How would you machine this object?

[xerigen]

Hi, I'm doing a project for school, and I need to know how to machine a specific part without the use of CNC. So, basic machine shop tools. Manual mill, drill press, etc.

Here is an isometric image: <br>[br]


and then I made 3 views of it in autocad:


I basically need to know step by step how I would take a block of AISI 1020 steel and machine this product. I've done a lot of research, I just can't seem to find how to machine the weird angles and cuts in this drawing. Help would be GREATLY appreciated. Thanks a lot!

[AMCTony]

First, Square up the stock to size. Then drill your holes. Next, mill all of the square edge cuts and recesses, looks like there are 2 of them. Next thing is to use angle block or a sine bar to setup for the angles. you can use an endmill or flycutter to cut these faces then. I like angle blocks for angles that are not all that precise. The last opp is to cut the slot into the 1.12 dia. hole. Finally, have a beer. This is how I would make this part but it is not the only way. This should be gravy, just take your time and double check your setups.

P.S. A Depth Mic. WILL be helpfull.

[xerigen]

Thanks a TON! See, the thing is, I'm a freshman in college, and I was assigned to create this project along with two other group members. Well, my professor doesn't like to give a lot of help, saying that's how it is in the real world, so I was left to research it myself. Well, unfortunately my group members are busy welding and sandcasting this item, and my only skill or knowledge in mechanical engineering so far is two years of CAD experience in high school.

I would just like to say I really appreciate your help, as I have an oral report soon on my strategy to machine the "clutch lever" and this helps tremendously!

[ctate2000]

Tell your professor in the real world a ME would write a work order for the tool room.

[dertsap]

Originally Posted by xerigen Well, my professor doesn't like to give a lot of help, saying that's how it is in the real world,!

maybe someone should tell the prof that teachers teach in the real world

at least help you get in the right direction

[Konrad]

My way....
Milling stock..... one side [large face] 1.44" first, then... use this face against the solid jaw on the milling vice and push on opposite side with something round, like a 1/2" round aluminium rod 2 to 3 inch long, this will push it nice toward the jaws, so you can square up the sides, mill thickness last.
Drill large hole first, 1/32" smaller, & ream to 1.124", 1.125", [you made your drawing to 1.12 ??] ... this could be the toughest job, reamers usually go about 1.126"....[oversize by .001"] when solid reamer is used.
Measure reamer first, if solid, it should measure 1.124" [plus 0", minus .0005"] I would use a expandable reamer and set it first at about 1.122" and make a dummy hole first to set your reamer.

Then lay out all your mill away faces, also .44 bolt hole, drill and tap first, [the taped hole not showing for the bolt?] and band saw cut on a vertical band saw [if you have one?] up to about 1/16, 1/8" to the line.
Mill with about a 1" end mill the two square steps, then with a combination square tilt the part in the vice [set degree with bubble]....then mill with carbide or HSS face mill or end mill,... if you don't have a face mill.
Drill all other holes, cut slot with a 1/8" slitter, if you are good on the band saw, you can use band saw, make two cuts.
Konrad

[AMCTony]

If your professor really wants to live in the real world, then send him and the university purchasing department a bill for the project including charges for consulting with him on the project, additional R&D, Engineering/blueprinting, and Manufacturing if you make this part. Also bill him for the for the extra outsourcing of professional services that you were forced to seek due to him assigning other "consultants" to your engineering team and was unable to "enlist" their services and had to go elsewhere. Lets see... 2 hours design consultation, 2 hours CAD Time, 2 hours process verification, 5 hours outside sourcing, 2 hours manufacturing time, Tooling and materials, Travel expense, Office and clerical, 1 hour onsite final product presentation.

Engineering Charge: 11 Hours @ $160.00 = $1760.00
Manufacturing : 2 Hours @ $100.00 = $200.00
Tooling and Material: 1 @ $75.00 = $ 75.00
Travel: 1 @ $100.00 = $100.00
Office: 1 @ $50.00 = $50.00
On Site Presentation 1 Hour @ $225.00 = $225.00
this is Overtime

GRAND TOTAL: $2410.00

If he wants everyone to live in the real world then this should bring him into it with the rest of us.

BTW Make sure that you charge %1.5 per month = %18 yearly late fee on bills not paid after 30 days.

[tobyaxis]

Originally Posted by xerigen Well, my professor doesn't like to give a lot of help, saying that's how it is in the real world, so I was left to research it myself.

Sounds to me that you need a New Professor, or he needs an attitude adjustment . This type of instruction is why this country is having problems.

What he should be doing is training you in a specific direction and help when things need to be explained . Not just turning his back on you and saying "Welcome to the Real World". That is B.S. because if he did that enough
at a job they would get rid of him or he may meet up with the wrong people .

I'm glad you got the help you need and feel free to stop by any time. Help will always be here. (not that i helped any this time).

[AMCTony]

I am in full agreement with Toby. You are at a university to RECIEVE HELP LEARNING to prepare you for real world challenges. Why pay for an education and have to teach yourself anyway. It is most likely too late in the year to get a new Prof. but if you run into this in the future get a new one if possible asap.

[greg b]

once the job has been squared up and you have put the holes in ,a slitting saw in the mill can be used to remove that angle stock quite fast and also put that slot in quite accurately. you will need to finish the angles with a flycutter or end mill , if super accutate !on a grinder with sine bars .
greg b

[cobolt cutter]

All the advise these people are giving is Great, and Good!
I only wished I have these guys when I was in college!
Yes, I had the same kind of Professor!
It's GREAT TO FIND A Community like this!
you Guy's make me PROUD to be part of the MACHINIST world!

[Shandon]

Cool problem!! Kudos to your prof. and his style! The class is only what you make it.

SF