1. 1 Manufacturing Projects Flexible Manufacturing Copyright © Texas Education Agency, 2013. All rights reserved.

2. Manufacturing Projects You will have to produce two projects: simple top and machine vise. Your grade for each will be determined by using the project rubric. You will have to read the plans and manufacturing steps to complete the assignment. 2 Copyright © Texas Education Agency, 2013. All rights reserved.

3. Manufacturing a Top 3 Copyright © Texas Education Agency, 2013. All rights reserved.

4. Top Plans 4 1.25 0.50 2.50. 0.75 Dia. 0.25 Dia. Copyright © Texas Education Agency, 2013. All rights reserved.

5. Manufacturing Steps Cut a 0.75 in. diameter piece of aluminum to a 2.50 in. length. Chuck the piece in the lathe and face the end. Machine this end to a 0.25 in. X 1.25 in. section. Sand and polish the top shaft. Remove and flip the piece, chuck the 0.25 in. end into the chuck about 0.75 in. 5 Copyright © Texas Education Agency, 2013. All rights reserved.

6. Manufacturing Steps, Con’t Face this end and run some clean up passes on the length of the remaining material. Cut a taper back 0.75 in. from the end. Sand and polish the top. Remove and test the spinning of the top. 6 Copyright © Texas Education Agency, 2013. All rights reserved.

7. Project Rubric for the Top Top: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance, the section receives the maximum points. If the measurement is not within tolerance, the points can be from 0 and up. Add the points for a grade. 7 Section of Part DiameterLengthPoints MaxPoints Received Overall measurement 20 points 0.25 in. diameter 15 points 0.75 in. diameter 15 points Taper25 points Finish15 points Spin10 points Grade: Copyright © Texas Education Agency, 2013. All rights reserved.

8. Manufacturing a Vise 8 Copyright © Texas Education Agency, 2013. All rights reserved.

9. Exploded View of Vise Parts 9 1 7 4 3 2 9 8 6 5 Copyright © Texas Education Agency, 2013. All rights reserved.

10. Vise Bill of Materials 10 PART NUMBER QUANITYNAMESIZE 11BASE0.75 X 2.50 X 5 21FIX JAW0.75 X 2.50 X 2 31MOVABLE JAW0.75 X 2.50 X 2 41FRONT JAW0.75 X 2.50 X 2 51SCREW1.25 DIA. X 3.75 61HANDLE0.37 DIA. X 3 72JAW FACES0.50 X 1 X 2.50 81JAW LOCK0.12 X 0.75 X 1.50 97FASTENER0.25–28 BOLTS X 0.75 LONG 101SETSCREW (NOT SHOWN) 0.12 SETSCREW X 0.75 LONG Copyright © Texas Education Agency, 2013. All rights reserved.

11. Vise Cut Sheet Cut the following pieces of metal: 0.75 in. X 2.50 in. material 12 in. long 1.12 in. diameter piece 4 in. long 0.37 in. diameter 3.25 in. long 0.50 in. X 1 in. metal 5.75 in. long 0.12 in. X 0.75 in. 1.50 in. long Use the 12 in. long piece and cut the base and the three(3) jaws from it. 11 Copyright © Texas Education Agency, 2013. All rights reserved.

12. Vise Base Plan 12 0.75 0.25 0.75 4.500.75 5.00 2.50 1.00 0.501.25 DRILL 2 HOLES 0.25 DIA. 0.37 Copyright © Texas Education Agency, 2013. All rights reserved.

13. Manufacturing Steps for Base Square the 0.75 in. X 2.50 in. X 5 in. piece on the mill. Using an end, mill cut the 1 in. wide X 0.50 in. deep slot through the material. Flip the part over and mill the 0.25 in. deep cavity in the bottom of the material. Measure and drill the 0.25 in. holes in the base and countersink the bottom of the hole. Sand and polish the base and put away for later assembly. 13 Copyright © Texas Education Agency, 2013. All rights reserved.

14. DRILL 0.20 HOLE TAP 0.25 -20 THREADS Vise Fix Jaw Plan 14 0.37 0.75 2.50 1.00 2.000.75 0.50 0.75 0.25 1.25 0.37 1.500.50 DRILL 2, 0.25 HOLES Copyright © Texas Education Agency, 2013. All rights reserved. DRILL 0.20 HOLE TAP 0.25-20 THREADS

15. Manufacturing Steps for Basic Jaw Shape (Note) All three jaws are the basic shape. The bottoms of the jaws are the same with the sides machined away and a hole tapped in the bottom for fastening them in place. 15 Copyright © Texas Education Agency, 2013. All rights reserved.

16. Movable Jaw Plan 16 0.250.37 0.75 2.50 1.00 DRILL #3 BIT X 0.50 DEEP TAP TO 1/4–28 THREAD SIZE 1.25 0.37 1.500.50 DRILL 2, 0.25 HOLES 2.000.75 0.50 0.75 0.25 BORE 0.50 DIA. X 0.375 DEEP HOLE 1.00 #8 –32 SETSCREW DRILL #29 (0.13) HOLE Copyright © Texas Education Agency, 2013. All rights reserved.

17. Manufacturing Steps for Movable Jaw The slots for the jaw faces are milled into two pieces. These slots are the same on both jaws. The holes for the faces are the same on both jaws. The movable jaw will have a matching 0.50 in. hole for the end of the vise screw. This jaw will need a setscrew hole drilled and tapped to hold the screw in place. See plans. 17 Copyright © Texas Education Agency, 2013. All rights reserved.

18. Front Jaw Plan 18 2.00 0.37 0.75 2.50 1.00 0.75 DRILL #3 BIT X 0.50 DEEP TAP TO 1/4–28 THREAD SIZE 1.25 DRILL 0.49 DIA. TAP TO 0.50—13 1.00 Copyright © Texas Education Agency, 2013. All rights reserved. 0.50

19. Manufacturing Steps for Front Jaw The front jaw will be drilled and tapped for the vise screw (0.50-13 threads). 19 Copyright © Texas Education Agency, 2013. All rights reserved.

20. Movable Jaw Lock Plate Plan 20 0.75 1.50 0.75 0.37 0.12 DRILL 0.25 HOLE Copyright © Texas Education Agency, 2013. All rights reserved.

21. Manufacturing Steps for Movable Jaw Lock Plate Lay out and drill the 0.25 in. hole in the 0.12 in. X 0.75 in. plate. Countersink this hole for the fastener. 21 Copyright © Texas Education Agency, 2013. All rights reserved.

22. Vise Screw Handle Plan 22 0.37 3.00 THREADED TO 0.50-13 THREADS 3.75 0.75 1.00 0.50 0.37 DRILL SETSCREW GROOVE 0.12 FROM END 0.12 WIDE CUT 0.12 DEEP HANDLE 3.000.37 DIA. Copyright © Texas Education Agency, 2013. All rights reserved.

23. Manufacturing Steps for Vise Screw Handle Mount the material in a set of v-blocks and drill the 0.15 in. hole through the piece at the handle end. Mount the 1.12 in. rod in the lathe and turn the material to the thread diameter. 23 Copyright © Texas Education Agency, 2013. All rights reserved.

24. Manufacturing Steps for Vise Screw Handle, Con’t Chuck the handle end in the lathe and turn the smaller diameter for the threads. Thread the screw on the lathe or use a die to cut the 0.50-13 threads. Cut the groove in the end of the screw. 24 Copyright © Texas Education Agency, 2013. All rights reserved.

25. Jaw Faces Plan 25 0.37 0.25 0.50 DRILL #1 BIT X 0.50 DEEP TAP TO 0.25–28 THREAD SIZE 2.50 1.50 1.00 0.25 0.50 Copyright © Texas Education Agency, 2013. All rights reserved.

26. Manufacturing Steps for Jaw Faces Cut the 0.50 in. X 1 in. bar into two, 2.50 in. long sections. Machine the ends smoothly. Mill the bevel on the edge. Lay out and drill the two holes. Tap the threads into the holes. 26 Copyright © Texas Education Agency, 2013. All rights reserved.

27. Exploded View of Vise Parts 27 1 7 4 3 2 9 8 6 5 Copyright © Texas Education Agency, 2013. All rights reserved.

28. Assembling the Vise Bolt the jaw faces to the two slotted jaws. Bolt the fix jaw assembly to the base using the 0.25 in. X 0.75 in. fastener. Slide the movable jaw onto the base, turn the assembly over, and install the jaw lock with the fastener. Copyright © Texas Education Agency, 2013. All rights reserved.

29. Assembling the Vise, Con’t Mount the front jaw onto the base with the fastener. Install the screw through the front jaw and into the movable jaw. Tighten the setscrew in the moveable jaw to hold the screw into that jaw. Test vise for ease of movement. Copyright © Texas Education Agency, 2013. All rights reserved.

30. Project Rubric for the Machine Vise Machine Vise: Measure each section. Write the measurement in the blanks provided. If the measurements are within tolerance, the section receives the maximum points. If the measurement is not within tolerance, the points can be from 0 and up. Add the points for a grade. 30 Section of Part SizeMachiningFinishPoints MaxPoints Received Base16 points Fix Jaw16 points Moveable Jaw 16 points Front Jaw16 points Screw/ Handle 16 points Jaw Faces16 points Grade: Copyright © Texas Education Agency, 2013. All rights reserved.