Anonymous
timer Asked: Apr 30th, 2020

Question Description

I want you to write a project report. and you can see the requirement down I have upload it.

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A B C D 4 5 3 1 4 Isometric view Scale: 1:1 3 3 4 2 2 2 DESIGNED BY: DATE: p843s475 7/3/2019 CHECKED BY: DATE: SIZE WMK 7/3/2019 Wichita State University 1 Letter SCALE 1:1 WEIGHT (kg) N/A DRAWING NUMBER 00A1 - Universal Coupling This drawing is our property; it can't be reproduced or communicated without our written agreement. D SHEET 1/2 I _ H _ G _ F _ E _ D _ C _ B _ A _ A 1 A B C D 4 4 3 Top view Scale: 1:2 All tolerances are +/-0.0003" 1 5 Bill of Material: Product1 Number Name Component 1 Center Block AISI 4340 2 Collar AISI 1040 3 Fork AISI 4340 4 Holding Pin AISI 1040 5 Pin AISI 4340 2 3 Description Steel steel steel steel steel DESIGNED BY: 2 Front view Scale: 1:2 4 DATE: p843s475 7/3/2019 CHECKED BY: DATE: SIZE WMK 7/3/2019 Wichita State University 1 Letter SCALE 1:1 WEIGHT (kg) N/A DRAWING NUMBER 00A2 - Universial Coupling This drawing is our property; it can't be reproduced or communicated without our written agreement. D 3 SHEET 2/2 I _ H _ G _ F _ E _ D _ C _ B _ A _ A 2 1 IME 258 Manufacturing Methods and Materials I Term Project Product Manufacturing: Process and Materials Selection I. Project Overview The goal of the term project is to provide to all students of IME 258 lecture (i.e., IME 258) and laboratory (i.e. IME 258L) a virtual experience for planning and sequencing the manufacturing operations required to produce a product (assembly) in large quantities. This will be performed with the help of a commercially available software (aPriori). This software will also be used to calculate the total cost of the product. This total cost includes raw material cost, machining/manufacturing cost, finishing cost, labor cost, etc. As a secondary goal for all students taking IME 258L, tool paths for the CNC machining of one of the parts of the product to be subject to manufacturing planning and sequencing will also be written using another commercially available software (MasterCAM). If done well, this effort will be rewarded with a maximum 10-pt extra credit. If not done well, there will be a maximum 10-pt penalty. Students not taking this laboratory for credits can still work on this secondary goal for lecture extra credit (10-pt max), but there is no penalty for not working on this part. This project is individual. That is, each student is expected to work on the manufacturing planning/sequencing and on tool-path generation for the selected product independently of other students. Virtual group discussions are encouraged, but project deliverables are expected to be the original work of the student submitting them for grading. Software access, project details and criteria for evaluation are given below. II. How to Access aPriori and MasterCAM/CATIA? The aPriori software is available to you via VPN remote connection to the computers at the John Bardo Center (Experiential Engineering) rooms 112 and 340. There are 12 computers at EE112 and 35 at EE340 with the software available to us on a 24/7 basis. Besides aPriori, the computers at EE112 also have MasterCAM and CATIA, and the computers at EE340 also have CATIA. However, there are free student versions of MasterCAM and CATIA that you can install on your personal computer. Instructions to download these software are posted on Blackboard. Let us reserve EE112 and EE340 for aPriori work as much as possible. If you have a way to install MasterCAM and CATIA on a computer of your own, do so. 1 DO NOT GO TO EE112/EE340 IN PERSON. To run aPriori remotely via the EE112/EE340 computers, follow instructions posted on Blackboard. To accommodate all students of IME 258, and allow equal access to all software, especially MasterCAM, for which we only have 12 seats, we will have to implement a user schedule. The user schedule is posted on Blackboard, under the folder titled “Term Project”. Note that there are days with open scheduling. Open scheduling means that you can login any time, but if the computers are busy, you will have to try again later. That is, during open scheduling, login is on a first come first served basis. Users are limited to 4 hours of continuous remote connection. Where to get help with aPriori software? Go through the enclosed aPriori tutorial (pdf file titled aPrioriOverview) and aPriori video lesson, under the folder titled “aPriori Help”. Also, plan to attend Zoom help sessions with your lecture and/or laboratory instructor/TA during regular class/laboratory schedules beginning on the week of April 20. 2 III. Project Details: For IME 258 lecture-only students Required: Provide virtual planning and sequencing of manufacturing operations as per details given in sections V to VII below. You must work with one of the product options provided by your instructor (enclosed). One is called “Screw Jack” and the other is called “Universal Coupling”. Select one product for virtual planning and sequencing of manufacturing operations. Download the “.stp” files of the parts of the product of your choice, and the assembly drawing with bill of materials (BOM). Save these files in a convenient location. Extra Credit (EC) (if done well, 10-pt EC; if not done, no penalty): Inspect the various parts of the product of your choice. Decide on a part that could be effectively manufactured by CNC machining. Parts that are suited for other processes such as sheet metal operations, welding or deformation processing should not be selected for CNC machining. For grading purposes, show diagrams indicating what features of the part will be made by CNC machining. Justify why you selected this part for machining. You may use aPriori to make this justification objective. Use MasterCAM to create a .emcx-9 file including the CNC tool paths required to complete the features to be made by CNC machining. Also for grading, you will need to provide this .emcx-9 file. Zoom video-presentation not required. IV. Project Details: For IME 258 laboratory and laboratory-only students Required, Part 1: Provide virtual planning and sequencing of manufacturing operations as per details given in sections V to VII below. You may work with the assembly (product) that you had identified/designed earlier. Alternatively, you can work with one of the product options provided by your instructor (enclosed). One of these options is called “Screw Jack” and the other is called “Universal Coupling”. If you choose to complete your analysis with one of these instructorprovided products, download the “.stp” files of the parts of the product of your choice, and the assembly drawing with bill of materials (BOM), and save these files in a convenient location. Required, Part 2 (if done well, 10-pt EC; if not done well, 10-pt penalty): Inspect the various parts of the product of your choice. Decide on a part that could be effectively manufactured by CNC machining. Parts that are suited for other processes such as sheet metal operations, welding or deformation processing should not be selected for CNC machining. For grading purposes, show diagrams indicating what features of the part will be made by CNC machining. Justify why you selected this part for machining. You may use aPriori to make this justification objective. Use MasterCAM to create a .emcx-9 file including the CNC tool paths required to complete the features to be made by CNC machining. Also for grading, you will need to provide this .emcx-9 file. Required, Part 3 (if not done, 30-pt penalty): Using Zoom, a recording of yourself explaining your project results, lessons learned and opportunities for improvement. 3 V. What to do for your project? 1. Definition of process for each part in your product: a. Based on process selection guidelines learned in lecture/laboratory, provide a list of different manufacturing methods or processes that may be utilized to make each one of the parts in your product. b. Prepare to input the information required by aPriori to evaluate the cost to manufacture each part using the process alternatives listed by you, and run aPriori to obtain part cost. Note, it is important to have more than one process for each part to be able to provide cost comparisons between alternatives. 2. Definition of alternative materials for each part in your product: a. List alternative materials that may be used to substitute the materials requested in the BOM. b. Have aPriori conduct an evaluation of the impact of the alternative materials on product performance and cost. 3. Tolerance analysis: a. Pick at least two parts in your product, and add suitable dimensional and geometric tolerances. b. Run aPriori tolerance analysis to show tolerance values that avoid the need for extra finishing operations, and tolerance values that demand extra finishing operations. VI. Reporting your Work to your Instructor Upload a report (submitted individually) to Blackboard’s dropbox as per your instructor’s instructions. Your report should be written in “Times New Roman size 12”, and have 1-inch margins all around. Write using single spaces. Convert your file to a pdf prior to uploading to Blackboard. The report should contain the following: 1. A cover page with WSU name/logo, class title (Manufacturing Methods and Materials I), project title (choose one that reflects the product that you are evaluating), author name, last name and WSU ID, date of submission, and any other information that you may want to include to identify your project. One page limit. 2. An introduction stating your project goals. One page limit. 3. An analysis section where you document: a. The product design that you are evaluating. Show the parts and assembly of your product using illustrations and text describing your illustrations logically. You can 4 use the parts and assembly drawings provided to you. You are allowed to modify these parts if you think doing so will improve product cost or manufacturability. Document any modifications introduced in this section of your report. Two page limit. b. A description of all the processes evaluated for each part in your product. A description of all the materials evaluated for each part in your product, including relevant mechanical properties. A description of the stock shape and dimensions for each part and each process combination. Be graphical. That is, include figures and/or tables illustrating or defining your processes and materials. Your text should describe these figures and tables logically. If you are providing CNC tool paths for one of the parts in your product, either for regular credit or for extra credit, provide a justification stating why this part is suitable for CNC machining, and provide screen shots of your MasterCAM tool paths. Three page limit. c. Add tables, figures, charts, etc. showing the results of your analysis from aPriori, and text describing these tables, figures, charts, etc. logically. You do not have to describe details about aPriori’s algorithms or methods of analysis, but you should provide results that support your recommendations and conclusions. You can take screenshots from aPriori, but make sure your report shows them clearly (legible). Five page limit. d. Describe your tolerance analysis in your report. Again, be graphical. Show your tolerances on your part drawings, and show aPriori forms and results of your tolerance analysis. Two page limit. 4. Recommendations/conclusions from your analysis. One page limit. 5. Electronic attachment 1: Submit your MasterCAM .emcx-9 file via the Blackboard’s dropbox titled “MasterCAM tool path”, as per instructions given above. 6. Electronic attachment 2: Submit your Zoom presentation via the Blackboard’s dropbox titled “Term Project Zoom Presentation”, as per instructions given above. 5 VII. Evaluation Criteria Your instructor will assign a score to your project/report based on the following rubric: TOTAL /250 Poor Average Excellent Cover sheet Missing = 0/5. Project name and all student names included = 5/5. Introduction Missing = 0/45. Project name or at least one student name/WSU ID misspelled, page limit violated = 3/5. Documentation of product design being evaluated Missing = 0/50 Process description/materi als selection aPriori results, tolerance analysis Project goal may be stated, but individual contributions are missing or are not descriptive (only list team member title such as “team leader”, “process engineer”, etc.); or individual contributions are stated, but project goal is unclear. A clear goal will state what product is being evaluated and what evaluation is being performed = 25/45. Project goals and individual contributions are included and page limit is not violated = 45/45. Note: if page limit is violated, a 5-pt penalty will be assigned. Missing = 0/50. Included, but some parts may have been evaluated for only one process, or without alternative material. If applicable, choice of CNC machining is not fully and objectively justified = 30/50. Missing or figures, tables, charts, etc. are not legible = 0/50 Figures, tables, charts, etc. are shown, but text does not describe these illustrations or text is missing altogether = 30/50 Included, and all parts have been evaluated for at least two processes and one alternative material, and if applicable, choice of CNC machining is fully and objectively justified = 50/50. Note: if page limit is violated, a 5-pt penalty will be assigned. Assembly drawing and/or some part drawings are missing, and/or text does not describe provided illustrations = 30/50. /5 /45 Assembly and all part drawings are described logically. Text described provided illustrations = 50/50. Note: if page limit is violated, a 5-pt penalty will be assigned. /50 Figures, tables, charts, etc. are shown and are legible, and text describes these illustrations logically = 50/50. Note: if page limit is violated, a 5-pt penalty will be assigned. /50 /50 6 Recommendations /Conclusions Missing = 0/45. Included, makes some sense, but does not reflect results from aPriori analysis = 30/45 Spelling/ grammar Many typos and grammatical errors = 0/5. Many typos, but good grammar = 2/5. Included, makes sense, and reflects results from aPriori analysis = 45/45. Note: if page limit is violated, a 5-pt penalty will be assigned. Good spelling and good grammar = 5/5. /45 /5 Notes: 1. Your report will be checked for plagiarism using Blackboard tools. Make sure your text is original, and do not share it with other students. If the tools show high level of plagiarism, you will receive 0/250, and you will be reported to university authorities. 2. Lec-only students: a. Your MasterCAM .emcx-9 file, as per the requirements stated above is optional. If you do this well, you will receive a maximum 10-point EC. If you don’t do this well, you will receive no penalty. b. Recordings of yourself presenting your project are not required. 3. Lab and lab-only students: a. Your MasterCAM .emcx-9 file, as per the requirements stated above is required. If you do this well, you will receive a maximum 10-point EC. If you don’t do this well, you will receive a maximum 10-point penalty. b. Prepare, using Zoom, a recording of yourself explaining your project results, lessons learned and opportunities for improvement. This is required for you. If you don’t do this well, you will receive a maximum 30-point penalty. 7 ...
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