1 manufacturing projects flexible manufacturing copyright © texas education agency, 2013. all...

1

Manufacturing ProjectsFlexible Manufacturing

Copyright © Texas Education Agency, 2013. All rights reserved.

Manufacturing Projects

• You will have to produce two projects: simple top and machine vise.

• Your grade for each will be determined by using the project rubric.

• You will have to read the plans and manufacturing steps to complete the assignment.

2Copyright © Texas Education Agency, 2013. All rights reserved.

Manufacturing a Top


Top Plans

4

1.25 0.50

2.50

.0.75 Dia.

0.25Dia.


Manufacturing Steps

• Cut a 0.75 in. diameter piece of aluminum to a 2.50 in. length.

• Chuck the piece in the lathe and face the end.• Machine this end to a 0.25 in. X 1.25 in. section.• Sand and polish the top shaft.• Remove and flip the piece, chuck the 0.25 in.

end into the chuck about 0.75 in.


Manufacturing Steps, Con’t

• Face this end and run some clean up passes on the length of the remaining material.

• Cut a taper back 0.75 in. from the end.• Sand and polish the top. • Remove and test the spinning of the top.


Project Rubric for the TopTop: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance, the section receives the maximum points. If the measurement is not within tolerance, the points can be from 0 and up. Add the points for a grade.

7

Section of Part

Diameter Length Points Max Points Received

Overall measurement

20 points

0.25 in. diameter

15 points

0.75 in.diameter

15 points

Taper 25 points

Finish 15 points

Spin 10 points

Grade:


Manufacturing a Vise


Exploded View of Vise Parts

9

1

74

3

2

9

8

6

5


Vise Bill of Materials

10

PARTNUMBER

QUANITY NAME SIZE

1 1 BASE 0.75 X 2.50 X 52 1 FIX JAW 0.75 X 2.50 X 23 1 MOVABLE JAW 0.75 X 2.50 X 24 1 FRONT JAW 0.75 X 2 .50 X 25 1 SCREW 1.25 DIA. X 3.756 1 HANDLE 0.37 DIA. X 37 2 JAW FACES 0.50 X 1 X 2.508 1 JAW LOCK 0.12 X 0.75 X 1.509 7 FASTENER 0.25–28 BOLTS X

0.75 LONG10 1 SETSCREW

(NOT SHOWN)0.12 SETSCREW X

0.75 LONG


Vise Cut Sheet

Cut the following pieces of metal:• 0.75 in. X 2.50 in. material 12 in. long • 1.12 in. diameter piece 4 in. long• 0.37 in. diameter 3.25 in. long• 0.50 in. X 1 in. metal 5.75 in. long• 0.12 in. X 0.75 in. 1.50 in. long• Use the 12 in. long piece and cut the base and

the three(3) jaws from it.11Copyright © Texas Education Agency, 2013. All rights reserved.

Vise Base Plan

12

0.75

0.25

0.75

4.500.75

5.00

2.50

1.00

0.50 1.25

1.25

DRILL 2 HOLES 0.25 DIA.

0.37


Manufacturing Steps for Base

• Square the 0.75 in. X 2.50 in. X 5 in. piece on the mill.• Using an end, mill cut the 1 in. wide X 0.50 in. deep

slot through the material.• Flip the part over and mill the 0.25 in. deep cavity in

the bottom of the material.• Measure and drill the 0.25 in. holes in the base and

countersink the bottom of the hole.• Sand and polish the base and put away for later

assembly.


DRILL 0.20 HOLE TAP 0.25 -20 THREADS

Vise Fix Jaw Plan

14

0.37

0.75

2.50

1.00

2.000.75

0.50

0.75

0.25

1.25

0.37

1.500.50

DRILL 2,0.25 HOLES


DRILL 0.20 HOLE TAP 0.25-20 THREADS

Manufacturing Steps for Basic Jaw Shape

• (Note) All three jaws are the basic shape. • The bottoms of the jaws are the same with the

sides machined away and a hole tapped in the bottom for fastening them in place.


Movable Jaw Plan

16

0.25 0.37

0.75

2.50

1.00

DRILL #3 BIT X 0.50 DEEPTAP TO 1/4–28 THREAD SIZE

1.25

0.37

1.500.50

DRILL 2,0.25 HOLES

2.000.75

0.50

0.75

0.25BORE 0.50 DIA. X 0.375 DEEP HOLE

1.00

#8 –32 SETSCREWDRILL #29 (0.13) HOLE


Manufacturing Steps for Movable Jaw

• The slots for the jaw faces are milled into two pieces.

• These slots are the same on both jaws. • The holes for the faces are the same on both

jaws.• The movable jaw will have a matching 0.50 in.

hole for the end of the vise screw.• This jaw will need a setscrew hole drilled and

tapped to hold the screw in place. See plans.17Copyright © Texas Education Agency, 2013. All rights reserved.

Front Jaw Plan

18

2.00

0.37

0.75

2.50

1.00

0.75

DRILL #3 BIT X 0.50 DEEPTAP TO 1/4–28 THREAD SIZE

1.25

DRILL 0.49 DIA.TAP TO 0.50—13

1.00


0.50

Manufacturing Steps forFront Jaw

• The front jaw will be drilled and tapped for the vise screw (0.50-13 threads).


Movable Jaw Lock Plate Plan

20

0.75

1.50

0.75

0.37

0.12

DRILL 0.25 HOLE


Manufacturing Steps for Movable Jaw Lock Plate

• Lay out and drill the 0.25 in. hole in the 0.12 in. X 0.75 in. plate.• Countersink this hole for the fastener.


Vise Screw Handle Plan

22

0.37

3.00

THREADED TO 0.50-13 THREADS

3.75

0.751.00

0.50

0.37 DRILL

SETSCREW GROOVE0.12 FROM END0.12 WIDE CUT 0.12 DEEP

HANDLE

3.00 0.37 DIA.


Manufacturing Steps for Vise Screw Handle

• Mount the material in a set of v-blocks and drill the 0.15 in. hole through the piece at the handle end.

• Mount the 1.12 in. rod in the lathe and turn the material to the thread diameter.


Manufacturing Steps for Vise Screw Handle, Con’t

• Chuck the handle end in the lathe and turn the smaller diameter for the threads.

• Thread the screw on the lathe or use a die to cut the 0.50-13 threads.

• Cut the groove in the end of the screw.


Jaw Faces Plan

25

0.37

0.25

0.50

DRILL #1 BIT X 0.50 DEEPTAP TO 0.25–28 THREAD SIZE

2.50

1.50

1.00

0.25

0.50


Manufacturing Steps for Jaw Faces

• Cut the 0.50 in. X 1 in. bar into two, 2.50 in. long sections.

• Machine the ends smoothly. • Mill the bevel on the edge.• Lay out and drill the two holes.• Tap the threads into the holes.


Exploded View of Vise Parts

27

1

74

3

2

9

8

6

5


Assembling the Vise

• Bolt the jaw faces to the two slotted jaws.• Bolt the fix jaw assembly to the base using the

0.25 in. X 0.75 in. fastener.• Slide the movable jaw onto the base, turn the

assembly over, and install the jaw lock with the fastener.


Assembling the Vise, Con’t

• Mount the front jaw onto the base with the fastener.

• Install the screw through the front jaw and into the movable jaw.

• Tighten the setscrew in the moveable jaw to hold the screw into that jaw.

• Test vise for ease of movement.


Project Rubric for the Machine ViseMachine Vise: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance, the section receives the maximum points. If the measurement is not within tolerance, the points can be from 0 and up. Add the points for a grade.

30

Section of Part

Size Machining Finish Points Max Points Received

Base 16 points

Fix Jaw 16 points

Moveable Jaw

16 points

Front Jaw 16 points

Screw/Handle

16 points

Jaw Faces 16 points

Grade:


1 manufacturing projects flexible manufacturing copyright © texas education agency, 2013. all...

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