MEAM.Design - IPD 501 - CHECK
Check
Dates
Th F15: Assigned
- Project introduction.
Tu F20: Check PDR, SolidCAM Training
- Be prepared to discuss different design options and challenges in class.
- Compile sketches, brief size estimates, and required materials for the three designs IN A SINGLE .pdf and email this to medesign@seas.upenn.edu by 2:00PM before class. Title both the file and email as "501-CHECK-PDR-PennKeys".
Th F22: Check CDR, CAM Reviews Begin
- Be prepared to discuss the design and manufacturability of your chess set in class.
- Produce a 1400x1050 pixel JPG rendering of your chess set along with a BOM (including McMaster part #'s and total cost) and email to medesign@seas.upenn.edu by 2:00PM. Title both the rendering file and the email as "501-CHECK-DESIGN-CDR-PennKeys".
- Submit a pack-and-go ("501-CHECK-CAD-PennKeys"), a complete manufacturing process (in body of email), and your final BOM by 8:00 PM.
- TL-1 Demo
Fr F23: McMaster Order
- TAs will submit one McMaster order for each team's approved BOM to business office at 9AM. There will be a $250 limit per team.
Th M15: Check (Pieces) Due
- Bring your chess set to class.
Tu M20: Check Due, Check Reflection Due
- Bring your final chess set with the board to class.
- Complete the Canvas reflection for Check by 2:00PM before class.
Assignment
Working in a team of four or five, use SolidWorks, SolidCAM, the Haas TL-1, and any other tools to create a full chess set, including the board.
Deliverables
1. Complete chess set with board.
Guidelines
- A member of the teaching staff must be present when you first cut your parts on the TL-1. A schedule with the TA's available times can be found on Piazza. Your ENTIRE team must be present for the training.
- Your parts will be oriented such that the origin sits at the intersection of the machine's Z axis and the 2" off the face of the chuck, with positive Z pointing towards the tailstock.
- To allow for post machining (mill, secondary manual lathe ops), you may want to leave a short section at a standard diameter for insertion into a collet.
- Alternatively, you can pre-machine chess piece blanks and a threaded mandrel to fixture onto the TL-1 to avoid having to flip your part later.
- The parts can be sent out for anodizing after they are all completed. The anodizing supplier asks that you have a 1/4-20 threaded hole somewhere on each part.
- Any woodworking should be done in the Fabrication Lab in the School of Design.
- See below for materials that will be provided. All other material must be requested and ordered by the teaching staff, preferably from McMaster.
- Material budget: $250/team.
Materials
We have dedicated 6061-T6 aluminum stock for use in Check. Please still list on the BOM so that we can make sure we have enough in stock.
- Stock: 1.125" OD and 1" OD rod.
Setup
- The TL-1 will be set up with an 8" chuck with a maximum spindle speed of 1800 RPM.
- We will pre-set right and left-handed carbide turning/facing tools, two grooving/part-off tools, and a drill and tap for the 1/4-20 threaded holes for anodizing. The tool table (in .TAB format) can be found here.
- The chuck on the TL-1 will be checked for collisions by creating a fixture in SolidCAM with the following dimensions:
| Chuck Dimension | Value | |
| Jaw Width | 1.75 | |
| Jaw Height | 3.125 | |
| Step Width | 0.375 | |
| Step Height | 1.0 | |
| Thickness | 1.0625 | |
| Number of Jaws | 3 |
- The MiniMill will be set up with the HRT160 rotary table for post machining. Any usage of the rotary table will require review and approval from the teaching staff. You can use this for at most four parts.
