Round Test Specimen Polisher

Figure 1: The polishing machine Lab Testing, Inc. Tasked the capstone teams with reverse
engineering and redesigning.

The round test specimen polisher can be divided into six subsystems: The base, the
powertrain, the swing arm, the chuck, the paper reel, and the electrcal box. The
machine was disassembled so that each part in the machine could be labeled with a part
number and measured in order to be modeled.
 Swing Arm
Description: The swing arm is a subassembly of the polisher that swings back and forth
continuously to move the sandpaper against the test specimen.

Figure 2: The original swing arm on the polisher.

















Figure 3: Left: CAD Model of the original part (SolidWorks), Right: CAD Model of the improved design (SolidWorks)

The improved design was mostly focused on making the swing arm easily
manufacturable in small quantities. While the original swing arm frame is cast, the
redesign can be manufactured with traditional machining methods and assembled. This
eliminates the need for a mold, which can cost tens of thousands of dollars.
 Base
Description: The base provides stability to the machine and allows the various
subsystems in the machine to integrate.

Figure 3: The original base (circled in red) is a single cast piece.
















Figure 5: Left: CAD Model of the original part (SolidWorks), Right: CAD Model of the improved design (SolidWorks)

The improved design was mostly focused on making the base easily manufacturable in
small quantities. While the original base is cast, the redesign can be manufactured with
traditional machining methods and assembled. This eliminates the need for a mold,
which can cost tens of thousands of dollars.

 Drawings
Description: Once each part of the polishing machine was modeled in SolidWorks, an
engineering drawing was created. Below are some examples of the drawings I created.

4 3 2 1



D D
.15
.21

.11
.19
2X R .25
.08

DETAIL C
.20
.30
SCALE 1 : 1

DETAIL B

SCALE 1 : 1

1.31
1.27

.24

.06
0
R.21
.80
R.126
10.65
.65
.12

R.50 0
.40
R.25 .08
.275

C 1.00
.55 .35
B
.65
C
1.400

.73 1.05
R.10
R.20
R.25
R.385 R.21
R.126 2.00

.31
R.425
2.18 2.06

.85
6.48 .65

DETAIL A
SCALE 1 : 1

R1.00
2X 5/16-18 UNC

3X 10-32 UNF .40

.375
.12

B .27
A
3.40 B
C
.47
1.14
.47
.10

1.20
4.46
.15
.575

2X 10-32 UNF R1.85 .40

.12
.375

.275

UNLESS OTHERWISE SPECIFIED:

DIMENSIONS ARE IN INCHES DRAWN

NAME

WJS
DATE

11/06/18

A TOLERANCES:
CHECKED WJS 11/08/18 TITLE:
A

FRACTIONAL

Swing Arm
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

INTERPRET GEOMETRIC Q.A.
PROPRIETARY AND CONFIDENTIAL TOLERANCING PER:
COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL: Cast Alloy Steel
SIZE DWG. NO. REV

4-1 2
DRAWING IS THE SOLE PROPERTY OF

C <INSERT COMPANY NAME HERE>. ANY

REPRODUCTION IN PART OR AS A WHOLE FINISH
WITHOUT THE WRITTEN PERMISSION OF NEXT ASSY USED ON
<INSERT COMPANY NAME HERE> IS
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: SHEET 1 OF 1

4 3 2 1

Figure 4: Drawing for the Swing Arm frame in the Swing Arm subassembly.

 2 1


+.001
.12 - .000

.17

B
60° B

.10
.12

.01

.01

1.06 .10


.29

#10-32 Machine Threads

UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
DRAWN WJS
AYC
11/06/18
11/07/18 TITLE:
A

FRACTIONAL CHECKED

Paper Spool
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL

MFG APPR.

PROPRIETARY AND CONFIDENTIAL

INTERPRET GEOMETRIC
TOLERANCING PER:
Q.A.
Shaft

COMMENTS:
THE INFORMATION CONTAINED IN THIS MATERIAL: Plain Carbon Steel
SIZE DWG. NO. REV

4-13 3
DRAWING IS THE SOLE PROPERTY OF

<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
<INSERT COMPANY NAME HERE> IS
NEXT ASSY USED ON
FINISH
A
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 2:1 WEIGHT: SHEET 1 OF 1

2 1

Figure 5: Drawing for the Paper Spool Shaft in the Swing Arm subassembly.

2 1
.50
R.425


B FILLET R .10
R.453
1.325
.85
B
.335

.43
2X R .10

.34 .20

.10 X 45°
1.10
5.31

3.015 .14 2.60

.39
.84

.30
.425 .50 .175 M7x1.0 Tapped Hole
.325
UNLESS OTHERWISE SPECIFIED: NAME DATE

A DIMENSIONS ARE IN INCHES

TOLERANCES:
FRACTIONAL
DRAWN

CHECKED
WJS
AYC
11/06/18
11/08/18 TITLE:
A
Swing Arm to
ANGULAR: MACH BEND
ENG APPR.
TWO PLACE DECIMAL
THREE PLACE DECIMAL MFG APPR.

PROPRIETARY AND CONFIDENTIAL

INTERPRET GEOMETRIC
TOLERANCING PER:
Q.A.
COMMENTS:
Base Mount
THE INFORMATION CONTAINED IN THIS MATERIAL: Cast Alloy Steel
SIZE DWG. NO. REV

6-6
DRAWING IS THE SOLE PROPERTY OF
<INSERT COMPANY NAME HERE>. ANY
REPRODUCTION IN PART OR AS A WHOLE
WITHOUT THE WRITTEN PERMISSION OF
<INSERT COMPANY NAME HERE> IS
NEXT ASSY USED ON
FINISH
A
PROHIBITED. APPLICATION DO NOT SCALE DRAWING SCALE: 1:2 WEIGHT: SHEET 1 OF 1

2 1
Figure 6: Drawing for the Swing Arm to Base Mount in the Base subassembly.