Explore high-paying careers in clean, high-tech Connecticut manufacturing.

Name of NGM Educator:

Haoyu Wang, Ph.D., Manufacturing and Construction Management

Central Connecticut State University

Name of Host Company:

Edac Technologies & Gros-Ite Precision Components

Grade Level:

college level

Student Work Types:

Task Abstract:

Design a series of tools to manufacture and inspect an aerospace part with complex shape and tight geometric tolerances. The tools include turning fixtures, milling fixtures, and constrain fixtures, etc. Generate a CAD model and detailed drawings with GD&T and conduct FEA analysis for each tool.

Task Objectives:

Students will learn how to:

• Read engineering drawings and process sheets with GD&T.
• Start the conceptual design of each tool based on the process.
• Search standardized locating, supporting, and clamping devices
• Design locating datum features and features to assemble other parts on the tool base with appropriate GD&T.
• Plan inspection after each process.
• Run FEA analysis to optimize the design.

Esssential Understandings/Questions:

• How does GD&T connect design, manufacturing, and inspection?
• What is the appropriate material for the tool base (density, cost, strength, machinability, etc.)?
• How do I know if the part is fully located on the tool? Are there over-constraints?
• What if there is no standardized supporting and clamping devices for my design?
• What should be the appropriate clamping force?
• What fluid power should be used?
• How will the tool be attached to the CNC machine? How it will be setup?

Task Description:

Students will

• Analyze the stock drawing, part drawing, and process sheets
• Locate datum features based on GD&T specifications
• Conceptual design and layout of each tool with Google Sketchup
• Calculate clamping forces
• Search vendors’ catalogues and on-line database for standardized locating, supporting, and clamping devices
• Modeling the part and the tool in a parametric CAD system, such as SolidWorks, Unigraphics, etc.
• Assemble the part, the designed tool, and all standardized devices
• Run FEA analysis on the assembly
• Optimize the design
• Detail the drawings of all designed parts of the tool with appropriate GD&T

Resources Required:

• Google Sketchup
• Parametric CAD system, such as SolidWorks, Unigraphics
• GD&T handbook
• Machinery's Handbook

Prior Learning Required:

• CAD
• Manufacturing processes

classroom

Individual or Group Work: 

group work

Educator Comments:

Working with manufacturing engineers to design inspection, machining, and lifting fixtures for aerospace parts with complex geometry and tight geometric tolerances is an invaluable experience. The project follows the industrial tool design process and includes the major components for a successful tool design. It will help students to know how GD&T links the design, manufacturing, and inspection processes. They will realize that locating, supporting, and clamping are all very important for tool design. The students will understand that materials of the part and tool will both affect the machining results. They will also understand the different requirements for designing inspection fixtures, machining fixtures, and welding fixtures. Students will learn how to use FEA analysis to optimize the design and reduce the cost.