MECH 311 Course plan for MECH 311 Manufacturing Processesusers.encs.concordia.ca/~m_rembac/M311 Lab...

Concordia University

Summer 2013

Course Instructor:

Dr. Cheung

Lab Instructor:

Michael Rembacz

MECH 311

Course plan for MECH 311 – Manufacturing Processes

Laboratory

1

Table of Contents LAB CONTENT ................................................................................................................................................ 3

Marking ..................................................................................................................................................... 3

Pre-Lab1 .................................................................................................................................................... 3

Safety Quiz ............................................................................................................................................ 3

Lab 1 .......................................................................................................................................................... 4

Introduction .......................................................................................................................................... 4

Metrology .............................................................................................................................................. 7

Inspection of Gyroscope components ................................................................................................ 12

Lab Sequence .......................................................................................................................................... 16

Pre-Lab 2 ................................................................................................................................................. 16

Instructional Video - How to use the Mill ........................................................................................... 16

Mill Operating Quiz ............................................................................................................................. 16

Instructional Video – Gyroscope Frame Part 1 ................................................................................... 16

Lab 2 ........................................................................................................................................................ 17

Machining Frame Part 1 ...................................................................................................................... 17

Pre-Lab 3 ................................................................................................................................................. 17

Instructional Video – Gyroscope Frame Part 2 ................................................................................... 17

How to use the Drill Press Instructional Video ................................................................................... 17

Drill Press Operating Quiz ................................................................................................................... 17

Lab 3 ........................................................................................................................................................ 17

Machining Frame Part 2 ...................................................................................................................... 17

Pre-Lab 4 ................................................................................................................................................. 18

Instructional Video - How to use the Lathe ........................................................................................ 18

Lathe Operating Quiz .......................................................................................................................... 18

Instructional Video – Gyroscope Rotor ............................................................................................... 18

Lab 4 ........................................................................................................................................................ 18

Machining Rotor Part 1 ....................................................................................................................... 18

Pre-Lab 5 ................................................................................................................................................. 19

Lab 5 ........................................................................................................................................................ 19

Machining Rotor Part 2 ....................................................................................................................... 19

Pre-Lab 6 ................................................................................................................................................. 19

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Lab 6 ........................................................................................................................................................ 19

Computer Numerically Controlled Machining (CNC) .......................................................................... 19

Final Assembly..................................................................................................................................... 19

Welding Gyroscope Stand ................................................................................................................... 20

Welding Safety .................................................................................................................................... 20

Final Report ............................................................................................................................................. 21

Useful Documents ....................................................................................................................................... 22

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LAB CONTENT

Marking

Item % Total

Qu

izze

s Safety Quiz 5

20 Mill Operating Quiz 5

Lathe Operating Quiz 5

Drill press Operating Quiz 5

Ass

ign

me

nts

Assignment #1 – Drawings Grades given in final report. Participation

marks deducted if not completed on

time.

Assignment #2 – Process Sheet – Frame Part 1

Assignment #3 – Process Sheet – Frame Part 2

Assignment #4 – Process Sheet – Rotor

Assignment #5 – Process Sheet – Shaft

Assignment #6 – Process Sheet – Ring

Fin

al R

ep

ort

Drawings resubmission with corrections 21

80

Process sheets resubmission with corrections 34

Final component and assembly drawing 8

Inspection report of student made components 10

Sample calculations of selected process sheet line for all required values. 7

Total Grade 100

Total Lab Participation 30

[(𝑇𝑜𝑡𝑎𝑙 𝐺𝑟𝑎𝑑𝑒) 𝑥 70% ] + [𝑃𝑎𝑟𝑡𝑖𝑐𝑖𝑝𝑎𝑡𝑖𝑜𝑛 𝐺𝑟𝑎𝑑𝑒] = 𝐹𝑖𝑛𝑎𝑙 𝐿𝑎𝑏 𝐺𝑟𝑎𝑑𝑒

Notes:

1. 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 section until

the student has attained a grade of 100%.

2. Students 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.

3. Participation grades are earned by attending labs, on time and submitting all required

assignments.

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.

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Lab 1

Lab #1 will be in the EDML B staging area with to introduce the students to the EDML and the MECH 311

lab. Attendance is mandatory.

Each student will be equipped with:

Traditional Vernier caliper

Digital Vernier caliper

Micrometer

Frame

Rotor

Shaft

Assembly and components board is available at the center of the table.

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 (see figures belowError! Reference source not found.).

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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.

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.

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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

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 dangling jewellery / rings

No cell phones

Tie back long hair

Completed material from previous classes (if applicable)

No food or drink allowed in the lab

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Metrology

Metrology is a very important part of the design and manufacturing process. Unless numerical values

are specified and measured, one cannot ensure proper fitment between parts. No part can be made

without some form of measurement. In the next section of this lab, you will be introduced to a scale of

measurement used commonly in engineering and manufacturing environments.

Introduction to Vernier Scale

Pierre Vernier (1580-1637) in 1631 invented the linear scale. This scale is one of the simplest to use for

measurement, and offers a fine discrimination. The Vernier scale is used in all modern measuring

devices. Two instruments we will be covering are the Vernier caliper and Micrometer, both of which use

a form of the Vernier scale.

Introduction to Vernier Caliper

The modern Vernier caliper, as shown in the figure above, was invented by Joseph R. Browning and his

father (Fundamentals of Dimensional Metrology 3rd Ed p. 106). Browning went on to form Brown &

Sharp Manufacturing Co., which today is one of the major manufacturers of measuring instruments and

tooling. The Vernier caliper is one of the most versatile measuring tools used by engineers and

machinists. The caliper can be used to measure the following features: linear distances / outside

diameters, internal diameters, and depth.

The steps to measure a part with the Vernier caliper are outlined in the figure below.

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How to read the Vernier caliper

Notes

The zero reference on

the Vernier scale.

Main scale

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Based on what you have just learned, determine the following Vernier caliper readings?

Answer: Answer:

Once done, ask your instructor or teaching assistant to verify your answers.

How to use Micrometer

The micrometer caliper is another tool using a derivative of the Vernier scale. Owing to their different

geometry, micrometers are able to achieve a higher precision than Vernier calipers. The micrometer

uses screw threads in place of a movable jaw. There are many types of micrometers, such as the caliper,

inside micrometer, depth micrometer, etc. The micrometer, however, is less versatile than the Vernier

caliper because each micrometer has a fixed measuring range, normally up to 1”. For example, if you

wanted to measure a 2.50” part, you would need a 2”-3” micrometer. If the part was .50”, then you

would need a 0”-1” micrometer.

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The steps to measure a part with the micrometer caliper are outlined in the figure below.

Additionally, your micrometer may be equipped with a Vernier scale, potentially measuring to 4 decimal places (i.e. one ten thousandth of an inch), see figure below.

11

Based on what you have just learned, determine the following micrometer caliper readings.

Answer: Answer:

Once done, ask your instructor or teaching assistant to verify your answers.

12

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 Vernier 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:

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

Don’t:

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.

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Table 1. Dimensions for Gyroscope Frame

Dimension Value Dimension Value

1 12

2 13

3 14

4 15

5 16

6 17

7 18

8 19

9 20

10 21

11 22

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Table 2. Dimensions for Gyroscope Rotor

Dimension Value

1

2

3

4

5

6

7

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Table 3. Dimensions for Gyroscope Shaft

Dimension Value Dimension Value

1 4

2 5

3 6

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. Due at the beginning

of Lab #2.

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 as per

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-lab/resources/drawing-

requirements/

See examples for assistance.

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-lab/self-

learning/examples/

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-lab/resources/drawing-requirements/

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-lab/resources/drawing-requirements/

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-lab/self-learning/examples/

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-lab/self-learning/examples/

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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.

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, 4, 5, 2, 3 & 6

Pre-Lab 2

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. Must get 100% to attend the lab.

Instructional Video – Gyroscope Frame Part 1

Watch Video on how-to machine Frame (Part 1)

Student Requirements

Make notes / process sheet from demonstration to be used during the manufacturing.

Process sheet form on EDML website on useful documents page.

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-

lab/resources/documentation/

Resources

Instructional Video - How to use the Mill – Moodle

Mill Operating Test – Moodle

Gyroscope Frame Part 1 Video – Moodle

Process Sheet Template and Examples – EDML website

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-lab/resources/documentation/


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Lab 2

Machining Frame Part 1

Instructor / TA demonstration – Students to add to notes taken from pre-lab video.

Student manufacturing

Cleaning


Have instructor or TA verify process sheet before leaving

Pre-Lab 3

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



Make notes / process sheet from demonstrations for Frame part 2.

Resources

Gyroscope Frame Part 2 Video – Moodle

Instructional Videos - - How to use the Mill & How to use the Drill Press – Moodle

Drill Press Operating Test – Moodle


Assignment #2

Frame Part 1 process sheet due at the beginning of Lab #3

Lab 3

Machining Frame Part 2

Instructor/TA demonstration – Students to add to notes taken from pre-lab video.


Cleaning


Have instructor or TA verify process sheet before leaving

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Pre-Lab 4

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


Instructional Video – Gyroscope Rotor

Watch Video on how-to machine rotor


Make notes / process sheet from demonstration.

Resources

Instructional Video - How to use the Lathe – Moodle

Gyroscope Rotor Video – Moodle


Assignment #3

Frame Part 2 process sheet due at the beginning of Lab #4

Lab 4

Machining Rotor Part 1

Instructor/TA demonstration – Students to add to notes taken from pre-lab video.


Cleaning


Have TA verify process sheet before leaving

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Pre-Lab 5 Review lathe operational video and rotor demonstration is necessary.


Make notes / process sheet from demonstration.

Resources

Instructional Video - How to use the Lathe – Moodle

Gyroscope Rotor Video – Moodle


Assignment #4

Rotor process sheet due at the beginning of Lab #5

Lab 5

Machining Rotor Part 2

Complete Rotor if necessary

Instructor/TA demonstration – Students take notes for shaft and ring.

Student manufacturing of ring and shaft

Cleaning

Pre-Lab 6

Assignments #5 & 6

Rotor and shaft process sheets due at the beginning of Lab #6

Lab 6

Computer Numerically Controlled Machining (CNC)

During lab #6, students will be able to observe the functionality of a 3 Axis Milling machine in order to

do an engraving process on the gyroscope frame.

Time permitting, there will also be demonstrations on manufacturing of the gyroscope frame and rotor

via a CNC mill and CNC lathe.

Final Assembly

For the final assembly of the gyroscope, students will be introduced to the use of basic hand tools as

well as the techniques and procedures required to assemble the gyroscope.

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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 the figure below for the welding drawing of the gyroscope stand.

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 work piece, 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 Helmet (with proper shade of lens) Safety glasses Gloves Proper ventilation

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Final Report

The report must be formatted as follows:

1. ENCS Lab Expectation of Originality Form

2. Title Page (name, section, date, ID#)

3. Table of Contents

4. Introduction

4.1 Brief introduction to the project and machines used and the parts being fabricated

5. Frame

5.1 Detailed Technical Drawing (Proper drawing, landscape format, title block)

5.2 Process plan – Process Sheet

5.2.1 Sample calculations for one complete process indicated by the instructor.

5.3 Inspection report

5.4 Conclusion (Comment on how well (or not) your frame turned out)

6. Rotor





6.4 Conclusion (Comment on how well (or not) your rotor turned out)

7. Shaft





7.4 Conclusion (Comment on how well (or not) your shaft turned out)

8. Ring



8.3 Conclusion (Comment on how well (or not) your ring turned out)

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9. Assembly Drawing + Assembly Procedure + Bill of Materials

9.1 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.

9.2 Assembly drawing is a view of the gyroscope with all the components shown as they go

together. (i.e. 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.

Isometric or exploded views are NOT suitable. Include all necessary sections to best

describe the assembly.

9.3 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.

10. Overall conclusion

10.1 How did your gyroscope turn out? Any problems?

10.2 Any comments on how the lab should be improved for future sessions?

Useful Documents

Please visit the useful documents page of the EDML website:

http://www.mie.concordia.ca/facilities/engineering-design-and-manufacturing-

lab/resources/documentation/

For all forms and templates required for this lab.



MECH 311 Course plan for MECH 311 Manufacturing Processesusers.encs.concordia.ca/~m_rembac/M311 Lab...

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