final manufacturing lab report

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Final Manufacturing Lab Report: Threaded Hinge Clamp Matt Worthington & Jean Carlo Sotomayor MER-101 Section 2 (Engineering Graphics) Mechanical Engineering Professor Glenn P. Sanders

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Page 1: Final Manufacturing Lab Report

Final Manufacturing Lab Report: Threaded Hinge Clamp

Matt Worthington & Jean Carlo SotomayorMER-101 Section 2 (Engineering Graphics)

Mechanical EngineeringProfessor Glenn P. Sanders

Page 2: Final Manufacturing Lab Report

Introduction

The goal of this project was to manufacture a fully functioning thread-driven,

hinge clamp. Over the course of the term we would manufacture one or two parts at

a time each week. The manufacturing procedure of each individual part was usually

described to us verbally by the professor as well as through diagrams and guides.

We learned to use different machines, such as the Milling machine, the band saw, the

lathe, and the belt sander. From week to week we became more familiar with the

machinery and the process started to flow more smoothly. After several weeks, all

the necessary parts to put the clamp together had been manufactured, and it

became time to assemble the clamp.

Once assembled the clamp proved to be fully functioning. The Clamp is

driven by a threaded bolt with a crank shaft through one end. It is composed of four

braces (2 of Brace A) and (2 of Brace B) that our structurally held together by two

different sized pins (Pin A & Pin B). The clamp opens and closes by turning the

crank shaft counterclockwise or clockwise, respectively. The threaded bolt is fixed

to one hinge (Hinge B) and turns through the other Hinge (Hinge A) to open and

close the clamp. The end on each brace where the braces meet when the clamp

closes has a swivel grip on each side to tightly hold the object(s) which are being

clamped together.

Page 3: Final Manufacturing Lab Report

Brace A

To manufacture Brace (as seen in figure 1) we started with an approximately

(6.0x4.0x0.11 inch) metal plate (as seen in figure 2). First we laid the paper

blueprint with the to scale representation of the desired product printed on it. After

creasing the edges to keep the paper in the same spot, we used the center punch and

hammer to mark the center holes on the plate. Next, we used a steel ruler, compass

and scribe to make the appropriate arcs around each center-punched hole (as seen

in figure 2) to prepare the plate for the proceeding cutting and drilling work.

Once the stainless steel plate was ready to be drilled we set it in the vice of

the milling machine and started by predrilling all the center-punched holes. Then

we proceeded to drill the five ¼ inch diameter holes on the brace (as seen in figure

3). We used the same bit to predrill a hole in the center of the fillet arc which we

proceeded to drill with a 5/8 inch bit. The digital readout on the machine was very

useful and precise and helped make this a more efficient process.

After drilling the six collective holes with the appropriate sized bits to

achieve the step (seen in figure 3), we then filed all the metal burrs in and around

the drill holes. Next, we used the steel rule and the scribe to create and connect arcs

of different sizes (seen in Figure 2) with tangent lines and prepare the plate for

cutting. Next, we moved on to the band saw in order to cut out the shape we had

just outlined (as seen in figure 4). The band saw prevented us from following the

curve with utmost precision, so their were several cuts to be made on each rounded

end in order to prepare the sheet for a reasonable amount of sanding. The sheet

grew hot a couple times due to the friction of the sander on the rather rough edges.

After several intervals of precision sanding, interrupted by dunks in the water to

cool the sheet down, we ended up with a decent quality finished

Page 4: Final Manufacturing Lab Report

(Figure 1) (Figure 2)

This diagram shows the finished brace plate. This diagram shows the plate with the scribed arcs

and their radii/location.

(Figure 3) (Figure4)

this diagram shows the plate after the holes are drilled this diagram shows the tangent lines connecting the arcs

and outlining the figure

Page 5: Final Manufacturing Lab Report

Brace B

The process for manufacturing Brace B was almost ientical to that of Brace A

but it involved a little less cutting and drilling due to the less complicated nature of

the part as seen in (Figure-1). Again we began by using hand-drawing techniques to

get a general layout of the drill holes, and created an outline of the part. Once the part

was mapped out, a center punch was used to create hole so the drill doesn’t slip. With all

this complete, we brought our plate to the drill, and used the digital readout to create a

hole that is accurate with the dimensions seen in (Figure 1). With the hand drawn holes

we could tell whether or not our holes are being drilled in the right spot. After the

drilling, it was necessary to smooth down any protruding metal created by the drilling.

We then carefully used the band saw to cut out the outline of the part, including the filets.

Finalizing the piece by using the electric sander to smooth down any rough edges that

were created during the cutting.

(Figure-1)

Page 6: Final Manufacturing Lab Report

Pin A & Pin B

Both Pin A & Pin

B started from stock

metal cylinders of

roughly 1.25 in length

and 0.31 in diameter

(as seen in figure 2a &

2b). For Pin A we used

the Lathe with the

digital coordinate

readout, while for

Pin B we used the lathe with an Analog layout/adjustment knob. The steps for

manufacturing the Pins was very similar .

For Pin A in, we set the stock piece in the lathe and made 2 cuts to shorten

the piece to the required length of 1.13in (as seen in figure 3a & 4a) and zero the x-

coordinate of the machine. We then set the diameter rating on the lathe to .25 in (as

seen in figure 5a & 6a) and proceeded to cut a .19 in diameter shoulder on the piece.

We used a file while the piece was still being turned to dull the edges of the shoulder

into a slight chamfer. We then stopped the machine, turned the piece around and

repeated the same steps to make an identical cut on the other side (as seen in figure

7a). These steps resulted in a finish product (as seen in figure 1a).

The manufacturing of Pin B was slightly less efficient due to the analog

position/diameter readout, but the process was rather Identical. Again we set the

stock piece in the lathe and made 2 cuts to shorten the piece to the required

length, this time of 0.875 in (as seen in figure 3b & 4b) and zero the x-coordinate

of the machine. We then set the diameter rating on the lathe to .25 in (as seen in

figure 5b & 6b) and proceeded to cut a .188 in diameter shoulder on the piece.

We used a file while the piece was still being turned to dull the edges of the

shoulder into a slight chamfer. We then stopped the machine, turned the piece

Page 7: Final Manufacturing Lab Report

around and repeated the same steps to make an identical cut on the other side (as

seen in figure 7b). These steps resulted in a finish product (as seen in figure 1b).

Page 8: Final Manufacturing Lab Report

Pin A Process

Figure 1aFigure 2a Figure 3a

Figure 5a

Figure 4a

Figure 7a

Figure 6a

Page 9: Final Manufacturing Lab Report

Pin B Process

Figure 3bFigure 2b

Figure 3b

Figure 5b

Figure 4b

Figure 6b

Figure 7b

Page 10: Final Manufacturing Lab Report

Hing A & Hinge B

Hinge A & Hinge B (as seen in figures 1A & 1B) were manufactured one by

each lab partner. For Hinge A, we were given a stock cylindrical steel piece of about

1.01 inches in height and 0.75 inches in diameter. This piece was already cut to size

so there was no need to make a zero-cut using the lathe. Upon setting the piece in the

Lathe, two rough cuts of approximately 0.27 inches in diameter were made with

application of some oil lubricant (about half the distance of the desired length each

time). The final cut was made by setting the diameter to 0.25 inches and running it

along the face until the desired 0.125 inch shoulder length was arrived at. The edges

of the piece were then filed down, the part was flipped around and the above process

was repeated to arrive at a symmetrical part with the appearance and dimensions of

(figure-1). The part was then placed in the milling machine, which was pre-zeroed, to

center-drill and then drill a 5/16 diameter hole in the center body of the hinge. The

hand tapping machine was then used to thread the hole by first correctly positioning

the part in the vice using the guide accessory and then using the tapper to thread the

hole. It became clear the importance of using the guide accessory first to make sure

the part is lined up perfectly, when after the initial threads were a little tight and the

part was put back into the tapping machine, the guiding tool was neglected to be used

and the structural integrity of the part was nearly sacrificed. Adjusting the position to

the original tapping and running it through again managed to take care of this

problem and resulted in the finished product (as seen in Figure 1B).

A nearly identical process was undertaken for Hinge B to arrive at a part with

dimensions seen in (Figure 2B). The difference, aside from the dimensions, was that

the hole was not threaded in this piece, but rather it was center-bored using the

milling machine and as seen in (Figure-2B). But the flat edge as seen in this same

figure was created using the milling machine. The milling machine was pre-set to

make a flat swipe cut across the surface. Overall this laboratory was rather

straightforward and routine, and each student was only responsible for one hinge.

Both hinges came out rather nicely.

Page 11: Final Manufacturing Lab Report
Page 12: Final Manufacturing Lab Report

Grip A & Grip B

For the manufacturing of the grips we started out with two metal blocks of

dimensions seen in (Figure-1A & Figure-1B). We then drilled the blocks with .312

inch diameter holes by setting them in the milling machine, center-drilling and then

drilling all the way trough. The blocks were then set in the lathe, which had been

equipped with the appropriate readout to make a 45 degree cut into the center of

the respective blocks by sweeping the end-mill bit all the way across it. Each block

was then flipped and another 45 degree cut as made to create a perpendicular

groove all the way across one side of the block and complete the manufacturing of

the grip. The figures below show the precise dimensioning and details of each part.

(Figure-2A)(Figure-1A) (Figure-3A)

(Figure 1B) (Figure 2B) (Figure 3B)

Page 13: Final Manufacturing Lab Report

Part List

• Brace A (2)

• Brace B (2)

• Pin A (3)

• Pin B (3) • Also supplied with threaded turn-bolt and pin

• Hinge A (1) for final assembly

• Hinge B (1)

• Grip A (1)

• Grip B (1)

Assembly Process

In the final lab, once all the necessary individual parts had been assembled, it

became time to assemble the clamp. First the two Brace Bs were connected using

three Pin Bs, Hinge B, and Grip B. This section of the clamp had to be assembled first

because the Brace Bs are held inside the two Brace A plates using a pin B. After

laying Brace A down on the table and inserting the remaining pins, hinge and Grip

into the appropriate holes, we carefully placed the second Brace A on the top

shoulder of the pins, hinge, and grip. This process proved fairly challenging, and

required a bit of filing of the holes to make all the pins fit in the right place. After the

frame of the clamp was structurally achieved, we used the rounded end of a hammer

to mushroom the tops of the pins and grips down to keep them from sliding out. We

then threaded the crankshaft through the threads of Hinge A and into the center

bore of Hinge B. After finagling the bolt into place we used an Allen wrench to screw

in the little pin through the back of Hinge B and into the threaded bolt to fix the bolt

to the Hinge. The clamp was then fully functioning and ready to use

Page 14: Final Manufacturing Lab Report

Conclusion

Overall we both agree that this was a great-hands on project. It was really

cool to learn how to use the different types of heavy machinery. Manufacturing each

individual part was satisfying, but seeing it all come together in the end was

awesome and provided a great sense of accomplishment when everything fit

together and functioned properly. The professor and lab supervisor both did a great

job overseeing the operations in the lab, and they were very helpful when questions

came up. The lab reports grew to be a little tedious, but they were a good way to

reinforce the procedure and practice using the language and terminology. Overall

the project was an enjoyable one, and the Lab as a whole was more fulfilling and

interesting than any other we have experienced here at Union.