MECH 311. Manufacturing Processes Laboratory Manual. Concordia University Fall Course Instructors: Dr. Packirisamy Dr.

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1 MECH 311 Manufacturing Processes Laboratory Manual Concordia University Fall 2014 Course Instructors: Dr. Packirisamy Dr. Cheung Lab Instructor: Michael Rembacz

2 Table of Contents MECH 311 Manufacturing Processes Laboratory... 3 LAB CONTENT... 3 Marking... 3 Pre-Lab Safety Quiz... 3 Lab Introduction... 4 Metrology... 7 Metrology Examples... 7 Inspection of Gyroscope components... 8 Lab Sequence Pre-Lab Instructional Video - How to use the Mill Mill Operating Quiz Instructional Video Gyroscope Frame Part Lab Machining Frame Part Pre-Lab Instructional Video - How to use the Lathe Lathe Operating Quiz Instructional Video Gyroscope Rotor Lab Machining Rotor Machining Shaft Pre-Lab Instructional Video Gyroscope Frame Part How to use the Drill Press Instructional Video Drill Press Operating Quiz Lab Machining Frame Part Machining Ring

3 Pre-Lab Lab Welding Gyroscope Stand Welding Safety Pre-Lab Lab Advanced Manufacturing Demonstrations Lab Exam Useful Documents

4 MECH 311 Manufacturing Processes Laboratory LAB CONTENT Marking Quizzes Item Grade Total Weight Safety Quiz 5 Mill Operating Quiz 5 Lathe Operating Quiz 5 Drill press Operating Quiz 5 Inspection Quiz 10 Assignment #1 Drawings 15 Assignment #2 Process Sheet Frame Part 1 6 Assignment #3 Process Sheet Rotor 6 50 Assignment #4 Process Sheet Shaft 6 Assignment #5 Process Sheet Frame Part 2 6 Assignment #6 Process Sheet Ring 6 Assignment #7 Inspection report of student made components 5 Assignment #8 Assembly Drawing and B.O.M 10 Assignment #9 Assembly Procedure 5 Manufacturing Evaluation Instructor / TA evaluation of completed assembly Assignments Lab Exam Notes: Validating the students ability to derive processes for unique parts. During Lab #6 1.5 hours Total In order to obtain full marks on a specific quiz, the student must pass (obtain 100%) on the first attempt. Each following attempt will result in a deduction of 0.5% of that specific quiz until the student has attained a grade of 100%. 2. Student must have passed the required quizzes before the specified labs. If not, they will not be able to participate in the lab and therefore not be able to manufacture their parts. Pre-Lab1 Safety Quiz Access the EDML Moodle metasite and read CON-EDML-004. Complete the Mandatory Safety Quiz with minimum grade of 100%. You must attain a grade of 100% before participating in Lab 2. Follow the link below for instructions on how to access the quiz. Follow the instructions on the M311 Laboratory Moodle page to complete the safety quiz. 3

Lab 1 Introduction What is the EDML? The Engineering Design and Manufacturing Laboratories [EDML] are the heart of manufacturing in Concordia s Mechanical and Industrial Engineering department.

Protocols are in place to establish a clear way for students, at all levels, to have the opportunity to work with professional industrial quality machinery.

5 Lab 1 Introduction What is the EDML? The Engineering Design and Manufacturing Laboratories [EDML] are the heart of manufacturing in Concordia s Mechanical and Industrial Engineering department. Renovated in 2007, the facility is divided into two areas, EDML A [advanced] and EDML B [basic], located in the Hall Building. The space is designed with emphasis on safety and efficiency. Protocols are in place to establish a clear way for students, at all levels, to have the opportunity to work with professional industrial quality machinery. Exposure and even access to advanced CNC and CMM machinery is possible! While the primary mission of the EDML is to provide undergraduate manufacturing support, it also serves as an example of excellence and provides space and support for all levels of students to attain their manufacturing objectives. During fall and winter, courses such as MECH 311 (Manufacturing Processes) and MECH 490 (Capstone Mechanical Engineering Design Project) make heaviest use of the facility and outside these courses, graduate, post graduate and extracurricular student organizations are given opportunities for training, access and service. To pursue this mission, the EDML is equipped with three CNC mills, one CNC Lathe, four conventional mills, three conventional lathes, sheet metal facilities, welding facilities and other machinery typical for a metal working environment including, but not limited to, hand tools, grinders, band saws and drill presses. The student side of the EDML, located in H-0024 (EDML B), is open to students from within the faculty, working on course related design projects, as well as extra-curricular projects, such as Concordia s Formula and BAJA SAE vehicles. It is important to understand the manufacturing processes involved in the design and fabrication of a component as an improperly designed part normally results in increased costs, wasted material and wasted time. By understanding these processes, the engineer can make choices in his or her design to reduce costs, reduce waste, and facilitate the fabrication of a component. 4

6 For example, an engineer is tasked with designing a sealed box. The engineer decides to make it out of steel, and to weld it from the inside. He or she takes it to the machine shop, where the designs are rejected because it is impossible to weld inside a sealed box. Had the engineer understood the process of welding, he or she would have been able to avoid this costly mistake, in terms of downtime and resources. What is MECH 311? Introduction to the gyroscope. The lab component of MECH 311 Manufacturing Processes is a hands-on laboratory whereby students are provided with the means to learn various machining techniques and processes from milling, drilling, turning, facing, welding and much more. The objective of this lab is to help these students better understand the processes involved when manufacturing as well as provide them with a simple engineering assembly to fabricate and assemble from the beginning of design, through manufacturing till the final assembly. The gyroscope that we produce in this lab is a simplified model of a traditional gyroscope modified to suit different manufacturing needs taught in this course. A breakdown of the gyroscope assembly can be seen on the components board in the EDML B staging area or in the figure below. 5

7 Safety Checklist (Students MUST comply with all items listed below before entering each lab session. Students must supply their own glasses /proper shoes / clothing for this lab.) Safety Quiz Safety glasses(correct CSA certification) Closed toe shoes (No sandals, flip-flops, etc. as per CON-EDML-004) Old clothes / Lab coat / Coveralls (you will get dirty!) No loose clothing No shorts or skirts No dangling jewellery / rings No cell phones Tie up long hair No food or drink allowed in the lab Completed assignments 6

8 Metrology Open ipad to access EDML APP and go through the metrology section. Complete examples when done. Metrology Examples Answer: Answer: Once complete, ask your instructor or teaching assistant to verify your answers. Answer: Answer: Once complete, ask your instructor or teaching assistant to verify your answers. 7

9 Inspection of Gyroscope components Measure Existing Gyroscope Now that you have been exposed to basic measuring principles, you are required to fill in the missing dimensions indicated on the following drawings. Fill in Missing Dimensions You will be provided with a digital caliper, and will use this device to record all the missing dimensions on the technical drawings of the gyroscope components. Do s and Don ts of Using a Digital Caliper Do: Don t: Treat your caliper with respect, it is a delicate instrument Turn off caliper after use to preserve battery Place caliper in its protective case / box when not in use Unlock the set screw before opening the jaws Use your caliper as a scriber (i.e. to scratch or mark a surface) Drop or mistreat / abuse your caliper Force the jaws of the Vernier caliper open (check the set screw prior to use) Lay your caliper in a dangerous position, where it could fall Set it down in a dirty environment, as any foreign object debris (FOD) could damage the instrument, and subsequently your measurements. Lay your caliper in coolant as this will distort the measurements. 8

10 Table 1. Dimensions for Gyroscope Frame DO NOT ASSUME SYMMETRY Dimension Value Dimension Value

11 FIGURE 13. SKETCH OF GYROSCOPE ROTOR Table 2. Dimensions for Gyroscope Rotor Dimension Value

12 FIGURE 24. SKETCH OF GYROSCOPE SHAFT Table 3. Dimensions for Gyroscope Shaft Dimension Value Dimension Value (Outer Diamter) (Countersink Max Diam.) Once completed, please ensure to have your instructor or TA sign the data sheets. You will use this data to complete the required technical drawings due for Lab #2. Assignment #1 Assignment #1 is to create technical drawings of the three measured components. First draft due lab 2, final draft due Lab #6. Each technical drawing must include: Parts must be drawn using a 3D CAD software. Then 2D technical drawings will be generated. Minimum 2 views Sufficient dimensions detailing all aspects of the parts Correct use of the Concordia titleblock (see below) Correct scale (1:1) Proper drawing standards as per MECH 211 and MECH 313 (ASME Y14.5) Correct Units Drawing requirements and examples are located on the Engineering Design and Manufacturing Lab (EDML) Metasite on Moodle. 11

13 Lab Sequence The lab groups are divided into two sub sequences, A and B. This alternates based on when the student will machine the frame or the rotor, shaft and ring. Your sequence will be assigned during Lab #1. Pre-Lab 2 If you are in Sequence A, follow the labs in this order: 1, 2, 3, 4, 5 & 6 If you are in Sequence B, follow the labs in this order: 1, 3, 2, 4, 5 & 6 Instructional Video - How to use the Mill Introduction to the milling machine (anatomy) 3 Axis movement + Quill (Digital Readout) Guarding and Lighting Starting and Stopping Procedures Changing Speeds and Gears Installing / Removing Tools Work Holding (Vice, parallels, vice handle) Establishing reference points. (edge finder) Cutter Direction (Climb vs Conventional Milling) Mill Operating Quiz Quiz to determine level of student capability. You must attain a grade of 100% to attend the lab. Instructional Video Gyroscope Frame Part 1 Watch Video on how-to machine Frame (Part 1) Take notes! Steps, tools, speeds Student Requirements Make notes / process sheet from demonstration to be used during the manufacturing. Process sheet form is on the EDML Moodle page in useful documents page. Excel form to be used. Assignment #1 Technical Drawings due for revision Lab #2 Resources Instructional Video - How to use the Mill and Mill Operating Test Moodle Gyroscope Frame Part 1 Video Moodle Process Sheet Template and Examples EDML Moodle 12

14 Lab 2 Machining Frame Part 1 Instructor / TA demonstration Students add to notes taken from pre-lab video. Student manufacturing Cleaning Student Requirements Have instructor or TA verify process sheet before leaving Pre-Lab 3 Instructional Video - How to use the Lathe Introduction to the lathe 2 Axis movement + Compound Rest (Digital Readout) Tailstock Guarding and Lighting Starting and Stopping Procedures Changing Speeds (Gears) Installing / Removing Tools (tool post & Tailstock) Work Holding (3 Jaw Chuck) Establishing reference points. Direction of Rotation (Cutter orientation) Lathe Operating Quiz Quiz to determine level of student capability. You must attain a grade of 100% to attend the lab. Instructional Video Gyroscope Rotor Watch Video on how-to machine rotor - Take notes! Steps, tools, speeds Student Requirements Make notes / process sheet from demonstration to be used during the manufacturing. Process sheet form is on the EDML Moodle page in useful documents page. Excel form to be used. Resources Instructional Video - How to use the Lathe Moodle Gyroscope Rotor Video Process Sheet Template and Examples Assignment #2 Frame Part 1 process sheet due at the beginning of Lab #3 13

15 Lab 3 Machining Rotor Instructor/TA demonstration Students to add to notes taken from pre-lab video. Student manufacturing Cleaning Machining Shaft Instructor/TA demonstration Student manufacturing Cleaning Student Requirements Have TA verify process sheet before leaving Pre-Lab 4 Instructional Video Gyroscope Frame Part 2 Watch Video on how-to machine Frame (Part 2) How to use the Drill Press Instructional Video Watch video on operating the drill press and how-to for drilling processes done in the lab. Drill Press Operating Quiz Quiz to determine level of student capability. Must get 100% to attend the lab. Student Requirements Make notes / process sheet from demonstrations for Frame part 2. Resources Instructional Video - How to use the Mill Moodle Gyroscope Frame Part 2 Video Moodle Drill Press Operating Test Moodle Process Sheet Template and Examples EDML Moodle Assignments #3 & 4 Rotor and Shaft process sheets due at the beginning of Lab #4 Lab 4 Machining Frame Part 2 Instructor/TA demonstration Students to add to notes taken from pre-lab video. Student manufacturing Frame Polishing (optional) Cleaning 14

16 Machining Ring Instructor/TA demonstration Student manufacturing Cleaning Student Requirements Have instructor or TA verify process sheet before leaving Pre-Lab 5 Assignment#5 and 6 Frame Part 2 and Ring process sheets due at the beginning of Lab #5 Assignments #7 Inspection reports due at the beginning of Lab #5 Lab 5 CNC Demo See pocketing process on frame and how a CNC Mill operates (20 minutes) CNC Demonstration of Frame and Rotor on CNC Mill and Lathe Assembly Final Assembly of Gyroscope Introduction to hand tools (30 minutes) Manufacturing Evaluation of completed gyroscope. Testing Spinoff! Measure time of how long the gyroscope would spin. (15 minutes) Welding MIG welding of stand. (25 minutes per group of 4) (2 x 25 = 50 minutes) Overall lab conclusion and final report overview (5 minutes) Welding Gyroscope Stand Students will also be able to fabricate a stand for the gyroscope using a GMAW welding process. The stand will consist of three parts that will be held in a welding fixture to assure consistency and repeatability. See figure 65 below for the welding drawing of the gyroscope stand. 15

17 Welding Safety Welding and brazing causes harmful ultraviolet light, radiation and high heat. Do not look at the light from welding or brazing without wearing the proper welding mask. You will cause damage to your eyes even if you catch a flash of light from welding. Welding and brazing causes harmful fumes. Only weld or braze with proper ventilation turned on. Welding and brazing causes sparks of molten metal; ensure that you have the proper clothing if you are near someone welding. Large amounts of heat build-up which last a long time in the workpiece, table, welding gun, etc. Make sure you handle all the parts and tools with proper gloves and take care not to lean, step on or pick-up any hot parts Welding uses high voltage! Ensure that you are not touching any part of the electrode before you start welding. Proper safety equipment is needed when welding, which includes: Apron Safety glasses Proper ventilation Helmet (with proper shade of lens) Gloves Pre-Lab 6 Assignments #1 Final submission of technical drawings due at the beginning of lab #6. These final drawings to be submitted will reflect the dimensions of the parts you have made. Drawing dimensions must match the inspection dimensions. Assignments #8 Assembly drawing and Bill of Materials are due at the beginning of lab #6. Bill of Materials (BOM) is a list of all components required to assemble the final product. Include: quantity, was part purchased or fabricated, drawing number of fabricated parts, description of parts, etc. The BOM can be included on the assembly drawing if it fits. Assembly drawing is a view of the gyroscope with all the components shown as they go together. (ie. fully assembled) Each component should be labeled with a number which corresponds to the same number on the bill of materials. Assembly drawings typically only have overall dimensions of the assembly and do not have all the dimensions from the working drawings, although dimensions are not always required on assembly drawings. Sufficient assembly views should be included to ensure all components are clearly indicated. 16

18 Assignments #9 Assembly Procedure is a detailed step by step guide for workers on how to assemble the product. Imagine you are writing these steps for someone that has never seen it before. Instructions, images and task explanations are examples of what can be included in the assembly procedure. Lab 6 Advanced Manufacturing Demonstrations The advanced manufacturing demonstrations will go through various different processes of workholding and manufacturing of the mill and the lathe. Possible techniques include but are not limited to: Mill Lathe Clamping work piece to the table Clamping Kit Machining round features using a rotary table How to clamp a circular work piece in the vise or on the table. How to use a dividing head Turning with a center support External Threading Taper Turning Boring Lab Exam (1.5 hours) The lab exam will test the students ability in analyzing two work pieces, and determining the processes on how they should be manufactured. Each process must be detailed to provide suitable information for someone to manufacture the described components. Useful Documents Please visit the useful documents heading of the EDML Moodle website for all forms, templates required for this lab. 17

Name: Machine Tool Technology ( )

Name: Machine Tool Technology (58.0501) Directions: Evaluate the student by checking the appropriate number to indicate the degree of competency. Rating Scale (0-6): 0 No Exposure no experience/knowledge