Rodney Katz - Prototype Design and Manufacturing Manual
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PROTOTYPEDESIGNAND
MANUFACTURINGMANUAL
DEPARTMENTOF
MECHANICAL
ENGINEERING
RODNEYKATZ, MICHAELLEWIS Rev.0
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TABLEOF CONTENTS
Introduction...................................................1
PARTI Design...............................................2
1 FirstSteptoDesign.............................2
2 Prototyping.........................................3
2.1 ExamplePrototypeDevice..........6
3 TopDownMachining..........................7
4 Alignment!..........................................9
4.1 AlternateMethods....................13
5 Bearings.............................................17
6 Motor................................................17
7 Orings...............................................18
8 PipesandTubes................................21
8.1 Fittingsforpipes........................21
9 Materials...........................................22
9.1 RawMaterials............................22
9.2 Aluminum....Error!Bookmarknot
defined.
9.3 Steel...........................................23
9.4 PVC.............................................23
9.5 Delrin.........................................24
9.6 Plexiglas.....................................25
10 Drawings........................................26
10.1 CommonDrawingmistakes.......27
10.2 Dimensioning............................27
10.3 Tolerances.................................35
10.4 AnilamCNCMill........................35
PartII Manufacturing................................39
1 Posts.................................................39
1.1 ImportantNotesforposts........43
2 CNCMilling.......................................44
2.1 Setupmethods..........................44
3 ORings.............................................48
3.1 AxialOrings..............................48
3.2 RadialOrings............................51
4 DrillingandTapping.........................54
4.1 Tapping......................................54
Appendices.....................................................I
References......................................................I
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INTRODUCTION
The purpose of this manual is to present best practices for the design and
manufacturingofprototypedevices,lowvolumemachinedpartsandassemblies.
Itisimportanttonotethatmanyofthemethodsandtechniquesoutlinedinthemanual
arespecifictotheUVicMech.MachiningFacility.
Figure1.1Mixerdevice
The manual is structured around the design and manufacturing of a single device
(shown above in Figure 1.1) which encompasses many typical characteristics of
mechanicalfeaturesfoundintheDept.MechanicalEngineeringresearchapparatus.
Thisdesign is very efficient tomachine, incorporates inherent alignment,uses stock
materialreadilyavailableinthemachineshopandisfamiliarwiththeshopmachinists.
Themanualwillalsoincludecomparisonexamplesoflesseffectivedesignsofthesame
device.These
methods
are
often
initially
thought
tobeeasier
tofabricate
but
donot
lend thesameadvantagesoftherecommendedsampledesignshownabove
Designmethodologyisaverybroadsubject;thismanualonlycoversthebasics.
Extendedtopicslikehighvolumemanufacturing,rapidprototypingandtechniquesused
outsidetheMech.Eng.Shoparenotcoveredinthismanual.
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PARTI DESIGN
1 FIRSTSTEPTO DESIGN
Designofadeviceshouldalwaysbeginwithopeningcommunicationwiththespecific
shoporfacilitywherepartswillbemanufactured.
Thecapabilitiesoftheshoporfacilityneedtobecarefullyconsideredinordertodesign
economicallyfeasibledevices orequipment:
o Machineryandshopspecificexpertise,CNCmilling,lathecapability,sheetmetal
capabilities,welding capabilities,heavymachining,precisiongrinding,waterjet
cutting, EDM,rapidprototyping,etc.)
o Shoppreferredmanufacturingmethodsandmaterials.
o Machine tool (lathe, mill) capacity. What is the largest or smallest size
workpieces and cutting tools the shops machines can comfortably
accommodate.
o Timelinerequiredtodeliverparts.
While inthedesignphase,continuallycommunicatingwithshoppersonnelwillalways
leadtodesignswhicharelessexpensiveandmoreefficienttobuild.
Whenever possible, design parts in inches. The rationale being the machine shops
cuttingtool andmaterialinventoryareintheimperial(inch)system.Designinginmetric
then converting to inches leads toodddimensions thus complicating thedesign and
machiningprocess,resultinginamorecostlyandtimeconsumingpart
Alwayskeep inmind stockmaterial sizeswhendesigningparts.This isparamount to
achievinganeconomicallyfeasibledesign.Oftenthestockmaterialsizewillbesufficient
to accommodate yourdesignwith little additionalmachining required. InCanadawe
stillworkwith stockmaterial sizes in the inch systemasmostofourmaterial comes
fromU.S.suppliers.
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2 PROTOTYPING
Generallyprototypepartsshouldincorporatethefollowing:
o InherentAlignment. Partsautomaticallyfitintoplace.Thiseliminatestheneed
forpostmachiningandhandtoolmodificationinordertofitpartstogether.
Bosses and other features should be incorporated in the design to assure
alignmentoffinalassemblies.
o Abilitytobeadjustedwith littlerework.Thiscouldmeanaddingextraholesor
elongating holes for unforeseen additions orwhen youmay feel adjustability
couldberequired.
o Theuseofeasilymachinablemateriali.e aluminum,acetyl(Delrin),PVC(plastic)
whereeverpossible.Eventhoughthesematerialsmaybetwiceorthreetimes
thecostofsteel, their fabricatingandmachiningcostswillbedrastically lower
resultinginalessexpensivepart.
o Reduce thenumberofpartswith tight tolerances (to lower costand increase
machiningefficiency).
o Sizepartswithaconsiderationformaterialyield.E.g.aluminumsheetcomesin
48X96sheets.Ifyourequirefourpieces12X12thiswillresultinmuch
wastematerial. Reconsider the design toworkwith 12 X 12 pieces. Sheet
metaldoesnot consumematerial for cutswhereasplatematerial (3/16and
thicker)willconsumeapproximately3/16percutduetothesawingandclean
upprocess.Platematerial isalso supplied in12 increments.Therefore if four
12X12platesarerequiredthiswillproducealargeamountofexcessmaterial.
Trytoworkthedesignwithpartsizesof11.75X11.75
o Tappedholes#632andlargershouldbedrilledallthewaythroughinmaterials
up to thick ifpossible asopposed toholesdrilled to specificdepths. It is
alwayseasiertotapathroughholeopposedtoablindhole(holethatdoesnot
penetrate). Theholemayonlybetappedpartiallythrough.
o Whendesigningaholeforapressfitdowelpin, incorporateasmallerdiameter
throughholewhichcanbeusedtopushorknockthedowelpinoutifrequired.
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Thiswilloftenbethecase.(SeeFig.2.1below). Ifnothroughhole ispresent it
willbeverydifficulttoremovethedowelpinandremovalmethodswillresultin
damagingthepinandthemaybethehole.
Figure2.1Thruholeinshafttoallowremovalofdowelpin
o
Tabs or marks for realigning parts if they are going to be placed back in a
machine for postmachining operations. This is often the casewhen the part
needsholesalignedtoeachotherfrombothends. Anotherreasonforalignment
markswouldbeorifthepartneedstobeorientedinaspecificrotationalangle
atassemblytime.(SeeFigure2.2).
Figure2.2Circularpartandfixturewithgroovesforrealignment
o Flatson roundparts.Thisallows for thepart tobe replaced intoavisewitha
knownorientationforpostmachiningormodificationsatalaterdatefrom(See
Figure2.3)
DowelpinShaft
Thruholetopushoutdowel
Scratchmarks
forrealignment
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Figure2.3Roundpartwithflatselfalignsinvise
Avoidweldingparts together.Weldingdoesnot allow formajor changes if required.
Separatingpartscanbevery labour intensiveandsometimescloseto impossible. It is
alsoverydifficulttoaccuratelyalignweldedparts.
Design theassemblyofsufficientsizetoavoidworking inconfinedspaces.Alsoavoid
theuseoftinyscrewsi.e. #256andsmaller.
Trytokeepthefastenerthreadtypeselectiontoaminimum.#1032isaverypractical
size for much of the metal work performed in the shop and is easily tapped.
(use a #1024forplastics)
Utiliseasmanyofftheshelfitemsaspossible.Thesewillsavemanyhoursofdesignand
machining work, paying for themselves many times over. Often offtheshelf
componentsmaynotmeetalltherequirementsbutcanbemachinedtoaccommodate
thedesignrequirements.
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2. 1 EXAMPLE PROTOTYPEDEVICE
ThemixerdeviceshowninFigure2.4isthe exampleprototypeassembly.
Keycomponents,whichwillbediscussedinthemanual,arenotedonthediagram.
Figure2.4MixerDevice
Motor
(gearsdrivemainshaft)
Post
NPTThreadedHole
(Cylindersurfaceisspotfaced)
ControlPanel
TopPlate
(Topdownmachined)
NPTandISOFittings
Oringseals
Bearings
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3 TO PDOWNMACHINING
Flat parts (Top and Bottom plate)machined using amanual or CNCmill should be
designed inorderthattheyaremachinedononeortwosidesonly.This iscalledTop
Down. Trytoavoidhavingfeaturesmachinedinthesidesofplates.
o The actual process of cutting material is relatively quick. It is the setup and
positioningof materialandpartsthattakesmajorityofthetime.
o Ifapartcanbesetuponceand thencutwithout rotatingor repositioning the
partmachiningefficiencywillincreaseexponentially.
o Figure 3.1 shows an example of a part which requires multiple setups to
machine.Thispartwillneedtoberepositioned inthevisefourtofivetimesto
drill all the required holes in the sides consumingmuch time and effort. The
more often a part is repositioned (clamped) in the machine the greater the
possibilityofmisalignmentofthefeatures.
o Alsothelonglengthofthispartcreatestwopossibleproblems:
ThemillingmachinebeingusedmaynothavetherequiredtravelintheZ
axisneededtodrilltheendholes(showninthethirdsetupofFigure3.1).
Rememberthedrillchuckisextendsapproximately 3inches,thedia.
drill extends 4 and the part on end extends approximately 6 high,
resultinginaconsumptionof 13ofthemillingmachinesZaxistravel.
Ifthepartismachinedwhileonendthestabilityofthepartmaynotbe
enoughtopreventmaterialflexandresultininaccurateholepositioning.
Thepartclampedonend(Fig3.1C)willalsoaccentuatethedeviationof
the hole positioning ( 0.1degreeoffperpendicularon a 6protruding
clampedpartinthevisewillcauseapositioningerrorofthedrilledhole
by0.010)Trying toensuring thepart isclampedperpendicularby this
amountorbetterisverytimeconsuming).
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Figure3.1MultiplesetupsrequiredforapartthatcannotbemachinedTOPDOWN
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4 ALIGNMENT!
Alignmentofparts and features isoneof themost important aspectsofmechanical
design.
Ifpartsaredesignedwithalignmentinmindatalltimesitwillpreventmuchfrustration
andaddedcostinthefinalassembly.
Figure4.1PostwithendbossesandextraholesinOD
Onebasicmethod toalignparts is tousepostswithbossesonbothends.Figure4.1
showsanexampleofapostwhichincorporatesbossestoaidalignment.
Incorporatingabossoneachsideoftheposthastheaddedadvantageofallowingthe
posttobeheld inthe lathechucksothecritical lengthcanbemeasuredoffthefront
faceofthechuckjaws(the Zdatum).
Theprocedureusedintheshopforaccuratelymachiningthistypeofpostdesignisvery
efficient.
Figure4.2showshowpostswithintegralbossesareusedintheassembly.
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Figure4.2Alignedplatesandpostsassembly
Oncethepartsareassembledthetwoplateswillbealignedsufficientlyinorderthatno
fussingorfiddlingwillberequiredtoattainthedesiredresult.
Thismethod allows theplates tobeefficientlymilledanddrilledTopDownwithone
setup.Norepositioningisrequired.
Thismethod canbe altered to suitmanydifferent applicationswhile stillmaintaining
alignmentofplatefeatures(eg.centreholes,shaftholes,bearingboresetc.):
o
Platescanbedifferentshapesifrequired(Fig.4.3)
o 2or3postscanbeusedinsteadof4(Figure4.3)
o Notallpostsneedtobethesamediameter
o Platethicknessescanbedifferent
ThemachiningprocessforpostsisinPartII Manufacturing,Section1(Page39).
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Figure4.3
3post
design
with
difference
shaped
plates
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Carchassis TappingMachine
Table SubmersibleChassis(fitsintube)
Winch 3postdesign
Figure4.4Examplesofhowpostscanbeused
Figure4.4showsexamplesofhowpostscanbeused.(eg.Carchassis,table,ROV,etc.)
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4. 1 ALTERNATE METHODS
This sectionpresents someof the alternatives tousing roundpostswithbosses.The
alternativesmayappeareasiertofabricatebutareoftenmuchmoretimeconsumingto
machineandassembleandtheydonotincorporateinherentalignmentfeatures.
Figure4.5showsadesignsimilartotherecommendedmethod
o Thesquarepostsaredifficulttomachine.
o Multiplesetupsarerequiredtomachinetheposts.
Figure4.5Plateassemblyusingsquareposts
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Figure4.6andFigure4.7showthetwoplateassemblywithanglebrackets
Anglebracketsareappealingbecausetheyseemsimpletomachine(justcutto length
anddrill).Anoteof caution!Oftenwhatappears simple to fabricate results inbeing
ratherdifficultandcumbersome.Themethod inFigure4.6 isvery timeconsuming to
machine as the top andbottomplates cannotbemachined topdown.A totalof 64
holesmustbedrilled.Halfoftheholesalsoneedtobetappedinthesidesoftheplates.
Figure4.6Plateassemblyusinganglebrackets
Unstable
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Thesecondanglebracketmethoduseswelds.
o This assembly requires16welds . Considerable time is required to setup and
weld.Properalignmentoftheplateswillbevirtuallyimpossibleoftenrequiring
somepostmachiningorhandwork.
o Intermsofprototypingweldingdoesnotallowpartstobeeasilymodified.
Figure4.7Plateassemblyusingweldedanglebrackets
Figure4.8showsaweldedversionofawinchframe.ThewinchinFig4.8wouldtakea
considerableamountof timeandefforttoconstructdueof thenumberofweldsand
therequirementthattheframebeaccuratelyalignedforbearingsblocks.
Figure4.8WeldedWinchFrame
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NOTE:ThereisatimeandplaceforweldingbutinmostassembliesusedintheMech.Eng.
Dept.itisnotappropriate.Weldingofsmallaluminumpartsisverydifficultandshouldbe
avoided.
Figure4.9belowshowsthetwoplateassemblyusingCchannel.Thismethodisappears
relativelyquicktomachinebuthassignificantalignmentlimitations:
o Cchannel comes in standard sizes therefore spacingof theplateshas limited
options. Spacersmustbeusedtoadjustplatespacing.
o ThesizeofextrudedcchannelisnotalwaysaccurateandtheCchannelsidesare
oftennotperpendicular.
o Ensuringtheholesaredrilleddirectlyoppositeoneanother intheCchannel is
verydifficult.
o SecurelyholdingtheCchannelpartsinthevicefordrillingiscumbersome.
Figure4.9Plateassemblyusingcchannelforposts
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5 BEARINGS
Bearings of many varieties are often used in mechanical design and are of utmost
importancetothefunctionalityoftheassembly.
Machinedfeaturesthatacceptbearingsmustusuallybemadetotightertolerancesthan
otherfeatures.
Ifaboreholeforabearingistoosmallrequiringexcessforcetoseatthebearingitwill
oftencausethebearingtorunroughandleadtoprematurefailure.
Ifaboreholeistooloosethebearingwillsloparoundandreducethealignmentofthe
shaft.
Alwaysincludetolerancesindrawingsfordimensionsrelatedtobearings.
Ifpossiblehave thebearingsavailableat timeofmachining.Thiswillgreatlyhelp the
machinistcorrectlysizethebearingborehole.
6 MOTORMOUNTING
Mostsmallandmidsizemotors incorporateabossandboltholesontheirface(Figure
1.1).
The motors boss assures concentric alignment of the motorshaft to the mounting
surface.
Correct tolerancingof theboss receivingbore is very important. Ifpossiblehave the
motoravailabletothemachinisttochecktheboresizeandfitattimeofmachining.This
willoftenavoidtimeconsumingreworkofparts.
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Figure6.1Motorwithbossandboltholes
7 ORINGS
Oringsareoneofthemostcommontypesofsealsused.Theyareextremelyefficient
and very inexpensive. Themachiningprocesses required to accommodateOrings is
oftensimpleifthepartisdesignedwithconsideration.
SealingusingOringsallows foreasydisassemblyof theapparatus ifmodificationsor
cleaningisrequired.
Figure7.1Orings
Boss
Boltholes
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TypesofORingSealingConfigurations
o Axial:oringsealisonthefaceofapart.
o Radial:oringseal isontheouteror innerwallofapart.Radialsealsonsmall
shaftscansignificantlydecreasethestrengthoftheshaft.Inthiscaseitisbetter
togroovetheinnerdiameteroftheparttheshaftwillfitinto.
o AvoidtheuseofRadialOringconfigurations ifpossible,theyaremoredifficult
tomachineand requiremuch tighter tolerances inall respects. Note that the
PlexiglasOringcontainerconfigurationinthesampleMixerdeviceusesanaxial
seal.Thereareseveralreasonsforthischoice:
o It iseasiertomachinevs.aradialseal. Ifaradialsealwereused,thePlexiglas
container
I.D.
wouldhave
tobeaccurate
and
concentric.
This
is
often
not
the
caseinstocktubularmaterial.InordertoattainanaccurateandconcentricI.D.
onatubeitmustbeboredonalathewhichisverytimeconsuming.Foranaxial
sealonlytheendsofthecontainerneedtobemachinedwhichisaquickprocess
o A radial seal is often makes it difficult to remove the end caps especially in
oceanographicinstruments.
Figure7.2 AxialORingseal RadialORing seal
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Figure7.3 Axialgland Radialgland
ThegrooveinwhichtheORingsitsiscalledthegland(fig7.3)
AppendixVandVIshowtablesforglandsizes.
ThemachiningprocessforOringglandsisinPartII Manufacturing,Section3
(Page48).
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8 PIPES AN DTUBES
Pipes:Pipesizesarereferredtobasedontheirnominalinnerdiameters,nottheirouter
diameters.i.e.a schedule40 pipewillhaveanO.D.of 1.050
o
Note:Thenominal innerdiameterofpipeusuallydoesnotmatch thephysical
inner diameter. This is due to the different wall thicknesses (referred to as
schedulesizesi.esched.40orsched.80).Differentpipematerialshavedifferent
O.D.sizesi.e.copperpipehasanO.D.of0.875vs. steelandaluminum
pipehavinganO.D.of 1.050.
Tubes: Tube sizes are referred to based on their actual physicalO.D. i.e. 1 tube is
physically1.00O.D.
Pipe isoften lessexpensive than tube therefore it isusedwhen largerquantitiesare
requiredinthedesignorwhenfluidtransportisrequired.Tubeisusedwhenaspecific
diameterisrequired.
8. 1 PIPEAN DFLUIDFITTINGS
ThefollowingarethemostcommonfluidfittingsusedintheMech.Eng.Dept.research
apparatus
NPT (NationalPipeThread) isa standard forpipe fittings.NPT fittingsare tapered to
produceaneffectivefrictionsealwhenscrewedintothematingfitting.
Note:A NPTfittinghas threadO.D.ofapproximately1/2.
NPT fittingsarenotused in thinmaterialor sheetmetal.Aminimumof four threads
mustbeengagedtoproduceareliableseal.
ISOfittingshavestraightthreadsandincorporateanOringinthebasetocreateaseal.
Themating surface for theseoringsmustalwaysbe spotfaced toproducea reliable
seal.Seetheoffsetholeinthetopcapofthesampledevice.Thespotfaceisrequiredto
produceasurfacewithmachiningmarksconcentricwith theOringseal. If this isnot
donethestriationsoranyscratches intheplasticplatewouldallowa leak.Whenever
OringsareusedanymachiningmarksorscratchesmustbeconcentricwiththeOring.
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9 MATERIALS
This section lists some of themore commonmaterials used in theUVicMech. Eng.
Machine Shop. Consult McMasterCarr (www.mcmaster.com) for more detailed
informationonthematerialsizes,characteristicsandcost.
9. 1 STOCKMATERIALS
Whendesigningkeepinmindthestandardsizesofstockmaterials.
o In most cases stock materials cannot be depended on for accurate sizes or
geometrictolerances(perpendicularsides,parallelism,etc.)
o An example exception is precision ground steel rod which is ground to tight
tolerances.
o Ifhighprecisionalignmentisrequiredthestockmaterialmustoftenbemachined
onthesignificantmatingsurfaces.Aluminumplatehasgoodsurfaceflatnessas
opposedtoaluminumextrusionandisapproximatelytwicetheprice.Useof
aluminumplatecanoftenreducetheamountofmachiningrequiredpayingfor
itselfinthe
final
result.
9. 2 ALUMINUM
AluminumismostoftenthematerialofchoiceintheMech.Eng.MachiningFacility.
AluminumCharacteristicsandAdvantages
o Lightweight
o Largesizeselection
o
Goodstrength
o Goodcorrosionresistance
o Easytomachine
o
Cleantowork
o Goodesthetics
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o Highheatconductivity
o Easilyrecyclable
o Readilyavailable
o Difficulttoweldproperly
o Canbeanodizedtoachieveaveryhighlycorrosionresistantsurfaceandcoloured
surface.
9. 3 STEEL
MildSteel Characteristics
o
Highstrength
o Heavy
o Corrodeseasily(rust)
o EasytoWeld
o Certaintypesofsteelprovedifficulttomachine
o Lowcost
o Considerablymorecostlytomachinethanaluminum
Mild steel isnotusedextensively in theMech.Eng.Machining facility. It is generally
usedforshafts,heavyweldedstructures,axelsetc.
StainlessSteelcharacteristics
o Verygoodcorrosionresistance(Oceanographicapplications)
o Hightemperature
o Veryhighstrength
o Veryheavy
o
Expensive
o Weldseasily
o Costlytomachine,useonlywhereabsolutelynecessary
9. 4 PV CPLASTIC
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PVCcharacteristics:
o Good corrosionresistance
o Easytomachine
o Lightweight
o Can be bonded easily.Note: Amechanical interconnectivity of the two parts is
alwaysrequiredwhenbondingPVC.ItisnotadvisabletobuttjointPVC.
o
Notrecommendedforwearapplicationsduetohighfrictioncoefficient.
9. 5 DELRIN(ACETAL)
Delrin(Acetal) isoftenusedasareplacementforaluminumparts.Dueto itsexcellent
machinability try to implement it into designswhere possible.Onemajor advantage
being that itdoesnotneed any coating tobe corrosionproof. It alsoproduces very
estheticallypleasingpartsdueitssheenandcolour.
Delrin(Acetal)hasthefollowingcharacteristics:
o Excellentmachinability
o Corrosionproof
o Goodrelativestrength
o
Lightweight
o Toughandwearresistant
o Verylowfrictioncoefficient
o Solventandfuelresistant
o Whiteorblackincolour
o Commonlyavailableinroundrod/bar,sheet,andplate
SomeapplicationsofDelrin:
o
Bushingsforlowspeedapplications
o Wearpads
o Fluidfittings
o Gears,pulleys,idlers
ImportantNotes:
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O Delrincannoteasilybebondedtoitselforothermaterials.
9. 6 PLEXIGLAS
Plexiglascharacteristics:o Lightweight
o Opticallyclear
o Brittle
o Scratcheseasily
o Lowoperatingtemperatureband
o Commonlyavailableinsheet,tubeandsolidround
o
Bondstoitselfveryeasily
Plexiglascanbebentusingheat.
o Bending Plexiglas is not recommended for prototype design because changes
andadjustmentscannotbemade.
o AccuratelyheatbendingPlexiglasiscanprovetobedifficult.
Plexiglas canbeeasilybonded togetherwithabuttjoint resulting in relatively strong
bond(Figure9.1).
o
SurfacesmustbesmoothandflatforbondingPlexiglasi.e. routedormilled.
Figure9.1Plexiglasbondedbuttjoint
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10 DRAWINGS
Trytoalwaysincludeanassemblyviewwithasetofsubmitteddrawings.
o Thiswillhelptheshopunderstandthepurposeofthepartsandwhereextracare
shouldbetakenwhenmachining.Iftolerancesordimensionswereomittedina
drawing itwilloftenallowtheshoptomakean informedjudgment iftheyare
notabletocontactyou.
Makesurethedrawingscaleisnotedsoifdimensionsneedtobecheckedoraremissing
theycanbemeasuredoffthedrawing.
Whenprototyping,printingdrawingswitha1:1scalecanbeusefultoseetheaffectsof
changesonthepart.
General information should be included in the drawing title block. An example title
blockisshowninFigure10.1.
o Detailstoinclude:scale,quantity,material,part#,contactinfo,tolerances
Figure10.1ExampleTitleBlock
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10.1 COMMONDRAWINGMISTAKES
Toomanydecimalsplaces
Dimensionsreferencedfromwrongsideofpartedge
Fonttobigortoosmall(shouldbe12pt. 14pt.)
Arrowheadstoobig
Toomanyhiddenlinesshownmakingdrawingdifficulttointerpret(useasectionviewif
neededtoshowhiddendetails)
Toomuchinformationononedrawingsheet(usemorethanonedrawingsheettoshow
partmoreclearlyifthisisthecase)
10.2
DIMENSIONING
Useordinatedimensioningtomakedrawingseasiertoread.
Mark the origin of a part based on the origin which will be used when the part is
machined.
Draw ordinate lines on the side of the part which is closest to the detail they are
showingthepositionof.
The following pages show examples of drawingswhich are cluttered and difficult to
understandfollowedbyadrawingwhichusesbestpracticesfordimensioningdrawings.
Dimensiondrawing features according to the shoppreferredmethodor specificCNC
millthatwillbeused.(Seesection10.4AnilamCNCMill,page35)
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Figure10.2OrdinateDimensioning
3.000
2.625
0 1.0
00
.375
1.6
25
2.8
75
3.0
00
3.1
88
.500
4.7
50
5.0
00
0
.250
.500
1.000
2.000
3.2
50
1.250
1.635
.260
.375 THRU 3PL
.250 THRU 3PL
1.000 THRU
R.300 TYP
.250 NOM
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3.000
2.625
0 1.0
00
.375
1.6
25
2.8
75
3.0
00
3.1
88
.500
4.7
50
5.0
00
0
.250
.500
1.000
2.000
3.2
50
1.250
1.635
.260
.375 THRU 3PL
.250 THRU 3PL
1.000 THRU
R.300 TYP
.250 NOM
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4.750
3.188
5.000
.250
1.000 THRU
2.875
.260
1.635.500
1.000
.375
1.000
1.625
3.000
THRU 3PL.250
3.250
.500
THRU 3PL.375
2.000
1.000
2.625
.25
1
3.000
Figure10.3Exampleofbaselinedimensioning
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Notesaboutdrawing(Figure10.3):
Useofbaselinedimensionsmakesdrawingtooclutteredandhardtoread
Elevationviewshownwithhiddenlinesisconfusing.Shouldhavehiddenlinesremoved.
Slotlengthdimensionshouldbedonetothetotallengthofslot(asshownbelow).
.260
1.375
.2
Undesirableslotdimensioning
.260
1.635
.2
Preferredslotdimensioningstyle
Figure10.4Dimensioningofaslotlength
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Notesaboutdrawing:
Dimensionlinesaredifficulttofollow.Ordinatedimensionsshouldbeonthesideofthe
partclosesttothefeaturetheyaredefining(showninFigure10.7).
Elevationviewofpartshouldbeshownwithouthiddenlines(Figure10.5).
.250 NOM
.250 NOM
Figure10.5Elevationviewwithandwithouthiddenlines
Dimensionlinesshouldnottouchthepart.
.260
.260
Figure10.6Dimensionlinespacing
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1.25
0
3.250
1
.000
4
.750
5
.000
3
.188
0
.250
1.001.000
2.000
2.625
3.000
.375
1.6
25
2.875
.500
3
.000
.500
1.635
1.000 THRU
.375 THRU 3PL
R.3
.250 THRU 3PL
.250 NOM
Figure10.7Easytoreaddrawingusingordinatedimensions
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Desirabledrawingcharacteristics:
Thedrawingaboveusesthepreferredstyleofdimensioning.
Dimensionlinesarespacedaparttoavoidclutteringthedrawing.
Dimensionsareclosetothefeaturetheydescribe.
Theslotscentrepositionisdimensionedandthewidthandtotallengthareshown.
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10.3 TOLERANCES
Tolerancesareaveryimportantaspectofdrawingswhichareoftenoverlookedandare
notgiventheattentiontheyrequire.
Alldimensions
should
have
an
associated
tolerance.
An
efficient
tolerancing
method
includes
asection
to
the
includesasectiontothedrawingsheetstitleblockwhichdefinesthestandardtolerancesbasedonnumberof
tolerancesbasedonnumberofdecimalplaces(shownin
Figure10.8).
Tolerances
.xxx 0.003
.xx 0.01
.x 0.015
Unlessotherwisenoted
Figure10.8DrawingBlockforStandardTolerances
Ifcertaindimensionscanaccommodatewider tolerance then removetheappropriate
decimals. Whenspecificallyneededaddtolerancestoindividualdimensionstohighlight
theprecisionrequired.
10.4 ANILAM CN CMILL
TheCNCMillingmachineusedextensively intheMech.Eng.MachineShoputilisesan
Anilamcontrolsystem.
Thefollowingfiguresshowthecontrolsystemsdifferentinputscreens(conversational
programming)forvariouscannedcycles.
o
Acannedcycleisasetofmachineoperationsinitiatedbyasinglelineofcode.It
usesafillintheblanktypeinterface.
Usethescreensshownbelowtodeterminetheappropriatemethodtodimensionpart
featureswhichwillbeCNCmilled(diagramsarespecifictoAnilamcontrolsystem).
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Figure10.9Inputscreenforboltholecircle
Figure10.10Inputscreenforrectangularprofile
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Figure10.11Inputscreenforcircularprofile
Figure
10.12
Input
screen
for
rectangular
profile
Figure10.13Inputscreenforcircularpocket
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Figure10.14Inputscreenforframepocket
10.4.1 ANILAMCANNEDCYCLEDEFINITIONS
Profile:CircularorRectangular.CNCmillcutstheoutlineoftheshape.Cuttercanbeon
the insideoroutsideof the shape.Profilesareused formilling theoutside contours,
slotsandholes.
Pocket:CircularorRectangular.CNCmillcutsallofthematerialinsideoftheshapetoa
specifieddepth.
Frame: CNC mill cutsa rectangular groove. This can have any radius on the corners
(commonlyusedforrectangularoringgrooves).
Note:Allthesecycles requiretheshapescentreposition, length,width ordiameter,
thereforeitismosthelpfultodimensiondrawingswiththeserequirementsinmind.
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PARTII MANUFACTURING
1 POSTS
The drawing below (Figure 1.1) shows the best practices for dimensioning a postdrawingwhenusingthemachiningmethodoutlinedonthefollowingpages.
3.7
5
0.25
3.5
00
.5
.750-.002
+.000
2 PL
1/4-20
1.0 NOM
UVic Fac ulty of Engineering
Hole Tapper
Drawn by REV.
SCALE: 1:1 MATERIAL:
MLDate:
SHEET 1 OF 1
Part: Qty.
A
1
7/22/2009
Comments:
Dimensions in inchesunless noted.
Tolerances:
.xxx .003
.xx .010
.x .015unless otherwise stated
Project:
Standoff
Break all sharp edges
Figure1.12DDrawingforPost
Thepostdrawingaboveshowsthedatumposition(zero)asthebaseoftheleftboss.
This isdonebecause the criticaldimension for thispart is3.500andnot theoverall
lengthof4.0.
Note: Ifalignment isverycritical(eg.topandbottomplatesneedtobealignedwithin
0.003ofeachother) then theouterdiameterof thepostmustbemachined first to
maintainconcentricitythroughoutthemachiningprocess.Thisisbecausestockmaterial
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isoftennotperfectlyround.Machiningthefullouterdiameterlengthisrarelyrequired
inmostapplications.
Latheprocessformachiningmultiplepostswithbosses
Step1FacefirstendofpostandsetZaxisto
zeroonlathedigitalreadout
Step2Turnbosstorequireddiameterand
approximatedepth.
Step3Centredrill Step4Drillendtotapdepth
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Step5Tap.Repeatsteps15forallposts Step6Zerotoolagainstchuckusingshim(make
suretoaccountforshimthickness)
Step7Faceoppositeendofpostto
approximatelythetotallength
Step8Centredrill.Repeatsteps7and8forall
identicalposts
Step9Turnsecondbosswithlivecentre
(Z=criticallengthofpost)
Step10Drillbossofoppositeendtotapdepth
Z
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Step11Tapsecondend Step12Chamferallsharpedges
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2 CNC MILLING
2. 1 SETUPMETHODS
2.1.1
FLATPARTS
FlatpartsareoftenmachinedonaCNCmillusingafixtureplate(Shownbelow).Thishas
manyadvantagesoverconventionallymachinedpart.
o If the part does not have any features in its ends or sides only one setup is
required(Topdownmachining).Thisbeingtherationalefornotplacingholesin
thesidesofflatpartswhenitcanbeavoided.
o Theoutsideofthepartcanbemachinedinonestep.
o Precisecopiesofthesamepartcanberapidlymachined(i.e.leftandrightsides,
topandbottom).
Figure2.1Flatpartwithfixturingplate
Fixtureplate
Part
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Figure2.2Fixturingplatesetupinvise
2.1.2 CIRCULARPARTS
When themilling forceswillbe in the Zaxisonly (eg.Drilling) a circularpart canbe
bolteddowntoaplate(ShowninFigure2.3).
Figure2.3CircularPartbolteddownthroughcenter.
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Inothercaseswherelateralandradialcuttingforceswillbeappliedtothepartajigcan
be used. Figure 2.4 shows an example of a very simple, effective circularholdingjig
which iscommonlyused in theshop.Thescratchmarkson thepartandjigallow the
parttobereplacedintothemillinthecorrectorientationforpostmachiningoperations
ormodifications.
Figure2.4Circularpartwithjig
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Figure2.5Circularpartandjigsetup
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3 ORINGS
3. 1 AXIAL ORINGS
ReduceRPM
speeds
when
grooving
Figure3.1showsanexampleaxialoringgroove.
.100.005 2.50 NOM
1.580.003
1.750.003
Figure3.1AxialOringGroove
1. Determinethewidthofthetoolbeingused.Inthiscasethetoolwidthis0.0525.
.0525
2. Usingthefollowingformula,determinetheXpositionfortheO.D.oftheOringgroove
Oring O.D. 2Tool Width
1.750 20.0525 1.645
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WorkpieceMUSTberotatingforsteps3and4.
3. Usingtherightsideofthetool,establishthetoolpositionontheO.D.oftheworkpiece
andentertheO.D.oftheworkpieceintoXonthedigitalreadout(eg.2.500).
4. Usingthetipofthetool,establishthetoolpositiononthefrontfaceoftheworkpiece
bytouchingofflightly.Enter0.000intoZonthedigitalreadout.
TouchoffthetoolwheretheOringgroovewillbelocated.Thescoremarkcreated
fromthetoolwilldisappearwhentheOringgrooveiscut.
Steps5to7willberoughcuts.Roughcutsareusually0.010smallerthanthefinal
tolerance.Thisisperformedtoimprovesurfacefinishandtolerances.
5. MovetoolinXaxisto1.590andthenmovetoolinZaxisto0.090.
.090
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6. MovetoolinXaxisoutto1.635.Thisis0.010smallerthanthecalculatedvaluefrom
step2.
7. Performthefinishingcut.MoveXto1.580,nextmoveZinto0.100andthenmove
Xoutto1.625.
This shouldbedone inone fluidmotion.The tool shouldneverbecome stationaryon the
workpiecewhenperforminganycuts.Thiscancausechatterandexcessiveheatgeneration
andwhenmachiningplasticitwillcreateapoorsurfacefinishandthesealmayleak.
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3. 2 RADIAL ORINGS
ReduceRPMspeedswhengrooving
Figure3.2showsanexampleradialoringgroove.
.145.005
.250
1.50 NOM
1.320.003
Figure3.2RadialOringGroove
1. Determinethewidthofthetoolbeingused.Inthiscasethetoolwidthis0.0525.
.0525
2. UsethefollowingformulatodeterminethefinalZpositionforthewidthoftheOring
groove.
Groove width Tool Width 'Z' distance from datum surface
0.145 0.0525 0.25 0.343
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WorkpieceMUSTberotatingforsteps3and4.
3. Usingtheleftsideofthetool,establishthetoolpositionontheendoftheworkpiece
and enter the width of the tool into Z on the digital readout (eg. 0.0525). This
establishedtherightsideofthetoolaszerointheZaxis.
4. Usingthetipofthetool,establishthetoolpositionontheO.D.oftheworkpieceand
entertheO.D.oftheworkpieceintoXonthedigitalreadout.(eg.1.500)
TouchoffthetoolwheretheOringgroovewillbelocated.Thescoremarkcreated
fromthetoolwilldisappearwhentheOringgrooveiscut.
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Steps5to7willberoughcuts.Roughcutsareusually0.010smallerthanthefinal
tolerance.Thisisperformedtoimprovesurfacefinishandtolerances.
5. MovetoolinZaxisto0.260andthenmovetoolinXaxisto1.320.
6.
Move tool in Zaxis to 0.333.This is0.010 smaller than thecalculatedvalue fromstep2.
7. Performthefinishingcut.MoveZto0.250,nextmoveXinto1.300andthenmove
Zto0.343.
Thisshouldbedoneinonefluidmotion.Thetoolshouldneverbecomestationaryonthe
workpiecewhenperforminganycuts.Thiscancausechatterandexcessiveheatgeneration
andwhen
machining
plastic
it
will
create
apoor
surface
finish
and
the
seal
may
leak.
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4 DRILLINGAN DTAPPING
CentreDrill:
o Useanytimethereisachancethedrillbitmayglanceoffthematerialorwhen
holesneedtobepreciselypositioned(ie.holesonaradius,drilling intoahard
material,etc.).Centredrillsareusedveryoftenwhendrillinginthelathe.
DrillingPlexiglas:
o Plexiglaswilloftentocrackwhenthedrillbitexitsthroughtheothersideofthe
part.Topreventthis,slowdownthedrillfeedforthe last 1mmor1/16while
drillbitexitsthematerial.ThisheatsthePlexiglastomakethe last1/16more
pliabletopreventcracking.Useextracarewhendrillingholesgreaterthan5/16
diameter.
4. 1 TAPPING
Taps:Usedtocutinternalthreads.Thevarioustypesoftapsare:
Spiralpointtapsarethemostcommonlyused.Thefirst3to4threadsonthesetaps
arepartialthereforetheydonotcutfullthreads forthecompletelengthof
engagement. IfthisisrequiredseeBottomingtapsbelow.
o BottomingTap:Usedtocutthreadstothebottomofablindhole.Abottoming
tapdoesnothaveataperedcuttingedgethereforeaplugtapmustbeusedfirst.
Donotuseabottomingtaptocutthreadsinanunthreadedhole.
Tapdrillbit:Specificsizeddrillbitforacertaintap(eg.#6drillfora1/420tap).
PercentageofThread:Thepercentageofthreadreferstotheamountofthreadinterms
ofthetotal threaddepth (crestto root).Usea largertapdrillbit to lower the thread
percentandviceversa.Decreasingthethreadpercentminimizesthetorqueonthetap
anddramaticallyhelpstoavoidbreakingthetap.Italsospeedsupthethreadingpro
Note: Use a bottoming tap only when thread depth is critical (ie. 1/2 plate
requiring 3/8 thread depth). Regular taps will not cut full threads to the
bottomofahole.
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Figure4.1Threadpercentageexample
TPI:ThreadsPerInch
Metricthreadsarespecifiedbythedistancebetweenthethreads
Die(externalthreads):Usedtocutexternalthreads.
NPTThreads:(NationalPipeThread)Thesearetaperedthreadsforsealingfluids
Maximumdepthoftappedholesshouldnotexceed3XDiameterofTap.Usaullytwice
thetapdiameterisallthatisrequiredtoprovidemaximumholdingforce.
100%Thread 70%Thread 50 %Thread
CrestRoot
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APPENDICES
MachiningTolerances II
TapDrillSizes III
DrillingandMillingSpeeds IV
ORingGlandSizes(Axial) V
ORingGlandSizes(Radial) VI
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Tapdrillandbodydrillsizes(fromshop)
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Drilling,millingspeeds(fromshop)
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REFERENCES
Osborn,Joe.2006.TipsonDesigningCostEffectiveMachinedParts.[Online]OMWCorporation.
Availableat:http://www.omwcorp.com/partdesign.html.[Accessed19June2009].
McMasterCarr.2009.[Online]McMasterCarrSupplyCompany.Availableat:
http://www.mcmaster.com.[Accessed07August2009].
ParkerORingHandbookORD5700,Parker,2007.
http://www.parker.com