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Acrylic Clock Process Design

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lane-beard
12 diapositives · 261 Views · Nov 27, 2014

This document outlines the comprehensive process for designing and fabricating an acrylic clock, including detailed setup and machining operations. It specifies the tools required, such as a horizontal machining center and cutting tools, along with crucial operation descriptions. Key process parameters for machining the clock base and background are presented, ensuring high-quality finishes. Additionally, it examines product costs, pricing strategies, and potential profit scenarios based on different sales prices. A concise guide is included for assembly steps utilizing acrylic adhesive.

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Acrylic Clock Process Design
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  1. Ideas-Unlimited Acrylic Clock Process Design Adrian Allen Steven Lona Nicholas Tracy

  2. Set Up Number Operation Description Machine Tool Description 10 Cut-off 0.75 in. x 2.0 in. cross sections of cast sheet acrylic stock to a length of 5.75  .015 in. Cut-off Saw 20 Fabricate background housing on the planar surface opposite datum feature A 4 axis horizontal machining center 30 Polish all surfaces of the base Propane torch or buffer with finishing compounds PROCESS SUMMARY FOR BASE

  3. 0.25 0.75 A 0.50 2.00 B 5.75 Set Up 20 Sketch Scale: 1:1 Units: Inches

  4. Set Up 20 Descriptionfor Clock Base REQUIRED TOOLS • MACHINE TOOLS: Horizontal Machining Center, HS 1 • FIXTURE: Chick Vise Attached to Tombstone • CUTTING TOOLS: 0.5 Inch Double Flute End Mill • MISCELLANEOUS TOOLS: Edge Finder, Dial Indicator

  5. Process 20 Description for Base Operation Number Operation Description Tool Number Tool Description Important Process Parameters 1 Slot mill opposite datum feature A in one pass 1 0.5 inch end mill d = .25 in. w = 4.25 in. V = 314 fpm F = 0.0042 in/th

  6. Set Up Number Operation Description Machine Tool Description 10 Cut-off a 0.75 in. x 5.5 in. cross section of cast sheet acrylic stock to a length of 8  .015 in. Cut-off Saw 20 Fabricate clock housing, PSU logo, and circular contours on the planar surface opposite datum feature A. End mill side and upper notch required for base union on datum feature C. 4 axis horizontal machining center 30 Polish all surfaces of the background Propane torch or buffer with finishing compounds PROCESS SUMMARY FOR BACKGROUND

  7. Hole Diameter = 2.3125 in. Hole Depth = 0.5625 in. Diameter = 3.75 in. 1.8750 in. 7.00 in. 5.1250 in. 5.2500in.

  8. Set up 20 Description for Clock Background REQUIRED TOOLS • MACHINE TOOLS: Horizontal Machining Center, HS 1 • FIXTURE: Chick Vise Attached to Tombstone • CUTTING TOOLS: 0.5 Inch Double Flute End Mill, 1/32 Inch Double Flute End Mill, and a 1/8 Inch Double Flute End Mill • MISCELLANEOUS TOOLS: Edge Finder, Dial Indicator

  9. Process 20 Description Clock Background

  10. Assembly for Acrylic Clock • Join the base and the background using a acrylic adhesive as the final step

  11. Product Cost • ¾” Acrylic Sheet = $260 (96”x 48”) • Clock Insert = $5.90/piece + Shipping • Batteries = $.55/piece • Adhesive = $25.00 • License = $350 • Labor Costs = $.90/clock • Machining Costs = 7.50/clock • Cost per Clock = $23.78

  12. 3 Scenarios • If we use a selling price of $25, • Then our break even point is 62 clocks • If we use a selling price of $30, • Then our break even point is 34 clocks • If we fully utilize one acrylic sheet (78 clocks) and use a selling price of $25, • Our profit will be approximately $446