MCEN 3025

COMPONENT DESIGN

Spring 2016

I completed this homework set individually:

MEID: _________________________ Section (circle one): 2pm

3:30pm

Homework 5: Due at the start of class on Tuesday, March 1st

Reminder: Quantitative problems use the specified Homework Format (see MCEN 3025
Common Syllabus). For all qualitative questions, submit typed answers. Combine papers
with staple and include MEID and section (2pm or 3:30pm) on the front page.
1.

Machining You are provided a 2.5 diameter, 17 long bar stock of aluminum.
Describe the sequence of machining processes using a lathe and mill to produce
the keyed shaft shown in the drawing below. Sketch the result of each
manufacturing process.

1) Load stock part in chuck with about 9.5 exposed (could expose only 8 and face from both sides,
but thats more intensive) and face the outer face to 2.5 diameter
a. Realistically, you should buy sized-up stock so that there is material to take off for
precision facing
2) Face off front edge (maximum 0.5) taken off
3) Turn down outer face to a diameter of 2.25 to a depth of 6.875 in the z-direction from the faced
end of the stock
4) Turn down outer face to a diameter of 1.85 to a depth of 4.875 in the z-direction

MCEN 3025

COMPONENT DESIGN

Spring 2016

5) Turn down outer face to a diameter of 1.25 to a depth of 1.25 in the z-direction
6) Tilt the tool post to 45 degrees and create the chamfers at 6.875 and 1.25
a. Since this wasnt covered in class, be lenient on this one.
b. I would accept create chamfer as an acceptable answer.
c. This can also be done when finishing the outer edge facing cuts (i.e. after steps 3 and 5)
7) Center drill end
8) Drill hole to a depth of 1.5
9) Flip part in collet/chuck with remaining material exposed.
10) Face end to length of 16
a. If part was originally held in step 1 with 8 exposed, face outer edge to 2.5
11) Repeat steps 3-8 on this side (symmetrical lathe cuts)
12) Move part to the mill, fixturing it horizontally with v-block clamping and one side over-hung for
flat milling.
a. This is also something not covered in class, so be lenient when grading
13) Edge find to zero dead center of the part as this is where we will be measuring from.
a. Also allow for zeroing from one end since thats what the drawing portrays
14) Center drill at (0,0) and drill 3/8 hole in the center of the part to a depth of 1.25
15) Center drill at (7.375, 0) and drill hole to a depth of 0.625
16) Switch to a endmill and zero the z-axis to 0.625 from center (this can be done by touching
the endmill to the top face of the outermost cut)
17) Mill a slot at z = 0 from (-8, 0) to (-3, 0) (-3 accounting for the radius of the tool)
a. This finishes the key slot
18) Switch to a bigger endmill (this can be done with any reasonably sized endmill, I would use a
1 endmill but its imprecise) and re-zero the z-axis the same way we did in step 16
19) Moving in the y-direction, mill across the top of the part at x = 3.625 (assuming a 1 endmill) and
move in an s pattern until all the material on the flat face is gone.

20) Done!
**Full credit given if most of these processes are addressed**

MCEN 3025

COMPONENT DESIGN

Spring 2016

MCEN 3025

COMPONENT DESIGN

Spring 2016

2. Design Project Collaborate with your teammates to determine a custom

component that you will need to machine for your drill powered vehicle. The

MCEN 3025

COMPONENT DESIGN

Spring 2016

final dimensions/geometries are not critical at this point in time. Build a CAD
model and a dimensioned drawing for the component. Answer the following
questions and staple a screenshot of the CAD and drawing to this homework
assignment.
a. What is the function of this component?
b. Justify why this component needs to be custom machined and cannot be
purchased.
c. Describe the machining processes required to produce the custom
component including a sketch of the component after each process.
A thorough description, justification, and machining
3. Machining Describe how to machine the features on the part shown below
using a mill. If a feature is not machinable, describe how it could be modified to
become machinable.
a. Rectangular extrude
b. 3-hole bolt pattern
c. Rectangular cavity

a
b

a)

This part can be machined by offsetting the tool radius and simply making a rectangle of those
dimensions. The important part here is that following rectangular contour, the rest of the face
material has to be removed.

MCEN 3025

COMPONENT DESIGN

Spring 2016

b) 3-hole pattern is just a matter of drilling 3 holes in the correct places. This is easy in a mill or
even a drill press if precision isnt important.
c) This is not machinable in its current state. If a small radius was added to the corners, an endmill
of that size could be used to cut out that pocket.

4. Dimensioning and Tolerancing List everything that is wrong with this

drawing:

1.

2.
4.

No title block.
-Tolerances are not shown
-Material is not shown
-Units are not shown
No isometric view.
Thickness of the part is not shown.

MCEN 3025

COMPONENT DESIGN

5.
6.
7.
8.

Spring 2016

Length of the part is not shown.

Only one view is shown.
Squares position is not defined.
Cannot mill out a square
-Milling out a real square will leave rounded corners which you should specify. This will also
determine the size of the end mill you will use.
9.
The holes positions are not fully defined.
-Using a center line is fine if its defined.
10.
Two of the holes are dimensioned using their diameters, while the larger hole is dimensioned
using its radius. Be consistent and use diameters.
11.
The holes are dimensioned off of each other instead off of a common datum. This stacks the
tolerances.
-Ordinate dimensions would be the best for this part.
-This is acceptable, however, when the hole positions relative to each other is more important
than their locations on the part. But if thats the case you should specify it.
**Full credit given if most of these points are addressed**