Adrian AllenSteven LonaNicholas Tracy

Ideas-Unlimited

Changes since last time…•New logo was added to repertoire.

•Material change from ¾” to ½” acrylic.

•New through hole design for clock insert.

•New base design. (no adhesive)

•Inscription added to clock base.

PROCESS SUMMARY FOR BASE 

Set Up Number Operation Description

Machine Tool Description

10 Cut-off 0.50 in. x 2.25 in. cross sections of cast sheet acrylic stock to a length of 5.25 .015 in.

Cut-off Saw

20 Fabricate background housing on the planar surface opposite datum feature A

3 axis vertical machining center

30 Polish all surfaces of the base Propane torch

 

B

5.25 +/- 0.015

2.25 +/- 0.015

0.125 +/- 0.01

A

Set Up 20 SketchScale: 1:1Units: Inches

0.4375 +/- 0.01

0.50

0.125+/- 0.01

Set Up 20 Descriptionfor Clock Base

REQUIRED TOOLS

MACHINE TOOLS: Vertical Machining Center, VF-OE

FIXTURE: Kurt Vise with 1 ¼” parallels

CUTTING TOOLS: 7/16 inch Double Flute End Mill

MISCELLANEOUS TOOLS: Edge Finder, Dial Indicator

 

Operation Number

Operation Description

Tool Number Tool Description

Important Process Parameters

1 Slot mill opposite datum feature A in one pass 

1 7/16 inch end mill

d = .125 in.w = 5.25 in.V = 314 fpmF = 0.0042 in/th

 

Process 20 Description for Base

PROCESS SUMMARY FOR BACKGROUND 

Set Up Number Operation Description Machine Tool Description

10 Cut-off a 0.50 in. x 5.25 in. cross section of cast sheet acrylic stock to a length of 8 .015 in.

Cut-off Saw

20 Fabricate clock housing, PSU logo, and circular contours on the planar surface opposite datum feature A.

3 axis vertical machining center

30 Polish all surfaces of the background

Propane torch

 

5.2500 +/- 0.015 in.

Diameter = 3.75 +/- 0.005in.Hole Diameter = 2.3125 +/-0.005 in.

8.00

+/-

0.01

5in. Logo goes here

Set up 20 Description for Clock Background

REQUIRED TOOLS

MACHINE TOOLS: Vertical Machining Center

FIXTURE: Kurt Vise with 1 ¼” parallels

CUTTING TOOLS: 1/2”, 1/4”, 1/8”, and 1/32” Double Flute End Mills

MISCELLANEOUS TOOLS: Edge Finder, Dial Indicator

Process 20 Description Clock BackgroundOperation Number

Operation Description

Tool Number

Tool Description

Important Process Parameters

1 End mill circular contours on the planar surface opposite datum feature A.

1 1/2 inch end mill

d = 0.60in.V = 314 fpmF = 0.0042 in/th

2 End mill clock housing on the planar surface opposite datum feature A.

2 1/2 inch end mill

d = 0.600 in.V = 314 fpmF = 0.0042 in/th

3 End Mill PSU logo on the planar surface opposite datum feature A.

3 1/4 inch, 1/8 inch, and 1/32 inch end mills

d = 0.02 in.V = 314 fpmF = 0.0042 in/th

Assembly for Acrylic Clock

Join the base and the background by press fitting Insert battery into clock insertPlace clock insert into clock housing

Bill of MaterialsAcrylic Sheet (48 x 96)inch = $215

Clock Insert = $5.90 (30 count) = $177

Batteries = $0.55 (30 count) = $16.50

Cost Analysis•Break even point – 22 clocks

–Selling Price of $50

•Want to produce 8 extra for the 3 group members and 5 professors.

Gantt Chart

ID Task Name Start1 Completed Second Prototype Thu 9/27/01

2 Create Production Schedule Tue 10/16/01

3 Order Acrylic Materials Thu 10/18/01

4 Order Batteries and Clock Inserts Thu 10/18/01

5 Receive Materials Thu 11/1/01

6 Production Run Tue 11/6/01

7 Thanksgiving Break Wed 11/21/01

8 Production Run Cont. (if necessary) Tue 11/27/01

7 10 13 16 19 22 25 28 31 3 6 9 12 15 18 21 24 27 30 3 6 9 12October 2001 November 2001 December 2001