Comment on the level of surface finish and geometric precision (i.e. deviation from nominal geometry) of the part.

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1 IELM 215. Mini Project. Topic: Precision manufacturing Many modern products use millimeter scale components, with component sizes of the order of few mm, and feature sizes of the order of microns (feature refers to some small portion of the geometrical shape of the part, for example a hole). In this project, each group will be assigned one component, for which you must study the geometry, and study its manufacturing. For each part, the current manufacturing process is mentioned (this is the process by which this part is currently manufactured). In doing this project, you must perform the following tasks. The results of each task must be part of your project report. Task 1. Qualify the geometry of the part and make a CAD model using CATIA. In order to measure the part, you will need to use optical measurement instruments (e.g. Optical profiler or profile projector), which is available through the DMSF facility in HKUST. You will need to make a booking for use of this instrument with the help of your Lab TA. Comment on the level of surface finish and geometric precision (i.e. deviation from nominal geometry) of the part. Task 2. Using the internet or references from the library, write an evaluative description of its current manufacturing process, including 2.1. How this process works (use figures if required) 2.2. What is the process capability, including (a) What is the smallest and largest feature size it can produce (b) Any limitations on the feature shapes, e.g. only 2D, only rotational etc. (c) The best accuracy that this process can achieve (d) The best surface roughness the process can achieve. [Hint: one way to find out is to find which company manufactures equipment for this process, and see the company website for the specs of their best machines]. Task 3. For each part, find one alternate process that could be used to produce it (note: these are production components, keep in mind that the alternate process should be able to produce parts in bulk, e.g. 1 million parts per year, economically). Describe the alternate process using the same way as task 2. Task 4. For the processes in tasks 2 and 3, make a table, comparing them, with comments on the following items: (a) Process capabilities (shape, feature size, accuracy, surface, range of materials) (b) Production costs (as a function of production volume) (c) Throughput rates [Hint: you only need to comment on which process is better for each aspect, and comment on why it is better]. Task 5. Suppose that a new design requires the same component but scaled down in size by a factor of 5 times, find out the process that could be used to manufacture the new part economically, giving a brief description of this process.

2 The components for the mini project (Each group should one: first come, first served): Mini Project 1. Plastic worm with Fan at one end. Material: PP Worm gear with fan, length ~6mm Mini Project 2. Stamping gear Process: Fine blanking Material: mild steel Stamping gear, part diameter ~11mm (note the gear teeth)

3 Mini Project 3. Plastic filter with grating Material: PP or similar plastic) Note: you must also consider how the injection mold is fabricated (laser cutting). Mini Project 4. Stamping component Process: Fine blanking Material: Copper Plastic filter with grating, length ~6mm Top view Bottom view Stamping component made of copper, part length ~4mm Mini Project 5. Plastic gear Material: PP Two views of the small plastic gear, diameter ~2mm

4 Mini Project 6. Lens cover Electro plating Material: PP or similar Note: you must also consider how the injection mold is fabricated in this case; electro forming is used Lens cover (non-functional part), diameter ~4mm Mini Project 7. Electric motor laminations Process: laminations made by blanking; lamination stack welded by laser Material: mild steel Motor laminations, diameter ~3.5mm Mini Project 8. Cylindrical punching tools Material: High Carbon Steel Process: [you must find out] [Notes: these punching tools are used to punch circular alignment holes in thin Printed circuit boards (PCB s); the circuit boards are made of 0.1mm plastic, coated on both sides by Copper plate of 0.01mm; expected life of each tool is 200,000 punching operations].

5 Punching pins, total length ~17-20mm

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