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Old Main

Old Main. Finalized Process Plans. Front Face Process Plan. Finalized Process Plans (cont.). More Detailed Front Face Process Plans. Finalized Process Plans (cont.). Side Face Process Plan. Finalized Process Plans (cont.). More Detailed Side Process Plans. Top Plate Tooling 4” Face Mill

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Old Main

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  1. Old Main

  2. Finalized Process Plans • Front Face Process Plan

  3. Finalized Process Plans (cont.) • More Detailed Front Face Process Plans

  4. Finalized Process Plans (cont.) • Side Face Process Plan

  5. Finalized Process Plans (cont.) • More Detailed Side Process Plans

  6. Top Plate Tooling 4” Face Mill 1” End Mill Machine 3-Axis Milling Machine Fixturing Vacuum Fixture Description Cut to shape then perform a cut off operation Bottom Plate Tooling 4” Face Mill 1” End Mill ¾” Spot Drill Machine 3-Axis Milling Machine Fixturing Vacuum Fixture Description Spot drill feature then end mill the over hang Finalized Process Plans (cont.)

  7. Finalized Process Plans (cont.) • Triangular Roof • Initial Stock is 1.25” x 1.25” x 6’ solid square 6061 Aluminum • Cut into 12” sections using bar feeder • Cut each 12” section in half (diagonally) on band saw using 45 degree wedges for guidance • Mount 12” triangular sections in rotary vise on machining center • Cut off 4 individual roof components using 1/8” end mill

  8. Tower Base Section Tooling 3” Face Mill 3/8” End Mill Fixturing Multiple Chick Vises (mounted in parallel) V-blocks Machine 3-Axis Mill Description End mill to cut off corners. Refixture to add effects Tower (cont.) Middle Section Tooling 3” Face Mill 3/32” End Mill Fixturing Multiple Chick Vises (mounted in parallel) V-blocks Machine 3-Axis Mill Description Same procedure as base section Finalized Process Plans (cont.)

  9. Tower (cont.) Top Section Tooling Center Drill 3/8” Drill 7/8” Drill 1.5” End Mill 3/16” End Mill 1/32” Radius Concave Cutting End Mill Turning Tool Cutoff Tool Fixturing 3-Jaw Chuck Machine 5-Axis Mill Lathe Possibly of lathe with bar feeder and live tooling Base Tooling End Mill Drill No Special Fixturing Required Machine 3-Axis Mill Columns Just a cut off operation is required Finalized Process Plans (cont.)

  10. Production Schedule

  11. Reduction in Machine Time Total Time for machining is now 105 min. Cut our labor and machine cost by 40% New cost is $52.50 per Old Main New Per Unit cost of $87.43 Going to produce 18 this semester Accounting for 10 to be given away to faculty and group Going to sell 8 at $250 per Old Main Give Profit of around $200. New Findings & Decisions

  12. Triangular Roof 1.25” square x 6’ long Qty. needed: 2 Price: $51.24 ea. Tower 1.25” diameter x 6’ Qty. needed: 1 Price: $33.94 Tower 1.25” square x 6’ Qty. needed: 1 Price: $51.24 Tower 2.25” square x 3’ Qty. needed: 1 Price: $101.30 Columns 5/16” diameter x 6’ Qty. needed: 8 Price: $4.95 ea. Flat Roof 4”w x 0.5” thick x 6’ Qty. needed: 3 Price: $65.48 ea. Bill of Materials

  13. Sides 1.5” x 3” x 0.125” x 6’ box tube Qty. needed: 1 Price: $67.50 Front/Back 3’ x 8’ Qty. needed: 1 Price: $118.00 Base 1’ x 6’ sheet of walnut Qty. needed: 2 Price: $24.00 ea. Clock 15/16” Clock insert Qty. needed: 18 Price: $5.95 ea. Bill of Materials (cont.)

  14. Breakdown • Triangular Roof: $102.48 (3) • Tower (upper): $33.94 • Tower (middle): $51.24 • Tower (base): $101.30 • Columns: $39.52 (8) • Flat Roof: $196.44 (3) • Sides: $67.50 • Front/Back: $118.00 • Base: $48.00 • Clock Insert: $107.10 Total: $862.52

  15. Final Costs • Material Cost for 18 Old Mains: $862.52 • Machine Cost for 18 Old Mains: $945 • Cost to Produce = $1807.52 • Sell 8 Old Mains at $250 a piece: $2000 • Net Profit = $192.48

  16. Questions/Comments

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