A M210-3 - Interpret Per Asme Y14.5-2009 - Scale: 1:1 Weight: 1.3 Sheet 1 of 5 2 1 2 1

2 1

.001 A .001 A .001 B B B .50 B

R.218 1.88

A .63

.001 2.40 2.13

A NOTES: UNLESS OTHERWISE SPECIFIED: NAME DATE TITLE: A

DRAWN A. BALOGH 1/30/2019 1) DEBURR ALL EDGES .015 MAX. DIMENSIONS ARE IN INCHES TOLERANCES: CHECKED ANGLE PLATE 1/X or .X 1/64 (.0156) APPROVED .XX .010 .XXX .005 MATERIAL X 1 CR 1018 STEEL SIZE DWG. NO. REV 125 ALL SURFACES FINISH PROJECTION A M210-3 - INTERPRET PER ASME Y14.5-2009 - SCALE: 1:1 WEIGHT: 1.3 SHEET 1 OF 5 2 1 2 1

.50 + HOLE RADIUS + FINISH ALLOWANCE B B

MATERIAL TO BE REMOVED WITH BANDSAW 1.91 .63 + HOLE RADIUS + FINISH ALLOWANCE

2.43 2.16

7/16 (.438) REAM THRU

ROUGHING GEOMETRY

A UNLESS OTHERWISE SPECIFIED: NAME DATE TITLE: A DIMENSIONS ARE IN INCHES DRAWN A. BALOGH 1/30/2019 TOLERANCES: CHECKED ANGLE PLATE 1/X or .X 1/64 (.0156) APPROVED .XX .010 .XXX .005 MATERIAL X 1 CR 1018 STEEL SIZE DWG. NO. REV 125 ALL SURFACES FINISH PROJECTION A M210-3 - INTERPRET PER ASME Y14.5-2009 - SCALE: 1:1 WEIGHT: 1.3 SHEET 2 OF 5 2 1 2 1

B B

2.00 STOCK

2.25 2.50 STOCK CUT ON BANDSAW STOCK SURFACE IDENTIFICATION

SURFACE H (PARALLEL TO DATUM A) SURFACE A (DATUM A) SURFACE F (INSIDE OF .50" DIMENSION) B B SURFACE D (PARALLEL TO DATUM B)

SURFACE B (DATUM B) SURFACE C SURFACE G (PERPENDICULAR (PARALLEL TO TO DATUM A) SURFACE PERPENDICULAR TO DATUM A) FINISHED SURFACE SURFACE E IDENTIFICATION (INSIDE OF .63" DIMENSION)

RADIUS BLENDING INSTRUCTIONS

1) TOUCH OFF SIDE OF INSERT ON FACE B WITH FEELER GAGE (NOTE: YOU MUST COMPENSATE FOR FEELER GAGE THICKNESS)

B 2) MEASURE DISTANCE BC B ______

3) MEASURE THICKNESS D WITH BALL MICROMETER ______R2 D 4) TO CALCULATE Y-AXIS POSITION: E = (BC)-(D+R1-R2) E = ( )-( + - )=

R1 5) TO DETERMINE Z-AXIS DEPTH OF A CUT, MEASURE DISTANCE FROM FACE A TO BOTTOM OF R1 USING TEST E INDICATOR C B (NOTE: INDICATOR MAX TRAVEL = .030")

DIMENSION B-C

A UNLESS OTHERWISE SPECIFIED: NAME DATE TITLE: A DIMENSIONS ARE IN INCHES DRAWN A. BALOGH 1/30/2019 TOLERANCES: CHECKED ANGLE PLATE NOTES: 1/X or .X 1/64 (.0156) APPROVED R1 = CORNER RADIUS OF PART .XX .010 .XXX .005 MATERIAL R2 = NOSE RADIUS OF CUTTING TOOL INSERT X 1 CR 1018 STEEL SIZE DWG. NO. REV 125 ALL SURFACES FINISH PROJECTION A M210-3 - INTERPRET PER ASME Y14.5-2009 - SCALE: 1:1 WEIGHT: 1.3 SHEET 5 OF 5 2 1 Points Earned ANGLE PLATE

Total Points Possible 12 INSPECTION REPORT Student Name

Linear Dimensions 1) 1.88 +/- .010 2) 2.40 +/- .010 3) 2.13 +/- .010

4) 0.63 +/- .010 5) .50 +/- .010 Corner Radius

A 1) R.218 reamed w/ good surface finish

A 2) R.218 corner radius blended Geometric Dimensioning and Tolerancing 1) Surface A flat w/in .001 2) Surface C perpendicular to Datum A w/in .001 3) Surface B perpendicular to Datum A w/in .001

4) Surface D parallel to Datum B w/in .001

A Overall appearance (clean, deburred, free of chips)

ANGLE PLATE PROJECT PLANNING WORK SHEET

OPERATION TOOLS CS/RPM Bandsaw 1) Cut 2” X 2.5” X 2.25” stock 195 SFM Combination Square Indicol 2) Tram mill head and vise to Indicator within .0005” Tramming Plate 4 X 780 = RPM 3) Mill Side 1 to clean (part Octomill 2.25 on parallels) Parallels ___ RPM X .002 X 4 = IPM

4) Mill Side 2 to clean (side 1 againt fixed jaw, part on Brass Pin parallels, pin on moveable jaw)

5) Mill Side 3 to 2.430” (side 1 on against fixed jaw, side 2 Dial Calipers on parallels, pin on moveable jaw)

Squaring Block 6) Mill Side 4 to 1.910” (side

1 on parallels, no pin)

HSS ⌀1 1/4” Endmill 4 X 7) Mill Side 5 to clean (hang = RPM R8 Collet part off side of vise) Coolant ___ RPM X .001 X 6 = IPM 4 X 780 = RPM 8) Mill Side 6 to 2.160” Octomill 2.25 ___ RPM X .002 X 4 = IPM 9) Layout part for hole Layout Dye

location Height Gage

10) Find hole location on Edgefinder 1000 RPM MAX mill using DRO Drill chuck

11) Center drill hole #3 Center Drill 600-1000 RPM Coolant

Drilling Drilling Hole Z Drill 4 X 12) Drill hole = RPM Coolant

7/16 Reamer 4 X 13) Ream hole = RPM Cutting Oil

14) Remove excess material Vertical Bandsaw 125-200 SFM 4 X 500 Trimill = RPM 2 15) Rough Surface F Ball Micrometer

0-1” Micrometer ___ RPM X .002 X 3 = IPM 16) Rough Surface E

17) Align bottom of thru- Test Indicator

hole Indicol

18) Calculate depth of cut to Test Indicator

blend radius Indicol Shim Stock 19) Calculate cutter position 2-3” Micrometer to blend radius

Blending Blending the Radius Ball Micrometer 20) Finish machine Surface E

to blend radius

21) Repeat steps 17-20 to

blend radius on Surface F

4 X = RPM 22) Machine Surface A to 2 1/2” Flycutter .63” dimension ___ RPM X .001 X 1 = IPM 23) Align Surface A vertically Indicator with knee; Machine Surface

Indicol C to .50” dimension

24) Align Surface A vertically

Finishing with knee; Machine Surface B to clean 25) Seat Surface B on parallels; Machine Surface D Parallels to 2.13” dimension

26) Machine Surface H to

1.88” dimension

27) Machine Surface G to

2.40” dimension Deburring Tool 28) Clean and deburr File Acetone

“Squaring Up A Block” Detailed Procedure for Preparing Raw Stock for the Angle Plate

After “tramming” the milling machine head and aligning the vise per recommended procedures, follow the sequence below to produce six sides which are flat, perpendicular and parallel, and milled to rough dimensions as calculated. Refer to the “Stock Surface Identification” sheet on the angle plate print.

Side #1

1) Remove burrs from workpiece and clean. Clean vise. 2) Set workpiece in vise on two parallels with large surface facing up. Select the shortest parallels possible which provide sufficient clearance for the surface to be machined and ensure maximum clamping surface area. 3) Tighten workpiece in vise. Do not clamp on bandsaw cut surfaces. 4) Mount face mill in machine spindle. “Touch off” cutter on top of workpiece with quill. Use gentle pressure to avoid chipping cutting edges. Tighten quill clamp. Set dial on knee (Z-axis) to zero. Lower knee one full revolution with crank to move workpiece away from cutting tool. 5) Clear workpiece to side of cutting tool and raise knee back to “touch off” position. Raise workpiece .020”-.030” past “touch off” position to set depth of cut. 6) Set correct RPM. On milling machines with variable speed drives, do this with spindle on. On milling machines with belt drives, do this with spindle off. 7) Turn spindle on. Check for correct direction of cutting tool rotation. Mill off top of workpiece using power feed on X-axis. Take multiple passes if necessary to machine entire surface. Make adjustments with Y-axis. 8) Turn machine off. Remove and clean workpiece. Deburr newly-formed edges.

Side #2

1) Clean vise and parallels. 2) Place deburred workpiece on two parallels with Side #1 against fixed jaw of vise. 3) This time, place a soft metal pin (copper, brass or aluminum) between the workpiece and the moveable vise jaw horizontally. Tighten workpiece in vise. 4) Repeat all procedures from Side #1. 5) Turn machine off. Remove and clean workpiece. Deburr newly-formed edges.

Side #3

1) Clean vise and parallels as before. 1) Place deburred workpiece in vise with Side #1 against fixed jaw of vise and Side #2 on one parallel. Use the pin again between the workpiece and the moveable vise jaw. 2) Partially tighten vise. With soft-faced, or dead-blow, hammer, tap workpiece down until both sides make positive contact on one parallel and tighten some more. Repeat and finish tightening. 2) Repeat all procedures from Side #2. 3) Measure the workpiece with a dial caliper. Continue to machine to rough size for width of part (2.430”). Make adjustments with knee crank (Z-axis). Do not take cuts over .030” when workpiece is clamped in vise against pin. 4) Turn machine off. Remove and clean workpiece. Deburr newly-formed edges.

Side #4

3) Clean vise and parallels as before. 4) Place deburred workpiece in vise with Side #1 on two parallels and Sides #2 and #3 clamped between jaws. The pin is no longer necessary. Tighten vise as before and tap down workpiece until both sides make positive contact on both parallels. 5) Repeat all procedures from Side #3, but machine to rough size for height of part (1.910”). 6) Turn machine off. Remove and clean workpiece. Deburr newly-formed edges.

Side #5

1) Clean vise and parallels as before. 2) Place deburred workpiece in vise on two parallels with approximately 1/2" protruding from the right side of the vise. Tighten vise and tap down workpiece as before. 3) Mount end mill in machine spindle using R8 collet. Raise workpiece so the length of the end mill will cut the entire surface. (End mill flute length must be at least 2”.) 4) Recalculate and adjust RPM. Turn spindle on. Check for correct direction of cutting tool rotation. “Touch off” end mill on surface. Set zero for X-axis on digital read out. 5) Clear workpiece behind cutting tool. Move workpiece .010”-.020” past “touch off” position with X-axis to set depth of cut. Machine surface by hand-feeding on Y-axis. Use conventional milling technique (ie feed workpiece toward you and against direction of cutting tool rotation). Use coolant. 6) Repeat only until surface cleans up completely (ie bandsaw cut pattern disappears). Then, take a “spring pass” (ie without changing depth of cut) back across the surface. Use climb milling technique for “spring pass” (ie feed workpiece away from you and with direction of cutting tool rotation). 7) Turn machine off. Remove and clean workpiece. Deburr newly-formed edges.

Side #6

1) Clean vise and parallels as before. 2) Place deburred workpiece in vise with Side #5 on two parallels. Tighten vise as before and tap down workpiece until both sides make positive contact on both parallels. 3) Remount face mill in machine spindle. Readjust RPM. “Touch off”, set depth of cut and machine surface following all procedures from Side #4, but machine to rough size for depth of part (2.160”). 4) Turn machine off. Remove and clean workpiece. Deburr newly-formed edges.

Feature Control Frame

GD&T Basics Basic Dimension Cheatsheet Datum Reference

Characteristic Symbols CHARACTERISTIC TYPE OF DATUM SYMBOL TOLERANCE ZONE INTERPRETATION NAME CONTROL REFERENCE FLATNESS SPACE BETWEEN TWO PARALLEL PLANES

NONE STRAIGHTNESS (INDEPENDENT SPACE BETWEEN TWO PARALLEL LINES FORM CIRCULARITY OF OTHER SPACE BETWEEN TWO COAXIAL CIRCLES (roundness) FEATURES) CYLINDRICITY SPACE BETWEEN TWO COAXIAL CYLINDERS

PERPENDICULARITY

SPACE BETWEEN TWO PARALLEL PLANES ORIENTATION REQUIRED ANGULARITY (RELATIVE TO DATUM REFERENCE)

PARALLELISM

SPACE WITHIN A CYLINDER (LOCATED POSITION RELATIVE TO DATUM REFERENCES) SPACE WITHIN A CYLINDER (LOCATED CONCENTRICITY LOCATION REQUIRED RELATIVE TO DATUM REFERENCES) SPACE BETWEEN TWO PARALLEL PLANES SYMMETRY (LOCATED RELATIVE TO DATUM REFERENCES) SPACE BETWEEN TWO COAXIAL CIRCLES CIRCULAR RUNOUT (RELATIVE TO DATUM REFERENCE) RUNOUT REQUIRED SPACE BETWEEN TWO COAXIAL CYLINDERS TOTAL RUNOUT (RELATIVE TO DATUM REFERENCE) PROFILE OF A A BOUNDARY THAT IS THE SHAPE OF THE SURFACE TRUE PROFILE OF THE TOLERANCED SURFACE PROFILE OPTIONAL A TWO-DIMENSIONAL BOUNDARY THAT IS PROFILE OF A LINE THE SAME SHAPE OF THE TRUE PROFILE OF

THE TOLERANCED FEATURE