Handle Cane Adapter

Handle Cane Adapter

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0”-6”)

ii)Micrometers (0”-1”, 1”-2”)

iii)Lathe

iv)Mill with vise and digital axis monitor

v)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

vi)4-40 Cobalt Steel Hand Tap with @ least 1” thread length

vii).089” HSS drill bit with @ least 1” drilling depth

viii)¼” 120° Hole-Starting CarbideCenter Drill with @ least 0.2” drilling depth

ix)1”HSS drill bit with @ least 1” drilling depth

x)1” HSS Reamer with @ least 1” drilling depth

xi)0.75” HSS drill bit with @ least 1” drilling depth

xii)0.75” HSS Reamer with @ least 1” drilling depth

xiii)Indexing Head

xiv)Single Edge Edge-Finder

xv)File

b)Purchase - none

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1.5” diameter rawABSrod to 1.25” diameter and 2.5” length using lathe @ 500 RPM

b)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

c)Touch off all holes with a center drill and then drill all holes with drill bits using the mill

d)Remove part from vise and hand tap all holes

e)Drill large bore holes using lathe

f)Ream large holes using lathe

a)Remove part from lathe and gently turn hand taps through existing tap threads again to remove burrs created by previous operation. Hand tap holes in the mill vise

g)Chamfer/De-burr edges with file

1. Time Estimate

a)30 minutes using lathe

b)30 minutes for alignment of part in millwithedge finder

c)30 minutes drill small holes using the mill

d)30 minutes to tap all holes

e)60 minutes to align and drill large holes

f)30 minutes to re-tap and de-burr threads that have

TOTAL: 210 minutes or 3.5 hours

Motor Mount

1. Tools

a)Available in Machine Shop

i)½” HSS end mill bit with @ least 1” of mill depth

ii).089” HSS drill bit with @ least 1” drilling depth

iii)Mill with vise and digital axis monitor

iv)Lathe

v)4-40 Cobalt Steel Hand Tap with @ least 1” thread length

vi)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

vii)Single Edge Edge-Finder

viii)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

ix)Dial Calipers (0” – 6”)

x)Micrometers (0”-1”, 1”-2”)

xi)File

b)Purchase

i)M1.6x0.35 tap w @ least 0.5” thread depth

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1.25” diameter raw ABS rod to 1” diameter and 1” length using lathe @ 500 RPM

b)Use edge finder with the mill to create a datum based upon part geometry fixed in the vise (see drawing for manufacturing dimensions)

c)Touch off all holes with a center drill and then drill all holes with drill bits using the mill

d)Remove part from vise and hand tap all holes

e)Mill off top half of rod

f)Remove part from mill and gently turn hand taps through existing tap threads again to remove burrs created by previous operation. Hand tap holes in the mill vise

g)Chamfer/De-burr edges with file

1. Time Estimate

a)30 minutes using lathe

b)30 minutes for alignment of part in millwithedge finder

c)120 minutes for drilling using the mill

d)30 minutes to tap all holes

e)30 minutes using mill to make flat face

TOTAL: 240 minutes or 4 hours

Roller Arm (2)

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” – 6”)

ii)Micrometer (0” – 1”)

iii)Lathe

iv)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

v)Prototrac Mill

vi)1/8” HSS drill bit with @ least 1” drilling depth

vii)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

viii)Single Edge Edge-Finder

ix)4-40 Cobalt Steel Hand Tap with @ least 1” thread length

x)3/8” HSS end mill bit with @ least 1” of mill depth

xi)3mm HSS drill bit with @ least 1” drilling depth

xii).087” HSS drill bit @ least 1” drilling depth

xiii)Indexing Head

xiv)File

b)Purchase

i)1/32” HSS Corner-Rounding end mill bit

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1” Aluminum rod using lathe @ 600RPM to .402” radiusand length of 0.3”

b)Cut rod using lathe to .188” diameter in specified region (see drawing for manufacturing dimensions)

c)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

d)Touch off all holes with a center drill and then drill all holes with drill bits using the mill

e)Machine with Prototrac Mill using end mill bit for removal of material and filleting

f)Hand tap holes in the mill vise

g)Chamfer/De-burr edges with file

1. Time Estimate

a)120 minutes using lathe

b)120 minutes for prototrac set-up and part alignment using edge finder

c)120 minutes to drill all holes

d)120 minutes to remove material and fillet

e)30 minutes to tap holes

TOTAL:510 minutes or 8.5 hours

Shaft Mount

1. Tools

a)Available in Machine Shop

i).089” HSS drill bit with @ least 1” drilling depth

ii)4-40 Cobalt Steel Hand Tap with @ least 1” thread length

iii)½” HSS end mill bit with @ least 1” of mill depth

iv)Dial Calipers (0” – 6”)

v)Mill with vise and digital axis monitor

vi)Micrometer (0” – 1”)

vii)Lathe

viii)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

ix)Single Edge Edge-Finder

x)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

xi)Indexing Head

xii)File

xiii)6mm drill bit with plunge capability with @ least 1” mill depth

b)Purchase

i)¼” end mill bit with plunge capability with @ least 1” mill depth

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Turn 1” ABS rodusing lathe @ 500RPM to .751” diameter and length of 0.5”

b)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

c)Touch off all holes with a center drill and then drill all holes with drill bits using the mill

d)Plunge mill the 0.236” diameter hole

e)Hand tap holes in the mill vise

f)Cut the radial cutout using the mill

g)Mill off top section

h)Chamfer/De-burr edges with file

1. Time Estimate

a)30 minutes using lathe

b)60 minutes for alignment of part in millwithedge finder

c)120 minutes to drill, mill and tap holes

d)30 minutes to mill top surface

TOTAL: 240 minutes or 4 hours

Bearing Shaft – 6112K310

1. Tools

a)Available in Machine Shop

i)Lathe

ii)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

iii)Dial Calipers (0” –6”)

iv)Micrometer (0” – 1”)

v)File

b)Purchase - none

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 3mm Aluminum rod to length of 0.91” using lathe @ 600RPM

b)If needed, turn part in lathe to achieve proper interference fit in roller arms

c)Chamfer/De-burr edges with file

1. Time Estimate

a)30 minutes to cut to length and fit

TOTAL: 30 minutes or 0.5 hours

Bump Dowel Pins (4)

1. Tools

a)Available in Machine Shop

i)Lathe

ii)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

iii)Dial Calipers (0” –6”)

iv)Micrometer (0” – 1”)

v)File

b)Purchase - none

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1/8” Aluminum dowels to length of 0.57” using lathe @ 600RPM

b)If needed, turn part in lathe to achieve proper interference fit in roller arms

c)Chamfer/De-burr edges with file

1. Time Estimate

a)120 minutes to cut to length

TOTAL: 120 minutes or 2 hours

Outer Collar

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” –6”)

ii)Micrometer (0” – 1”)

iii)Bandsaw

iv)Lathe

v)Mill with vise and digital axis monitor

vi)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

vii)Indexing Head

viii)File for de-burring and chamfering

ix)½” HSS end mill bit with @ least 1” of mill depth

x)1” HSS Reamer with @ least 1” drilling depth

b)Purchase

i)HSS countersink tool bit for 4-40 machine screw (82°)

ii)0.129” HSS drill bit with @ least 1” drilling depth

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Use edge finder with the mill to create a datum based upon part geometry fixed in indexing head vise (see drawing for manufacturing dimensions). Raw stock is 1.25” OD 1/8” thick ABS tube, 3” length

b)Ream tube ID with lathe @ 600RPM feeding @ 2”/min

c)Touch off all holes with a center drill and then drill all holes with drill bits using the mill, then follow with countersink bit.

d)Cut excess cylinder length of tube with band saw and finish surface with mill.

e)Cut tube to appropriate semicircle angle

f)Chamfer/De-burr edges with file

1. Time Estimate

a)30 minutes to create datum and align part in mill indexing head.

b)60 minutes to center drill, drill, and countersink all holes

c)60 minutes using the band saw and mill

d)30 minutes using the file

TOTAL: 180 minutes or 3 hours

Outer Collar Full

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” –6”)

ii)Micrometer (0” – 1”)

iii)Bandsaw

iv)Mill with vise and digital axis monitor

v)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

vi)Indexing Head

vii)File for de-burring and chamfering

viii)½” HSS end mill bit with @ least 1” of mill depth

b)Purchase

i)HSS countersink tool bit for 4-40 machine screw (82°)

ii)0.129” HSS drill bit with @ least 1” drilling depth

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Use edge finder with the mill to create a datum based upon part geometry fixed in indexing head vise (see drawing for manufacturing dimensions). Raw stock is 1.25” OD 1/8” thick ABS tube, 3” length

b)Touch off all holes with a center drill and then drill all holes with drill bits using the mill, then follow with countersink bit.

c)Cut excess cylinder length of tube with band saw and finish surface with mill.

d)Chamfer/De-burr edges with file

1. Time Estimate

a)30 minutes to create datum and align part in mill indexing head.

b)60 minutes to center drill, drill, and countersink all holes

c)60 minutes using the band saw and mill

d)30 minutes using the file

TOTAL: 180 minutes or 3 hours

PCB Holder (4)

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” –6”)

ii)Band saw

iii)Vise Grips

iv)File for de-burring and chamfering

b)Purchase (none)

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Raw material is ¾” OD , ½” ID ABS rod

b)Cut to dimensions with band saw

c)*Make sure one edge is radially oriented

d)Chamfer/De-burr edges with file

1. Time Estimate

a)120 minutes using the band saw

b)30 minutes using the file accompanied with Vice Grips

TOTAL: 150 minutes or 2.5 hours

PCB Cover

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” – 6”)

ii)Micrometer (0” – 1” , 1” – 2”)

iii)Lathe

iv)Mill with vise and digital axis monitor

v)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

vi)¾” HSS drill bit with @ least 6” drill depth

vii)¾” Reamer bit with @ least 2” of flute length

viii)0.089” HSS drill bit with @ least 1” drilling depth

ix)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

x)Single Edge Edge-Finder

xi)4-40 Cobalt Steel Hand Tap with @ least 1” thread length

xii)3/8” HSS end mill bit with @ least 1” of mill depth

xiii)File

b)Purchase (none)

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1.25” ODFiberglass rod using lathe @ 600RPM to 1” diameter and length of 5.976”

b)Drill a ¾” hole through the rod, in the direction concentric with the rod

c)Ream Fiberglass rod all the way through using ¾” reamer @ 600RPM, feeding @ 2”/min

d)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

e)Touch off all holes with a center drill and then drill all holes with drill bits using the mill

f)Mill off length section using end mill bit

g)Hand tap shaft through holes in the mill vise

h)Chamfer/De-burr edges with file

1. Time Estimate

a)60 minutes using lathe, cutting and reaming

b)90 minutes to align part and drill all holes

c)60 minutes to remove material with end mill

d)30 minutes to tap holes

e)30 minutes using the file

TOTAL:270 minutes or 4.5 hours

Motor Cover

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” – 6”)

ii)Micrometer (0” – 1” , 1” – 2”)

iii)Lathe

iv)Mill with vise and digital axis monitor

v)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

vi)¾” HSS drill bit with @ least 6” drill depth

vii)¾” Reamer bit with @ least 2” of flute length

viii)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

ix)Single Edge Edge-Finder

x)3/8” HSS end mill bit with @ least 1” of mill depth

xi)File

b)Purchase

i)HSS countersink tool bit for 4-40 machine screw (82°)

ii)0.129” HSS drill bit with @ least 1” drilling depth

iii)1/8” end mill bit with plunge capability with @ least 1” mill depth

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1.25” OD Fiberglass rod using lathe @ 600RPM to 1” diameter and length of 5.976”

b)Drill a ¾” hole through the rod, in the direction concentric with the rod

c)Ream ABS rod all the way through using ¾” reamer @ 600RPM, feeding @ 2”/min

d)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

e)Touch off all holes with a center drill and then drill all holes with drill bits and countersink bit using the mill

f)Mill off length section using end mill bit

g)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

h)Mill slots in the part with 1/8” end mill bit

i)Hand tap shaft through holes in the mill vise

j)Chamfer/De-burr edges with file

1. Time Estimate

a)90 minutes using lathe, cutting, drilling, and reaming

b)90 minutes to align part, drill, and countersink

c)60 minutes to remove material with end mill

d)30 minutes using the file

TOTAL: 270 minutes or 4.5 hours

Battery Cover

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” – 6”)

ii)Micrometer (0” – 1” , 1” – 2”)

iii)Lathe

iv)Mill with vise and digital axis monitor

v)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

vi)¾” HSS drill bit with @ least 6” drill depth

vii)¾” Reamer bit with @ least 2” of flute length

viii)¼” 120° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

ix)0.089” HSS drill bit with @ least 1” drilling depth

x)Single Edge Edge-Finder

xi)3/8” HSS end mill bit with @ least 1” of mill depth

xii)File

b)Purchase

i)HSS countersink tool bit for 4-40 machine screw (82°)

ii)0.035” HSS drill bit with @ least 1” cutting depth

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1.25” OD Fiberglass rod using lathe @ 600RPM to 1” diameter and length of 5.976”

b)Drill a ¾” hole through the rod, in the direction concentric with the rod

c)Ream ABS rod all the way through using ¾” reamer @ 600RPM, feeding @ 2”/min

d)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

e)Touch off all holes with a center drill and then drill all holes with drill bits using the mill

f)Mill off length section using end mill bit

g)Chamfer/De-burr edges with file

1. Time Estimate

a)60 minutes using lathe, cutting and drilling

b)60 minutes to align part, drill, and countersink

c)60 minutes to remove material with end mill

d)30 minutes using the file

TOTAL: 210 minutes or 3.5 hours

Handle Tube

1. Tools

a)Available in Machine Shop

i)Dial Calipers (0” – 18”)

ii)Micrometer (0” – 1”, 1” – 2”)

iii)Lathe

iv)Mill with vise and digital axis monitor

v)Negative-Rake Carbide Insert General Purpose 1/8” Lathe tool bit

vi)¾” HSS drill bit with @ least 6” drill depth

vii)¾” Reamer bit with @ least 2” of flute length and @ least 10” overall length

viii)3/8” HSS end mill bit with @ least 1” of mill depth

ix)Single Edge Edge-Finder

x)0.089” HSS drill bit with @ least 1” drilling depth

xi)4-40 Cobalt Steel Hand Tap with @ least 1” thread length

xii)File

b)Purchase

i)HSS countersink tool bit for 4-40 machine screw (82°)

ii)1/8” HSS end mill bit with @ least 0.375” of mill depth

iii)25/64” HSS end mill bit with @ least 1” of mill depth

iv)1/16” HSS end mill bit with @ least 0.375” of mill depth

v)0.129” HSS drill bit with @ least 1” drilling depth

vi)¼” 82° Hole-Starting Carbide Center Drill with @ least 0.2” drilling depth

vii)0.035” HSS drill bit with @ least 0.5” drilling depth

viii)0.094” HSS drill bit with @ least 0.5” drilling depth

1. Resources

a)Skilled Machinist in Machine Shop

b)Team Members – Aaron, Lauren, Jake

1. Instructions

a)Cut 1.25” OD Fiberglass rod using lathe @ 600RPM to 1” diameter and length of 13”

b)Drill a ¾” hole through the rod, in the direction concentric with the rod, using the lathe

c)Ream Fiberglass rod through the rod using ¾” reamer @ 600RPM, feeding @ 2”/min.

d)Use edge finder with the mill to create a datum based upon part geometry fixed in vise (see drawing for manufacturing dimensions)

e)Touch off all holes with a center drill and then drill and countersink holes with drill bits using the mill