPE ------unit. - PURPOSE: To design a prototype of a swimming pool floating aid for children with mobility disabilities and children who use wheelchairs. The Little Mermaid is a personal floatation device that allows children to move around in the pool independently by rotating a hand cycle. A rotary pump inside the handle pumps water up through the hole of the floor of the hose inside the tube body by using the water pressure. The water comes through the hose inside the tube body and is sprayed through a nozzle to rotate the propeller in the rear of the float, moving the float forward.

The Little Mermaid – Inflatable pool float for wheel chair bound kids who have limited use of their legs.

Hyperlink: http://www.yankodesign.com/2010/11/05/ disadvantaged-little-tyke-can-swim/

Price: Prototype

The size is limited to smaller children

Pool Floats

There are a lot of different flotation devices out on the market today but non that support what I am trying to do with this project. They are simply modified lifejackets for different uses

Flotation pad for children that have very limited use of their physical self

Modified life jacket to keep people afloat.

These modified pool floats although effective can be very uncomfortable and very restricting to the users. In cases like the head float it doesn’t allow that individual to swim or have any part of their body out of water. Head floatation for people with handicaps to keep their head up so they don’t sink Very uncomfortable

Supportive

Gait Trainer Good Seat Design

Durable Designed for a wide range of clients with varying abilities, Rifton Pacer gait trainers provide outstanding support in learning to walk, maintaining momentum, Assistance in walking and building muscle skills. When appropriately supported and positioned in a Pacer, thousands of people of all ages have enjoyed the benefits of gait training such as Provides good improved cognition, muscle development, and skeletal growth. movement The Rifton Pacer gait trainer is renowned for its modular design, durability, and flexibility.

The Gait Trainer is a walking device for people with handicaps that have trouble walking. In the figure below it shows a child in the device but they can be used for adults as well. The Gait trainer is very similar to a regular walker but it is much more supportive. It has a seat the goes between the legs of the person and is strapped to the frame in 4 different locations.

of the person and support in certain locations that make the user feel comfortable.

Gait Trainer in Use

Devices like this one can be

very expensive, up to $2100.

Gait Trainer Seat

URL: http://www.rifton. com/products/mob ility/pacergaittrain ers/

APPENDIX B - SURVEY WITH RESULTS Pool Float for Children and Young Adults with Handicaps CUSTOMER SURVEY

Children and young adults with handicaps enjoy playing in the pool, but can be limited due to their disabilities. The Pool Float for children and young adults with handicaps will allow them to be more independent. The purpose of this survey is to gain a better understanding of customer features for a Pool Float to assist children and young adults with fun filled pool activities. How important is each feature to you for the design of a new Pool Float for Children with Handicaps?

Please circle the appropriate answer. 1 = low importance 5 = high importance Avg 1 2 3 4(1) 5(50) N/A 5.0 1 2(1) 3(5) 4(20) 5(25) N/A 4.4 1 2 3 4(9) 5(42) N/A 4.8 1 2(1) 3(13) 4(17) 5(18) N/A(2) 3.9 1(9) 2(3) 3(27) 4(6) 5(6) N/A 2.9 1(1) 2(4) 3(16) 4(19) 5(11) N/A 3.4 1 2(2) 3(6) 4(22) 5(20) N/A(1) 4.1 1(2) 2(4) 3(6) 4(28) 5(10) N/A(1) 3.7 1(6) 2(9) 3(6) 4(18) 5(12) N/A 3.4 1(4) 2(9) 3(22) 4(15) 5(1) N/A 3.0

How satisfied are you with the current Pool Floats for children with Handicaps? Please circle the appropriate answer. 1 = very UNsatisfied 5 = very satisfied Avg 1(3) 2(7) 3(10) 4(4) 5(1) N/A(26) 1.3 1 2(4) 3(16) 4(4) 5(1) N/A(26) 1.5 1(2) 2(7) 3(11) 4(4) 5(1) N/A(26) 1.4 1(6) 2(6) 3(9) 4(4) 5 N/A(26) 1.2 1 2(3) 3(17) 4(4) 5(1) N/A(26) 1.5 1(4) 2(5) 3(12) 4(4) 5 N/A(26) 1.3 1(2) 2(9) 3(9) 4(5) 5 N/A(26) 1.3 1(4) 2(5) 3(9) 4(5) 5(2) N/A(26) 1.4 1(8) 2(10) 3(5) 4(2) 5 N/A(26) 1.0 1(2) 2(2) 3(13) 4(7) 5(1) N/A(26) 1.5

How much would you be willing to pay for a Pool Float for Children with Handicaps?

APPENDIX C - QUALITY FUNCTION DEPLOYMENT (QFD)

Austin D. Sillies Pool Float for Childeren with Handicaps 9 = Strong 3 = Moderate 1 = Weak

313919999 9315 1.1 5.5 0.14 14% 1 3 3 9 9 3 9 1 9 1 4.6 1 4.6 0.12 12% 9 9 3 9 9 3 9 9 9 1 4.9 1.1 5.4 0.14 14% 1 3 3 1 1 3 3 1 3.0 0.08 8% 1 3 3 9 3 1 3 3 1 3.0 0.08 8% 93313 331 331 3.4 1 3.4 0.09 9% 3 1 3 9 3 9 3 4.1 1 4.1 0.10 10% 3 5 3 9 3 1 9 3 3.3 1 3.3 0.08 8% 1 5 3 3 9 3 9 1 9 3 9 4 1 4.0 0.10 10% 3 1 3 3 1 9 1 3.3 1 3.3 0.08 8% 3.03 1.48 3.51 4.38 4.95 4.54 3.61 2.10 5.43 0.85 4.90 2.82 1.70 43.3 39.6 1.0 1.0 0.07 0.03 0.08 0.10 0.11 0.10 0.08 0.05 0.13 0.02 0.11 0.07 0.04 1.0

APPENDIX D – OBJECTIVES

APPENDIX E: PART DETAILS

APPENDIX F: MATERIAL DETAILS

Physical Properties Metric English Comments

Density 2.7 g/cc 0.0975 lb/in³ AA; Typical

Mechanical Properties

Hardness, Brinell 95 95 AA; Typical; 500 g load; 10 mm ball Hardness, Knoop 120 120 Converted from Brinell Hardness Value Hardness, Rockwell A 40 40 Converted from Brinell Hardness Value Hardness, Rockwell B 60 60 Converted from Brinell Hardness Value Hardness, Vickers 107 107 Converted from Brinell Hardness Value

Ultimate Tensile Strength 310 MPa 45000 psi AA; Typical

Tensile Yield Strength 276 MPa 40000 psi AA; Typical

Elongation at Break 12 % 12 % AA; Typical; 1/16 in. (1.6 mm) Thickness

Elongation at Break 17 % 17 % AA; Typical; 1/2 in. (12.7 mm) Diameter

Modulus of Elasticity 68.9 GPa 10000 ksi AA; Typical; Average of tension and compression. Compression modulus is about 2% greater than tensile modulus.

Notched Tensile Strength 324 MPa 47000 psi 2.5 cm width x 0.16 cm thick side-notched specimen, Kt = 17.

Ultimate Bearing Strength 607 MPa 88000 psi Edge distance/pin diameter = 2.0

Bearing Yield Strength 386 MPa 56000 psi Edge distance/pin diameter = 2.0 Poisson's Ratio 0.33 0.33 Estimated from trends in similar Al alloys.

Fatigue Strength 96.5 MPa 14000 psi AA; 500,000,000 cycles completely reversed stress; RR Moore machine/specimen

Fracture Toughness 29 MPa-m½ 26.4 ksi-in½ KIC; TL orientation.

Machinability 50 % 50 % 0-100 Scale of Aluminum Alloys

Shear Modulus 26 GPa 3770 ksi Estimated from similar Al alloys.

Shear Strength 207 MPa 30000 psi AA; Typical

Electrical Properties

Electrical Resistivity 3.99e-006 ohm-cm 3.99e-006 ohm-cm AA; Typical at 68°F

Thermal Properties

CTE, linear 68°F 23.6 µm/m-°C 13.1 µin/in-°F AA; Typical; Average over 68-212°F range.

CTE, linear 250°C 25.2 µm/m-°C 14 µin/in-°F Estimated from trends in similar Al alloys. 20-300°C.

Specific Heat Capacity 0.896 J/g-°C 0.214 BTU/lb-°F

Thermal Conductivity 167 W/m-K 1160 BTU-in/hr-ft²-°F AA; Typical at 77°F Melting Point 582 - 652 °C 1080 - 1205 °F AA; Typical range based on typical composition for wrought products 1/4 inch thickness or greater; Eutectic melting can be completely eliminated by homogenization.

Solidus 582 °C 1080 °F AA; Typical

Liquidus 652 °C 1205 °F AA; Typical

Processing Properties

Solution Temperature 529 °C 985 °F

Aging Temperature 160 °C 320 °F Rolled or drawn products; hold at temperature for 18 hr

Aging Temperature 177 °C 350 °F Extrusions or forgings; hold at temperature for 8 hr

APPENDIX G: BILL OF MATERIALS

APPENDIX H: SCHEDULE

Austin Sillie s Pool Float Sep 29-Oct 5 29-Oct Sep - 12 6 Oct - 19 13 Oct - 26 20 Oct 2 - Nov 27 Oct Nov 3 - Nov 9 - 16 10 Nov - 23 17 Nov - 30 24 Nov - 7 1 Dec - 14 8 Dec - 21 15 Dec - 28 22 Dec 4 - Jan 29 Dec 11 Jan 5- Jan - 18 Jan12 - 25 19 Jan 1 - Feb 26 Jan - 8 2 Feb - 15 9 Feb - 22 16 Feb 1 - Mar 23 Feb - 8 2 Mar - 15 9 Mar - 22 16 Mar - 29 23 Mar 5 - Apr 30 Mar - 12 6 Apr 19 13- Apr - 26 20 Apr 9

APPENDIX I – ACCURACY/QUALITY