ASU Instrument and Prototype Machine Shop

ASU Instrument and Prototype Machine Shop
Ira A. Fulton Instrument & Prototype Machine Shop Orientation (Time: < 60 minutes) Opening, introduction slide – check web links ( links slide) each year. "If you have a difficult task, give it to a lazy person; they will find an easier way to do it." — Hlade's Law. Dennis Golabiewski February 21, 2019 ASU Instrument and Prototype Machine Shop

Job Submission & Tracking
Orientation is Required For Everyone Submitting manufacturing drawings to the Machine Shop for the production of components. Job Submission & Tracking Log in using your asurite logon Orientation Machine Shop FROM THE DEANS OFFICE All students, whether submitting jobs for research faculty or their own 490 or Capstone projects, must have first completed the one hour machine shop orientation session and be registered with the machine shop before any job requests can be accepted! As of January 1, 2009 labor fees will be put in place. Please check our webpage. It is not enough to do your best; you must know what to do, and THEN do your best. W. Edwards Deming February 21, 2019 ASU Instrument and Prototype Machine Shop

490 Projects and approved 200 & 300 level courses are due
6 weeks prior to last day of semester Summer Projects must be < 3 days work. ALL JOBS ARE NOW SUBMITTED ONLINE Any submissions for class projects cannot be guaranteed for the end of a semester if they are submitted after the due date. Work backlog in the shop is generally 3 – 6 weeks. All jobs are now submitted on line SolidWorks files can be ed (with job #) to : Professors & Researchers If you need your parts completed sooner, there is the option to pay for HIGH PRIORITY (see mshop webpage) to have your work moved forward in the job queue. February 21, 2019February 21, 2019 ASU Instrument and Prototype Machine Shop

Instrument & Prototype Machine Shop Personnel
Manager: DENNIS G. Phone 96(5 –7163) Room 170a R.S.S. Bldg 2 SHOP LEADS: BUTCH BAUER & MARTY JOHNSON R.S.S. Bldg. 1 Room 130 Phone 96(5–6030) shop Shop Hrs. 7:30am / 11:45pm -- 12:15pm CLOSED / 3:00 pm Student computers ( RSS 2 Room 170B ) accessible during shop hours only. Staff: MACHINIST David Mushier MACHINIST SR. Forest (Ben) Schwatken David Gillespie INSTRUMENT MKR/DESIGNER Martin Johnson Harold (Butch) Bauer February 21, 2019 "In theory there is no difference between theory and practice, but in practice there is.“ Yogi Berra ASU Instrument and Prototype Machine Shop

Shop Location shop office train Tyler street parking The Science Graduate asks "How does it work ?" The Economics Graduate asks "How much does it cost ?" The Engineering Graduate asks "How can we make it ?" The Liberal Arts Graduate asks "Do you want fries with that ?" — Jesse N. Schell. February 21, 2019 ASU Instrument and Prototype Machine Shop

Shop Rules Never! walk into the shop without permission! Wait inside the door for someone to assist you. Never! come to the shop with open toe shoes, sandals or flip-flops, you will not be allowed entry! Because this is a continuous problem. Read RULES 1and 2 several times if needed! Safety glasses are available inside the shop door. Once you receive permission. Put them on before walking any further into the shop to speak with your machinist. PLEASE Return our SAFETY GLASSES or Leave $6.00 with SHOP LEAD Not following these rules may result in termination of your use of the machine shop services and cessation of your “work in progress”! "Nothing in the world is more dangerous than sincere ignorance and conscientious stupidity." - Martin Luther King Jr. February 21, 2019 ASU Instrument and Prototype Machine Shop

List of TOPICS in this PPT
Terminology Machines, Machine Tools, Tools and Tooling Machine Tool Types (our Tool Room / Machine Shop) Methods of manufacture on and off campus Parts we DO NOT build Materials selection, properties & finishes Concept Designs, Functionality & Development Prototype Styles Prototype, Design Intent, Intelligent Design Prototype Design submission Design tools ( i.e. CAD/CAM/CAE F.E.A. ) Design drawing detailing. ( GD&T, tol’s, dim’s & DATUMS) Detailed drawing examples Methods of manufacture/design in Industry FEA in Industry Q: What is the difference between Mechanical Engineers and Civil Engineers? A: Mechanical Engineers build weapons, Civil Engineers build targets." February 21, 2019 ASU Instrument and Prototype Machine Shop

TERMINOLOGY CAD (computer aided design) (computer aided drafting) CAM (computer aided manufacturing) (computer aided machining) CNC (computer numerical control “G-CODE programs”) CAE (computer aided engineering) FEA (finite element analysis - pretesting) RP (rapid prototyping = FDM, SLA, SLS, LC, 3d printing … ) GD&T (geometric dimensioning & tol’s) PLM (product lifecycle management) concept to distribution management BD&T (Shop requires Basic dimensioning and tolerancing ) “It's a damn poor mind that can only think of one way to spell a word.” Andrew Jackson February 21, 2019 ASU Instrument and Prototype Machine Shop

Machines Machine Tools Tools Tooling
Always remember you're unique, just like everyone else Machines Cars, lawnmowers, computers, vending, copying Machine Tools Milling machine, extruding machine, drill press… (fabricating ) Tools Axe, hammer, wrench, pencil, pc mouse, SolidWorks, Cosmos, a Big Stick Tooling Endmills, lathe bits, grinding wheels, lawn mower blade “We do not loan out any tools, OF ANY KIND” dg

Machine Tools & Mfg. Tools
@ the Ira A Fulton School of Engineering / Instrument & Prototype Machine Shop Vertical & horizontal knee milling machines Tool room lathes 2 & 3 axes CNC vertical knee mills 3 axes Tool Room Mills 2 - 4 axes Machining Centers 2- ½ axes CNC tool room lathe Pedestal Surface Grinder Pedestal I.D. / O. D. Cylindrical Grinder Metal cutting band saws Shears, Brakes, Punches and Presses These are standard Tool Room or Prototype Shop tools February 21, 2019 ASU Instrument and Prototype Machine Shop

Machine Shop & Mfg. Processes
Learn about Machine Tools: What they are called. How they work . What they do. The tolerances they are capable of achieving. The types of surface finishes they generate. A basic understanding will help you design for the tools we have at ASU. Knowing more about machining is simply using the information you have in your toolbox! Understanding your manufacturing options will help you design prototype parts that will include: Improve performance Reliability for testing Reduced re-design and/or manufacture time. Once you have determined the function of a feature on a part you should know the “quality” of finish and the “degree” of accuracy required to achieve the results you desire in your part. Even if you're on the right track, you'll get run over if you just sit there. Will Rogers ASU Instrument and Prototype Machine Shop February 21, 2019

There are 3 machine tool groups that do the majority of work in our machine shop. They are: Mills (INCLUDING CNC Machine Centers) Lathes Grinders. For your projects at ASU, if you plan on using the Machine Shop, learn as much as possible about the capabilities of these machines. The time spent will: Aid in designing parts we can produce. Cut down production time. Leave you with a better understanding of what we must do to manufacture your parts and leave you with a greater appreciation of the skills of machinists. February 21, 2019 ASU Instrument and Prototype Machine Shop

Milling Machines Horizontal Knee Mill Milling is the process of removing material from a workpiece (part) by moving the workpiece (fixed to the movable table) past a fixed position head/ram, rotating multi or single tooth/flute milling cutters (tool bit). The cutting action of teeth around the center axis of the milling cutter provides a fast, accurate method to machining. The machined surface may be flat, angular, or a multi dimensional curve or curve surface. The adjoining surfaces or edges (features) may also be milled to produce any combination of shapes and contours. The machine used for these applications is properly referred to as a milling machine tool or a machining center. Today live tooling lathes can duplicate some of these operations eliminating the need for multiple set-ups on separate machine tools. The shop has both CNC and manual, vertical and horizontal knee mills. Precision) ±0.0005”or ±0.013mm. These tolerances are operation and operator dependent and under ideal new equipment conditions and unlimited time constraints. These are the current shop capabilities relative to specific operations. OPERATIONS Today milling machines are also used for drilling, reaming, boring, counter boring, counter sinking, tapping, grooving and chamfering holes. Know the difference between the operations above. They are different in their degree of accuracy and function. Learn ( ) these terms and use them in your drawings. It will clarify the requirements of a feature for the machinist. Spindle Knee Spindle Vertical Knee Mill Knee February 21, 2019 ASU Instrument and Prototype Machine Shop

CNC Machining Centers The Fulton Machine Shop has 2 Machining Centers
(ALSO MILLING MACHINES) The Fulton Machine Shop has 2 Machining Centers Accuracy on these machines can be as good as: ±0.0005” or ±0.0127mm These tolerances are operation depend. VF3YT VF4 February 21, 2019 ASU Instrument and Prototype Machine Shop

Tool Room Lathe Machine Tools
Operations commonly done with a lathe: Turning……machining (cylinder) the OD (outside diameter) Boring………machining (cylinder) the ID (inside diameter) Facing………machining a smooth surface on the end of a piece Thread Cutting……making threads on either the OD of ID Taper Cutting……turning/boring a conical OD or ID Drilling……clearing a hole thru the center (rotation axis) of a piece. Grooving……for O-rings, E-clips, snap rings, oil grooves, etc. Turning or boring are the machining operation that produce cylindrical features on parts. It is defined as machining external diameter (O.D) and internal diameter (I.D.) surfaces. With the workpiece mounted on one of several types of head stocks. The workpiece rotates about the centerline of the headstock . A single-point lathe tool-bit moves parallel to the axis of rotation of the workpiece and at a distance from the workpiece that will force contact between the work piece and the tool bit. This interference of the tool bit on a workpiece will remove a portion of the O.D. or I.D. surface of the part. Taper turning is similar with the exception that the cutter path is at an angle to the work piece axis. Similarly, in contour turning, the distance of the cutter from the work axis is varied to produce the desired shape. This is usually achieved by the use of templates on tracer lathes and G-code programs on CNC machines. Various types of single flute lathe bits are used to generate the best result with respect to feature shape & type of material being machined Tail Stock Tool Post Cross slide Spindle / Chuck Or Head Stock February 21, 2019 ASU Instrument and Prototype Machine Shop

Tool Room Surface & Cylindrical Grinding Machines
Surface grinding is the process of passing a workpiece fixed to a table moving longitudinally and transversely under a fixed location, high speed, rotating grinding (generally stone) wheel. Diamond and other material wheels are used for harder or softer materials. Cylindrical grinding is the process of moving a rotating piece (as in a lathe) against a rotating grinding wheel. The grinding wheel can be moved either across the outer or the inner diameter of a cylindrical work piece. Newer CNC grinders can finish grind tapers, contours and steps in a single operation. The grinders in our shop is similar those on this page. Precision, NEW MACHINE TOOL ”or mm (average human hair± approx ” or 0.076mm) Our grinders do not do contoured surfaces. February 21, 2019 ASU Instrument and Prototype Machine Shop

For boring inside diameters
Perishable Tooling Mill, Perishable Tooling Lathe, tool bits Grinding, wheels COURSE For ruff finish END MILLS For milling outside shapes, inside pockets or 3d-5d surfaces O.D. TOOLS For cutting outside diameters or finish faces FINE For very tight tolerances and excellent finishes DRILLS For hole making. This is the fastest way to remove material! TAPS For inside threads DIAMOND For very hard materials i.e. super alloys or Heat treated Steels I.D. TOOLS For boring inside diameters Taper drills For roughing tapered holes February 21, 2019 ASU Instrument and Prototype Machine Shop

A few more Types of Manufacturing
Laser Cutting / Etching Water Jet Wire EDM Die Sinking Injection, Gravity Molding, Extruding, Die Casting, Foam Molding, Hot Forming, Investment Casting, Rapid Injection Molding CNC Graphite Laminating Die Casting Investment Casting Liquid Metal Injection Part Stamping Hot Forming Specialty Machine Tools SEE FOR VIDEO FILES DEMONSTRATING THESE METHODS Rapid Prototyping SLA (obsolete…. kind of), 3d Printing, SLS, FDM, LC SLSC: SLS (or selective laser sintering). Actual production materials (nylon, glass filled, alum. Filled, metal filled) can be used. FDM (or fused deposition modeling). Builds in ABS and other plastics, good for functional testing of parts. LC (laser consolidation) FDM for metals SLS Composite for metal, plastic and dry resin mixtures "If you can't fix it with duck tape you haven't used enough.“ Red Green February 21, 2019 ASU Instrument and Prototype Machine Shop

Rapid Prototypes & Time Compression
Rapid Prototyping, SLA, SLS, FDM, LC: Gives an accurate, smooth surface, with fine detail. The resins and powders used can now produce many plastic, glass filled plastic, metal and metal filled plastic parts. SLA Stereo lithography Apparatus (the first of all R.P.) SLS (or selective laser sintering). Actual production materials (nylon, glass filled, metal filled) can be used. Even difficult features such as live hinges are possible. The finished surface can have a resolution as small as or 0.05mm. Now metal & plastic composites FDM (or fused deposition modeling). Builds in ABS and other poly plastics, good for functional testing of parts. LC (laser consolidation) a type of FDM only for metals. Including S.S. 316 & 420, Inconel 625, CPM-9V, H-13 and Titanium alloys. New metals are being added to the list daily. Extremely accurate. High cost. Prices will continue to drop. Most of the materials above can also be machined after (secondary operations) they are processed by R.P. February 21, 2019 ASU Instrument and Prototype Machine Shop

Rapid prototype examples
With table in the up position a layer of resin or powder is rolled on. Then, a laser or solidification compound is used to harden the material for part definition. The table lowers to accommodate for appropriate part resolution and the process is repeated until the part is complete. 3D printing & other RP’s reduce the need for prototype MOLDS and/or machined pieces. To view some rapid prototype videos type in rapid prototype at February 21, 2019 ASU Instrument and Prototype Machine Shop

Finish Chart Different features may require better finishes You can call out special finish requirements in your drawings as needed February 21, 2019 ASU Instrument and Prototype Machine Shop

PARTS WE DO NOT BUILD Any part that can be purchased in a hardware store or instrumentation supply store will not be made in the shop. The Shop does not supply ANY Hardware or Tools. Examples O-ring e-clips screws nuts bolts washers cotter pins shear pins lock pins bushings bearings electrical carpentry adhesives tools plumbing hoses files (metal) saws gages brackets If you need to have purchased hardware altered and the changes are something the shop can do, we will. There are some things we can not machine. Check with the shop to see if we can or will need to be machined outside. Materials are purchased by you through the shop office. Outsourced work and Special tooling your cost. We don’t make DO-OVERS without charging shop time and material costs. Your job goes to the bottom of the queue. All pipe over 6" (152mm) in diameter must have the words "large pipe" painted on it, so the Contractor will not mistake it for small pipe. U.S. Government Purchasing Spec.’s February 21, 2019 ASU Instrument and Prototype Machine Shop

Hardware and Fasteners
Determining what hardware to use and how to fasten assemblies is an engineering function. You need to decide how your parts will be held together. The shop cannot make that decision for you. If you are looking for recommendations on where and how to use fasteners and adhesives the internet can supply that information for you. Adhesives are quickly replacing typical hardware in many designs. Remember though, with the use of adhesives there is the possibility you parts will never come apart! If you are using hardware such as screws, nuts, bushings or bearings be sure to supply them to the shop. This will ensure that the machinist knows exactly what you need for fit and function. The shop can purchase hardware for you but, in addition to the charge for the hardware there is an ASU fee, “up to 28% required handling ”. Hardware and Fasteners February 21, 2019 ASU Instrument and Prototype Machine Shop

Weldments & Sheet Metal
We do welding, brazing and silver soldering in our Machine Shop. There are limitations. See the Shop Lead Question, What at can be welded? Answer: Only like metals. There is also a Weld Shop on campus. Sheet metal bending, folding and hole punching can be done at the shop, again there are many limitations. If you have more questions about these operations check with the shop leadman. Fred Sierra R.S.S. 1 Rm. 130 The Development Shop can do some Chemical welding. Check with us. February 21, 2019 ASU Instrument and Prototype Machine Shop

Test in F.E.A. software (as needed) to determine potential problems.
Intelligent Design & Design Intent Spend more time visualizing your finished part or assembly before you start your design. Use a Solid Modeler, they’re easy to learn and help with visualization. Check the Manufacturability of Designs. Understand the function of each feature. Discover what can go wrong. What is the real intent of your design? Limit your design accordingly. Adding unnecessary features is generally not a good practice. Know Parts vs. Assemblies. This is a common problem with new Engineers and Designers that don’t understand manufacturing methods. Find cost effective, functional and machineable materials. Determine at the onset all manufacturing capabilities available to you. What are their costs? Which methods are needed? Know Machine Tool & Rapid Prototype limitations Know the needed tolerances required for the functionality of each part and feature. Test in F.E.A. software (as needed) to determine potential problems. "An engineer makes a $500 item with $50 worth of parts. A designer then adds $450 worth of crap.“ anonymous February 21, 2019 ASU Instrument and Prototype Machine Shop

Design Stage Integration
Every day new tools for project development are introduced. Concept, Prototype and Manufacturing designs are now a single process. The introduction of CAD/CAM, CAE, FEA, RP and PLM (product lifecycle management) has moved the actual work from the old “Concept, Prototype, Testing and Production” stages to the Computer generated Prototype & Production stage. Concepts can change with a few clicks and retesting can be done in minutes instead of days or weeks. At the development stage, designs and material can be changed and manipulated as well as tested for structural integrity, functionally and production time. These are all things we really would like to know as soon as possible. These CAD/CAM/PLM/FEA tools are your crystal ball! Now that the Prototype stage of component and assembly development has been radically changed. Old school techniques of build and test then build again are becoming historical foot notes. Today's CAD (computer aided design) and FEA ( finite element analysis ) coupled with RP (rapid prototyping) are pushing industry into the Time Compression mode with either single or no physical testing required before releasing for production. Projects that engineers and designers spent six months to a year developing are now being moved from concept to market in less than six weeks. I am careful not to confuse excellence with perfection. Excellence, I can reach for; perfection is God's business. Michael J Fox February 21, 2019 ASU Instrument and Prototype Machine Shop

CAD-Driven Design Process FROM: February 21, 2019 ASU Instrument and Prototype Machine Shop

Prototype Considerations
Remember, concept sketches are not appropriate for submission to any Machine Shop. If they are photos, artist rending or paper napkin sketches, they will very likely not contain the information needed to re-produce parts. Submission to our shop will require fully defined prototype designs and detailed drawings. This also applies to repairs. These requirements are for all engineering disciplines. Although a concept sketch is not suitable for shop submission it is sometimes helpful to bring one to the shop as a reference for any questions you may have about the direction you are moving with regard to the manufacturability of your part. Just make sure you’ve placed some over all dimensions, tolerances, material call out and quantity required. Please don’t come to the shop and try to draw a picture of your part in our heads. We don’t go there! Using CAD for your prototype design is an advantage in the overall process at several different levels. If you do not know a CAD package learn one as soon as you can. February 21, 2019 ASU Instrument and Prototype Machine Shop

Prototypes generally fit into 1 of 3 categories.
Typical Prototypes Prototypes generally fit into 1 of 3 categories. Non-functioning display models. Used for marketing and display purposes. Partially functioning models. Also used in marketing or for testing specific features of a component. This is a prototype that generally demonstrates function and form. It may also be used in obtaining patents and licenses. Fully functional models. Generally used for physical test. This is generally a prototype that appears to be a product purchased off the shelf in a store . All of the prototypes have a commonality in that they require fully defined drawings in order to build them to specifications needed for functionality or esthetic requirements. Again, using CAD software to create a virtual prototype can save you and the shop time and effort. CAD Parts will automate the process of generating useful and accurate drawings. When Engineers and Designers do this it saves time and effort in ever subsequent process and identifies weak designs & parts. February 21, 2019 ASU Instrument and Prototype Machine Shop

SolidWorks, SolidSimulation & Ansys February 21, 2019 ASU Instrument and Prototype Machine Shop

SolidWorks, Cosmos and Ansys and other engineering software is available for everyone in the Fulton School of Engineering. Software will be installed on ASU computers and student laptops and have a 1 semester license. Authorization by a faculty member is required. Be aware that other F.E.A. software packages work inside SolidWorks. (i.e. Comsol, Abacus, FRED, Nastran, Algor and others) WHERE TO GO: Student Desk in the ECG Lobby February 21, 2019 ASU Instrument and Prototype Machine Shop

Submission Data & Files
CAD (computer aided design) part and drawing files need to be submitted with hard copies of your drawings (We can accept most types of scan able media). This will help expedite your work through the shop in a timely manner. This will also insure that we build your parts the way you intended or at least the way they were drawn. Any errors you make in the design of your part will show up in your final part. If we notice something that appears to be problematic we will contact you. There is no guarantee we will find or ever see your mistakes! Just because you can draw it doesn’t mean we can build it. We will do an initial quick review of your drawings. Check back in a day or two, to see if your submission has been placed in the Queue. We will also be able to give you an approximate start date. Hand drawn parts must meet the same standards as CAD files The ideal engineer is a composite ... He is not a scientist, he is not a mathematician, he is not a sociologist or a writer; but he may use the knowledge and techniques of any or all of these disciplines in solving engineering problems. N. W. Dougherty February 21, 2019 ASU Instrument and Prototype Machine Shop

CAD Parts & Drawings All drawings must be to scale and the scale must be called out in the title block. Drawings can be in either Inch OR Metric dimensions but the two units must not be mixed in a drawing unless both units are attached to every dimension. (dual dimensioning). All drawings must be done using third angle projection. Drawings must contain enough views to fully define the part. Some drawings will need only 2 views, most will need at least 3 views. Do not put ( )’S around every dimension! Drawings should be dimensioned from DATUMS (start points). As the designer it is your responsibility to make a decision as to where the datums for each view are to be located. Datums are generally chosen by functionality of a feature such as a mating edge or hole centerlines. We cannot use CAD part files as MFG. drawings. They do not contain tolerance information or datum locations. We need your CAD drawing files. February 21, 2019 ASU Instrument and Prototype Machine Shop

Realistic Parts These parts cannot be produce… Although these are extreme examples, they are indicative of the problems the shop sees from both R.A’s and students that rush through the design process “The I.D. (inside diameter) of all pipe must not exceed the O.D. (outside diameter) – otherwise the hole will be on the outside.” U.S. Government Purchasing Spec.’s February 21, 2019 ASU Instrument and Prototype Machine Shop

Realistic Parts Don’t put too much work into a bad design. February 21, 2019 ASU Instrument and Prototype Machine Shop

3rd Angle Projection Top Front Right side February 21, 2019 ASU Instrument and Prototype Machine Shop

3rd Angle Projection YES February 21, 2019 ASU Instrument and Prototype Machine Shop

1st Angle Projection No February 21, 2019 ASU Instrument and Prototype Machine Shop

Service for Researchers
Machine Shop Design Service for Researchers Would you try these On paper drawings. February 21, 2019 ASU Instrument and Prototype Machine Shop

Enough views to fully define a part.
February 21, 2019 ASU Instrument and Prototype Machine Shop

Example of a title block w/ tolerance call-outs
Tolerances are called out for 2, 3 and 4 place dimensions. There is a material box and a comments box in this TITLE BLOCK. Title Blocks can be customized for your individual needs. To override the title block callouts attach tolerances directly to the dimension. February 21, 2019 ASU Instrument and Prototype Machine Shop

Drawing Requirements All drawings must contain a specific material call out. All drawings need a quantity call out or only one will be produced . Hole features should be labeled and dimensioned to the centerline of the hole. This will avoid confusion with regard to the function of the feature ( What about spines?... You do not need to dimension splines if you supply us by way of CAD files.) Face features should be dimensioned to edges or edge points. Dimension angles from horizontal or vertical edges if possible. CAD drawings must be submitted as both data files and hardcopies. (part and drawing data files must be included) Drawings done by hand must meet the same detailing requirements as CAD drawings. (next slide). If you are using a different CAD system (SW-ASU) check with the shop to determine the type of data file you will need to export to our system. We have direct translators for most major CAD systems, not all. USE NOMINAL SIZES WHEN POSSIBLE ( metric mm or english inch ) “I have never let my schooling interfere with my education.” Mark Twain February 21, 2019 ASU Instrument and Prototype Machine Shop

Hand Drawings Hand drawings will be held to the same standards as CAD drawings. We do not have time to verify the accuracy of non-associative drawing software applications. (NO VISIO,PC paint, or other non-CAD software DRAWINGS) DO NOT USE THEM! Every drawing must be TO SCALE. The scale of your drawing must be CLEARLY noted on your drawings. If a view is out of scale the scale for that view must be noted with that view. Any drawing not to scale will be returned for correction (if we can reach you). We should be able to measure your hand drawings for quick verification of accuracy. I am unaware of any engineering or design firm using hand drawings. It is a good idea to learn CAD A.S.A.P. "I find that the harder I work, the more luck I seem to have." Thomas Jefferson ( ) February 21, 2019 ASU Instrument and Prototype Machine Shop

Quick Tips Pg 1 TIP Position parts in the easiest to understand arrangement and most efficient way to dimension. This way Not this way “Everything should be made as simple as possible, but not one bit simpler.” Albert Einstein February 21, 2019 ASU Instrument and Prototype Machine Shop

Quick Tips Pg 2 TIP Internal sharp corners tend to weaken a piece and are difficult to produce. External sharp corners create hazardous edges. Sharp corners are general seen as stress, fracture or injury points. Avoid using them whenever possible. In most instances internal sharps are not machineable in our shop. External edges should have chamfers, radii or call outs to “break” sharp edges. Generally the larger the corner radii are the stronger the piece becomes. Lean toward larger radii when possible. When designing pocketed areas inside sharp corners for a single component cannot happen unless the pocket is a through pocket or the job is sent to a shop equipped to perform that type of machining. One option is to split the component into a component group for assembly. When a sharp corner is needed it best to note so on your flat sheets. If it is not designated some machining operations will automatically leave small radii due to the design of cutting tools. February 21, 2019 ASU Instrument and Prototype Machine Shop

Quick Tips Pg 3 TIP Depth of holes are generally dictated by the diameter of the hole and the density of the material. 2 ½ - 5 times the diameter is a good rule of thumb. Depth/Diameter ratio. Deep hole drilling is possible but you should check with the shop before proceeding too far with your design of deep features. Draft on parts is easier to machine if the draft is in standard increments. ( ½°, 1°, 2°, 3°, 5°, 10°, 15°). These degree increments are used extensively in the aero-space and molding industry. ( reason = tooling) Thin walls and razor edges should be avoided in prototype machining. This type of work usually requires specialty machining. The Thin Wall Rule is Wall depth to be no more than 3-½ times the thickness of wall. NO razor edges. This problem manifests itself differently with a range of materials. The shop will not do feather edges… A minimum of ”or approx. 0.80mm thickness on walls and edges is required. (the thin wall RULE applies here) If you insist and we agree to try, we will not guarantee the outcome! February 21, 2019 ASU Instrument and Prototype Machine Shop

Quick Tips / Charts Pg 4 TIP Use and notate the correct fit for the intended function of the feature. This is true in both single component and assembly design. February 21, 2019 ASU Instrument and Prototype Machine Shop

Quick Tips / Charts Pg 5 TIP
Holes are generally started with drills. There are however, other methods employed to create holes requiring greater precision. Tolerancing holes and shafts independently. February 21, 2019 ASU Instrument and Prototype Machine Shop

Quick Tips Pg 6 TIP GD&T is the international standard for detailed part drawings. It clarifies a part drawing in an accurate way leaving few or no questions during the manufacturing process. Understanding GD&T requires a high level of commitment and an eye for detail on the part of engineers and designers. If used incorrectly it can add confusion rather than clarification during the manufacturing and inspection stages of part production. The shop does not require that you use GD&T but welcomes it on the condition it is used correctly. For information on the correct employment of this tool there are numerous sights on the internet. February 21, 2019 ASU Instrument and Prototype Machine Shop

ASME Y14.5M-1994 symbols for geometric tolerancing & specs.

Feature Control Frame ________________ ___ February 21, 2019 ASU Instrument and Prototype Machine Shop

Feature Control Examples

CAD Assemblies It is okay to submit an assembly file and assembly drawing but, only as a supplemental submission to all component part and drawing files. In S.W. files are associative. Remember, if you do not submit all your associated files we will not be able to open any of them. When designing, an understanding of manufacturing and machining will help you to recognize the difference between a single part and assemblies. PLEASE DO NOT bring in an assembly and expect us to determine breakout points. We are not the engineers, we may not know the functionality of your parts. If you need some advice please come and talk to us. Assembly drawings are for your design verification and use with F.E.A. software. They help the machine shop only as a visual aid and (reference only) verification. ( )’s = ref. Dim. Only. Each component in your assemble will require a minimum of one fully detailed drawing. (understand stack tolerances) If your assembly contains exactly mirrored or duplicate components only one needs to be defined. The call out for a mirrored or duplicated piece can be made on the drawing sheet. February 21, 2019 ASU Instrument and Prototype Machine Shop

Cosmos F.E.A. Cosmos- lite (now SolidSimulation) is an F.E.A. package already availably in Solidworks. Simple static stress, flow and circuit analyses can be applied directly to your components prior to manufacture. Additional Cosmos F.E.A. modules work directly inside your part and assembly files. (Ansys 10 is also available) Availably through E.T.S. Help Desk (Goldwater Bldg. For ASU computers and student laptops only ) Just a few Examples of Cosmos Applications Steady state (static) or transient thermal analysis Radiation, heat flux and thermal stresses Mold flow analysis / Circuit flow analysis (library and definable materials) Fluid and gas flow analysis (library plus definable fluids and gasses) Kinematics and motion analysis (for wear, movement interference and stresses) Isotropic and directional analysis on all of the above If your project (490) is too time consuming for the shop to complete in the allowed time and the information you require can be derived from the F.E.A. software, you may need to consider using that option for your project. February 21, 2019 ASU Instrument and Prototype Machine Shop

Cosmos Examples: February 21, 2019 ASU Instrument and Prototype Machine Shop

Thanks to computer simulators and other cutting edge tools of the trade, racing safety is no longer something achieved only through crash and burn, trial and error. Anti-lift flaps prevent body lift during the sideways motion of an uncontrolled car. This stops the car body from lifting into the air and gain uncontrollable flight. This was achieved through F.E.A. and computer simulations. Modern Marvels: Racetrack Tech * February 21, 2019 ASU Instrument and Prototype Machine Shop

Some Helpful Links February 21, 2019 ASU Instrument and Prototype Machine Shop

Cad Workstations 4 CAD The Shop Offices R.S.S. Bldg. 2 Room 170B 7:00am/3:30pm Monday - Friday Questions? February 21, 2019 ASU Instrument and Prototype Machine Shop

ASU Instrument and Prototype Machine Shop

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