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Manufacturing Progress Report and Systematic Errors in Shaft Fabrication

This report discusses progress made in shaft fabrication, including stiffness calculations, dimensions, and manufacturing details. It also covers systematic errors such as vibration and tool wear affecting the process.

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Manufacturing Progress Report and Systematic Errors in Shaft Fabrication

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  1. Group 2 – Progress Report 2/23/09

  2. Purpose (Justin) • Talk about progress the past week • Fabrication of shaft • Shaft exercise • Lessons learned • Getting ahead of schedule

  3. Gantt Chart (Justin) • (Switch to Excel)

  4. Stiffness Calculation (Corey)

  5. Spindle Shaft Dimensions (Corey)

  6. Stiffness Calculation (Corey) Keq=10.426 N/μm

  7. Pre-process Plan (Yi Fei) • Face-off right most face • Drill live center • Rough cut section A, B, C, and then D • Finish cut section A, B, C, and then D • Cut part to length, take part out C B D A

  8. Process Plan (Yi Fei) • Face-off right most face • Drill live center • Turn down whole length to 1.07” diameter • Rough cut and finish cut section C, B, and then A • Take part out, cut to length, turn part around • Rough cut and finish cut section D C B D A

  9. Manufacturing (Mark) • Details

  10. Manufacturing (Mark)

  11. Manufacturing (Mark)

  12. Test Cut Results (Corey) • The measured diameters were greater than the target diameter • The largest diameters were measured from the cantilevered cuts • ~.003 error in touching off tool • Free end cuts were performed last

  13. Fabricated Shaft (Corey)

  14. (Non) Systematic Errors (John)

  15. Nonsystematic Errors - Thermal From Manufacturing Engineering and Technology - Kilpakjian CTE=12.2 µm/m-°C ∆L~1 µm

  16. Non-Systematic Errors: Vibration • Rotating machinery may excite natural frequencies of lathe, tool, or shaft. → Be sure work-piece is centered → Hold shaft with both chuck and live-center → Hold shaft as close to cutting zone as possible

  17. Systematic Errors: Tool slip or work-piece slip • Cutting forces may cause the tool or work-piece to shift because both are held with friction forces only. • Cause a shift in mean results →Use moderate feed-rates and depths of cut (accuracy more important than time for this operation) Cutting forces on order of 250N-1000N http://www.sabanciuniv.edu/mdbf/mechatronics/eng/Arastirmalar/Projeler/images/clip_image008.jpg

  18. Systematic Errors: Tool Wear • Any tool wear will result in oversized dimensions • Not enough cutting done to be a large factor of error →Check tool-zeroing often Taylor-Tool Life Expectancy Eqation: V_c*T^n = C

  19. Concerns • Will the current shaft work? • Making sure the second shaft gets manufactured ‘properly’

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