Modeling & Manufacturing Using Alpha_1 Samuel Drake.
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Transcript of Modeling & Manufacturing Using Alpha_1 Samuel Drake.
![Page 1: Modeling & Manufacturing Using Alpha_1 Samuel Drake.](https://reader036.fdocuments.us/reader036/viewer/2022062322/5697bfc91a28abf838ca8c69/html5/thumbnails/1.jpg)
Modeling & ManufacturingUsing Alpha_1
Samuel Drake
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1984 -- Start of what became the AML
• Purchased 5-Axis Vertical Machining Center• First Manufactured Item – 3D surface for a
shaped charge• Second Demonstration Item – Injection mold
for a teaspoon that had been modeled by Beth Cobb. Made Plastic spoons with an Alpha_1 logo
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Adding Capability to the AML
• 1989 Mill-Turn• 1991 Stereo Lithography Rapid Prototyping • 1992 Sinking EDM• 1994 5-Axis Horizontal Machining Center• 1995 Wire EDM• ?? Coordinate Measuring Machine• 2002 Move to High Bay in Kennecott• 2005 High Speed 5-Axis Machining Center
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Moving into Kennecott
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Major Machine Lineup in AML
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Parts on Demand Systemand Bushing Maker
• ~1989 Started working with Hill AFB• Origins of what became FeatureCAM• Developed Bushing Maker Software with EGS• Live Demo in AML• Demo with EGS at Hill AFB
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Early Work on FeatureCAM
• Prior work with Samuel Sela on defining features for feature-based design
• Basic concepts for FeatureCAM came from talking with Russ Fish on how to automate “Parts on Demand System”
• Concepts of using stock and part is what is left after subtracting manufacturing features.
• Work with Chi Cheng Ho and Beth Cobb on making manufacturing features.
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Modeling and Manufacturing Air Force Parts -- F4 Sway Brace
None of the Air Force drawings were technically correct
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1993 Modeling and Manufacturing
First Complex Assembly
Front Upright, Spindle, Hub, Caliper, Brake Rotor for Mini-Baja
Went together with no rework, forever proving the value of manufacturing from solid models
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Early 90’s--Work with DARPA on Modeling and Manufacturing Diesel Engine
• Major modeling effort with many of the Alpha_1 staff involved in modeling different parts. Made animated video of running engine
• Made 1/3 scale model using Stereo Lithography Rapid Prototyping
• Machined 1/3 scale model from Aluminum• Part way thru, DARPA wanted it to actually run.
Made it run on compressed air
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Collaborative Work with DARPA
• ~ 1995 – Early use of web-based collaboration with Stanford and others (Michigan State?, Cornell?) to design and build electro-optical tracker
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Collaborative Work with UNC and Henry Fuchs
• Optical Sensor Ball• Multiple Camera System for Video
Conferencing• Plastic Mold for Stereo video/optical head
mount display for surgery• Multi angle mirror device
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1996 -- More ComplexModeling and Manufacturing
Final Drive for Formula SAE
First Use of Wire EDM to cut splines and gears
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More Gear and Splines
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FormulaSAE Intake Manifold
Made wax cores using FDM Rapid Prototyping Machine. Cores wrappedwith composite. Wax melted after compositewas cured
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Manufacturing a FormulaSAE Carusing Alpha_1 and FeatureCAM
2006 Car with the Team Captain
• Composite Chassis• Wheel Centers• Front and Rear
Suspension with integrated brakes
• Final Drive with quick change Gears
• Intake Manifold• Gear Shifter• Throttle Body
Alpha_1/FeatureCAMParts
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Drilling for OilDiamond Drill for high speed drilling
Modeled from “napkin sketches plus cutter locations
New Design with rotating cutters
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Multi-Mode Microwave Antenna for L3 Comm
Replaced 44 parts with 3 parts by realizing the desired shape was a ruled surface that could be cut with a 4-axis wire EDM
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Full Scale Diesel Engine Parts
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Current Work using FeatureCAM