GEORGI INSTITUTE OF TECHNOLOGY George W. Woodruff School of Mechanical Engineering ME 2110 Creative Decisions and Design Fall 2010 Studio 3b - Machining In order to successfully design and build a product, you must understand the capabilities of the supplies at your disposal. For example, you must understand how motors and sensors work. Furthermore, you must have knowledge of manufacturing processes, such as machining with milling machines and water-jet cutting machines. This project will help you develop an understanding of the basic machining principles, and will introduce you to three specific processes: a) milling, b) turning and c) water-jet cutting. In this studio, you will be tasked to machine and build a winch assembly. The winch will be tested in a competition environment against the other students in your studio. Details of this competition will be disclosed in Studio Handout 3c. You will create three components, shown in the drawings at the end of this handout. The bearing block is a rectilinear piece that you will make on the mill. The spool is a cylindrical piece that you will make on the lathe. You will draw the motor mount plate electronically, in either utocd or OMX Layout, and it will be cut on the water jet machine. The bearing block and spool will be made out of Delrin, and the motor mount plate will be made out of 1/8 -thick aluminum sheet. Part 1 Bearing Block 1) Use the mill to machine one end of the square Delrin stock to create a perpendicular face. Use side milling with the workpiece horizontal. Remove as short of a section as needed to create a fully perpendicular surface. 2) On the other end of the stock, use side milling to machine the workpiece to length. 3) Remove the cut-out rectangular section of the part. Use face milling with an axial depth of cut no greater than 0.050. Multiple horizontal and vertical passes will be needed. 4) Drill a hole in the full-thickness segment of the workpiece using the 9.00 mm drill bit in the machining kit. TIP: Mark the hole location using the calipers to score the surface at the desired dimension. djust the calipers to the desired dimension from the workpiece edge and lock using the locking screw. With one inside edge of the caliper against the workpiece edge, lightly drag the free caliper tip along the surface to create a score line. This must be done from two surfaces to create intersecting lines at the hole location. 5) Drill a hole in the reduced-thickness segment of the workpiece using the 3/16 drill bit.
Part 2 Spool 1) Chuck the round Delrin stock into the lathe by tightening the chuck teeth onto the outside diameter without butting the end against the chuck face. Turn the lathe on at a low speed and check for concentric rotation. 2) t the appropriate speed for cutting, face the free end of the workpiece to create a perpendicular end surface. Remove as little material as necessary to create a perpendicular surface. 3) Remove and re-chuck the workpiece such that the new perpendicular surface is butted against the chuck face. 4) Face the workpiece to length by using an axial depth of cut no greater than 0.015. 5) Turn the workpiece s diameter to create the longer side of the spool. Use radial depths of cut no more than 0.015 which will remove 0.030 from the diameter. Be sure to account for the 2 different diameter sections. 6) Flip the piece over in the chuck and fixture it by clamping to the 1.125 L x 0.425 OD section. Use the appropriate clamping force such not to severely damage the workpiece surface. 7) Turn the free end to create the 2 different diameter sections on the short side of the spool. Part 3 Motor Mount Plate Each person will be required to produce one motor mount plate. The plate itself will be produced using the OMX water-jet cutter, and will be attached to the body of the winch. The plate may also be used in your machine for the final ME 2110 project. The plate will be cut out of 1/8-inch thick aluminum. In order to cut an object on the water jet, the design must be created in utocd or OMX Layout (provided in the ME 2110 computer lab). If created in utocd, the design must be saved as a 2007.dxf file and imported into OMX Layout. Procedure: 1) Open OMX Layout and go to File > Import from other CD and select the.dxf file of your drawing. (lternatively you can draw the part in OMX Layout using the drawing tools provided in this software). 2) Make sure to delete any lines or features that will not be cut by the water-jet machine. 3) On the Special tool bar on the right side of the screen, click Clean. Keep all default options and additionally select the Remove unnecessary dots option. 4) Use the Measure tool at the bottom of the screen to make sure your part is the correct size. If it is not, select all lines and click on the Size icon on the left side of the screen to apply the appropriate scale factor. 5) Save the.dxf file (this is one of the files you will submit as a deliverable). 6) IMPORTNT STEP: Right click on the Quality icon at the bottom of the screen and select ll. Left click on the 3 icon. Note that all lines should turn purple. 7) Right click on the Lead I/O icon on the left side of the screen and select utopath (dvanced and Configure). Leave all options as default and click on the utopick
button. Click OK to continue. If you get an error message, make sure you have completed Step 6. 8) Click on the Path icon on the right side of the screen. new window will pop up and a prompt will tell you to pick the starting point. Click at the beginning of the green line. The tool path will be shown as a red line, displaying where material will be cut out. Double check to make sure that the tool path is correct. 9) On the bottom right side of the screen, click the small Render as Solid button to see how the part will look when finished. 10) Still in on the popup window, click on save to save the.ord file that will be used by the water-jet cutter to make the part (this is the other file you must submit as a deliverable). Studio Deliverables: The studio deliverables are summarized in the following Table. Week 5 Deliverables due at the beginning of studio Week 6 (9/28) Deliverables due at the beginning of studio Week 7 (10/5) Deliverables due at the beginning of studio Week 8 (10/12) First Week in Computer Lab Motor mount plate drawing, Three completed and verified mechatronics tasks in list One machined component ll 5 mechatronics tasks (Lists or B), Both machined components, and PBSIC program for winch operation First Week in Machine Shop One machined component Motor mount plate drawing Three completed and verified mechatronics tasks in list B This studio is pass/fail. You must complete the assigned tasks to pass the course.
GT - ME 2110 Bearing Block REV. SHEET 1 OF 1 1.0 (nominal) 0.354 0.01 9 mm Drill Bit C 1.0 (nominal) 2.00 1.00 0.1875 0.01 3/16" Drill Bit C 0.250 C-C DIMENSIONS RE IN INCHES TWO PLCE DECIML 0.01 THREE PLCE DECIML 0.005 Break all edges unless otherwise specified MTERIL Delrin SIZE DWG. NO. SCLE 1:1
90 Thread # 6-32 B-B GT - ME 2110 Spool REV. SHEET 1 OF 1 2.50 1.375 0.375 1.125 B 0.1065 #36 Drill Bit 0.750 1.0 (nominal) B 0.425 h7 0.02 0.350 h9 DIMENSIONS RE IN INCHES TWO PLCE DECIML 0.01 THREE PLCE DECIML 0.005 MTERIL Delrin Break all edges unless otherwise specified SIZE DWG. NO. SCLE 1:1
SCLE 1:1 GT - ME 2110 Motor Mount REV. SHEET 1 OF 1 2.000 0.1875 0.125 R 0.098 0.196.250 1.250 1.221 0.118 3 holes on P.C.D. Ø1.221 1.024 DIMENSIONS RE IN INCHES R1.000 MTERIL l-6061 Sheet SIZE DWG. NO. SCLE 2:1
MCHINE SHOP SFETY LWYS WER SFETY GLSSES Even when you are not working on a machine, you must wear safety glasses. chip from a machine someone else is working on could fly into your eye. MCHINING Follow directions. If you don t know how to do something, ask. Before you start the machine: Study the machine. Know which parts move, which are stationary, and which are sharp. Double check that your workpiece is securely held. Remove chuck keys and wrenches. Do not leave machines running unattended. Clean up machines after you use them. dirty machine is unsafe and uncomfortable to work on. Do not use compressed air to blow machines clean. This endangers people's eyes and can force dirt into machine bearings. Report all broken or non-working machines. CLOTHING, JEWELRY, ND HIR Wear long pants (to your shoes). Wear short sleeves or roll up sleeves. Wear closed toe shoes and socks. Remove all jewelry - watches, bracelets, rings, necklaces, dangling earrings. Long hair or beards must be tied back. If your hair is caught in spinning machinery, it will be pulled out if you're lucky. If you're unlucky, you will be pulled into the machine. No ties, scarves, and dangling clothes. SFE CONDUCT IN THE MCHINE SHOP Be aware of what's going on around you. For example, be careful not to bump into someone while they're cutting with the bandsaw (they could lose a finger!). Concentrate on what you're doing. If you get tired, leave. Don't hurry. If you catch yourself rushing, slow down. Don't rush speeds and feeds. You'll end up damaging your part, the tools, and maybe the machine itself. Listen to the machine. If something doesn't sound right, turn the machine off. Don't let someone else talk you into doing something dangerous. Don't attempt to measure a part that's moving. No fooling around. VIOLTIONS OF THESE RULES WILL RESULT IN IMMEDITE REMOVL