ProjectReport Sample

University of Houston

Industrial Engineering Department

Engineering Design and Prototyping

Professor: Ali K. Kamrani

PROTOTYPING PROJECT

Balasubramanian, Pradeep

Kalaveena, Harideep

Sarcina, Adriana

1

Table of Content

List of Figures ................................................................................................................................. 4

List of Tables .................................................................................................................................. 5

Abstract ........................................................................................................................................... 6

Chapter I. Introduction .................................................................................................................... 7

Chapter II. Procedures .................................................................................................................... 8

II.1 Gear – Part I .......................................................................................................................... 8

II.1.1 Design of gear components and assembly structure in CATIA software ...................... 8

II.1.2. DFA analysis ................................................................................................................. 8

II.1.3. D-Chains and D-Trees ................................................................................................ 10

II.1.4. Worst Case Arithmetic Method for Missing pieces .................................................... 13

II.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103 and X-104 using the limits FN2, LC10 and LC11 respectively .............................................................. 14

II.1.6. Specifications for positional control for features X-115 and X-104, X-104 and X-108, X-103 and X-104 ................................................................................................................... 15

II.1.7. Process plan ................................................................................................................ 15

In order to create the process planning, Kamrani the next list of machine are going to be used and evaluated to find the best one based in an information analysis. ........................... 15

II.1.8. Statistical Process Control .......................................................................................... 15

II.2 Drilling Jig – Part 2 ............................................................................................................ 16

II.2.1. DFA Analysis.............................................................................................................. 16

II.2.2. Modular System Characteristics based in physical attributes ..................................... 16

Chapter III. Results ....................................................................................................................... 17

III.1 Gear – Part I ...................................................................................................................... 17

III.1.1 Design of gear components and assembly structure in CATIA software ................... 17

IIII.1.2. DFA analysis ............................................................................................................ 18

III.1.3. Components’ D-Chains and D-Trees ........................................................................ 21

III.1.4. Worst Case Arithmetic Method for Missing pieces .................................................. 26

III.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103 and X-104 using the limits FN2, LC10 and LC11 respectively .............................................................. 28

2

III.1.6. Specifications for positional control for features X-115 and X-104, X-104 and X-108, X-103 and X-104 ........................................................................................................... 30

III.1.7. Process plan ............................................................................................................... 32

III.1.8. Statistical Process Control ......................................................................................... 36

III.2 Drilling Jig – Part 2 ........................................................................................................... 41

III.2.1. Analysis ..................................................................................................................... 41

III.2.2. Modular System Characteristics based in physical attributes ................................... 48

Chapter IV. Conclusions ............................................................................................................... 50

Chapter V. Appendix .................................................................................................................... 51

3

List of Figures

Figure 1 - D-Chain Shaft (Horizontal Axis) ................................................................................. 21

Figure 2 - D-Tree Shaft (Horizontal Axis) ................................................................................... 22

Figure 3 - D-Chain Input Gear (Vertical Axis) ............................................................................. 23

Figure 4 - D-Tree Input Gear (Vertical Axis) ............................................................................... 23

Figure 5 - D-Chain Cover (Vertical Axis) .................................................................................... 24

Figure 6 - D-Chain Cover (Horizontal Axis) ................................................................................ 25

Figure 7 - D-Tree Cover (Vertical Axis) ...................................................................................... 25

Figure 8 - D-Tree Cover (Horizontal Axis) .................................................................................. 25

Figure 9 - X-Chart for giving Input Gear data .............................................................................. 37

Figure 10 - R-Chart for giving Input Gear data ............................................................................ 37

Figure 11 - Scenario after first correction ..................................................................................... 38

Figure 12 - Scenario after second correction ................................................................................ 39

Figure 13 - Scenario after modify designer specification for Input Gear ..................................... 40

Figure 14 - Center Plate ................................................................................................................ 44

Figure 15 - Base ............................................................................................................................ 44

Figure 16 – Bolt ............................................................................................................................ 45

4

List of Tables

Table 1 - DFA Components 0, 1, 2 ............................................................................................... 18

Table 2 - DFA Components 3, 4 ................................................................................................... 19

Table 3 - DFA ............................................................................................................................... 20

Table 4 - Machine Specifications ................................................................................................. 32

Table 5 - Surface groups specifications ........................................................................................ 33

Table 6 - CNC Automated Machine Selection Software .............................................................. 35

Table 7 - Final list of machines selected ....................................................................................... 35

Table 8- Statistical data for Input Gear ......................................................................................... 36

Table 9 - DFA B&D Method for Drill Jig .................................................................................... 41

Table 10 - DFA Lucas Method for Drill Jig ................................................................................. 42

Table 11 - DFA B&D Method for Redesign ................................................................................ 46

5

Abstract

In the next report, it can be found the complete analysis and develop of two different

prototypes. The first one, is a gear that was design in CATIA software and completely studied,

including its dimensions and tolerances, estimated time of manual insertion and handling,

specifications of positional control, and other important features in the develop of the

components of the gear. The second prototype is a design with the mainly function of provide

precision to users when drilling a piece. Equally to the first prototype, it was calculated the

estimated time for manual insertion and handling, considering different methods to do the

calculations of it; also for this second piece it was created a new design, reducing the

components that create high assembly estimated times.

6

Chapter I. Introduction

In the next report, it will be cover all the analysis and related study for the design and the

manufacture of a gear and a drilling jig. The work will be divided in two chapters: the procedures

which explain the steps used for the development of each section, and the results that shows the

final proceeds and solutions obtained. Both chapters will be divided in two sections, the first one

will cover all the analysis and results of the gear and the second of the drilling jig.

For the gear analysis, it will be included nine subdivisions that will cover the following

points:

• The design and assembly of the parts in CATIA V5 software

• The design for assembly analysis

• The D-Chain and D-Tree for the parts required

• The calculation of the sizes for the missing pieces, using the worst-case arithmetic

method

• The calculation of tolerances for the parts required

• The specification for positional control for the same parts of the previous subdivision

• Other methods of form control

• The process plan for the parts including cost with manufacturing of the components

• Check if Statistical Process Control was used for the data collected as part of quality

control for outer diameter of input gear

For the drilling jig analysis, it will be included two subdivisions that will cover the

following points:

• The design for assembly analysis using the M&D method and Lucas method

• Identify the components in production and functional modules

Finally, it will be included a conclusion and the appendix, with some assumptions made for

the parts not required and the other tolerances’ calculations.

7

Chapter II. Procedures

II.1 Gear – Part I

II.1.1 Design of gear components and assembly structure in CATIA software

Before starting to draw the parts with the software, it was necessary to do required

calculations for those pieces which their dimensions weren’t presented in the original

documentation. To do so, the width of some of them was calculated by the worst case arithmetic

method, which will be better explained in the section II.1.4, and other sizes were estimated based

on the graphics given, or were calculated with the Geometric Dimensioning and Tolerance

tables, which can be found in the chapter 11 of the textbook Engineering Design and Rapid

Prototyping.

II.1.2. DFA analysis

In order to perform the DFA analysis, it was necessary to come up with the order of

assembly first. The first step was to check the best way to disassemble the gear, and then how to

assembly it, based in the backward order. After doing these, there were obtained five

components that are going to be assembly separately from the rest of the pieces:

Component 0 / X-120 Speed Sensor Assembly:

• X-124 Speed sensor

• X-122 “O” Ring

Component 1/ X-108 Assy-Input Gear:

• X-110 Gear Input

• X-109 Bushing

X-124 X-122

X-110 X-109

8

X-109

X-100

X-113

X-104

X-112

X-111 X-108

Component 2 / X-103 Cover Assembly:

• X-102 Cover

• X-105 Shaft Seal

• X-106 Seal “O” Ring

• X-109 Bushing

Component 3 / X-101 Housing Assembly:

• X-100 Housing

• X-111 Plug Cup

• X-109 Bushing

• X-104 Shaft

• X-112 Washer Thrust

• X-108 Assy-Input Gear (Component 1)

• X-113 Hub

• X-125 Shaft Control

• X-128 Sleve Control

• X-129 Ring Retainer

Component 4 / X-126 Shift Fork Assembly:

• X-126 Shift Fork

• X-127 Pin-Shift Fork

• X-114 Collar Shift

X-106 X-105

X-109 X-102

X-129

X-128

X-125

X-127

X-114

X-126

9

The final assembly will be considered in the order below:

• X-101 Housing Assembly (Component 3)

• X-126 Shift Fork Assembly (Component 4)

• X-130 Spring

• X-129 Ring Retaining

• X-115 Gear-Speed Sensor


• X-120 Speed Sensor Assembly (Component 0)


• X-116 Washer Thrust

• X-103 Cover Assembly (Component 2)

• X-107 Bolts

• X-118 Gear Output

• X-119 Spacer Gear


II.1.3. D-Chains and D-Trees

To solve tolerance relations in dimensional chains and dimensional trees, engineering

practice uses three basic methods:

• arithmetic method of calculation

• statistical method of calculation

• method of group interchangeability

As it was mentioned before, in the section II.1.4, it was used the arithmetic method of

calculation (Worst-Case method) to calculate all the dimensions related with the parts not

specified in the graphics given. Based on this, and the sizes given, the d-chains and d-trees were

created for the pieces that are shown below:

10

X-104 Shaft

X-110 Gear Input

11

X-102 Cover

12

II.1.4. Worst Case Arithmetic Method for Missing pieces

Since the dimensions of some pieces were not specified in the graphics given, they were

calculated with the worst case arithmetic method. Having the width of the hub, input gear,

bushing, and gear speed sensor, it was calculated the width of the washer thrust. Same as the

washer thrust, it was calculated other pieces, as it is shown in the section III.1.4.

In order to complete the calculations, it was used the dimensions given on the graphics,

and the formulas shown next:

Nominal dimension:

𝐹𝑛 = �𝑑𝑖𝑛𝑚

𝐼=1

− � 𝑑𝑖𝑛𝑛

𝑖=𝑚+1

Maximum dimension:

𝐹𝑚𝑎𝑥 = �𝑑𝑖𝑚𝑎𝑥𝑚

𝐼=1

− � 𝑑𝑖𝑚𝑖𝑛𝑛

𝑖=𝑚+1

Minimum dimension:

𝐹𝑚𝑖𝑛 = �𝑑𝑖𝑚𝑖𝑛𝑚

𝐼=1

− � 𝑑𝑖𝑚𝑎𝑥𝑛

𝑖=𝑚+1

Tolerance:

T(positive) = Fmax – Fn

T(negative)= Fmin - Fn

13

II.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103 and X-104 using the limits FN2, LC10 and LC11 respectively

To calculate the tolerances required in this section, the parts were identified and

analyzed as it is shown next:

• X – 115 and X -104

The diameter of the shaft in the area where the speed sensor is located is equal to

27 mm, and this was converted to inches and, using the tables FN2, the

dimensions and tolerances for the shaft and speed sensor were calculated.

• X – 108 and X -104

X-108 is a component which includes three pieces, the gear input (X-110) and

two bushings (X-109). For the tolerances of the assy-input gear and the shaft, it

was considered the shaft diameter as it is shown on the given graphics (25 mm),

and was calculated the dimensions and tolerances for bushings and shaft.

• X-103 and X-104

X-103 is a component which includes four pieces, the cover (X-102), shaft seal

(X-105), the seal “O” Ring (X-106) and the bushing (X-109). For the tolerances

of the cover assembly and the shaft, it was considered the shaft diameter as it is

shown on the given graphics (25 mm), and was calculated the dimensions and

tolerances for bushing, shaft seal and shaft.

14

II.1.6. Specifications for positional control for features X-115 and X-104, X-104 and X-108, X-103 and X-104

In order to protects the parts function and minimize the lowers production costs, it

is important to calculate the positional control of the holes and shaft mentioned in the

previous section. In order to do so, the diameter values of hole and shaft are subtracted.

The formula, for maximum material condition or minimum material condition, is the

diameter of the hole minus the diameter of the shaft. If the fit is clearance, the result

obtained will be positive, but if it is interference, the result will be negative. After making

the subtraction, it is assigned a value for the shaft and a value for the hole, to establish

their positional control.

II.1.7. Process plan

In order to create the process planning, Kamrani the next list of machine are going to be used and evaluated to find the best one based in an information analysis.

• Shaper

• Vertical Milling Machine

• Horizontal Surface Grinding Machine

• Lathe

• High Precision Lathe

• Horizontal Milling Machine

• Cylindrical Grinding Machine

II.1.8. Statistical Process Control The statistical control will calculate the upper control limits and lower control limits and

based on the results on the X and R Chart and it will be submit to corrections in order to find a

better process capability that allows the company to produce output within the specification

limits.

15

II.2 Drilling Jig – Part 2

II.2.1. DFA Analysis

To complete the design for assembly analysis, it will be used two methods, the B&D method, which is the same that will be used in the first section for the evaluation of the gear, and a second method, called Lucas. The last one mentioned will include a functional, feeding and fitting analysis.

For the functional analysis, it will be considered the essential parts for the product’s function and the non-essential parts. The formula required for the calculation is:

Ed(efficiency of the design) = A / (A+B) * 100, where A represents the essential parts and B the non-essential

It is expected to obtain an efficiency of 60%.

On the other hand, in the feeding analysis, it will be analyzed the handling and insertion process using the provided table and it is expected a 1.5 value for each part; it will be calculated the total feeding ratio with the following formula:

Feeding Ratio = ( Ʃ feeding index) / (Number of Essential Components – A)

In this case, the ideal ratio will be 2.5.

Finally, it will be calculated the fitting analysis for each part, taking the values from the automation manual, where it is expected a 1.5 value for each part; and again the fitting ratio will come from the next formula:

Fitting Ratio = ( Ʃ fitting index) / (Number of Essential Components – A)

The target for the fitting ratio is 2.5.

After doing the analysis mentioned, a redesign will take part if necessary.

II.2.2. Modular System Characteristics based in physical attributes

Given the physical characteristics of the drill jig, there is going to be identifying the function modules and the production modules.

16

Chapter III. Results

III.1 Gear – Part I

III.1.1 Design of gear components and assembly structure in CATIA software

The dimensions given in the graphics were convert into inches, and were used to compare

and find the tolerance table to make the corresponding calculations, which can be found on the

appendix (Chapter V), in the last part of this document, as well as all the assumptions made for

the estimated sizes.

The DVD that is attached below includes all the components designed with CATIA V5

software:

Note: The DVD includes also a copy of this report, presentation made in the class, and the design of the Drill Jig in

CATIA.

17

IIII.1.2. DFA analysis 1 2 3 4 5 6 7 8 9

Name of Assembly α β Part ID No.

Number of time the

operation is carried out

consecutively

Two-digit manual

handling code

Manual handling time per

part

Two-digit manual

insertion code

Manual insertion time per

part

Operation Time, in seconds

(2)*[(4)+(6)]

Operation cost, in cents

0.4*(7)

Figures for estimation of theorical minimum

parts COMPONENT 0 - X-120 SPEED SENSOR ASSEMBLY

X-124 1 10 1,5 00 1,5 3 1,2 1 SPEED SENSOR 360 0 1 98 9 9 3,6 0 SEP. OPERATION X-122 1 03 1,69 31 5 6,69 2,676 0 "O" RING 180 0

18,69 7,476 1

Design Efficiency 0,161 TM CM NM

COMPONENT 1 - X-108 ASSY-INPUT GEAR

X-110 1 10 1,5 00 1,5 10,5 4,2 1 GEAR INPUT 360 0 1 98 9 5 2 0 SEP. OPERATION X-109 2 00 1,13 11 5 12,26 4,904 0 BUSHING 180 0

27,76 11,104 1

Design Efficiency 0,108 TM CM NM

COMPONENT 2 - X-103 COVER ASSEMBLY

X-102 1 30 1,95 00 1,5 10,95 4,38 1 COVER 360 360

1 98 9 1,5 0,6 0 SEP. OPERATION

X-105 1 00 1,13 00 1,5 3,63 1,452 0 SHAFT SEAL 180 0

X-106 1 00 1,13 01 2,5 3,63 1,452 0 SEAL 'O' RING 180 0

X-109 1 00 1,13 11 5 6,13 2,452 0 BUSHING 180 0

25,84 10,336 1 Design Efficiency 0,116 TM CM NM

Table 1 - DFA Components 0, 1, 2

18

1 2 3 4 5 6 7 8 9


Number of time the


consecutively

Two-digit

manual handling

code


part

Two-digit manual

insertion code


part


(2)*[(4)+(6)]


0.4*(7)


parts COMPONENT 3 - X-101 HOUSING ASSEMBLY

X-100 1 30 1,95 00 1,5 3,45 1,38 1 HOUSING 360 360 1 98 9 9 3,6 0 SEP. OPERATION X-111 1 13 2,06 98 9 11,06 4,424 0 PLUG-CUP 360 0 X-109 1 00 1,13 11 5 6,13 2,452 0 BUSHING 180 0 X-104 1 10 1,5 06 5,5 7 2,8 1 SHAFT 360 0 X-112 1 00 1,13 00 1,5 2,63 1,052 0 WASHER-THRUST 180 0 X-108 1 10 1,5 00 1,5 3 1,2 1 ASSY-INPUT GEAR (COMPONENT 1) 360 0 X-113 1 10 1,5 00 1,5 3 1,2 1 HUB 360 0 X-125 1 10 1,5 06 5,5 7 2,8 1 SHAFT CONTROL 360 0 X-128 1 00 1,13 00 1,5 2,63 1,052 1 SLEEVE CONTROL 180 0 X-129 1 03 1,69 31 5 6,69 2,676 0 RING REATINING 180 0 61,59 24,636 6 Design Efficiency 0,292 TM CM NM

COMPONENT 4 - X-126 SHIFT FORK ASSEMBLY

X-126 1 00 1,13 00 1,5 10,13 4,052 1 SHIFT FORK 180 0

1 98 9 5 2 0 SEP. OPERATION

X-127 2 10 1,5 31 5 13 5,2 0 PIN-SHIFT FORK 360 0

X-114 1 00 1,13 06 5,5 6,63 2,652 1 COLLAR SHIFT 180 0

34,76 13,904 2 Design Efficiency 0,173 TM CM NM

Table 2 - DFA Components 3, 4

19

1 2 3 4 5 6 7 8 9


Number of time the


consecutively

Two-digit

manual handling

code


part

Two-digit manual

insertion code


part


(2)*[(4)+(6)]


0.4*(7)


parts DFA

X-101 1 30 1,95 00 1,5 3,45 1,38 1 HOUSING ASSEMBLY (COMPONENT 3) 360 360

X-126 1 20 1,8 06 5,5 7,3 2,92 1 SHIFT FORK ASSEMBLY (COMPONENT 4) 360 180

X-130 1 00 1,13 00 1,5 2,63 1,052 0 SPRING 180 0

X-129 1 03 1,69 31 5 6,69 2,676 0 RING REATINING 180 0

X-115 1 00 1,13 00 1,5 2,63 1,052 1 GEAR-SPEED SENSOR 180 0

X-117 1 03 1,69 01 2,5 4,19 1,676 0 RING REATINING 180 0

X-120 1 10 1,5 00 1,5 3 1,2 1

SPEED SENSOR ASSEMBLY (COMPONENT 0)

360 0

X-121 1 03 1,69 31 5 6,69 2,676 0 RING REATINING 180 0

X-116 1 10 1,5 00 1,5 3 1,2 0 WASHER-THRUST 360 0

X-103 1 30 1,95 38 6 7,95 3,18 1 COVER ASSEMBLY (COMPONENT 2) 360 360

X-107 4 10 1,5 92 5 26 10,4 0 BOLTS 360 0

X-118 1 10 1,5 00 1,5 3 1,2 1 GEAR OUTPUT 360 0

X-119 1 00 1,13 00 1,5 2,63 1,052 0 SPACER GEAR 180 0

X-117 1 0,3 1,69 31 5 6,69 2,676 0 RING REATINING 180 0

85,85 34,34 6 Design Efficiency 0,210

TM CM NM

Table 3 - DFA

20

III.1.3. Components’ D-Chains and D-Trees

X-104 Shaft

P3 P4 P6 P5 P8 P7 P1

P11 P10 P9 P2

4

20

Horizontal axis

156.1

1.56

4

58.1

1.56

27

3

94

3

Figure 1 - D-Chain Shaft (Horizontal Axis)

21

X-110 Input Gear

P4 1.56

P5

20

P7

58.1

-1.56

P1

P2

156.1

P3 4

P6 -4

P8

-94

P9

P10

-3

Figure 2 - D-Tree Shaft (Horizontal Axis)

P1 P5

P2

P3 P4

P6 P7

Using the worst-case arithmetic method, i.e. 101.9 (nominal value of highest diameter) minus 95 (nominal value for teeth diameter), equal 6.9

22

3.45 20.845

23.55

35.535

61.183

101.9

Vertical Axis

Figure 3 - D-Chain Input Gear (Vertical Axis)

P1

P2

P4

P3

P5

P6 P7

3.45

20.845 101.9

23.55

35.535 61.183

Figure 4 - D-Tree Input Gear (Vertical Axis)

23

X-102 Cover

P1

P1

P2

P2

P3

Vertical Axis

Horizontal Axis

P3

P4

P5 P6

P7

P5

P6

P7 P8

P9

P4

28

164

3

34 36.2

10.585

15.415

13.45

Figure 5 - D-Chain Cover (Vertical Axis)

Vertical Axis

24

Horizontal Axis

30.5

11 12

3.5

3.45

11.5

Figure 6 - D-Chain Cover (Horizontal Axis)

P1

P2

P4

P3

P5

P6

P7

164

34 36.2

28

10.585

3

15.415 P8 P9

-13.45

Figure 7 - D-Tree Cover (Vertical Axis)

P1

P2

30.5 11

12 P3

P4 P5

P7

3.5 11.5

P6

3.45

Figure 8 - D-Tree Cover (Horizontal Axis)

25

III.1.4. Worst Case Arithmetic Method for Missing pieces

As it was mentioned in the previous chapter, the dimensions given in the graphics are

used to calculate the sizes that were not given. Below, it is shown an example and explanation of

the calculations of worst case arithmetic method:

For the nominal dimension of the washer thrust, the nominal values of the gear speed

sensor, hub, gear input and bushing are subtracted from the shaft nominal value:

NomVal(washer-thrust) = (94-3) – (6 + 26.6 + 40 +13) = 5.4 mm

For the maximum dimension, it is required to use the maximum value of the shaft minus

the minimum value for the last part of the shaft. Then, also it is necessary to subtract the

minimum values for all the parts given.

MaxVal(washer-thrust) = (94.05 – 2.95) – (5.9 + 26.55 + 39.95 + 12.95) = 5.75 mm

For the minimum value dimension, it is required to use the minimum value of the shaft

minus the maximum value for the last part of the shaft. Then, also it is necessary to subtract the

maximum values for all the parts given.

+0.05

-0.05

+0.1 -0.1

6.0 mm

+0.05 -0.05 26.6mm

+0.05 -0.05 40 mm +0.05

-0.05 13mm

26

MinVal(washer-thrust) = (93.95 – 3.05) – (6.1 + 26.65 + 40.05+ 13.05) = 5.05 mm

The last calculation required is the tolerances, where the nominal value is subtracted from

the maximum value for positive tolerance and from the minimal value for the negative one.

Positive tolerance = 5.75 – 5.4 = + 0.35 mm

Negative tolerance = 5.05 – 5.4 = -0.35 mm

The same process is applied to calculate the dimensions of the hub.

Nom Val = (60.31 – 27.035)/2 = 16.6375 mm

MaxVal = (60.36 – 27.01)/2 = 16.675 mm

MinVal = (60.26 – 27.06)/2=16.6 mm

NomVal = (60.31 – 47.00)/2 = 6.655 mm

MaxVal = (60.36-46.96)/2 = 6.7 mm

MinVal = (60.26 – 47.04)/2 = 6.61 mm

NomVal=27-6 = 21 mm

MaxVal = 27.05 – 5.9 = 21.15 mm

MinVal = 26.95 – 6.1 = 20.85 mm

+0.35 -0.35 5.4 mm

27

III.1.5. Tolerances calculation for X-115 and X-104, X-104 and X-108, X-103 and X-104 using the limits FN2, LC10 and LC11 respectively

• X – 115 and X -104

26.95 mm +0.02 -0.00

1.0611 in +0.0008 -0.0000

27.00 mm +0.00 -0.01

1.063 in +0.0000 -0.0005

X-115 / X-104 (FN2)

Diameter of Shaft = 1.063 in

ds(max)= d – a = d = 1.0611 in

dh(min) =d = dh(min) = 1.0611 in

dh(max) = d+h = 1.0611 + 0.0008 = dh(max) = 1.0619 in

ds(min)= d-a-s = ds(min)= 1.0625 in

Range a h L 0.95- 1.19

0.6 +0.8 +1.9 1.9 0 +1.4

For interference fit, the allowance is the higher value, the hole tolerance is the non-zero value and for the shaft, is used the next formula:

s=|Lmin + a|=|0.0014-0.0019|= 0.0005 in

28

• X – 108 and X -104

• X-103 and X-104

25.00 mm +0.00 -0.02

0.9843 in +0.0000 -0.0008

25.02 mm +0.02 -0.00

0.9850 in +0.0008 -0.0000

X-109/ X-104 (LC10)


ds(max)= d – a = 0.9843 in

Since a =0.0007, d = 0.9850 in


dh(max) = d+h = dh(max) = 0.9858 in

ds(min)= d-a-s = ds(min)=0.9835 in

Range a h L 0.71 – 1.19

7.0 +8.0 -7.0 23.0 0 -15.0

For clearance fit, the allowance is the lower value, the hole tolerance is the non-zero value and for the shaft, is used the next formula:

s=|Lmin + a|=|-0.0015+0.0007|= 0.0008 in

25.00 mm +0.00 -0.03

0.9843 in +0.0000 -0.0012 +0.03

-0.00 25.03 mm

0.9853 in +0.0012 -0.0000

X-105 / X-104 (LC11)


ds(max)= d – a = 0.9843 in

Since a =0.001, d = 0.9853 in


dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in


Range a h L 0.71-1.19

10 +12 -10 34 0 -22


s=|Lmin + a|=|-0.0022+0.0010|= 0.0012 in

29

III.1.6. Specifications for positional control for features X-115 and X-104, X-104 and X-108, X-103 and X-104

• X-115 and X-104

• X – 108 and X -104

26.95 mm +0.02 -0.00

1.0611 in +0.0008 -0.0000

27.00 mm +0.00 -0.01

1.063 in +0.0000 -0.0005

-A-

M

M

L

M

L A

A

M A

L A

L

M -0.03 mm

-0.02 mm

-0.01 mm

-0.01 mm

25.00 mm +0.00 -0.02

0.9843 in +0.0000 -0.0008

25.02 mm +0.02 -0.00

0.9850 in +0.0008 -0.0000

30

• X-103 and X-104

-A-

M

L

M

L A

A

M A

L A

L

M

M

L

M

L A

A

M A

L A

L

M

0.01 mm

0.01 mm

0.03 mm

0.03 mm

25.00 mm +0.00 -0.03

0.9843 in +0.0000 -0.0012 +0.03

-0.00 25.03 mm

0.9853 in +0.0012 -0.0000

-A-

0.02 mm

0.01 mm

0.05 mm

0.04 mm

31

III.1.7. Process plan

As it was mentioned on the previous chapter, the machines that are going to be used are:

1. Shaper 2. Vertical Milling Machine 3. Horizontal Surface Grinding Machine 4. Lathe 5. High Precision Lathe 6. Horizontal Milling Machine 7. Cylindrical Grinding Machine

Now these machines have different levels of tolerances and surface finish values:

Tolerance Surface Finish Power (KWH) Efficiency Labor and

Depreciation

Machine Name lower upper lower upper

1 Shaper -75 750 10 100 4 0.58 1

2 Vertical Milling Machine -75 750 8 80 3.7 0.5 2

3 Horizontal Surface Grinding Machine -2.5 25 0.5 5 1 0.65 3

4 Lathe -20 200 4 40 4 0.7 2

5 High Precision Lathe -10 100 2 20 4 0.75 2.5

6 Horizontal Milling Machine -75 750 10 100 3.7 0.5 1.5

7 Cylindrical Grinding Machine -2.5 25 0.5 5 1 0.65 3

Table 4 - Machine Specifications

32

Consider The Input Gear:

The surface groups that have been identified on this input gear are:

Sequence 1

Tolerance Surface Finish

Description Surface Groups lower upper lower upper

Length cut Surface Group 1 -50 50 3 19

Diameters Surface Group 2 0 300 4 12

Shaft Hole Surface Group 3 0 60 4 20

Undercutting Surface Group 5 -30 30 3 15

Teeth Surface Group 6 0 30 5 10

Table 5 - Surface groups specifications

Using the formulae for the Information Axiom to decide the best machine for each job to be done:

Creating a program in MS Excel to automatically choose machines form the available ones based upon the information axiom.

33

An instance of the excel sheet is:

Information Sequence 1

Tolerance Surface Finish Total Min Value Activate

Surface Group 1

Shaper 2.1102132 2.302585093 4.41279829 0.72391884 1

Vertical Milling Machine 2.1102132 1.878770846 3.98898405

1

Horizontal Surface Grinding Machine 0 0.810930216 0.81093022

1

Lathe 1.145132304 0.875468737 2.02060104

1

Recommended

High Precision Lathe 0.606135804 0.117783036 0.72391884

1

Horizontal Milling Machine 2.1102132 2.302585093 4.41279829

1

Cyllindrical Grinding Machine 0 0.810930216 0.81093022

1

Surface Group 2

Shaper 1.011600912 3.80666249 4.8182634 0.9062404 1


1

Horizontal Surface Grinding Machine 0.09531018 1.504077397 1.59938758

1

Lathe 0.09531018 1.504077397 1.59938758

1

Recommended


1


1

Cyllindrical Grinding Machine 0.09531018 1.504077397 1.59938758

1

Surface Group 3

Shaper 2.621038824 2.197224577 4.8182634 0.72391884 1


1

Horizontal Surface Grinding Machine 0.09531018 1.504077397 1.59938758

1

Lathe 1.299282984 0.810930216 2.1102132

1

Recommended


1


1

Cyllindrical Grinding Machine 0.09531018 1.504077397 1.59938758

1

Surface Group 4

Shaper 2.621038824 2.890371758 5.51141058 0 1


1

Recommended Horizontal Surface Grinding Machine 0 0 0

1

34

Recommended Lathe 0 0 0

1

Recommended

High Precision Lathe 0 0 0

1

Recommended

Horizontal Milling Machine 0 0 0

1

Recommended

Cyllindrical Grinding Machine 0 0 0

1

Surface Group 5

Shaper 2.621038824 2.890371758 5.51141058 0.81093022 1


1

Recommended Horizontal Surface Grinding Machine 0 0.810930216 0.81093022

1

Lathe 1.481604541 1.185623666 2.66722821

1


1


1

Recommended

Cyllindrical Grinding Machine 0 0.810930216 0.81093022

1

Table 6 - CNC Automated Machine Selection Software

The functions of this automated machine-tool picking software are:

• Pick the best machine among the available machines based on the information axiom

• Ability to activate and de-activate the machines in case of non-availability or if the machine is not apt for the purpose.

The final list of machines according to the information axiom, given by the program for the surface group selected are:

Description Finalized Machines

Length cut High precision Lathe

Diameters High Precision Lathe

Shaft Hole High Precision Lathe

Undercutting Horizontal Milling Machine

Teeth Cylindrical Grinding Machine

Table 7 - Final list of machines selected

35

III.1.8. Statistical Process Control

The given data for input gear is:

Observation Sample 1 2 3 4 Range X Bar

1 102.00 101.97 102.10 102.08 0.13 102.04 2 101.91 101.94 102.10 101.96 0.19 101.98 3 101.89 102.02 101.97 101.99 0.13 101.97 4 101.10 101.09 101.05 101.95 0.90 101.30 5 101.08 101.92 101.12 101.05 0.87 101.29 6 101.94 101.98 102.06 102.08 0.14 102.02 7 102.09 102.00 102.00 102.03 0.09 102.03 8 102.01 102.04 101.99 101.95 0.09 102.00 9 102.00 101.96 101.97 102.03 0.07 101.99

10 101.92 101.94 102.09 102.00 0.17 101.99 11 101.91 101.99 102.05 102.10 0.19 102.01 12 102.01 102.00 102.06 101.97 0.09 102.01 13 101.98 101.99 102.06 102.03 0.08 102.02 14 102.02 102.00 102.05 101.95 0.10 102.01 15 102.00 102.05 102.01 101.97 0.08 102.01

0.22 101.91

R bar X Bar Bar

Table 8- Statistical data for Input Gear

36

The X-Charts and the R Charts are:

X-Chart:

Figure 9 - X-Chart for giving Input Gear data

R Chart:

Figure 10 - R-Chart for giving Input Gear data

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Range

UCLR

LCLR

Expon. (Range)

100.80

101.00

101.20

101.40

101.60

101.80

102.00

102.20

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Series1

Expon. (Series1)

37

Cpk = 0.008464

Cp=0.009353

Std Dev = 0.280579311

Obviously there are spikes in the charts. So, there are samples that need to be eliminated.

Figure 11 - Scenario after first correction

38

Figure 12 - Scenario after second correction

39

Figure 13 - Scenario after modify designer specification for Input Gear

Therefore the process is under one sigma level.

40

III.2 Drilling Jig – Part 2

III.2.1. Analysis

III.2.1.1 DFA Analysis

III.2.1.1.1 B&D method

1 2 3 4 5 6 7 8 9

Name of Assembly α β Part

ID No.

Number of time the


consecutively

Two-digit manual

handling code


part

Two-digit manual

insertion code


part


(2)*[(4)+(6)]

Operation cost, in

cents 0.4*(7)

Figures for estimation

of theorical minimum

parts

1 1 20 1,8 00 1,5 3,3 1,32 1 Base 360 180 2 2 30 1,95 00 1,5 6,9 2,76 0 End Bracket 360 360 5 2 10 1,5 38 6 15 6 0 Screw 360 0 3 1 20 1,8 00 1,5 3,3 1,32 1 Center Plate 360 180 4 2 10 1,5 00 1,5 6 2,4 0 Bolt 360 0 6 2 00 1,13 58 10 22,26 8,904 0 Nut 180 0

56,76 22,704 2 Design

Efficiency 0,106 TM CM NM

Table 9 - DFA B&D Method for Drill Jig

41

III.2.1.1.2 Lucas method

Fitting Assembly

TOTAL 10 2 6.8

Component Number

Component Description

Number of parts

Functional Assembly

Feeding Assembly

1

Base

1

A

1.5

2

End Bracket

2

B

1.1

5

Screw

2

B

1.1

3

Center Plate

1

A

1.0

4

Bolt

2

B

1.1

6

Nut

2

B

1.0

Table 10 - DFA Lucas Method for Drill Jig

1.5

3 2.4

2.0 2.0

1.0

2.4

2.0 2.0

18.3

42

Checking the essential and total quantity of parts, it is possible to obtain the efficiency of

the design:

Ed = 2 / 10 *100% = 20%

Evaluating the result obtained, the first indicator that it is important a redesign appears,

since the efficiency is too low and far from the objective value.

For the feeding analysis, the only piece that it is necessary to carry with two hands is the

base, and for that reason, it is assigned a 1.5 value. Also considering the symmetry and the end to

end part of each piece, it is required to sum 0.1 in some of the pieces. As it was mentioned in the

previous chapter, the expected index for each part is 1.5; some of the pieces have values of 1,

which is very low. Also, the feeding ratio was obtained:

Feeding Ratio = 6.8 / 2 = 3.4

For the fitting analysis, the base requires a non- assembly process, to give a pre-

orientation to the part. When analyzing the next part, the end bracket, the first question that it is

required is related with the orientation of the piece and the probability of assembly the part in the

wrong way. The answer for the question must be yes, since the piece is symmetric and the holes

have different sizes and, for that reason, it is required a redesign since these point. However, it

was completed the analysis, continuing with the screws which requires an insertion process and a

non-assembly process (screwing process). Same analysis was done for the rest of the parts,

obtaining their indexes.

The expected value for each index is 1.5, and some of the indexes obtained are too far

from the target, for example the value for each bracket is 2.7, which is almost double of the

expected index. Same situation is occurring with the fitting ratio, where the ideal value is 2.5 and

the result obtained is the following:

Fitting Ratio = 18.3 / 2 = 9.1

Also, considering the disassembly required, the efficiency of the process will decrease,

since it is required to remove the bolts and nuts, and obviously, this will move away more the

result from the ideal ratios.

After this evaluation, the best option is to redesign the piece in order to obtain better

efficiency that can meet the target.

43

III.2.1.2 Redesign

Figure 14 - Center Plate

Figure 15 - Base

44

Figure 16 – Bolt

For the redesign, it was considered three pieces, the base, which includes a hold with

groove for the bolt; the center plate, which it wasn’t change and the bolt which is used to

maintain the position of the center plate.

45

III.2.1.2.1 DFA with B&D method

1 2 3 4 5 6 7 8 9

Name of Assembly α β Part

ID No.

Number of time the


consecutively

Two-digit manual

handling code


part

Two-digit manual

insertion code


part


(2)*[(4)+(6)]


0.4*(7)


parts

1 1 30 1,95 00 1,5 3,45 1,38 1 Base 360 360

2 1 20 1,8 00 1,5 3,3 1,32 1 Center Plate 360 180

3 1 10 1,5 92 5 6,5 2,6 0 Bolt 360 0

13,25 5,3 2 Design Efficiency 0,453

TM CM NM

Table 11 - DFA B&D Method for Redesign

It can be observed that the efficiency obtained with the new design increased around 35% compared with the original design.

46

III.2.1.2.2 DFA with Lucas method

Fitting Assembly

Component Number

Component Description

Number of parts

Functional Assembly

Feeding Analysis

1

Base

1

A

1.5

2

Center Plate

1

A

1

3

Bolt

1

B

1

TOTAL 3 2 3.5

Ed = 2 / 3 * 100% = 66.7 %

The efficiency of the design obtained from the functional analysis meet the target expected with this new design. Also, the

ratios of feeding and fitting are very close to the ideal values, as it is shown next:

Feeding Ratio = 3.5 / 2 = 1.75

Fitting Ratio = 4.5 / 2 = 2.25

1.5

1.0

1.0 1.0

4.5

47

III.2.2. Modular System Characteristics based in physical attributes

Function Modules:

• Basic function: the basic function is given by the base, which helps to position the

rest of the pieces and works as a backstop when drilling.

• Auxiliary function: the screws and the end brackets have an auxiliary function, to

help maintaining the central plate in his position in an indirect way.

• Adaptive function: the central plate can be change to adapt and adjust the size of

the hole for the drilling.

• Special function: the nuts and the bolts have a special function, since they help to

maintain the central plate in its position in a direct way.

Production Modules:

• The piece gives to the user safety when drilling a piece

• Easy to manipulate for the user

• Allows changing the size of the hole that it is going to be drilled.

48

SLS Matrix

Components

Phisics

Arragment Proximity

Component 1 Component2 In Line Parallel In contact Separated Base End Brackets 1 0 1 0

Screws 1 0 1 0 Central Plate 1 0 1 0 Bolts 0 1 0 0 Nuts 0 1 0 0

End Brackets Base 1 0 1 0 Screws 1 0 1 0 Central Plate 1 0 1 0 Bolts 0 1 1 0 Nuts 0 1 1 0

Screws Base 1 0 1 0 End Brackets 1 0 1 0 Central Plate 1 0 0 1 Bolts 0 1 0 1 Nuts 0 1 0 1

Central Plate Base 1 0 1 0 End Brackets 1 0 1 0 Screws 1 0 0 1 Bolts 0 1 1 0 Nuts 0 1 1 0

Bolts Base 0 1 0 1 End Brackets 0 0 1 0 Screws 0 0 0 1 Central Plate 0 0 1 0 Nuts 1 0 1 0

Screws Base 0 1 0 1 End Brackets 0 1 1 0 Screws 0 1 0 1 Central Plate 0 1 1 0 Bolts 1 0 1 0

49

Chapter IV. Conclusions

The report gave a brief idea in how to make a rapid prototyping of pieces, an analysis of

assembly efficiency and times, tolerances, positional control, structures of D-chains and D-trees,

positional control, modular system, analysis of calculation of dimensions, etc. All those

procedures mentioned, that were developed during the work, are vital guidelines that all

companies must follow in order to design a prototype. The manufacture of a prototype is costly,

which makes more important all the analysis and calculation, which must be done very carefully,

since the failure of the prototype designed must not fail.

All the material covered can help to covered can help to future engineers to understand

the basics of computer aid manufacturing, and the way to design a prototype considered its

physical attributes, functions, assembly order and other key points for where the analysis start.

50

Chapter V. Appendix

51

18.00 mm +0.00 -0.50

• Assumption 1: Highest diameter of sensor is equal to 18 mm.

• Assumption 2: The lower diameter of sensor is equal to 12 mm.

• Assumption 3: The ring retainer is 1 mm from the top of the sensor.

• Note 1: Sizes were randomly assigned.

+0.00 -0.50 12.00 mm

+0.50 -0.00 1.00 mm

18.00 mm +0.50 -0.00

COMPONENT 0 – X-120 SPEED SENSOR ASSEMBLY

-0.00 12.00 mm +0.50

+0.00

-0.50 16.00 mm

X-122 – “O” Ring

+0.05 -0.05 1.00 mm

+0.00 -0.05 18.00 mm

1.00 mm +0.05 -0.05

+0.00

-0.50 18.00 mm

Ring Retainer +0.05 -0.05 1.00 mm

+0.00 -0.50 20.00 mm

9.00 mm +0.125 -0.00

30.00 mm +0.50 -0.00

16.00 mm +0.125 -0.00

53

COMPONENT 1 - X-108 ASSY-INPUT GEAR

• Note 2: It is required to calculate the tolerances.

25.00 mm +0.00 -0.02

0.9843 in +0.0000 -0.0008

25.02 mm +0.02 -0.00

0.9850 in +0.0008 -0.0000

X-109/ X-104 (LC10)


ds(max)= d – a = 0.9843 in

Since a =0.0007, d = 0.9850 in



ds(max) = d –a= 0.9843 in


Range a h L 0.71 – 1.19

7.0 +8.0 -7.0 23.0 0 -15.0


s=|Lmin + a|=|-0.0015+0.0007|= 0.0008 in

54

COMPONENT 2 - X-103 COVER ASSEMBLY

• Note 3: It is required to calculate the tolerances.

X-105 / X-104 (LC11)


ds(max)= d – a = 0.9843 in

Since a =0.001, d = 0.9853 in


dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in

ds(max) = d –a= 0.9843 in


Range a h L 0.71-1.19

10 +12 -10 34 0 -22


s=|Lmin + a|=|-0.0022+0.0010|= 0.0012 in

25.00 mm +0 00 -0.03

0.9843 in +0.0000 -0.0012 +0.03

-0.00 25.03 mm

0.9853 in +0.0012 -0.0000

55

X-109/ X-104 (LC11)

Diameter of Shaft = 0.9843in

ds(max)= d – a = 0.9843 in

Since a =0.0010, d = 0.9853 in


dh(max) = d+h = 0.9853 + 0.0012 = dh(max) = 0.9865 in

ds(max) = d –a= 0.9843 in


Range a h L 0.71-1.19

10 +12.0 -10 34 0 -22


s=|Lmin + a|=|-0.0022+0.0010|= 0.0012in

25.00 mm +0.00 -0.03

0.9843 +0.0000 -0.0012

25.02 mm +0.03 -0.00

0.9850 in +0.0012 -0.0000

113.95 mm +0.10 -0.00

119.95 mm +0.10 -0.00

4.7224in +0.004 -0.000

3.45 mm +0.15 -0.15

56

X-105 / X-102 (LC4)

d = 1.872 in

dh(min) = 1.872 in


ds(max) = d –a= 1.872 in

ds(min)= d-a-s = 1.8695 mm

Range a h L 1.19 – 1.97

0 +4.0 0 6.5 0 -2.5


s=|Lmin + a|=|-.0025+.000|= 0.0025 in

47.55 mm +0.00 -0.06

1.872 in +0.000 -0.0025

47.55 mm +0.10 -0.00

1.872 in +0.004 -0.000

12 mm +0.05

-0.05

57

COMPONENT 3 - X-101 HOUSING ASSEMBLY

25.02 mm +0.02 -0.00

0.9850 in +0.0008 -0.0000

58

X-112/ X-108 (LC11)


ds(max)= d – a = 0.9843 in

Since a =0.001, d = 0.9853 in


dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in

ds(max) = d –a= 0.9843 in


25.00 mm +0.00 -0.03

0.9843 in +0.0000 -0.0012

Range a h L 0.71-1.19

10 +12 -10 34 0 -22


s=|Lmin + a|=|-0.0022+0.0010|= 0.0012 in

+0.03 -0.00 25.03 mm

0.9853 in +0.0012 -0.0000

+0.35 -0.35 5.4 mm

+0.03 -0.00 54.80 mm

30.92 mm +0.00 -0.03

+0.05 -0.05 13 mm

• Assumption 4: The Plug cup has the same dimensions as the bushing.

• Assumption 5: The hole of housing for plug cup and bushing is same as the Input Gear hole for bushings.

+0.06 -0.00 30.80 mm

tickness: 2.00 mm

+0.05

-0.05

59

+0.00 -0.05 27.00 mm

+0.50 -0.00 23.00 mm

+0.50 -0.00

3.0 mm

+0.025 -0.025 27.035 mm

+0.04 -0.04 47.00 mm +0.05

-0.05 60.31 mm

+0.005 -0.005 6.655 mm

+0.0325 -0.0325 9.9825 mm

+0.01 -0.01 18.91 mm

+0.05 -0.05 26.60 mm

+0.25 -0.25 3.75 mm

60°

+0.25 -0.25 2.75 mm

+0.10 -0.10

21.0 mm

60

12.00 mm +0.00 -0.04

• Assumption 6: Both shafts have the same length.

• Assumption 7: Ring retainer X-129 has the same thickness as the rings retainers X-117.

+0.00 -0.20 156.2 mm

+0.20 -0.00 65.1 mm

+0.12 -0.00 1.5 mm

• Important: the shat is going to move 10 mm.

61

COMPONENT 4 - X-126 SHIFT FORK ASSEMBLY

12

• Nota 4: Diameter of shift fork is equal to biggest diameter of collar shift.

11.96 mm +0.02 -0.00

0.4708 in +0.0007 -0.0000

12.00 mm +0.00 -0.04

0.4724 in +0.0000 -0.0014

X-112/ X-108 (FN2)

d –a = 0.4724


ds(max)= d – a = 0.4724 in



Range a h L 0.40 – 0.56

0.5 +0.7 +1.6 1.6 0 +0.2


s=|Lmin + a|=|0.0002 – 0.0016|= 0.0014 in

+0.00

-0.44 73.94 mm

tickness: 9.5 mm

+0.50

-.000

62

• Assumption 8: Diameter of hole in collar shift is 0.5 bigger than the diameter of hub and has a tolerance of +0.5.

• Assumption 9: Diameter of pin dimensions are calculated based on the worst case scenario.

+0.04 -0.04 18.91 mm

+0.01 -0.01 6.30 mm

+0.25 -0.25 61.11 mm

+0.015 -0.015

6.305 mm

+0.22 -0.22 73.72 mm

+0.50 -0.00 12.50 mm

+0.00 -0.08 18.95 mm

+0.00 -0.01 6.29 mm

0.2476 in +0.0000 -0.0004

X-112/ X-108 (FN2)


ds(max)= d – a = 0.2476 in

Since a =0.0014, d = 0.2462 in


ds(max)= d – a = 0.2476 in



Range a h L 0.24- 0.40

0.4 +0.6 +1.4 1.4 0 +1.0


s=|Lmin + a|=|0.001 – 0.0014|= 0.0004 in

+0.02 -0.00 6.25 mm

0.2462 in +0.0006 -0.0000

+0.50 -0.00 15.75 mm

63

ASSEMBLY:

+0.12 -0.00 1.5 mm

+0.24 -0.00 3.0 mm

• Note 5: The holes for all the pieces are equal to the hole calculated for the shift fork.

11.96 mm +0.02-0.00

0.4236 in +0.0007 -0.0000

64

+0.13 -0.00 23.72 mm

0.934 in +0.005 -0.000

+0.06 -0.06 1.56 mm

+0.0000 1.2173 in -0.0012

30.92 mm -0.03 +0.00

Range a h L 0.95- 1.19

0.6 +0.8 +1.9 1.9 0 +1.4


s=|Lmin + a|=|0.0014-0.0019|= 0.0005 in

27.00 mm +0.00 -0.01

1.063 in +0.0000 -0.0005

26.95 mm +0.02 -0.00

1.0611 in +0.0008 -0.0000

X-115 / X-104 (FN2)


ds(max)= d – a = d = 1.0611 in


dh(max) = d+h = 1.0611 + 0.0008 = dh(max) = 1.0619 in


• Assumption 10: The ring retainer X-121 has same dimensions as X-117.

65

X-116 / X-117 (LC11)


ds(max)= d – a = 1.2174 in

Since a =0.001, d = 1.2184 in


dh(max) = d+h = 1.2164 + 0.0012 = dh(max) = 1.2196 in

ds(max) = d –a= 1.2174 in


Range a h L 0.71-1.19

10 +12 -10 34 0 -22


s=|Lmin + a|=|-0.0022+0.0010|= 0.0012 in

30.92 mm +0.00 -0.03

1.2174 in +0.0000 -0.0012

30.95 mm +0.03 -0.00

1.2184 in +0.0012 -0.0000

66

X-116 / X-104 (LC11)


ds(max)= d – a = 0.9843 in

Since a =0.001, d = 0.9853 in


dh(max) = d+h = 0.9833 + 0.0012 = dh(max) = 0.9865 in

ds(max) = d –a= 0.9843 in


25.00 mm +0.00 -0.03

0.9843 in +0.0000 -0.0012

+0.03 -0.00 25.03 mm

0.9853 in +0.0012 -0.0000 47.60 mm +0.05

-0.05

7.25 mm +0.25 -0.25

1.56 mm +0.06 -0.06

• Assumption 11: The bigger diameter of the washer- thrust is equal to the diameter of the hole for the shaft seal in the cover.

Range a h L 0.71-1.19

10 +12 -10 34 0 -22


s=|Lmin + a|=|-0.0022+0.0010|= 0.0012 in

67

X-118 / X-104 (LC4)


ds(max)= d – a = 0.9843

Since a = 0.00, d = 0.9843 in

dh(min) =d = 0.9843 in

dh(max) = d+h = 0.9843 + 0.0035 = dh(max) = 0.9878 in

ds(max) = d –a= 0.9843 in


25.00 mm +0.09 -0.00

0.9843 in +0.0035 -0.0000

Range a h L 0.71-1.19

0 +3.5 0 5.5 0 -2.0


s=|Lmin + a|=|-0.002+0.00|= 0.002 cm

18.00 mm +0.50 -0.00

33.4 mm +0.50 -0.00

• Assumption 12: The biggest diameter of the output gear is equal to the biggest diameter of the input gear.

102.0 mm +0.00 -0.20

15.4 mm +0.00 -0.04

47.65 mm +0.00 -0.10 60.69 mm +0.00

-0.18 70.19 mm +0.00

-0.24

2.5 mm +0.50 -0.00

• Assumption 13: The diameter of the output gear for the spacer is equal to the cover diameter for the shaft seal.

4.00 mm +0.50 -0.00

25.00 mm +0.00 -0.05

0.9843 in +0.000 -0.002

4.00 mm +0.50 -0.00

23.00 mm +0.00 -0.50

2.00 mm +0.00 -0.50 Width of the groove:

68

X-119 / X-104 (LC4)


ds(max)= d – a = 0.9843

Since a = 0.00, d = 0.9843 in

dh(min) =d = 0.9843 in

dh(max) = d+h = 0.9843 + 0.0035 = dh(max) = 0.9878 in

ds(max) = d –a= 0.9843 in


Range a h L 0.71-1.19

0 +3.5 0 5.5 0 -2.0


s=|Lmin + a|=|-0.002+0.00|= 0.002 cm

25.00 mm +0.00 -0.05

0.9843 in +0.000 -0.002

25.00 mm +0.00 -0.05

0.9843 in +0.0035 -0.0000

4.08 mm +0.00 -0.04

47.55 mm +0.10 -0.00

69

X-124 X-100

X-117 / X-104 (FN1)


ds(max)= d – a = 0.945 in

Since a = -0.011, d = 0.934 in

dh(min) =d = 0.934 in

dh(max) = d+h = 0.934 + 0.005 = dh(max) = 0.939 in

ds(max) = d –a = 0.945 mm

ds(min)= d-a-s = ds(min)=0.941 mm

Range a h L 0.71-0.95

0.2 +0.5 +1.1 1.1 0 +0.7

For interference fit, the allowance is the highest value, the hole tolerance is the non-zero value and for the shaft, is used the next formula:

s=|Lmin + a|=|0.007-0.011|= 0.004 in

24.00 mm +0.00 -0.10

0.945 in +0.000

-0.004 +0.13 -0.00 23.72 mm

0.934 in +0.005 -0.000

0.0591 in +0.0047 -0.0000

+0.06 -0.06 1.56 mm

+0.0000 1.2173 in -0.0012

30.92 mm -0.03 +0.00

+0.00 -0.12 1.62 mm

70

ProjectReport Sample

Documents

Transcript of ProjectReport Sample