Speed Molding Jig A Baccalaureate thesis submitted to the Department of Mechanical and Materials Engineering College of Engineering and Applied Science University of Cincinnati in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering Technology by Lucas Rice April 2014 Thesis Advisor: Professor Laura Caldwell ACKNOWLEDGEMENTS This project was made possible through the support and dedication of countless people who have invested in my education and life over the short span of my life. I would like to thank all of my University of Cincinnati faculty who have helped me gain my engineering degree and invested in me as a person. I want to specifically thank my Mom and Dad for their selfless efforts in educating, preparing, and supporting me in this journey of life. Always present, open to listen, willing to help and always so giving. I want to thank my precious wife Rachel for all of her tireless and ever present support in my senior year and every area of life. She is the biggest blessing in my life and keeps me running, a true example of a Proverbs 31 women. I love you Honey. Most of all, I thank my Lord and Savior Jesus Christ for giving me the mind and provision to succeed in school and for paving the way home. ii TABLE OF CONTENTS ACKNOWLEDGEMENTS ...................................................................................................... II TABLE OF CONTENTS ........................................................................................................ III LIST OF FIGURES ................................................................................................................ IV LIST OF TABLES ................................................................................................................... V ABSTRACT ............................................................................................................................ VI INTRODUCTION & RESEARCH .......................................................................................... 1 BACKGROUND .................................................................................................................................................... 1 PROBLEM ............................................................................................................................................................ 1 INTERVIEWS ....................................................................................................................................................... 2 RESEARCH .......................................................................................................................................................... 3 CUSTOMER FEEDBACK AND OBJECTIVES .................................................................... 6 SURVEY ANALYSIS ............................................................................................................................................. 6 OBJECTIVES ........................................................................................................................................................ 8 ENGINEERING CHARACTERISTICS ....................................................................................................................... 9 CONCEPT GENERATION AND SELECTION ................................................................... 10 DOUBLE SUPPORT DESIGN ............................................................................................................................... 10 SINGLE SUPPORT DESIGN ................................................................................................................................. 11 SLOT PIVOT DESIGN ......................................................................................................................................... 12 ADJUSTABLE ANGLE DESIGN ........................................................................................................................... 13 DESIGN SELECTION .......................................................................................................................................... 15 GEOMETRY .......................................................................................................................... 16 SPRING ANGLE POSITION CALCULATIONS ........................................................................................................ 16 DESIGN DETAILS ................................................................................................................ 17 FABRICATION ................................................................................................................................................... 22 PART ASSEMBLY .............................................................................................................................................. 25 DRAWINGS ....................................................................................................................................................... 31 PART SURFACE TREATMENT ............................................................................................................................ 31 MATERIALS ...................................................................................................................................................... 33 TESTING ................................................................................................................................ 34 PROCEDURE ...................................................................................................................................................... 34 RESULTS ........................................................................................................................................................... 34 TECH EXPO ........................................................................................................................... 38 SCHEDULE AND BUDGET ................................................................................................. 39 WORKS CITED ..................................................................................................................... 40 APPENDIX A – INTERVIEWS & RESEARCH .................................................................. 41 APPENDIX B - SURVEY ...................................................................................................... 45 iii APPENDIX C - QFD .............................................................................................................. 46 APPENDIX D - OBJECTIVES .............................................................................................. 47 APPENDIX E - SCHEDULE ................................................................................................. 48 APPENDIX F - BUDGET ...................................................................................................... 49 APPENDIX G – DETAILED DRAWINGS........................................................................... 50 APPENDIX H – BILL OF MATERIALS .............................................................................. 78 LIST OF FIGURES Figure 1 – Milescraft Crown 45 ................................................................................................ 3 Figure 2 – Crown Pro ................................................................................................................ 3 Figure 3 – Cut-N-Crown ........................................................................................................... 4 Figure 4 – Bench Dog ............................................................................................................... 4 Figure 5 – 12” Miter Saw.......................................................................................................... 5 Figure 6 – Double Support Design ......................................................................................... 10 Figure 7 – Single Support Design ........................................................................................... 11 Figure 8 – Slot Pivot Design ................................................................................................... 12 Figure 9 – Adjustable Angle Design ....................................................................................... 13 Figure 10 – Adjustable Spring Angle ..................................................................................... 14 Figure 11 – Adjustable Spring Angle Components ................................................................ 16 Figure 12 – Adjustable Spring Angle Setting Slots ................................................................ 16 Figure 13 – Isometric View .................................................................................................... 17 Figure 14 – Front View – Saw Guide ..................................................................................... 18 Figure 15 – Top View - Angle Measurement ......................................................................... 18 Figure 16 – Left View ............................................................................................................. 19 Figure 17 – Rear Isometric View ............................................................................................ 20 Figure 18 – Front View ........................................................................................................... 20 Figure 19 – Quick Release View ...........................................................................................