Old Main

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Old Main
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Finalized Process Plans

• Front Face Process Plan

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Finalized Process Plans (cont.)

• More Detailed Front Face Process Plans

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Finalized Process Plans (cont.)

• Side Face Process Plan

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Finalized Process Plans (cont.)

• More Detailed Side Process Plans

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Finalized Process Plans (cont.)

• Top Plate
• Tooling
• 4 Face Mill
• 1 End Mill
• Machine
• 3-Axis Milling Machine
• Fixturing
• Vacuum Fixture
• Description
• Cut to shape then perform a cut off operation

• Bottom Plate
• Tooling
• 4 Face Mill
• 1 End Mill
• ¾ Spot Drill
• Machine
• 3-Axis Milling Machine
• Fixturing
• Vacuum Fixture
• Description
• Spot drill feature then end mill the over hang

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Finalized Process Plans (cont.)

• Triangular Roof
• Initial Stock is 1.25 x 1.25 x 6 solid square
  6061 Aluminum
• Cut into 12 sections using bar feeder
• Cut each 12 section in half (diagonally) on band
  saw using 45 degree wedges for guidance
• Mount 12 triangular sections in rotary vise on
  machining center
• Cut off 4 individual roof components using 1/8
  end mill

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Finalized Process Plans (cont.)

• Tower
• Base Section
• Tooling
• 3 Face Mill
• 3/8 End Mill
• Fixturing
• Multiple Chick Vises (mounted in parallel)
• V-blocks
• Machine
• 3-Axis Mill
• Description
• End mill to cut off corners. Refixture to add
  effects

• Tower (cont.)
• Middle Section
• Tooling
• 3 Face Mill
• 3/32 End Mill
• Fixturing
• Multiple Chick Vises (mounted in parallel)
• V-blocks
• Machine
• 3-Axis Mill
• Description
• Same procedure as base section

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Finalized Process Plans (cont.)

• Tower (cont.)
• Top Section
• Tooling
• Center Drill
• 3/8 Drill
• 7/8 Drill
• 1.5 End Mill
• 3/16 End Mill
• 1/32 Radius Concave Cutting End Mill
• Turning Tool
• Cutoff Tool
• Fixturing
• 3-Jaw Chuck
• Machine
• 5-Axis Mill
• Lathe
• Possibly of lathe with bar feeder and live
  tooling

• Base
• Tooling
• End Mill
• Drill
• No Special Fixturing Required
• Machine
• 3-Axis Mill
• Columns
• Just a cut off operation is required

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Production Schedule
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New Findings Decisions

• Reduction in Machine Time
• Total Time for machining is now 105 min.
• Cut our labor and machine cost by 40
• New cost is 52.50 per Old Main
• New Per Unit cost of 87.43

• Going to produce 18 this semester
• Accounting for 10 to be given away to faculty and
  group
• Going to sell 8 at 250 per Old Main
• Give Profit of around 200.

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Bill of Materials

• Triangular Roof
• 1.25 square x 6 long
• Qty. needed 2
• Price 51.24 ea.
• Tower
• 1.25 diameter x 6
• Qty. needed 1
• Price 33.94
• Tower
• 1.25 square x 6
• Qty. needed 1
• Price 51.24

• Tower
• 2.25 square x 3
• Qty. needed 1
• Price 101.30
• Columns
• 5/16 diameter x 6
• Qty. needed 8
• Price 4.95 ea.
• Flat Roof
• 4w x 0.5 thick x 6
• Qty. needed 3
• Price 65.48 ea.

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Bill of Materials (cont.)

• Sides
• 1.5 x 3 x 0.125 x 6 box tube
• Qty. needed 1
• Price 67.50
• Front/Back
• 3 x 8
• Qty. needed 1
• Price 118.00

• Base
• 1 x 6 sheet of walnut
• Qty. needed 2
• Price 24.00 ea.
• Clock
• 15/16 Clock insert
• Qty. needed 18
• Price 5.95 ea.

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Breakdown

• Triangular Roof 102.48 (3)
• Tower (upper) 33.94
• Tower (middle) 51.24
• Tower (base) 101.30
• Columns 39.52 (8)
• Flat Roof 196.44 (3)
• Sides 67.50
• Front/Back 118.00
• Base 48.00
• Clock Insert 107.10
• Total 862.52

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Final Costs

• Material Cost for 18 Old Mains 862.52
• Machine Cost for 18 Old Mains 945
• Cost to Produce 1807.52
• Sell 8 Old Mains at 250 a piece 2000
• Net Profit 192.48

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Questions/Comments