Prototype Design and Manufacturing Manual

PROTOTYPEDESIGNAND
MANUFACTURINGMANUAL
DEPARTMENTOFMECHANICALENGINEERING
RODNEYKATZ,MICHAELLEWIS
Rev.0
PrototypeDesignandManufacturingManual
Rev.0
TABLEOFCONTENTS
Introduction...................................................1
10.2 Dimensioning............................27
PARTIDesign...............................................2
10.3 Tolerances.................................35
FirstSteptoDesign.............................2
10.4 AnilamCNCMill........................35
Prototyping.........................................3
PartIIManufacturing................................39
2.1
3
TopDownMachining..........................7
Alignment!..........................................9
4.1
ExamplePrototypeDevice..........6
1.1
2
CNCMilling.......................................44
2.1
AlternateMethods....................13
ImportantNotesforposts........43
Setupmethods..........................44
ORings.............................................48
Bearings.............................................17
Motor................................................17
3.1
AxialOrings..............................48
Orings...............................................18
3.2
RadialOrings............................51
PipesandTubes................................21
8.1
9
References......................................................I
9.2 Aluminum....Error!Bookmarknot
defined.
Steel...........................................23
9.4
PVC.............................................23
9.5
Delrin.........................................24
9.6
Plexiglas.....................................25
10
Tapping......................................54
Appendices.....................................................I
RawMaterials............................22
9.3
DrillingandTapping.........................54
4.1
Fittingsforpipes........................21
Materials...........................................22
9.1
Drawings........................................26
10.1 CommonDrawingmistakes.......27
Posts.................................................39
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INTRODUCTION
The purpose of this manual is to present best practices for the design and
manufacturingofprototypedevices,lowvolumemachinedpartsandassemblies.
Itisimportanttonotethatmanyofthemethodsandtechniquesoutlinedinthemanual
arespecifictotheUVicMech.MachiningFacility.
Figure1.1Mixerdevice
The manual is structured around the design and manufacturing of a single device
(shown above in Figure 1.1) which encompasses many typical characteristics of
mechanicalfeaturesfoundintheDept.MechanicalEngineeringresearchapparatus.
This design is very efficient to machine, incorporates inherent alignment, uses stock
materialreadilyavailableinthemachineshopandisfamiliarwiththeshopmachinists.
Themanualwillalsoincludecomparisonexamplesoflesseffectivedesignsofthesame
device. These methods are often initially thought to be easier to fabricate but do not
lendthesameadvantagesoftherecommendedsampledesignshownabove
Designmethodologyisaverybroadsubject;thismanualonlycoversthebasics.
Extendedtopicslikehighvolumemanufacturing,rapidprototypingandtechniquesused
outsidetheMech.Eng.Shoparenotcoveredinthismanual.
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PARTIDESIGN
1 FIRSTSTEPTODESIGN
Design of a device should always begin with opening communication with the specific
shoporfacilitywherepartswillbemanufactured.
Thecapabilitiesoftheshoporfacilityneedtobecarefullyconsideredinordertodesign
economicallyfeasibledevicesorequipment:
o Machineryandshopspecificexpertise,CNCmilling,lathecapability,sheetmetal
capabilities, welding capabilities, heavy machining, precision grinding, waterjet
cutting,EDM,rapidprototyping,etc.)
o Shoppreferredmanufacturingmethodsandmaterials.
o Machine tool (lathe, mill) capacity. What is the largest or smallest size
workpieces and cutting tools the shops machines can comfortably
accommodate.
o Timelinerequiredtodeliverparts.
Whileinthedesignphase,continuallycommunicatingwithshoppersonnelwillalways
leadtodesignswhicharelessexpensiveandmoreefficienttobuild.
Whenever possible, design parts in inches. The rationale being the machine shops
cuttingtoolandmaterialinventoryareintheimperial(inch)system.Designinginmetric
then converting to inches leads to odd dimensions thus complicating the design and
machiningprocess,resultinginamorecostlyandtimeconsumingpart
Always keep in mind stock material sizes when designing parts. This is paramount to
achievinganeconomicallyfeasibledesign.Oftenthestockmaterialsizewillbesufficient
to accommodate your design with little additional machining required. In Canada we
still work with stock material sizes in the inch system as most of our material comes
fromU.S.suppliers.
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2 PROTOTYPING
Generallyprototypepartsshouldincorporatethefollowing:
o InherentAlignment.Partsautomaticallyfitintoplace.Thiseliminatestheneed
forpostmachiningandhandtoolmodificationinordertofitpartstogether.
Bosses and other features should be incorporated in the design to assure
alignmentoffinalassemblies.
o Abilitytobeadjustedwithlittlerework.Thiscouldmeanaddingextraholesor
elongating holes for unforeseen additions or when you may feel adjustability
couldberequired.
o Theuseofeasilymachinablemateriali.ealuminum,acetyl(Delrin),PVC(plastic)
whereeverpossible.Eventhoughthesematerialsmaybetwiceorthreetimes
the cost of steel, their fabricating and machining costs will be drastically lower
resultinginalessexpensivepart.
o Reduce the number of parts with tight tolerances (to lower cost and increase
machiningefficiency).
o Sizepartswithaconsiderationformaterialyield.E.g.aluminumsheetcomesin
48X96sheets.Ifyourequirefourpieces12X12thiswillresultinmuch
waste material. Reconsider the design to work with 12 X 12 pieces. Sheet
metal does not consume material for cuts where as plate material (3/16 and
thicker)willconsumeapproximately3/16percutduetothesawingandclean
up process. Plate material is also supplied in 12 increments. Therefore if four
12X12platesarerequiredthiswillproducealargeamountofexcessmaterial.
Trytoworkthedesignwithpartsizesof11.75X11.75
o Tappedholes#632andlargershouldbedrilledallthewaythroughinmaterials
up to thick if possible as opposed to holes drilled to specific depths. It is
alwayseasiertotapathroughholeopposedtoablindhole(holethatdoesnot
penetrate).Theholemayonlybetappedpartiallythrough.
o Whendesigningaholeforapressfitdowelpin,incorporateasmallerdiameter
throughholewhichcanbeusedtopushorknockthedowelpinoutifrequired.
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Thiswilloftenbethecase.(SeeFig.2.1below).Ifnothroughholeispresentit
willbeverydifficulttoremovethedowelpinandremovalmethodswillresultin
damagingthepinandthemaybethehole.
Dowelpin
Shaft
Thruholetopushoutdowel
Figure2.1Thruholeinshafttoallowremovalofdowelpin
o Tabs or marks for realigning parts if they are going to be placed back in a
machine for post machining operations. This is often the case when the part
needsholesalignedtoeachotherfrombothends.Anotherreasonforalignment
markswouldbeorifthepartneedstobeorientedinaspecificrotationalangle
atassemblytime.(SeeFigure2.2).
Scratchmarks
forrealignment
Figure2.2Circularpartandfixturewithgroovesforrealignment
o Flats on round parts. This allows for the part to be replaced into a vise with a
knownorientationforpostmachiningormodificationsatalaterdatefrom(See
Figure2.3)
Figure2.3Roundpartwithflatselfalignsinvise
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Avoid welding parts together. Welding does not allow for major changes if required.
Separatingparts can be very labour intensive and sometimes close to impossible. It is
alsoverydifficulttoaccuratelyalignweldedparts.
Designtheassemblyofsufficientsizetoavoidworkinginconfinedspaces.Alsoavoid
theuseoftinyscrewsi.e.#256andsmaller.
Trytokeepthefastenerthreadtypeselectiontoaminimum.#1032isaverypractical
size for much of the metal work performed in the shop and is easily tapped.
(usea#1024forplastics)
Utiliseasmanyofftheshelfitemsaspossible.Thesewillsavemanyhoursofdesignand
machining work, paying for themselves many times over. Often offtheshelf
componentsmaynotmeetalltherequirementsbutcanbemachinedtoaccommodate
thedesignrequirements.
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2.1 EXAMPLEPROTOTYPEDEVICE
ThemixerdeviceshowninFigure2.4istheexampleprototypeassembly.
Keycomponents,whichwillbediscussedinthemanual,arenotedonthediagram.
NPTandISOFittings
Oringseals
Motor
(gearsdrivemainshaft)
NPTThreadedHole
(Cylindersurfaceisspotfaced)
TopPlate
(Topdownmachined)
Post
Bearings
ControlPanel
Figure2.4MixerDevice
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3 TOPDOWNMACHINING
Flat parts (Top and Bottom plate) machined using a manual or CNC mill should be
designedinorderthattheyaremachinedononeortwosidesonly. ThisiscalledTop
Down.Trytoavoidhavingfeaturesmachinedinthesidesofplates.
o The actual process of cutting material is relatively quick. It is the setup and
positioningofmaterialandpartsthattakesmajorityofthetime.
o If a part can be setup once and then cut without rotating or repositioning the
partmachiningefficiencywillincreaseexponentially.
o Figure 3.1 shows an example of a part which requires multiple setups to
machine.Thispartwillneedtoberepositionedinthevisefourtofivetimesto
drill all the required holes in the sides consuming much time and effort. The
more often a part is repositioned (clamped) in the machine the greater the
possibilityofmisalignmentofthefeatures.
o Alsothelonglengthofthispartcreatestwopossibleproblems:
ThemillingmachinebeingusedmaynothavetherequiredtravelintheZ
axisneededtodrilltheendholes(showninthethirdsetupofFigure3.1).
Rememberthedrillchuckisextendsapproximately3inches,thedia.
drill extends 4 and the part on end extends approximately 6 high,
resultinginaconsumptionof13ofthemillingmachinesZaxistravel.
Ifthepartismachinedwhileonendthestabilityofthepartmaynotbe
enoughtopreventmaterialflexandresultininaccurateholepositioning.
Thepartclampedonend(Fig3.1C)willalsoaccentuatethedeviationof
the hole positioning ( 0.1 degree off perpendicular on a 6 protruding
clampedpartinthevisewillcauseapositioningerrorofthedrilledhole
by 0.010) Trying to ensuring the part is clamped perpendicular by this
amountorbetterisverytimeconsuming).
Figure3.1MultiplesetupsrequiredforapartthatcannotbemachinedTOPDOWN
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Rev.0
4 ALIGNMENT!
Alignment of parts and features is one of the most important aspects of mechanical
design.
Ifpartsaredesignedwithalignmentinmindatalltimesitwillpreventmuchfrustration
andaddedcostinthefinalassembly.
Figure4.1PostwithendbossesandextraholesinOD
One basic method to align parts is to use posts with bosses on both ends. Figure 4.1
showsanexampleofapostwhichincorporatesbossestoaidalignment.
Incorporatingabossoneachsideoftheposthastheaddedadvantageofallowingthe
posttobeheldinthelathechucksothecriticallengthcanbemeasuredoffthefront
faceofthechuckjaws(theZdatum).
Theprocedureusedintheshopforaccuratelymachiningthistypeofpostdesignisvery
efficient.
Figure4.2showshowpostswithintegralbossesareusedintheassembly.
Rev.0
Figure4.2Alignedplatesandpostsassembly
Oncethepartsareassembledthetwoplateswillbealignedsufficientlyinorderthatno
fussingorfiddlingwillberequiredtoattainthedesiredresult.
This method allows the plates to be efficiently milled and drilled Top Down with one
setup.Norepositioningisrequired.
This method can be altered to suit many different applications while still maintaining
alignmentofplatefeatures(eg.centreholes,shaftholes,bearingboresetc.):
o Platescanbedifferentshapesifrequired(Fig.4.3)
o 2or3postscanbeusedinsteadof4(Figure4.3)
o Notallpostsneedtobethesamediameter
o Platethicknessescanbedifferent
ThemachiningprocessforpostsisinPartIIManufacturing,Section1(Page39).
10
Figure4.33postdesignwithdifferenceshapedplates
11
Rev.0
Rev.0
Carchassis
TappingMachine
Table
SubmersibleChassis(fitsintube)
Winch
3postdesign
Figure4.4Examplesofhowpostscanbeused
Figure4.4showsexamplesofhowpostscanbeused.(eg.Carchassis,table,ROV,etc.)
12
Rev.0
4.1 ALTERNATEMETHODS
This section presents some of the alternatives to using round posts with bosses. The
alternativesmayappeareasiertofabricatebutareoftenmuchmoretimeconsumingto
machineandassembleandtheydonotincorporateinherentalignmentfeatures.
Figure4.5showsadesignsimilartotherecommendedmethod
o Thesquarepostsaredifficulttomachine.
o Multiplesetupsarerequiredtomachinetheposts.
Figure4.5Plateassemblyusingsquareposts
13
Rev.0
Figure4.6andFigure4.7showthetwoplateassemblywithanglebrackets
Anglebracketsareappealingbecausetheyseemsimpletomachine(justcuttolength
and drill). A note of caution! Often what appears simple to fabricate results in being
rather difficult and cumbersome. The method in Figure 4.6 is very time consuming to
machine as the top and bottom plates cannot be machined top down. A total of 64
holesmustbedrilled.Halfoftheholesalsoneedtobetappedinthesidesoftheplates.
Unstable
Figure4.6Plateassemblyusinganglebrackets
14
Rev.0
Thesecondanglebracketmethoduseswelds.
o This assembly requires 16 welds . Considerable time is required to setup and
weld.Properalignmentoftheplateswillbevirtuallyimpossibleoftenrequiring
somepostmachiningorhandwork.
o Intermsofprototypingweldingdoesnotallowpartstobeeasilymodified.
Figure4.7Plateassemblyusingweldedanglebrackets
Figure4.8showsaweldedversionofawinchframe.ThewinchinFig4.8wouldtakea
considerable amount of time and effort to construct due of the number of welds and
therequirementthattheframebeaccuratelyalignedforbearingsblocks.
Figure4.8WeldedWinchFrame
15
Rev.0
NOTE:ThereisatimeandplaceforweldingbutinmostassembliesusedintheMech.Eng.
Dept.itisnotappropriate.Weldingofsmallaluminumpartsisverydifficultandshouldbe
avoided.
Figure4.9belowshowsthetwoplateassemblyusingCchannel.Thismethodisappears
relativelyquicktomachinebuthassignificantalignmentlimitations:
o Cchannel comes in standard sizes therefore spacing of the plates has limited
options.Spacersmustbeusedtoadjustplatespacing.
o ThesizeofextrudedcchannelisnotalwaysaccurateandtheCchannelsidesare
oftennotperpendicular.
o EnsuringtheholesaredrilleddirectlyoppositeoneanotherintheCchannelis
verydifficult.
o SecurelyholdingtheCchannelpartsinthevicefordrillingiscumbersome.
Figure4.9Plateassemblyusingcchannelforposts
16
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5 BEARINGS
Bearings of many varieties are often used in mechanical design and are of utmost
importancetothefunctionalityoftheassembly.
Machinedfeaturesthatacceptbearingsmustusuallybemadetotightertolerancesthan
otherfeatures.
Ifaboreholeforabearingistoosmallrequiringexcessforcetoseatthebearingitwill
oftencausethebearingtorunroughandleadtoprematurefailure.
Ifaboreholeistooloosethebearingwillsloparoundandreducethealignmentofthe
shaft.
Alwaysincludetolerancesindrawingsfordimensionsrelatedtobearings.
If possible have the bearings available at time of machining. This will greatly help the
machinistcorrectlysizethebearingborehole.
6 MOTORMOUNTING
Mostsmallandmidsizemotorsincorporateabossandboltholesontheirface(Figure
1.1).
The motors boss assures concentric alignment of the motorshaft to the mounting
surface.
Correct tolerancing of the boss receiving bore is very important. If possible have the
motoravailabletothemachinisttochecktheboresizeandfitattimeofmachining.This
willoftenavoidtimeconsumingreworkofparts.
17
Rev.0
Boss
Boltholes
Figure6.1Motorwithbossandboltholes
7 ORINGS
Oringsareoneofthemostcommontypesofsealsused.Theyareextremelyefficient
and very inexpensive. The machining processes required to accommodate Orings is
oftensimpleifthepartisdesignedwithconsideration.
Sealing using Orings allows for easy disassembly of the apparatus if modifications or
cleaningisrequired.
Figure7.1Orings
18
Rev.0
TypesofORingSealingConfigurations
o Axial:oringsealisonthefaceofapart.
o Radial: oring seal is on the outer or inner wall of a part. Radial seals on small
shaftscansignificantlydecreasethestrengthoftheshaft.Inthiscaseitisbetter
togroovetheinnerdiameteroftheparttheshaftwillfitinto.
o AvoidtheuseofRadialOringconfigurationsifpossible,theyaremoredifficult
to machine and require much tighter tolerances in all respects. Note that the
PlexiglasOringcontainerconfigurationinthesampleMixerdeviceusesanaxial
seal.Thereareseveralreasonsforthischoice:
o It is easier to machinevs. a radial seal. If a radial seal were used, the Plexiglas
container I.D. would have to be accurate and concentric. This is often not the
caseinstocktubularmaterial.InordertoattainanaccurateandconcentricI.D.
onatubeitmustbeboredonalathewhichisverytimeconsuming.Foranaxial
sealonlytheendsofthecontainerneedtobemachinedwhichisaquickprocess
o A radial seal is often makes it difficult to remove the end caps especially in
oceanographicinstruments.
Figure7.2AxialORingsealRadialORingseal
19
Figure7.3AxialglandRadialgland
Rev.0
ThegrooveinwhichtheORingsitsiscalledthegland(fig7.3)
AppendixVandVIshowtablesforglandsizes.
ThemachiningprocessforOringglandsisinPartIIManufacturing,Section3
(Page48).
20
Rev.0
8 PIPESANDTUBES
Pipes:Pipesizesarereferredtobasedontheirnominalinnerdiameters,nottheirouter
diameters.i.e.aschedule40pipewillhaveanO.D.of1.050
o Note: The nominal inner diameter of pipe usually does not match the physical
inner diameter. This is due to the different wall thicknesses (referred to as
schedulesizesi.esched.40orsched.80).Differentpipematerialshavedifferent
O.D.sizesi.e.copperpipehasanO.D.of0.875vs.steelandaluminum
pipehavinganO.D.of1.050.
Tubes: Tube sizes are referred to based on their actual physical O.D. i.e. 1 tube is
physically1.00O.D.
Pipe is often less expensive than tube therefore it is used when larger quantities are
requiredinthedesignorwhenfluidtransportisrequired.Tubeisusedwhenaspecific
diameterisrequired.
8.1 PIPEANDFLUIDFITTINGS
ThefollowingarethemostcommonfluidfittingsusedintheMech.Eng.Dept.research
apparatus
NPT (National Pipe Thread) is a standard for pipe fittings. NPT fittings are tapered to
produceaneffectivefrictionsealwhenscrewedintothematingfitting.
Note:ANPTfittinghasthreadO.D.ofapproximately1/2.
NPT fittings are not used in thin material or sheet metal. A minimum of four threads
mustbeengagedtoproduceareliableseal.
ISOfittingshavestraightthreadsandincorporateanOringinthebasetocreateaseal.
The mating surface for these orings must always be spotfaced to produce a reliable
seal.Seetheoffsetholeinthetopcapofthesampledevice.Thespotfaceisrequiredto
produce a surface with machining marks concentric with the Oring seal. If this is not
donethestriationsoranyscratchesintheplasticplatewouldallowaleak.Whenever
OringsareusedanymachiningmarksorscratchesmustbeconcentricwiththeOring.
21
Rev.0
9 MATERIALS
This section lists some of the more common materials used in the UVic Mech. Eng.
Machine Shop. Consult McMasterCarr (www.mcmaster.com) for more detailed
informationonthematerialsizes,characteristicsandcost.
9.1 STOCKMATERIALS
Whendesigningkeepinmindthestandardsizesofstockmaterials.
o In most cases stock materials cannot be depended on for accurate sizes or
geometrictolerances(perpendicularsides,parallelism,etc.)
o An example exception is precision ground steel rod which is ground to tight
tolerances.
o Ifhighprecisionalignmentisrequiredthestockmaterialmustoftenbemachined
onthesignificantmatingsurfaces.Aluminumplatehasgoodsurfaceflatnessas
opposedtoaluminumextrusionandisapproximatelytwicetheprice.Useof
aluminumplatecanoftenreducetheamountofmachiningrequiredpayingfor
itselfinthefinalresult.
9.2 ALUMINUM
AluminumismostoftenthematerialofchoiceintheMech.Eng.MachiningFacility.
AluminumCharacteristicsandAdvantages
o Lightweight
o Largesizeselection
o Goodstrength
o Goodcorrosionresistance
o Easytomachine
o Cleantowork
o Goodesthetics
22
Rev.0
o Highheatconductivity
o Easilyrecyclable
o Readilyavailable
o Difficulttoweldproperly
o Canbeanodizedtoachieveaveryhighlycorrosionresistantsurfaceandcoloured
surface.
9.3 STEEL
MildSteelCharacteristics
o Highstrength
o Heavy
o Corrodeseasily(rust)
o EasytoWeld
o Certaintypesofsteelprovedifficulttomachine
o Lowcost
o Considerablymorecostlytomachinethanaluminum
Mild steel is not used extensively in the Mech. Eng. Machining facility. It is generally
usedforshafts,heavyweldedstructures,axelsetc.
StainlessSteelcharacteristics
o Verygoodcorrosionresistance(Oceanographicapplications)
o Hightemperature
o Veryhighstrength
o Veryheavy
o Expensive
o Weldseasily
o Costlytomachine,useonlywhereabsolutelynecessary
9.4 PVCPLASTIC
23
Rev.0
PVCcharacteristics:
o Goodcorrosionresistance
o Easytomachine
o Lightweight
o Can be bonded easily. Note: A mechanical interconnectivity of the two parts is
alwaysrequiredwhenbondingPVC.ItisnotadvisabletobuttjointPVC.
o Notrecommendedforwearapplicationsduetohighfrictioncoefficient.
9.5 DELRIN(ACETAL)
Delrin(Acetal)isoftenusedasareplacementforaluminumparts.Duetoitsexcellent
machinability try to implement it into designs where possible. One major advantage
being that it does not need any coating to be corrosion proof. It also produces very
estheticallypleasingpartsdueitssheenandcolour.
Delrin(Acetal)hasthefollowingcharacteristics:
o Excellentmachinability
o Corrosionproof
o Goodrelativestrength
o Lightweight
o Toughandwearresistant
o Verylowfrictioncoefficient
o Solventandfuelresistant
o Whiteorblackincolour
o Commonlyavailableinroundrod/bar,sheet,andplate
SomeapplicationsofDelrin:
o Bushingsforlowspeedapplications
o Wearpads
o Fluidfittings
o Gears,pulleys,idlers
ImportantNotes:
24
Rev.0
O Delrincannoteasilybebondedtoitselforothermaterials.
9.6 PLEXIGLAS
Plexiglascharacteristics:
o Lightweight
o Opticallyclear
o Brittle
o Scratcheseasily
o Lowoperatingtemperatureband
o Commonlyavailableinsheet,tubeandsolidround
o Bondstoitselfveryeasily
Plexiglascanbebentusingheat.
o Bending Plexiglas is not recommended for prototype design because changes
andadjustmentscannotbemade.
o AccuratelyheatbendingPlexiglasiscanprovetobedifficult.
Plexiglas can be easily bonded together with a butt joint resulting in relatively strong
bond(Figure9.1).
o SurfacesmustbesmoothandflatforbondingPlexiglasi.e.routedormilled.
Figure9.1Plexiglasbondedbuttjoint
25
10
Rev.0
DRAWINGS
Trytoalwaysincludeanassemblyviewwithasetofsubmitteddrawings.
o Thiswillhelptheshopunderstandthepurposeofthepartsandwhereextracare
shouldbetakenwhenmachining.Iftolerancesordimensionswereomittedina
drawingitwilloftenallowtheshoptomakeaninformedjudgmentiftheyare
notabletocontactyou.
Makesurethedrawingscaleisnotedsoifdimensionsneedtobecheckedoraremissing
theycanbemeasuredoffthedrawing.
Whenprototyping,printingdrawingswitha1:1scalecanbeusefultoseetheaffectsof
changesonthepart.
General information should be included in the drawing title block. An example title
blockisshowninFigure10.1.
o Detailstoinclude:scale,quantity,material,part#,contactinfo,tolerances
Figure10.1ExampleTitleBlock
26
Rev.0
10.1 COMMONDRAWINGMISTAKES
Toomanydecimalsplaces
Dimensionsreferencedfromwrongsideofpartedge
Fonttobigortoosmall(shouldbe12pt.14pt.)
Arrowheadstoobig
Toomanyhiddenlinesshownmakingdrawingdifficulttointerpret(useasectionviewif
neededtoshowhiddendetails)
Toomuchinformationononedrawingsheet(usemorethanonedrawingsheettoshow
partmoreclearlyifthisisthecase)
10.2 DIMENSIONING
Useordinatedimensioningtomakedrawingseasiertoread.
Mark the origin of a part based on the origin which will be used when the part is
machined.
Draw ordinate lines on the side of the part which is closest to the detail they are
showingthepositionof.
The following pages show examples of drawings which are cluttered and difficult to
understandfollowedbyadrawingwhichusesbestpracticesfordimensioningdrawings.
Dimension drawing features according to the shop preferred method or specific CNC
millthatwillbeused.(Seesection10.4AnilamCNCMill,page35)
27
Rev.0
5.000
4.750
2.875
3.000
3.188
3.250
1.625
1.000
.375
.500
1.635
R.300 TYP
0
1.000 THRU
.250
.500
1.000
.260
1.250
2.000
2.625
3.000
.250 THRU 3PL
.375 THRU 3PL
.250 NOM
Figure10.2OrdinateDimensioning
28
Rev.0
5.000
4.750
2.875
3.000
3.188
3.250
1.625
1.000
.375
.500
1.635
R.300 TYP
0
1.000 THRU
.250
.500
1.000
.260
1.250
2.000
2.625
3.000
.250 THRU 3PL
.375 THRU 3PL
.250 NOM
29
Rev.0
5.000
4.750
3.188
1.000
.500
1.000 THRU
1.635
R.300 TYP
.250
.500
1.250
1.000
.260
2.000
2.625
3.000
.250 THRU 3PL

.375
1.000
1.625
.375 THRU 3PL
2.875
3.000
3.250
.250
Figure10.3Exampleofbaselinedimensioning
30
Rev.0
Notesaboutdrawing(Figure10.3):
Useofbaselinedimensionsmakesdrawingtooclutteredandhardtoread
Elevationviewshownwithhiddenlinesisconfusing.Shouldhavehiddenlinesremoved.
Slotlengthdimensionshouldbedonetothetotallengthofslot(asshownbelow).
1.375
.25
.260
Undesirableslotdimensioning
1.635
.25
.260
Preferredslotdimensioningstyle
Figure10.4Dimensioningofaslotlength
31
Rev.0
Notesaboutdrawing:
Dimensionlinesaredifficulttofollow.Ordinatedimensionsshouldbeonthesideofthe
partclosesttothefeaturetheyaredefining(showninFigure10.7).
Elevationviewofpartshouldbeshownwithouthiddenlines(Figure10.5).
.250 NOM
.250 NOM
Figure10.5Elevationviewwithandwithouthiddenlines
Dimensionlinesshouldnottouchthepart.
.260
.260
Figure10.6Dimensionlinespacing
32
Rev.0
5.000
4.750
3.188
3.000
1.000
.500
1.635
R.300 TYP
0
.250
.500
1.000
1.000
.260
1.250
1.000 THRU
2.000
2.625
.250 THRU 3PL
3.000
3.250
2.875
1.625
.375
.375 THRU 3PL
.250 NOM
Figure10.7Easytoreaddrawingusingordinatedimensions
33
Rev.0
Desirabledrawingcharacteristics:
Thedrawingaboveusesthepreferredstyleofdimensioning.
Dimensionlinesarespacedaparttoavoidclutteringthedrawing.
Dimensionsareclosetothefeaturetheydescribe.
Theslotscentrepositionisdimensionedandthewidthandtotallengthareshown.
34
Rev.0
10.3 TOLERANCES
Tolerancesareaveryimportantaspectofdrawingswhichareoftenoverlookedandare
notgiventheattentiontheyrequire.
Alldimensionsshouldhaveanassociatedtolerance.Anefficienttolerancingmethodincludesasectiontothe
includesasectiontothedrawingsheetstitleblockwhichdefinesthestandardtolerancesbasedonnumberof
tolerancesbasedonnumberofdecimalplaces(shownin
Figure10.8).
Tolerances
.xxx
0.003
.xx
0.01
.x
0.015
Unlessotherwisenoted
Figure10.8DrawingBlockforStandardTolerances
If certain dimensions can accommodate wider tolerance then remove the appropriate
decimals.Whenspecificallyneededaddtolerancestoindividualdimensionstohighlight
theprecisionrequired.
10.4 ANILAMCNCMILL
TheCNCMillingmachineusedextensivelyintheMech.Eng.MachineShoputilisesan
Anilamcontrolsystem.
Thefollowingfiguresshowthecontrolsystemsdifferentinputscreens(conversational
programming)forvariouscannedcycles.
o Acannedcycleisasetofmachineoperationsinitiatedbyasinglelineofcode.It
usesafillintheblanktypeinterface.
Usethescreensshownbelowtodeterminetheappropriatemethodtodimensionpart
featureswhichwillbeCNCmilled(diagramsarespecifictoAnilamcontrolsystem).
35
Rev.0
Figure10.9Inputscreenforboltholecircle
Figure10.10Inputscreenforrectangularprofile
36
Figure10.11Inputscreenforcircularprofile
Figure10.12Inputscreenforrectangularprofile
Rev.0
Figure10.13Inputscreenforcircularpocket
37
Figure10.14Inputscreenforframepocket
Rev.0
10.4.1 ANILAMCANNEDCYCLEDEFINITIONS
Profile:CircularorRectangular.CNCmillcutstheoutlineoftheshape.Cuttercanbeon
the inside or outside of the shape. Profiles are used for milling the outside contours,
slotsandholes.
Pocket:CircularorRectangular.CNCmillcutsallofthematerialinsideoftheshapetoa
specifieddepth.
Frame: CNC mill cutsa rectangular groove. This can have any radius on the corners
(commonlyusedforrectangularoringgrooves).
Note: All these cycles require the shapes centre position, length, width or diameter,
thereforeitismosthelpfultodimensiondrawingswiththeserequirementsinmind.
38
Rev.0
PARTIIMANUFACTURING
1 POSTS
The drawing below (Figure 1.1) shows the best practices for dimensioning a post
3.75
3.500
.25
drawingwhenusingthemachiningmethodoutlinedonthefollowingpages.
1/4-20
.5
2 PL
.750
+.000
- .002
1.0 NOM
Comments:
Dimensions in inches
unless noted.
Tolerances:
Break all sharp edges
Part:
Hole Tapper
Standoff
.xxx .003
Date:
Drawn by
7/22/2009
ML
.xx
.010
.x
.015
unless otherwise stated SCALE: 1:1 MATERIAL:
Figure1.12DDrawingforPost
UVic Faculty of Engineering

Project:
Qty.
REV.
1
A
SHEET 1 OF 1
Thepostdrawingaboveshowsthedatumposition(zero)asthebaseoftheleftboss.
This is done because the critical dimension for this part is 3.500 and not the overall
lengthof4.0.
Note:Ifalignmentisverycritical(eg.topandbottomplatesneedtobealignedwithin
0.003 of each other) then the outer diameter of the post must be machined first to
maintainconcentricitythroughoutthemachiningprocess.Thisisbecausestockmaterial
39
Rev.0
isoftennotperfectlyround.Machiningthefullouterdiameterlengthisrarelyrequired
inmostapplications.
Latheprocessformachiningmultiplepostswithbosses
Step1FacefirstendofpostandsetZaxisto
zeroonlathedigitalreadout
Step2Turnbosstorequireddiameterand
approximatedepth.
Step3Centredrill
Step4Drillendtotapdepth
40
Rev.0
Step5Tap.Repeatsteps15forallposts
Step6Zerotoolagainstchuckusingshim(make
suretoaccountforshimthickness)
Step7Faceoppositeendofpostto
approximatelythetotallength
Step8Centredrill.Repeatsteps7and8forall
identicalposts
Step10Drillbossofoppositeendtotapdepth
Step9Turnsecondbosswithlivecentre
(Z=criticallengthofpost)
41
Step11Tapsecondend
Rev.0
Step12Chamferallsharpedges
42
Rev.0
1.1 IMPORTANTNOTESFORPOSTS
Theoveralllengthneednottobemachinedasaccuratelyasthecriticallengthbetween
thebosses(showninstep9).
Whenturningthebossinstep2itcanbebeneficialtoleavethebossextralong.This
givesthethechuckjawsmoresurfaceareatoclampwhenturningwiththelivecentre.
Afterstep9thethisextralengthcanbefacedoffeasily.
43
Rev.0
2 CNCMILLING
2.1 SETUPMETHODS
2.1.1 FLATPARTS
FlatpartsareoftenmachinedonaCNCmillusingafixtureplate(Shownbelow).Thishas
manyadvantagesoverconventionallymachinedpart.
o If the part does not have any features in its ends or sides only one setup is
required(Topdownmachining).Thisbeingtherationalefornotplacingholesin
thesidesofflatpartswhenitcanbeavoided.
o Theoutsideofthepartcanbemachinedinonestep.
o Precisecopiesofthesamepartcanberapidlymachined(i.e.leftandrightsides,
topandbottom).
Part
Fixtureplate
Figure2.1Flatpartwithfixturingplate
44
Figure2.2Fixturingplatesetupinvise
Rev.0
2.1.2 CIRCULARPARTS
When the milling forces will be in the Zaxis only (eg. Drilling) a circular part can be
bolteddowntoaplate(ShowninFigure2.3).
Figure2.3CircularPartbolteddownthroughcenter.
45
Rev.0
Inothercaseswherelateralandradialcuttingforceswillbeappliedtothepartajigcan
be used. Figure 2.4 shows an example of a very simple, effective circular holding jig
which is commonly used in the shop. The scratch marks on the part and jig allow the
parttobereplacedintothemillinthecorrectorientationforpostmachiningoperations
ormodifications.
Figure2.4Circularpartwithjig
46
Figure2.5Circularpartandjigsetup
47
Rev.0
Rev.0
3 ORINGS
3.1 AXIALORINGS
ReduceRPMspeedswhengrooving
Figure3.1showsanexampleaxialoringgroove.
2.50 NOM
.100.005
1.580.003
1.750.003
Figure3.1AxialOringGroove
1. Determinethewidthofthetoolbeingused.Inthiscasethetoolwidthis0.0525.
.0525
2. Usingthefollowingformula,determinetheXpositionfortheO.D.oftheOringgroove
Oring O.D.
1.750
2 Tool Width
2 0.0525
48
1.645
Rev.0
WorkpieceMUSTberotatingforsteps3and4.
3. Usingtherightsideofthetool,establishthetoolpositionontheO.D.oftheworkpiece
andentertheO.D.oftheworkpieceintoXonthedigitalreadout(eg.2.500).
4. Usingthetipofthetool,establishthetoolpositiononthefrontfaceoftheworkpiece
bytouchingofflightly.Enter0.000intoZonthedigitalreadout.
TouchoffthetoolwheretheOringgroovewillbelocated.Thescoremarkcreated
fromthetoolwilldisappearwhentheOringgrooveiscut.
Steps5to7willberoughcuts.Roughcutsareusually0.010smallerthanthefinal
tolerance.Thisisperformedtoimprovesurfacefinishandtolerances.
5. MovetoolinXaxisto1.590andthenmovetoolinZaxisto0.090.
.090
49
Rev.0
6. MovetoolinXaxisoutto1.635.Thisis0.010smallerthanthecalculatedvaluefrom
step2.
7. Performthefinishingcut.MoveXto1.580,nextmoveZinto0.100andthenmove
Xoutto1.625.
This should be done in one fluid motion. The tool should never become stationary on the
workpiecewhenperforminganycuts.Thiscancausechatterandexcessiveheatgeneration
andwhenmachiningplasticitwillcreateapoorsurfacefinishandthesealmayleak.
50
Rev.0
3.2 RADIALORINGS
ReduceRPMspeedswhengrooving
Figure3.2showsanexampleradialoringgroove.
.250
1.50 NOM
1.320.003
.145.005
Figure3.2RadialOringGroove
1. Determinethewidthofthetoolbeingused.Inthiscasethetoolwidthis0.0525.
.0525
2. UsethefollowingformulatodeterminethefinalZpositionforthewidthoftheOring
groove.
Groove width
Tool Width
0.145
'Z' distance from datum surface
0.0525
51
0.25
0.343
Rev.0
WorkpieceMUSTberotatingforsteps3and4.
3. Usingtheleftsideofthetool,establishthetoolpositionontheendoftheworkpiece
and enter the width of the tool into Z on the digital readout (eg. 0.0525). This
establishedtherightsideofthetoolaszerointheZaxis.
4. Usingthetipofthetool,establishthetoolpositionontheO.D.oftheworkpieceand
entertheO.D.oftheworkpieceintoXonthedigitalreadout.(eg.1.500)
TouchoffthetoolwheretheOringgroovewillbelocated.Thescoremarkcreated
fromthetoolwilldisappearwhentheOringgrooveiscut.
52
Rev.0
Steps5to7willberoughcuts.Roughcutsareusually0.010smallerthanthefinal
tolerance.Thisisperformedtoimprovesurfacefinishandtolerances.
5. MovetoolinZaxisto0.260andthenmovetoolinXaxisto1.320.
6. Move tool in Z axis to 0.333. This is 0.010 smaller than the calculated value from
step2.
7. Performthefinishingcut.MoveZto0.250,nextmoveXinto1.300andthenmove
Zto0.343.
Thisshouldbedoneinonefluidmotion.Thetoolshouldneverbecomestationaryonthe
workpiecewhenperforminganycuts.Thiscancausechatterandexcessiveheatgeneration
andwhenmachiningplasticitwillcreateapoorsurfacefinishandthesealmayleak.
53
Rev.0
4 DRILLINGANDTAPPING
CentreDrill:
o Useanytimethereisachancethedrillbitmayglanceoffthematerialorwhen
holesneedtobepreciselypositioned(ie.holesonaradius,drillingintoahard
material,etc.).Centredrillsareusedveryoftenwhendrillinginthelathe.
DrillingPlexiglas:
o Plexiglaswilloftentocrackwhenthedrillbitexitsthroughtheothersideofthe
part.Topreventthis,slowdownthedrillfeedforthelast1mmor1/16while
drillbitexitsthematerial.ThisheatsthePlexiglastomakethelast1/16more
pliabletopreventcracking.Useextracarewhendrillingholesgreaterthan5/16
diameter.
4.1 TAPPING
Taps:Usedtocutinternalthreads.Thevarioustypesoftapsare:
Spiralpointtapsarethemostcommonlyused.Thefirst3to4threadsonthesetaps
arepartialthereforetheydonotcutfullthreadsforthecompletelengthof
engagement.IfthisisrequiredseeBottomingtapsbelow.
o BottomingTap:Usedtocutthreadstothebottomofablindhole.Abottoming
tapdoesnothaveataperedcuttingedgethereforeaplugtapmustbeusedfirst.
Donotuseabottomingtaptocutthreadsinanunthreadedhole.
Note: Use a bottoming tap only when thread depth is critical (ie. 1/2 plate
requiring 3/8 thread depth). Regular taps will not cut full threads to the
bottomofahole.
Tapdrillbit:Specificsizeddrillbitforacertaintap(eg.#6drillfora1/420tap).
PercentageofThread:Thepercentageofthreadreferstotheamountofthreadinterms
of the total thread depth (crest to root). Use a larger tap drill bit to lower the thread
percentandviceversa.Decreasingthethreadpercentminimizesthetorqueonthetap
anddramaticallyhelpstoavoidbreakingthetap.Italsospeedsupthethreadingpro
54
Crest
Rev.0
Root
100%Thread
70%Thread
50 %Thread
Figure4.1Threadpercentageexample
TPI:ThreadsPerInch
Metricthreadsarespecifiedbythedistancebetweenthethreads
Die(externalthreads):Usedtocutexternalthreads.
NPTThreads:(NationalPipeThread)Thesearetaperedthreadsforsealingfluids
Maximumdepthoftappedholesshouldnotexceed3XDiameterofTap.Usaullytwice
thetapdiameterisallthatisrequiredtoprovidemaximumholdingforce.
55
Rev.0
APPENDICES
MachiningTolerances
II
TapDrillSizes
III
DrillingandMillingSpeeds
IV
ORingGlandSizes(Axial)
ORingGlandSizes(Radial)
VI
II
Rev.0
Tapdrillandbodydrillsizes(fromshop)
III
Rev.0
Drilling,millingspeeds(fromshop)
IV
Rev.0
Rev.0
Rev.0
VI
Rev.0
REFERENCES
Osborn,Joe.2006.TipsonDesigningCostEffectiveMachinedParts.[Online]OMWCorporation.
Availableat:http://www.omwcorp.com/partdesign.html.[Accessed19June2009].
McMasterCarr.2009.[Online]McMasterCarrSupplyCompany.Availableat:
http://www.mcmaster.com.[Accessed07August2009].
ParkerORingHandbookORD5700,Parker,2007.
http://www.parker.com

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PROTOTYPEDESIGNAND

.250 THRU 3PL

.375 THRU 3PL

.250 THRU 3PL

.375 THRU 3PL

Break all sharp edges

UVic Faculty of Engineering

'Z' distance from datum surface

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