1. 1 GRASP SAAST 2005 Robotics University of Pennsylvania Dave Cappelleri Piston Project: Machining Basics

2. 2 GRASP Machining Overview - Handle 1.Rough Cut Stock to Length – Band Saw 2.Face Right Surface – Lathe 3.Face Left Surface /Make Part Desired Length – Lathe 4.Turn Outer Surface – Lathe 5.Drill Hole – Lathe 6.Tap Hole – Lathe/Hand Ø1/2 1.5 10-240.75 2 3 4 65

3. 3 GRASP Machining Overview - Piston 1.Face the Right/Left Surface – Lathe 2.Turn the Outer Surface – Lathe 3.Cut Part in Half – Horizontal Saw 4.Machine to Length – Lathe 5.Mill Flat Surface – Milling Machine 6.Drill Hole – Milling Machine 7.Counter Bore Hole – Milling Machine 8.Tap Hole - Hand 1 Ø1.5 1.25 10-240.62 1 2 3 7 4 0.81 5 6 0.75

4. 4 GRASP Machining Overview – Cam Wheel 1.Face Upper/Lower Surface – Lathe 2.Drill Hole in Center – Lathe 3.Counter Bore Hole in Center – Lathe 4.Drill Second Hole – Milling Machine 5.Counter Bore Second Hole – Milling Machine Ø1/4 Ø 2 Ø1/4 Ø3/8 0.75 0.19 0.25 AA AA 1 1 2 3 5 4 0.32

5. 5 GRASP Machining Overview – Body 1.Face the Right Surface – Milling Machine 2.Face the Left Surface – Milling Machine 3.Machine Rest of Body – CNC Machine 5.25 2 1 3 Machining Overview – Connection Arm 1.Draw Connection Arm in AutoCAD 2.Laser cut with X-660 Laser Cutter

6. 6 GRASP Machining Basics http://www.seas.upenn.edu/~robo2005/machineTut.htm Primary Machining for Piston Project: Lathe Milling Machine CNC Machine Primary Machining for Final Project: Laser Cutter

7. 7 GRASP Lathe Basics Purpose: To rotate a part against a tool whose position it controls Useful for fabricating parts and/or features that have a circular cross section

8. 8 GRASP Lathe Basics Main Power On/Off Spindle Speed Spindle Rotation Forward/Reverse Spindle Lathe Chuck Spindle: Part of lathe that rotates Workholding attachments held in spindle - three jaw chucks, collets, and centers

9. 9 GRASP Lathe Basics Quick Change Tool Holder x y (Axis of rotation) Move the CROSS SLIDE along the X-axis Move the SADDLE along the y-axis Tailstock Tailstock: supports end of the workpiece, or hold tools for drilling, reaming, threading, or cutting tapers. Carriage: controls and supports the cutting tool Saddle: mates with and slides along the ways. Cross slide: controls transverse motion of the tool A tool compound that allows angular tool movement.

10. 10 GRASP Lathe Basics TOOL QUICK CHANGE TOOL HOLDER LOCK HANDLE POWER FEED ON/OFF SADDLE POWER FEED ON/OFF UP-ON, DOWN-OFF CROSS SLIDE POWER FEED ON/OFF