I need slides for this part
There are many different gears in this tool. Find a gear model that is made using Powdered Metal.
Briefly list the necessary functions and characteristics of the part.
This part is made using the manufacturing process Powdered Metal Manufacturing. How does this manufacturing process fulfill each of the functions listed above?
How did you know this part was made using Powdered Metal?
The engineers at DeWALT designed this part with Powdered Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for:
Material selection (including the base material, and any additional material impregnation)
PM Chamfer
Uniform cross section for even compaction
Draft angles (are the draft angle requirements different for PM, and why is that important for this particular part?)
N530050 Detent Washer
Briefly list the necessary functions and characteristics of the part.
This part is made using the manufacturing process Sheet Metal Stamping/Bending. How does this manufacturing process fulfill each of the functions listed above?
The engineers at DeWALT designed this part with Sheet Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for:
Material thickness
Hole location and sizing (look up specific requirements for holes in relation to material thickness)
Bend radii (look up specific requirements for bends in relation to material thickness)
Stack-Up + DFM Lab + Report Guide F2023.docx Stack-Up Design Lab Guidelines ENME 371 Stack-Up + DFM Lab/Report Guidelines Electronic Copy Due online by 8 AM 10/18-10/19 (on the day of your lab) (Late penalties outlined in the syllabus will apply to late reports) OBJECTIVE To learn about and appreciate the importance of dimensional variance stemming from production processes and its effects on the design process. To learn methods for accounting for these variances in the design of mechanical assemblies. To become aware of major mass manufacturing processes, understand their capabilities, and understand the design of parts for these manufacturing processes. LEARNING OUTCOMES 1. Learn typical manufacturing process variations 2. Learn how to account for these variations in the design process 3. Apply statistical methods to a practical real-life design problem 4. Practice making design decisions 5. Learn to think critically about Design HONOR CODE STATEMENT: The report must include the Honor Code statement on the cover page signed by all team members, and a task assignment sheet (in the appendix) indicating which member was responsible for the various tasks relating to this deliverable. A Signed peer evaluation form must also accompany all reports! This deliverable will be turned in as slides. This is NOT a presentation but documentation via slides. The content requirement remains the same as a written report, but with figures and bullet points instead of traditional paragraph format. DESCRIPTION OF THE ASSIGNMENT 1. Perform a stack-up analysis on an existing design (The blade clamping mechanism of a DEWALT Miter Saw) 2. Evaluate the current design 3. Recommend any design or manufacturing process changes to make the design more robust 4. Talk about DFM elements for processes and components relevant to the DCD701 5. Present your results in a Lab report MATERIALS AND DOCUMENTS NEEDED 1. Hardware Set: Blade, Output Spindle, Inner Blade Clamp, Outer Blade Clamp, Blade Bolt, Ball Bearing, Gear Case Cover. There will be one set available for the entire class; it will be kept in our Lab. 2. Stack-up template (excel spreadsheet) 3. Drawing package including all 2-D drawings for all components listed above (included in the stack-up template) TASK 1 – Blade Clamp Assembly Function (5 pts) Briefly describe the design objectives of this blade clamp assembly. Think about what the design (the miter saw) does, and determine what the blade clamp system is supposed to do and how it does it. For this design to work, four things must be ensured: 1. The Blade Bolt can never bottom out (touch the bottom of) the output spindle threaded area (or we end up with a tightened bold but a loose blade) 2. The Head of the Bolt, never tightens against the end of the output spindle (or we end up with a tightened bolt but a loose blade again) 3. The Blade Bolt always has to have at least 12 mm of thread engagement with the spindle (To ensure enough strength and fatigue life, and to satisfy regulatory rules) 4. For blade assembly there should be no possibility for the blade hole to ever be smaller than the spindle diameter. In other words, the blade must always fit on the spindle with ease. Additionally, since the blade is spinning at significant speed we need to keep the blade imbalance below 14 g.mm. Study these design specifications, and provide any comments or express any additional thoughts you may have. 1 Stack-Up Design Lab Guidelines ENME 371 TASK 2 - Stack-Up Analysis (25 pts) For each of the four Design Specifications listed above, you will run a stack-up analysis based on the existing design’s drawings. STACK-UP 1: BLADE BOLT END TO BOTTOM OF SPINDLE THREAD STACK-UP 2: GAP BETWEEN BLADE BOLT HEAD AND SPINDLE STACK-UP 3: LENGTH OF THREAD ENGAGEMENT STACK-UP 4: RADIAL CLEARANCE BETWEEN BLADE AND SPINDLE For each of the stacks: 1. Create and label the sketch that will guide you through the stack-up. The sketch for stack-up 1 is already completed for you. The parameter in question is denoted as “X” on your sketch. 2. Calculate the mean (nominal) value of the parameter in question (Xnominal) For the individual part dimensions, assume that the nominal size is in the center of the Upper Specification Limit (USL) and the Lower Specification Limit (LSL). 3. Calculate the Standard Deviation for each dimension involved in the stack DEWALT uses the concept of process variation to describe dimensional variability. Each tolerance on a drawing is selected such that a manufacturing process capability (Cp) of 1 can be achieved. Set Cp=1 for each dimension in the stack, and calculate the standard deviation you expect to see on that dimension. By definition: ?? = ???−???6σ A Cp=1 means that ±3σ (99.7%) of parts are expected to fall between the USL and LSL specified in the drawings. 4. Calculate the cumulative standard deviation of the parameter in question, using the following equation: σ ??? = σ 1 2 + σ 2 2 + σ 3 2 + … 5. Calculate the expected range of the parameter in question using a 99.7% confidence interval. The 99.7% interval is equivalent to the nominal value, +/- 3σ as shown here: TASK 3 – Design Thinking (15 pts) 1. How well (or badly) does the current design achieve its design specifications? Give detailed explanations on your assessment. For stack 4 be sure to consider both constraints. 2. What changes, if any, would you make to this design to make it more robust? Explore changes in dimensions, manufacturing process capabilities and resulting tolerances, radical changes to the existing design, etc. Be sure to consider the effects of the proposed changes on all of the different stack-ups as a whole. 2 Stack-Up Design Lab Guidelines ENME 371 Task 4: Complete the DFM assignment for each of the following components (45 points) Read each step below carefully (each section is slightly different!). Use information from the in class manufacturing lecture, your own experience with the tool, and additional online research to answer the questions. Include screenshots from the 2D and 3D models to aid in your description. 1. N569258 Housing Assembly Side a. Briefly list the necessary functions and characteristics of the part. Example: the assembly side housing must not break if dropped. b. This part is made using the manufacturing process Injection Molding. How does this manufacturing process fulfill each of the functions listed above? Example: Injection Molding is a good manufacturing method for this part, as it allows you to use plastic materials, which are strong but not brittle. c. The engineers at DeWALT designed this part with Injection Molding in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: i. General moldability (show the direction of mold separation between the two halves; point out any undercuts which may require side pulls) ii. Consistent wall thicknesses iii. Rib and boss locations and sizes iv. Draft angles v. Fillets Example: DFM guidelines specify that wall thicknesses should be approximately uniform to avoid uneven cooling. Below is an area where a pocket is designed in to avoid a thick section in the part. 2. N527880 Detent Nut a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Die Casting. How does this manufacturing process fulfill each of the functions listed above? c. The engineers at DeWALT designed this part with Die Casting in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: i. General moldability (show the direction of mold separation between the two halves; how did the engineers avoid the need for undercuts in this part?) ii. Consistent wall thicknesses iii. Draft angles iv. Fillets 3 Stack-Up Design Lab Guidelines ENME 371 v. Material compatibility 3. N543525 Lock Ring a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Forging. How does this manufacturing process fulfill each of the functions listed above? c. The engineers at DeWALT designed this part with Forging in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: i. General moldability ii. Material selection iii. Draft angle iv. Tolerances capable with forging (is there evidence of secondary operations?) 4. There are many different gears in this tool. Find a gear model that is made using Powdered Metal. a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Powdered Metal Manufacturing. How does this manufacturing process fulfill each of the functions listed above? c. How did you know this part was made using Powdered Metal? d. The engineers at DeWALT designed this part with Powdered Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: i. Material selection (including the base material, and any additional material impregnation) ii. PM Chamfer iii. Uniform cross section for even compaction iv. Draft angles (are the draft angle requirements different for PM, and why is that important for this particular part?) 5. N530050 Detent Washer a. Briefly list the necessary functions and characteristics of the part. b. This part is made using the manufacturing process Sheet Metal Stamping/Bending. How does this manufacturing process fulfill each of the functions listed above? c. The engineers at DeWALT designed this part with Sheet Metal in mind. Look at the provided 2D and 3D models. Where can you see evidence that Design for Manufacturing guidelines were followed? Specifically look for: i. Material thickness ii. Hole location and sizing (look up specific requirements for holes in relation to material thickness) iii. Bend radii (look up specific requirements for bends in relation to material thickness) TASK 5 - Conclusion + Professionalism (7 pts) Conclusion: - Discuss implications and draw overall conclusions from the results. - Discuss things you have learned, as well as the questions to which you still don’t have answers. - How does this type exploration and analysis within this lab relate to design of products in general? - Can the team think of ways in which the customer experience of the DEWALT tool could be improved based on the results of this lab? - As a team, reflect on what aspects went well for this deliverable. - As a team, reflect on what aspects were the most challenging, and what changes the team could implement for future deliverables. Professionalism of report throughout including: writing clarity, narrative and visual formatting, grammar, use of appropriate citation style and in text referencing, etc. Use SI units. Task tracking details (3 pts) A score reflecting the detail level of the reported task tracking. 4 DPMO Chart DPMO UnilateralSigma 0.000006 0.000996 0.001355.9 0.002475.8 0.004485.7 0.008045.6 0.014325.5 0.025245.4 0.044075.3 0.076205.2 0.130485.1 0.221275 0.371634.9 0.618154.8 1.018334.7 1.661504.6 2.684924.5 4.297244.4 6.812084.3 10.695694.2 16.633464.1 25.621724 39.092483.9 59.080593.8 88.444593.7 131.153853.6 192.656253.5 280.341223.4 404.112873.3 577.086493.2 816.418683.1 1144.275833 1588.938152.9 2186.025582.8 2979.818592.7 4024.630572.6 5386.170502.5 7142.814662.4 9386.687412.3 12224.433412.2 15777.550702.1 20182.147762 25587.989801.9 32156.713251.8 40059.113571.7 49471.450941.6 60570.770891.5 73529.300461.4 88508.051711.3 105649.839091.2 125071.988751.1 146859.080851 171056.112250.9 197662.492050.8 226627.279730.7 257846.043680.6 291159.655030.5 326355.241230.4 363169.410060.3 401293.726220.2 440382.288500.1 480061.126670 STACK-UPS STACK-UP 1: BLADE BOLT END TO BOTTOM OF SPINDLE THREAD LabelDescriptionNominal+/- TolCpSTDEVSensitivity (-) Screw1Length of Blade Bolt (underside of head to end)-20140.32% (+) Outer1Outer Blade Clamp Thickness6.50.156.05% (+) Blade1Blade body thickness0.990.072.82% (+) Inner1Inner Blade Clamp Thickness11.010.14.03% (+) BB1Ball Bearing width70.062.42% (-) Spindle2Spindle Blade side END to Ball Bearing shoulder-24.60.14.03% (+) Spindle1Spindle Blade side END to screw thread depth20140.32% Xnominal =0.9 Arithmetic Stack-Up (+) ---> Clearance (-) ---> Interferance XNominal0.90 Tolerance2.48 XMax3.38 XMin-1.58 STACK-UP 2: GAP BETWEEN BOTTOM OF BLADE BOLT HEAD TO SPINDLE LabelDescriptionNominal+/- TolCpSTDEVSensitivity #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Xnominal =0 Arithmetic Stack-Up (+) ---> Clearance (-) ---> Interferance XNominal0.00 Tolerance0.00 XMax0.00 XMin0.00 NOTES: 1. Blade Bolt 2. Spindle 3. Bearing 4. Inner Blade Clamp 5. Blade 6. Outer Blade Clamp STACK-UP 3: LENGTH OF THREAD ENGAGEMENT LabelDescriptionNominal+/- TolCpSTDEVSensitivity #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Xnominal =0 Arithmetic Stack-Up (+) ---> Clearance (-) ---> Interferance XNominal0.00 Tolerance0.00 XMax0.00 XMin0.00 NOTES: 1. Blade Bolt 2. Spindle 3. Bearing 4. Inner Blade Clamp 5. Blade 6. Outer Blade Clamp STACK-UP 4: RADIAL CLEARANCE BETWEEN BLADE AND SPINDLE LabelDescriptionNominal+/- TolCpSTDEVSensitivityMake AND label your own drawing, and insert here #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! Xnominal =0 Arithmetic Stack-Up (+) ---> Clearance (-) ---> Interferance XNominal0.00 Tolerance0.00 XMax0.00 XMin0.00 DRAWINGS BLADE BOLT OUTER BLADE CLAMP INNER BLADE CLAMP SPINDLE BALL BEARING BLADE