ET 449 ADVANCE TOOLING     AND PROTOTYPING
 Semester Project

A semester project is required for each lab section.  The project will be a group effort with equal participation from each student.  Team members will evaluate the success of the group and the contribution of each individual team member.  The project will consist of program development for a 3D assembly consisting of a minumum of 6 components (excluding hardware).  Each group will create a working model and a production plan and production run for an advanced prototype of sufficient complexity.  A complete set of documentation is required including but not limited to the following:

      1.  Set of working drawings produced to scale on CAD
      2.  Prototype Development
      3.  Complete Documentation of CNC Programs
      4.  Setup Procedure for production
      5.  Program Verification
      6.  Tooling and fixture design and fabrication
      7.  Prototyping
      8.  Production Plan including OPERATION AND ROUTING SHEETS
      9.  Project presentation and demonstration of working model.
 

     NOTE: START WORKING OR YOUR PROJECT IMMEDIATELY!  A PROPOSAL WILL BE DUE BY WEEK 4 USING THE FORMAT BELOW:
                 If you have some ideas, see me to discuss as soon as possible.

*** SEE BOTTOM OF PAGE FOR FORMAT, POINTS, AND WEIGHTS*****

          PROPOSAL FORMAT (2 PAGES)

    Statement of the problem
 

    Objectives
 

    Sketches
 

     Bill of Materials
 

    Procedures
 

    Production plan (flow chart)

Some ideas for the semester project include the following.  Note design, fabricate, assemble, and test one of the follwing working models or mechanisms.

       1.  Stirling Engine:  Click here for an animated example.
 

       2.  Compressed air engine (not a Root's).  Click her for an animated example.
 

       3.  Hydraulic Pump. Click here for animated example.
 

       4.  Geneva cam indexing unit
 

                         Source:  http://www.20sim.com/webhelp4/Toolboxes/mechatronics/Cam_Wizard/CamMotionProfiles.htm#Geneva_Mechanism

       5.  Ball cam indexing unit
 

       6.  Rachet and paw indexing unit
 

       7.  Cam and Follower System at work within an Internal Combustion Engine

             Source:  http://www.ul.ie/~kirwanp/examplesofsystemsinuse.htm

           8.  Universal joint with drive coupling

 

 Other examples of mechanisms can be found at: http://www.flying-pig.co.uk/mechanisms/index.html

                                                                                       http://www.ul.ie/~kirwanp/index.htm

                                                                                        http://www.cs.cmu.edu/~rapidproto/mechanisms/examples.html#toc

                                                                                        http://www.keveney.com/Engines.html
 
 

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ET 449 Final/Project Format {250 Points Total}

PART A:  WRITTEN {150 Points Total}:
                 Weights are shown in brackets, sub-weights in parentheses.

Cover:  Letter of Transmittal [20]

I. Statement of Problem  [10]
A. Background and Requirements (5)
B. Objectives and Deliverables (5)

II. Procedures [10]

III. Methods of Production [20]
A. Operations (5)
B. Tooling Requirements (5)
C. Feeds and Speeds (5)
D. Set-Up Requirements (5)

IV. Results [25]
A. Description of Outcomes (5)
B. Description of Deliverables (5)
1. Models and Drawings  (5)
2. Tables (Feeds/Speeds, Tooling, Set-up Sheets (5)
3. Photos and/or Renderings (5)

V. Appendices (Exhibits of B1, B2, B3) [60  (20 points each)]

VI. References (APA format) [5]

PART B:  PRESENTATION and DEMONSTRATION {100}

I. Presentation [50]
 
            Note:  For the presentation (Power Point), highlight the major sections of the
                    written report.

II. Demonstration [50]

NOTE:  YOUR MECHANISM MUST WORK!
Device will be demonstrated and tested.   Each individual or team project will be coupled to an electric gear motor to verify operation of the mechanism(s).