Next Generation Manufacturing

Educators: Externships

Externship Summary - 2009
Work-based Learning Projects for the Classroom
Haoyu Wang, Ph.D.
Central Connecticut State University

Host Company(s): EDAC Technologies & Gros-Ite Precision Components

Project: Tool Design for Manufacturing of Aerospace Parts with Complex Geometry and Tight Geometric Tolerances

Task Abstract: Design a series of tools to manufacture and inspect an aerospace part with complex shape and tight geometric tolerances. The tools include, but are not limited to, turning fixtures, milling fixtures and constrain fixtures. Generate a CAD model and detailed drawings with Geometric Dimensioning and Tolerancing (GD&T) and conduct Finite Element Analysis (FEA) for each tool.

Grade Level: College

TASK OBJECTIVES

Students will learn how to:

Read engineering drawings and process sheets with Geometric Dimensioning and Tolerancing (GD&T).
Start the conceptual design of each tool based on the process.
Search standardized locating, supporting and clamping devices
Design locating datum features and features to assemble other parts on the tool base with appropriate Geometric Dimensioning and Tolerancing (GD&T).
Plan inspection after each process.
Run Finite Element Analysis (FEA) to optimize the design.

Esssential Understandings/Questions:

How does Geometric Dimensioning and Tolerancing (GD&T) connect design, manufacturing, and inspection?
What is the appropriate material for the tool base (density, cost, strength, machinability, etc.)?
How do I know if the part is fully located on the tool? Are there over-constraints?
What if there is no standardized supporting and clamping devices for my design?
What should be the appropriate clamping force?
What fluid power should be used?
How will the tool be attached to the CNC machine? How it will be setup?

Task Description: Students will:

Analyze the stock drawing, part drawing and process sheets
Locate datum features based on Geometric Dimensioning and Tolerancing (GD&T) specifications
Conceptual design and layout of each tool with Google Sketchup
Calculate clamping forces
Search vendors’ catalogues and on-line database for standardized locating, supporting and clamping devices
Modeling the part and the tool in a parametric Computer Aided Design (CAD) system, such as SolidWorks or Unigraphics.
Assemble the part, the designed tool and all standardized devices
Run Finite Element Analysis (FEA) on the assembly
Optimize the design
Detail the drawings of all designed parts of the tool with appropriate Geometric Dimensioning and Tolerancing (GD&T)

Resources Required:

Google Sketchup
Parametric Computer Aided Design (CAD) system, such as SolidWorks or Unigraphics
Geometric Dimensioning and Tolerancing (GD&T) handbook
Machinery's Handbook

Prior Learning Required:

Computer Aided Design (CAD)
Manufacturing processes

Context within which work is produced: Classroom

Individual or Group Work: Group

Special Needs: n/a

Educator Comments: Working with manufacturing engineers to design, inspect, machine and lift fixtures for aerospace parts with complex geometry and tight geometric tolerances is an invaluable experience. The project follows the industrial tool design process and includes the major components for a successful tool design. It will help students to know how Geometric Dimensioning and Tolerancing (GD&T) links the design, manufacturing and inspection processes. They will realize that locating, supporting and clamping are all very important for tool design. The students will understand that materials of the part and tool will both affect the machining results. They will also understand the different requirements for designing inspection fixtures, machining fixtures and welding fixtures. Students will learn how to use Finite Element Analysis (FEA) to optimize the design and reduce the cost.

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Educators: Externships

Externship Summary - 2009 Work-based Learning Projects for the Classroom Haoyu Wang, Ph.D. Central Connecticut State University

Externship Summary - 2009
Work-based Learning Projects for the Classroom
Haoyu Wang, Ph.D.
Central Connecticut State University