week 8 challenge-2 prashant Mahahan
In this report we have provided the rough locators and performed 3D finish on all the units. In designing the rough locators we have considered all the design considerartions for their height and position of mounting to ensure correct orientation and positioning of panel loading fow each panel. In performing 3D finish, we have kept into account the following:
1) Naming of parts and assemblies as per standards.
2) Structuring the tree
3) Nominality
4) Machining Cut
5) Fasteners Implementation
6) Adding Shim
7) Hole concentricity
8) Gap checking
9) Mylar Splitting
10)Avoiding clash between parts
11) Holes contouring standard
Unitwise representation of the above is given below covering all the points:
Unit-1
1) Naming of parts and assemblies as per standards.
2) Structuring the tree
3) Checking Nominality of diffrent parts.
4) Machining Cut
5) Fasteners Implementation
Shimming is not applicable in the base unit and holes. Holes contouring standards, hole concentricity has been checked.
Also, 4 tooling holes of dia 8 have been drilled on the base as shown below.
Holes for different units are drilled
Unit-2
1) Structuring of tree
2) Splitting with panel surface
3) Nominality
4) Hole concentricity
Fasteners are implemented in the unit and the gap is checked between units and shim is then inserted. There is no clash between parts.
Unit-3
1) Structuring the tree and renaming the parts as per standards
2) Nominality check
3) Machining Cut and Splitting
4) Fasteners implememtation
Other 3D finish activities like hole concentricity and clash between parts are also checked for each hole and part respectively.
Unit-4
1) Structuring the tree and remaning of parts as per standard
2) Splitting of mylar and machining cut for mounting and fasteners implementation
3) Nominality check
Other 3D finish activities like hole concentricity and clash between parts are also checked for each hole and part respectively.
Unit-5
1) Machining cut for mylars and for dock mounting and cylinder mounting
2) Machining on mounting surfaces
3) Splitting of mylar
4) Hole concentricity check
Concentricity check for cylinder
5) Fasteners
Other 3D finish activities like gap checking and clash between parts are also checked for diffrent parts. Aloso hole concentricity and pin concentricity with mounting hole is checked.
Unit-6
1) Structuring the tree and renaming parts and assemblies as per standard
2) Machining mounting surfaces
3) Nominality
4) Mylar splitting
Hole concentricity, shim addition, gap checking and fasteners are implmented to complete the 3D finish of this unit.
Unit-7
1)Structuring and renaming the tree
2) Nominality check of all parts
3) Machining cut on mounting ends
4) Fasteners implementation
Hole concentricity, shim addition, gap checking and mylar splitting are done to complete the 3D finish of this unit.
Unit-8
1) Structuring the tree
2) Maching the mounting areas
3) Hole concentricity
4) Nominality
5) Mylar splitting
6) Bought out addition
7) Fillet added in mylars
8) Gap checking
Unit-9
1) Structuring the tree and renaming and standard
2) Nominality Check
3) Splitting
4) Machining the mounting ends
Hole concentricity, shim addition, gap checking and fasteners are done to complete the 3D finish of this unit.
Unit-10
1) Hole concentricity
2) Machining
3) Fasteners implememtation
4) Nominality
Hole concentricity, shim addition, gap checking are checked to complete the 3D finish of this unit.
Unit-11
1) Hole Concentricity
2) Nominality
3)Machining for mounting
4) Structuring the tree
Shim addition, gap checking are done to complete the 3D finish of this unit.
Unit-12
1) Nominality
2) Machining
3) Applying Fillet
Shim addition, gap checking and hole concentricity along with mylar splitting are done as shown previously to complete the 3D finish of this unit.
Unit-13
1) Structuring the tree, renaming parts and machining on mounting ends
2) Concentricity of all holes
3) Splitting
4) Fasteners addition
Shim addition, gap checking are done to complete the 3D finish of this unit.
Rough Locators used for panel correct orientation and panel guiding in different units are given below:
In the above image, we have given rough locators for each panel to ensure their correct orientation and loading on the fixture. They are given at a distance of 2-5mm from the panel and have been provided with adjustment in the direction of the panel edge they are guiding. The height of rough locator is so selected that it guides the panel 10-15mm before entering into the pin. These rough locators are described below pictorially:
In unit 5, 2 rough locators are provided to hold the panel in its place and guide it for correct orientation.
Panel will be loaded on to the pins and rough locators will guide it.
To provide the pokayoke, we can see that if the panel is loaded in some other orientation, the rough locator will not let it load.
To save cost and prevent unnecessary long length, the rough locators has been mounted on the dolly plate with adjustment along the direction of the edge that it is guiding.
Same have been provided on the mirror side.
To fix the yellow panel, 6 rough locators are used. There are two more locators that will act as rough locator for yellow panel and pokayoke for blue panel, which will be loaded after the yellow panel. The height of rough locator is so selected that it guides the panel 10-15mm before entering into the pin.
All design considerations taken into account before designing.
2 ribs are added for strength as the rough locator is quite long and there can be vibration and bending.
We can see that if the panel is loaded in some other direction, it will foul with rough locator. For this panel, we do not require rough locator as it will be first loaded on the open clamp and then clamp is closed.
Nominality is maintained wherever the rough locator is perpedicular to all planes.
Link for 3d files:
https://drive.google.com/open?id=1w4DnfaHq-ySDCxEjAipd5eEsQO35XswM