Machining, Drawing, SolidWorks 01/08/2008 Lecture 2 1 Winter 2012 UCSD: Physics 121; 2012 2 Winter 2012 UCSD: Physics 121; 2012 3 Winter 2012 UCSD: Physics 121; 2012 4Machining, Drawing, SolidWorks 01/08/2008 Lecture 2 2 Winter 2012 UCSD: Physics 121; 2012 5 Winter 2012 UCSD: Physics 121; 2012 6 Winter 2012 UCSD: Physics 121; 2012 7 Winter 2012 UCSD: Physics 121; 2012 8Machining, Drawing, SolidWorks 01/08/2008 Lecture 2 3 Winter 2012 UCSD: Physics 121; 2012 9 Winter 2012 UCSD: Physics 121; 2012 10 Winter 2012 UCSD: Physics 121; 2012 11 Winter 2012 UCSD: Physics 121; 2012 12Machining, Drawing, SolidWorks 01/08/2008 Lecture 2 4 Winter 2012 UCSD: Physics 121; 2012 13 Winter 2012 UCSD: Physics 121; 2012 14 Winter 2012 UCSD: Physics 121; 2012 15 Winter 2012 UCSD: Physics 121; 2012 16 The canonical lathe tool: dimensions depend on material being workedMachining, Drawing, SolidWorks 01/08/2008 Lecture 2 5 Winter 2012 UCSD: Physics 121; 2012 17 lathe tools are usually shaped by the machinist using a grinding wheel a “boring bar” lets you get deep inside a part for making an inner diameter (for holes larger than available drill bits & reamers) Winter 2012 UCSD: Physics 121; 2012 18 Winter 2012 UCSD: Physics 121; 2012 19 Winter 2012 UCSD: Physics 121; 2012 20Machining, Drawing, SolidWorks 01/08/2008 Lecture 2 6 Winter 2012 UCSD: Physics 121; 2012 21 square end-mills are the workhorse bits: • pockets • slots • edge trim • facing ball-end mills make rounded pockets or spherical pockets; also fillets corner-rounders form rounded corners! conical end-mill for chamfers This device holds a lathe- like tool bit to become a fly-cutter, for surfacing large flat faces graphics from McMaster Carr online catalog: www.mcmaster.com Winter 2012 UCSD: Physics 121; 2012 22 graphics from McMaster Carr online catalog: www.mcmaster.com standard “jobber” drill: will flex/walk, follow pilot stub drill for less walk/greater rigidity reamers (straight or spiral) finish off hole (last several thousandths) precise hole diameter for insertion of dowel pins, bearings, etc. plunge while spinning, extract still countersink: for screw heads & deburring hole center drill establishes hole position with no walk Winter 2012 UCSD: Physics 121; 2012 23 Winter 2012 UCSD: Physics 121; 2012 24 some graphics from McMaster Carr online catalog: www.mcmaster.comMachining, Drawing, SolidWorks 01/08/2008 Lecture 2 7 Winter 2012 UCSD: Physics 121; 2012 25 Winter 2012 UCSD: Physics 121; 2012 26 • end-mill exposed (up-facing) face until all low spots gone, taking multiple passes at about 0.010 inches per pass • de-burr and rotate 180° in jaw about horizontal axis • end-mill new side (opposite first) until low spots gone • de-burr and measure; figure out amount remaining to cut • place back in vice, either finished side up • bring up knee until end-mill just touches and set knee dial to zero • make successive passes, bringing up knee until the prescribed amount has been removed • measure to make sure – get 1.55 dimension • place in jaw with large face up, rough edge extending beyond jaw side • use side of end-mill to shave edge; traveling in direction of cut (conventional cut) • once low spots done, cut opposite direction for smooth finish (climb cut) • de-burr, and rotate 180° about vertical axis, rough edge sticking out • smooth out this surface, measure (maybe even in place), and do final trims to bring it into spec.; de-burr Winter 2012 UCSD: Physics 121; 2012 27 Winter 2012 UCSD: Physics 121; 2012 28Machining, Drawing, SolidWorks 01/08/2008 Lecture 2 8 Winter 2012 UCSD: Physics 121; 2012 29 Winter 2012 UCSD: Physics 121; 2012 30 Winter 2012 UCSD: Physics 121; 2012 31 Winter 2012 UCSD: Physics 121; 2012 32Machining, Drawing, SolidWorks 01/08/2008 Lecture 2 9 Winter 2012 UCSD: Physics 121; 2012 33 Winter 2012 UCSD: Physics 121; 2012