Old Main Group

Design IssuesThere are no changes to the overall Design It will remain the way it is

The Attachment Issue is resolvedGoing to screw on the tower to the flat part

of the roof.The other parts of the roof will be fastened

with “metal strips” and a pin.

Production PlanFAME Lab will be used for majority of work. Currently finalizing fixtures, and programs Machines to be used are:

CNC Milling Centers and CNC Lathes

Going to utilize Skytop Machine Shop to make precise cuts on some components.

Final Machine Time per Old Main: 100 min.

Total Time to Complete 20: 33 Hrs, 15 min.

Front FaceFront Face Process Plan Set Up

No.Operation Description

Machine Tool Description

10 Cut-off a 9” X 0.125” cross section of 6061 Aluminum plate to a length of 15.5 .015”

Cut-off Saw

Face mill surface;Engrave all windows;Ball mill etchings around windows;Cut off each front face

20 3 axis vertical machining center

Front Face (cont.)More Detailed Front Face Process Plans

PROCESS 20Op. No. Op. Description Tool. No. Tool

DescriptionImportant Process Parametersd = 0.02 in.N = 667 rpmv = 16 ipmd = (1/128) in.N = 3000 rpmf = 30 ipmd = (1/64) in.

N = 7500 rpmv = 20 ipmd = 0.125 in.N = 7500 rpmv = 50 ipm

4 Cut plate into 8 pieces 8.75” X 3”

5 0.125” End Mill

3 Ball mill etchings around 6 windows with 0.01” increments

2 0.0625” Ball Mill

5” Face Mill

2 Engrave all windows with a spot drill

1 0.75” Spot Drill

1 Face mill surface in one pass

4

Side Faces

Set Up No.

Operation Description Machine Tool Description

10 Cut-off four 3” X 1.5” cross section of 0.125” thick 6061 Aluminum box tubing to a length of 3 .015”

Cut-off Saw

Face mill surface;Engrave all windows;Ball mill etchings around windows

30 Face mill surface 3 axis vertical machining center

40 Face mill surface 3 axis vertical machining center

20 3 axis vertical machining center

Side Face Process Plan

Side Faces (cont.)More Detailed Side Process Plans

PROCESS 20Op. No. Op. Description Tool. No. Tool

DescriptionImportant Process Parametersd = 0.02 in.N = 1000 rpmv = 16 ipmd = (1/128) in.N = 3000 rpmf = 30 ipmd = (1/64) in.N = 7500 rpmv = 20 ipm

PROCESS 30Op. No. Op. Description Tool. No. Tool

DescriptionImportant Process Parametersd = 0.02 in.N = 1000 rpmv = 16 ipmd = 0.145 in.N = 4000 rpmv = 14 ipm

PROCESS 40Op. No. Op. Description Tool. No. Tool

DescriptionImportant Process Parametersd = 0.02 in.N = 1000 rpmv = 16 ipm

1 Face mill surface in one pass 1 3” Face Mill

2 Engrave all windows with a spot drill

2 0.75” Spot Drill

3 Ball mill etchings around 6 windows with 0.01” increments

3 0.0625” Ball Mill

1 Face mill surface in one pass 1 3” Face Mill

2 Slot the top surface 4 0.1875” End Mill

1 Face mill surface in one pass 1 3” Face Mill

Flat RoofTop Plate of RoofBegin with one 5”x6’x0.5” plate of 6061 AlCut down to lengths of 21.875” to machineAfter machining, cut-off sections at 2.625”Each set up will produce 8 top roofsWill need to perform 3 set-ups to produce

24 top roofs

Flat Roof (cont)

Process Plans for Top Plate of Roof

Set Up No.

Operation Description

Machine Tool Description

10 Cut-Off a 5” x 0.5” cross section of 6061 Al plate to a length of 21.875” ± .005”

Cut-Off Saw

20 Face Mill SurfaceCut down edges

3 axis vertical machining center3” Face MillConcave Radius Cutter

30 Cut-Off each plate to a length of 2.625” ± .005”

Cut-Off Saw

Flat Roof (cont)Bottom Plate of RoofBegin with two 4”x6’x0.5” plates of 6061 AlCut down to lengths of 22.375” and a width

of 3.125” to machineMachine one side before flipping plate to

machine the otherEach set up will produce 4 bottom roofsWill need to perform 5 set-ups to produce

20 bottom roofs

Flat Roof (cont)

Process Plans for Bottom Plate of Roof

Set Up No.

Operation Description

Machine Tool Description

10 Cut-Off a 4” x 0.5” cross section of 6061 Al plate to a length of 22.375” ± .005”

Cut-Off Saw

20 End Mill the plate to a width of 3.125” ± .005”

3 axis vertical machining center1” End Mill

30 Face Mill SurfaceCut down edges

3 axis vertical machining center3” Face MillConcave Radius Cutter

40 Flip PlateFace Mill SurfaceEnd Mill a width of 1.5” to a depth of .250” ± .005”Spot Drill EdgesEnd Mill to a depth of .125” for column insertions

3 axis vertical machining center3” Face Mill1” End Mill.5” Spot Drill5/16” End Mill 

50 Cut-Off each plate to a length of 5.5” ± .005”

Cut-Off Saw

Triangular Roof Sections

Triangular Roof SectionsMaterial Ordered- 11/13/01Outsourcing to SkyTop Machine & Tool, Inc.Water Jet CuttingContract writtenMeeting for contract reviewFirst roof delivery/inspectionAll roofs delivered within 1 week of

approval

Outsourcing ReasonsIn-house production difficultiesFixturing triangular stockMany operations-

Difficulty maintaining required tolerancesNot time efficient

Water jet cutting can meet required tolerances and specificationsCost Effective

Base & Middle of Tower

Fixture bars at a 45° angle in the specialty jaws and end mill the flat on each corner (4)

Fixture on parallels and end mill steps (2)

On the middle, pocket hole for clock mounting

Base Process Plan Part 1Op. No.

Op. Description Tool Tool Description

Important Process Parameters

Cutting Parameters

d = .3535 in.* N = 4000 rpm

w= .375 in.V= 300 fpm v = 24 in/min

f = .004 in./thd = .02 in. N = 4000 rpmw= .375 in.V= 300 fpm v = 24 in/minf = .004 in./th

2 Finish mill 45 flats into corners of the middle of the tower

4 1/4” endmill

1 Rough mill 45 flats into corners of the middle of the tower

4 1/4” endmill

* Multiple cuts required.

Top of Tower

Drill hole 3 in center of stock for hollow portion of towerEnd mill flats and archway; rotate 45° and end mill flats plus ball mill columns (4)Contour dome and cutoff on lathe

Op. No.

Op. Description Tool Tool Description

Important Process Parameters

Cutting Parameters

d = .02 in. N = 750 rpmw= 1.5 in.V= 300 fpm v = 15 in/minf = .004 in./th

d = .25 in.* N = 5000 rpmw= .125 in.V= 300 fpm v = 7.5 in/minf = .004 in./th

* Multiple cuts required.

1 End mill flats on the top of the tower

6 1 1/2” endmill

2 End mill archways in top of the tower

4 1/4” endmill

Top Process Plan Part 3

Current StatusMaterial – Still waiting on material for front/backs and the triangular roof, as well as wood for bases.

Fixturing – Constructing fixtures is complete.

Tooling – All required tooling is available.

ScheduleID Task Name

1 Order Materials

2 Front/Back Face

3 Triangular Roof

4 Flat Roof

5 Wood for Base

6 Finalizing Plans, Programs, Fixtures

7 Making Cuttoffs, Preparing for m/c

8 Machine

9 Sides

10 Tower

11 Front/Back

12 Roof

13 Base

14 Outsourcing Triangular Roof

15 Assembly, Packaging, Finishing

S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W TNov 11, '01 Nov 18, '01 Nov 25, '01 Dec 2, '01 Dec 9, '01 Dec 16, '01

Delivery ScheduleDates when components will be complete: Bases: Dec. 1 Front/Backs: Nov. 30 Sides: Nov. 30 Flat Roof: Dec. 4 Triangular Roof: Dec. 3 Tower: Dec. 5 Assembly including Clock Faces: Dec. 5-7 Complete Product by December 7

Final Income StatementOld MainCost of Goods Sold

Units Produced 20

Variable CostsPurchase Cost Units Made Unit Price Cost

PieceTwo Sides 67.50 95 0.71 14.21Front/Back 118.00 44 2.68 53.64Roof (Triangle) 41.40 20 2.07 41.40Roof Outsourcing 446.00 20 22.30 446.00Roof (Flat Plate) 65.48 6 10.91 130.96

87.40 8 10.93 87.40Base 96.00 20 4.80 96.00Tower Part I 51.24 28 1.83 36.60Tower Part II 33.94 20 1.70 33.94Tower Part III 38.10 20 1.91 38.10Tower Outsourcing 40.00 20 2.00 40.00Columns 4.94 2.25 2.20 43.91Clock 5.95 1 5.95 119.00Bolts 10.00 20 0.50 10.00Metal Strips 10.00 20 0.50 10.00Poly Clear Gloss Finish 4.00 10 0.40 8.00Machining 1000.00 20 50.00 1000.00Total Variable Costs 110.46 2209.16

Total Fixed Costs - - -

Total Costs $2,209.16

Avg Cost per unit $110.46

ConclusionMaking a total of 206 Given away to the professors and 5

given away to the groupSell 9The cost per Old Main is $110.46Sell at $250, still make a profit

Questions/Comments