Old Main

Finalized Process Plans  Front Face Process Plan

Finalized Process Plans (cont.)  More Detailed Front Face Process Plans

Finalized Process Plans (cont.)  Side Face Process Plan

Finalized Process Plans (cont.)  More Detailed Side Process Plans

Finalized Process Plans (cont.)  Top Plate –Tooling 4” Face Mill 1” End Mill –Machine 3-Axis Milling Machine –Fixturing Vacuum Fixture –Description Cut to shape then perform a cut off operation  Bottom Plate –Tooling 4” Face Mill 1” End Mill ¾” Spot Drill –Machine 3-Axis Milling Machine –Fixturing Vacuum Fixture –Description Spot drill feature then end mill the over hang

Finalized Process Plans (cont.)  Triangular Roof –Initial Stock is 1.25” x 1.25” x 6’ solid square 6061 Aluminum –Cut into 12” sections using bar feeder –Cut each 12” section in half (diagonally) on band saw using 45 degree wedges for guidance –Mount 12” triangular sections in rotary vise on machining center –Cut off 4 individual roof components using 1/8” end mill

Finalized Process Plans (cont.)  Tower –Base Section Tooling –3” Face Mill –3/8” End Mill Fixturing –Multiple Chick Vises (mounted in parallel) –V-blocks Machine –3-Axis Mill Description –End mill to cut off corners. Refixture to add effects  Tower (cont.) –Middle Section Tooling –3” Face Mill –3/32” End Mill Fixturing –Multiple Chick Vises (mounted in parallel) –V-blocks Machine –3-Axis Mill Description –Same procedure as base section

Finalized Process Plans (cont.)  Tower (cont.) –Top Section Tooling –Center Drill –3/8” Drill –7/8” Drill –1.5” End Mill –3/16” End Mill –1/32” Radius Concave Cutting End Mill –Turning Tool –Cutoff Tool Fixturing –3-Jaw Chuck Machine –5-Axis Mill –Lathe – Possibly of lathe with bar feeder and live tooling  Base –Tooling End Mill Drill –No Special Fixturing Required –Machine 3-Axis Mill  Columns –Just a cut off operation is required

Production Schedule

New Findings & Decisions  Reduction in Machine Time –Total Time for machining is now 105 min. –Cut our labor and machine cost by 40% New cost is $52.50 per Old Main –New Per Unit cost of $87.43  Going to produce 18 this semester –Accounting for 10 to be given away to faculty and group –Going to sell 8 at $250 per Old Main –Give Profit of around $200.

Bill of Materials  Triangular Roof –1.25” square x 6’ long –Qty. needed: 2 –Price: $51.24 ea.  Tower –1.25” diameter x 6’ –Qty. needed: 1 –Price: $33.94  Tower –1.25” square x 6’ –Qty. needed: 1 –Price: $51.24  Tower –2.25” square x 3’ –Qty. needed: 1 –Price: $  Columns –5/16” diameter x 6’ –Qty. needed: 8 –Price: $4.95 ea.  Flat Roof –4”w x 0.5” thick x 6’ –Qty. needed: 3 –Price: $65.48 ea.

Bill of Materials (cont.)  Sides –1.5” x 3” x 0.125” x 6’ box tube –Qty. needed: 1 –Price: $67.50  Front/Back –3’ x 8’ –Qty. needed: 1 –Price: $  Base –1’ x 6’ sheet of walnut –Qty. needed: 2 –Price: $24.00 ea.  Clock –15/16” Clock insert –Qty. needed: 18 –Price: $5.95 ea.

Breakdown  Triangular Roof: $ (3)  Tower (upper): $33.94  Tower (middle): $51.24  Tower (base): $  Columns: $39.52 (8)  Flat Roof: $ (3)  Sides: $67.50  Front/Back: $  Base: $48.00  Clock Insert: $ Total: $862.52

Final Costs  Material Cost for 18 Old Mains: $  Machine Cost for 18 Old Mains: $945  Cost to Produce = $  Sell 8 Old Mains at $250 a piece: $2000  Net Profit = $192.48

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