Trabajo Final Escrito de Manufactura

8/7/2019 Trabajo Final Escrito de Manufactura

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Conventional manufacturing laboratory

Universidad Politcnica De Puerto Rico

Departamento De Ingeniera Mecnica

Conventional

manufacturing

laboratory

Daniel Lozada Prez #54654

Carlos Marrero Cruz #61422Julio E. Daz Cruz #67755

Prof. Jaime Balzac

ME. 1211 sec .31


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Contenido

Introduction..................................................................................................................... 2

Robot Information ........................................................................................................... 3

Design information ......................................................................................................... 4

Process evaluation for final design.............................................................................. 4

The robot final design.................................................................................................. 4

CAD drawings ............................................................................................................. 5

Material Specification ..................................................................................................... 6

Manufacturing process ................................................................................................... 8

Safety .......................................................................................................................... 8

Metrology .................................................................................................................... 9

Joining and assembly process .................................................................................. 10

Robot manufacturing and machines utilized ............................................................. 11

Electrical circuit and connections ................................................................................. 13

Conclusion.................................................................................................................... 14Appendix ...................................................................................................................... 15


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Abstract


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Introduction

The Battlebots competition is a learning program developed to promote and interest

students in the fields of mathematics, sciences and engineering.

The following work aims to understand the importance of the processes of conventional

manufacturing in mechanical engineering, for which we have been asked to build a

battlebot (fighting robot), in order to use knowledge gained in previous classes as

design and in the laboratory as the production of parts in the machine tool.

This robot is used for a type of above-mentioned competition which has various

regulations including; limits of weight (15 lb.), limitations in the choice of materials and

the prohibition of fire, acid and toxic products, this restricting us to take several

considerations in our design which will describe through work.


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Robot Information

Name Drum Devil

Type Spinning drum bot

Weight 13.5 lb.

Weapon spinning drum

Materials aluminum

Defense aluminum plates

type of wheels: rubber tires, non-inflatable

Class BotsIQ Mini class


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Design information

Process evaluation for final design

Our first design was based in the shape of the head of a black mamba snake; the

weapons were two steel saws. During the time in the lab the group made some

research and determined that the saws where not that effective in this kind of use so

we decided to change the weapon to a drum. Becausethe drum do a lot of damage to

his opponentsand as well serves as a defense. After changing the weapon we had to

adapt the body to match its weapon and that how we ended doing a drum battlebot.

The robot final design

The final design is a 12 by 12 inch case of aluminum with three walls of 5/16" thick, a

roof and floor of 1/16" thick of a rigid aluminum plate. a drum made of a hallow 10 inch

long cylinder of aluminum with two edges at 180 degrees of each other, and two

supportive caps made to fit at pressure to ensure optimalperformance , in one of the

caps we design a channel for the pulley to run to avoid excess of parts, instead is all in

one.


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CAD drawings


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Material Specification

Different types of materials have been investigated to see which brought together the

largest group of ideal conditions for our design. Among them we need a lightweight

material, resistant to impact, accessible, easy to Machining and Joining. After the

research we chose aluminum as our ideal material for its properties:

y Weight- Aluminum is light with a density one third that of steel, 2.700 kg/m3.

y Strength-Aluminum alloys commonly have tensile strengths of between 70 and

700 MPa. The range for alloys used in extrusion is 150 300 MPa. Unlike most

steel grades, aluminum does not become brittle at low temperatures. Instead, its

strength increases. At high temperatures, aluminums strength decreases. At

temperatures continuously above 100C, strength is affected to the extent that

the weakening must be taken into account.

y Machining-Aluminum is easily worked using most machining methods milling,

drilling, cutting, punching, bending, etc. Furthermore, the energy input during

machining is low.

y Joining-Features facilitating easy jointing are often incorporated into profile

design. Fusion welding, Friction Stir Welding, bonding and taping are also used

for joining.

y Corrosion resistance-Aluminum reacts with the oxygen in the air to form an

extremely thin layer of oxide. Though it is only some hundredths of a (my)mthick


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(1 (my)m is one thousandth of a millimeter), this layer is dense and provides

excellent corrosion protection.

y Zero toxicity-After oxygen and silicon; aluminum is the most common element

in the Earth's crust. Aluminum compounds also occur naturally in our food

Table of comparison

Materials Aluminum Steel Copper Zinc

Price(US$ per metric ton) 2.44k 800 9.53k 2.38k

Density(g/cm3) 2.7 7.9 8.9 7.1

Yield strength(MPa) 55-414 250-

1650

70 200-372

We chose aluminum mainly due to the weight limit of competition because it is a very

resistant and light metal.


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Manufacturing process

Safety

All hand and machine tools can be dangerous if used improperly or carelessly .working

safely is one of the first things a student or apprentice should learn because the safe

way is usually the correct and most efficient way.

Because of this we made a table that makes things easier when talking about safety.

Question check

Do I know how to operate this machine? YesWhat are the potential hazards involved?

Are all guards in place? Yes Am I doing something that I probably should not do? No

Have I made all the proper adjustment and tightened all locking boltsand clamps?

Yes

Are my procedures safe? Yes

Is the work piece secured properly? YesDo I have proper safety equipment? YesDo I know where the shop switch is? Yes

Do I think about safety everything that I do? Yes

* If you use the machine make sure to get someone who knows or learn before using.

*proper safety equipment: safety goggles and never wears loose clothing.

*always think in safety.


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Metrology

The ability to make accurate measurement on machined parts is vital necessity for

manufacturing processes. The system and measuring standards must be understood

and the ability to correctly use precision measuring instruments must be learned.

The instrument of measures that we use most was the caliper due to their great

versatility to measure widths, depths and external and internal diameters, In addition to

this with great accuracy bearing 3 decimals numbers. Another instrument we use was

the steel rule to make linear measures.

For example:

Parts instrument

Drum Caps Caliper

Robots Defense Plates Caliper

Robots Roof and Floor Ruler


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Joining and assembly process

In this part is considered the processes that are used to join two or more parts into an

assembled entity. The term joining is generally used for welding, brazing, soldering,

and adhesive bonding, which form a permanent joint between pasts. The term

assembly usually refers to mechanical methods of fastening parts together. Some of

these methods allow for easy disassembly, while others do not. In most cases, the

fastening method involves the use of discrete hardware components, called fasteners

that are added to the parts during the assembly operation.

In this part is not bad to say that it is one of the most important parts of the project and

occurs after the design and the manufacture of individual parts. After all ready-made

parts, need to think about which method of Assembly is the most suitable for each

piece, for example; Mechanical subject can be achieved by means of screws, rivets,

pins, wedges and unions by adjustment to pressure, made with other mechanical

fasteners are not permanent mechanics are more expensive and requires capacity-

building in the preparation of parties together.

Some parties join permanently with electric welding or gas, soft soldering, or hard, and

some stickers. Welding is carried out with the use of heat, pressure or both

In our case the more we use was the mechanical subject.


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Robot manufacturing and machines utilized

Taking into consideration the safety, metrology and the final design once we started the

process of manufacturing the first thing we took on the task of preparing the two

Supportive caps was made to fit at pressure in the tube (drum), one of the caps we

machined the channel for the pulley to run to Avoid Excess of parts. After that we made

the body of the robot taking into consideration the design measures and finally the

assembly of all parts.

For all this process we need machines including:

y The Milling- is a machining operation in which a workpart is fed past a rotating

cylindrical tool with multiple cutting edges. The axis of rotation of the cutting tool

is perpendicular to the direction of feed. This orientation between the tool axis

and the feed direction is one of the features that distinguishes milling from

drilling. In drilling, the cutting tool is fed in a direction parallel to its axis of

rotation. The cutting tool in milling is called a milling cutter and the cutting edges

are called teeth. The machine tool that traditionally performs this operation is a

milling machine.

y The Lathe- Historically, the lathe is the forerunner of all machine tools. The first

application of the lathe principle was probably the potters wheel. This machine

rotated a mass of clay and enabled the clay to be formed into a cylindrical

shape.


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The modern lathe operates on the same basic principle. The work is held and

rotated on its axis while the cutting tool is advanced along the lines of a desired

cut. The lathe is one of the most versatile machine tools used in industry. With

suitable attachments, the lathe may be used for turning, tapering, form turning,

and screw cutting, facing, drilling, boring, spinning, grinding, and polishing

operations.

y Drill- is a tool fitted with a cutting tool attachment or driving tool attachment,

usually a drill bit or driver bit, used for drilling holes in various materials or

fastening various materials together with the use of fasteners


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Electrical circuit and connections

Components of the circuit:

Electrical component Brief description

2 transmissions of 20: 1

3 motors of 900rpm/v

transmissions of 4: 1

1 sabertooth 2 x 25 of two channels for

traction

1 speedmax (speed control) for the

weapon

1 12v battery

1 receiver

1 on/off switch

Connection: The battery (negative side) to sabertooth and Speedmax, from sabertooth

to engines of the tires and from Speedmax to engine of the weapon. Battery (positive

side) to the (on / off) switch from the switch to sabertooth and Speedmax, from

sabertooth to engines of the tires and from Speedmax to engine of the weapon

sabertooth At receiver 2 negative in the port 0V, 2 positive in the port 5V, 1 S1 port, 1

port s2 which are for the control of the tires and plug into the receiver in the jumper

called allie and elev . Speedmax the receiver from the integrated cable connects to the

receiver from the jumper named throttle


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Conclusion


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rear plate:


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Floor:


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Lateral:


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Drum:


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Drum cap 1


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Drum cap 2


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Assembly 1


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Assembly 2

Trabajo Final Escrito de Manufactura

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