Tuesday, December 10, 2013

Blog 5- 2.008 Improvements

David Bian:
I felt I learned the most during the YoYo project and labs due to their interactive nature. Not only was I able to learn how to use MasterCAM, CNC machines, and the injection molding machine, but I also got to experiment by changing parameters and dimensions to see how they affected the parts produced. For readings and lectures, I felt I was exposed to a lot of different manufacturing tools and techniques, but that I didn't really learn anything from them because hardly any time was spent on any one topic. I feel that if readings were assigned to give us a rough idea of the topic, and then the lecture went into more focused detail, I would have learned a lot more. I would have liked to learn about process planning, variation and process control, cost, and 3D printing, in more detail.

Joey Campion:
I think the lectures where we had physical examples to pass around were most helpful. I can still remember the types of chips, additive manufacturing examples, and injection molding samples (good and bad) that we passed around. I think a hands on approach for meche type minds is most effective. I would have liked the readings to be posted online. Sifting through emails to get to them is a pain, especially because the format is sometimes unclear. Plus, you could get ahead in reading if they were posted earlier. 

Sarah Fay:
There are two areas of 2.008 that I imagine will be most often addressed for improvement in these evaluations, the clarity of instructions and the grading scheme. I would like to touch on these as well. As our team worked through the deliverables, we came across a lot of questions about what we were supposed to complete and how we were supposed to do that. We ended up sending a lot of questions to various 2.008 staff members when we were stuck, which was probably unpleasant for them as well as nerve-racking for us. Many of our questions were about what our Mastercam toolpaths should be and what tools were available to us, as some of the examples and the paperweight assignment did not always directly translate to our molds. We also discovered some of the tasks we needed to do late in the game, like machining the yo-yo sleeves and initial shafts, making the poster, reaming different holes on the molds, and making 50 yo-yos despite sometimes having 10/100 parts be unusable do to process variation testing. We recovered from all of our questions and situations, but having these remote pieces of the project more clearly lined out on stellar could reduce stress and email traffic.

            My concerns with the grading scheme are small. I understand that about half of grade for the class should be based on the lab work and the other half on the class/lecture work. I would prefer to have two tests instead of one, but I might be in a minority. I just found it hard to study so much information for a test worth so much in the middle of the semester, particularly because it was moved up a week and a half in the semester. While I was not a fan of the reading quizzes, I do see the value in having something that motivates students to come to class and do the reading. I find reading challenging, and because I read so slowly, I did not always have the time to read before class. I also am a student who would come to class no matter what, so I feel like the learning of the “nerd” work should be done there. I also feel like for the amount of work dedicated to the yo-yo project, a relatively small portion of our grade depends on it. Again though, I do understand the reasoning behind the current grading scheme. Overall, this class was my favorite of the semester. It was an appropriate amount of work and a whole lot of fun. I felt I learned a lot about manufacturing processes that I didn’t know before and that will be useful in the future. Thank you for all your hard work.

Rohan Kulkarni:
2.008 was a great experience that taught me many useful concepts. I actually ended up using what I learned during an interview for my externship. I found the design for manufacturing sections particularly helpful. As far as improvements,  reading quizzes did little to incentivize the reading as we didn't know how we were doing. Better guidelines for deliverables would have been appreciated ( especially in solid works dimensioning). I found the parts about process and operations control particularly interesting but lacking depth. 

Kirsten Lim:

Overall, I really enjoyed the class. My favorite lectures were definitely the ones from Stroud about the case studies of manufacturing processes. I thought that many of the lectures still blew through the material content, so I think covering less topics in more depth would be useful. Particularly processes which many of us don't have much physical intuition about such as some of the welding processes, micromachining, and casting. Additionally, I think some of the lectures in micromachining had too much content, and should be split up into more lectures. Lastly, I think having more resources that we could use to produce some of the deliverables would be useful. Often times, our team had to find additional resources or email the TAs. However, this problem will likely be solve by the team blogs in the future. One last note about the grading, I think the project should be a larger portion of the grade. A lot of practical experience is gained through the project, and I think it should be a greater percentage of our grade.

Nathan Spielberg:

I found the process of conception to manufacturing of a product, in our case a yoyo, a very valuable and rewarding experience. Many other programs do not get a chance to do this but it was a great experience to see how we can design something with manufacturing in mind, learn how to design molds for our parts, run all of the machines to make our parts, and then assemble our finished products. I found the material very interesting but if anything not as in depth as I would of liked. The class seemed like it covered a ton of material but skimmed over some processes just for the reason of not having time, and at sometimes I feel like more of a focus may have been useful. I would like to see assembly lines or collective integration of manufacturing processes addressed more in depth in the future. We learn about lots of processes but I think an additional lecture talking about how they all can be integrated in forming an optimized assembly line for example would be helpful. I thought machine vision could have been covered less in depth, maybe even for just half a lecture. Overall I liked the course because of the broad introduction to a variety of important manufacturing concepts and this class has made me realize that I want to take manufacturing classes in the future. 

Steve Sullivan:
 I think that there should be less pset work early in the semeseter when so much else is going on with the manufacturing of the molds / paperweights. I would also preferred more psets in place of the lecture quizzes, which I felt were too difficult. I liked the 3d printing lectures and would have appreciated more lectures on up and coming technology. I found myself learning Mastercam more easily when running through it and getting help from Dave, but usually fell behind when he gave a lecture to the whole class. I also learned Mastercam well from the guides posted on the course locker. More of these guides would have been helpful.

Blog 5- Team Video


Friday, December 6, 2013

Thursday, December 5, 2013

Blog Deliverable 4- Bugs Bunny Part Dimension Findings

The run chart, histogram, and Shewhart x-bar chart for the Bugs Bunny part can be seen below:

Some findings from the process:
  • Most of the Bugs Bunny parts were within 2 thousandths of an inch
  • Almost all the parts that we molded fell within the USL and LSL for the Bugs Bunny part, as seen on the Histogram; Most of our parts fall within our specification limits
  • For the Shewhart Xbar charts, almost all of the parts fell within the UCL and LCL; Most of our parts fall within our control limits.
  • At the end of the process, it looks as though the person measuring the parts may have gotten tired and not accurately measured the parts.
  • The process capability for the Bugs Bunny process was calculated to be 0.7384, which is pretty high in comparison to the other process capabilities that we found.

A link to the portion of our paper deliverable for the Bugs Bunny part can be found here.

Blog Deliverable 4- Comparison of the Design vs Measured Dimensions

We compared the part dimensions we measured to the dimensions we should have expected based off our design. The dimensions that are reported here are the critical dimensions of the yoyo parts. Therefore, these dimensions are the ones that we plotted on a histogram in our paper deliverable.

PARTDIMENSION NAMEDESIGN VALUE(INCHES)MEASURED VALUE (INCHES)
Red RingOuter Diameter1.970 +0.000/-0.0051.9523
Inner Diameter1.711.7266
Orange RingOuter Diameter2.210 +0.000/-0.0052.2279
Inner Diameter1.950 +.005/-0.0001.97
Basketball ThermoformExtruded Top Diameter1.711.7432
Bugs BunnyDiameter2.192.1948
BodyInner Diameter of main pocket2.192.203
Assembled Yo-YoString Gap.0750.1027

The red ring did not meet the target for the dimensions. The red ring inner and outer diameters were about 10-20 thousandths larger than the design specifications. This was likely because we did not account for the shrinkage correctly when designing our molds. Additionally, the rings may not have been balanced well to ensure the same thickness at all points on the ring. This would result in a large variation during the measurement of the rings, so our average measured value may not actually be representative of those parts. However, this did not affect the overall assembly of the yo-yo because we overcompensated for shrinkage for all of our mold designs.

The orange ring did not meet the target for the dimensions. Again these dimensions were 10-20 thousandths larger than the design specifications. As mentioned in the red ring blurb, these differences could be due to the fact that we did not account for the shrinkage correctly. It's also possible that the rings had varying thicknesses, resulting in a large variation in the diameter measurements.

The basketball thermoform did meet the target for the thermoform parts considering the level of variation that can occur during the thermoforming process (+/- 5%). The upper limit would be 1.83", so the thermoform diameter was within the target we were looking for.

The Bugs Bunny thermoform did meet the target. The average measured value for all our parts was less than 5 thousandths larger than the designed dimension value. This is within the process tolerance we used for machining our molds.

The body dimensions did meet the target. Although it was larger than 5 thousandths of an inch, the value was very close compared to the variation of the other parts. Additionally, this part was only about 10 thousandth of an inch larger than the diameter we specified, which actually ended up ensuring for a good snap fit inside the body.

The measured string gap did not meet the design target that we calculated. It was about 0.025" larger, which is about another half of the string diameter. We were aiming for 1.5 times the string diameter, based off Dave's recommendation. We believe that this error can be attributed to the fact that the nut was not embedded in the yoyo body such that one face of the nut is parallel to the bottom body face. The dimensions of the shaft spaces and the nut shaft was measured to be the correct dimension; however the crooked face of the nut caused a misalignment of the shaft with one halve of the body resulting in a larger string gap in the yoyo. We could probably fix this in the future by making a tigher fit for the shaft that the nut fits in. However, again this did not affect the performance of our yoyo too much overall.


Blog Deliverable 4- Components and Assembled YYs


Before Thanksgiving break, we had finished molding all of our yo-yo components.



Photos of Our Individual Components
The Red Inner Ring

One good design feature for this ring is an inner radius that allows for the ring to sit flush up against the thermoformed basketball part. 

The Orange Outer Ring

The Basketball Thermoform

Bugs Bunny Disk

Metal Ring

White Disk



Red Yo-yo Body

All Our Assembled Yo-yos

Our Final Yoyo


Notable key features of our yoyos are the butterfly shape of the body design. This makes for a comfortable shape when holding the yoyo. It also aids the alignment of the string around the inner shaft. Additionally, this yoyo is quite heavy, which makes it a good performance yoyo. The yoyo sleeps very well, allowing for complicated tricks as demonstrated by our own Steve Sullivan.




The thermoformed cover fits flush against the cover the face of the yoyo body, making it easy to sit the yoyo on a flat table. Additionally, there's a nice basketball detail on the cover, that's subtle enough that one doesn't really notice it, but adds a nice finishing detail to the yoyo.

Our team had a lot of success making many of our molds that didn't need to be changed. A lot of our molds made the parts according to the correct dimensions that we had design the parts to be. Many of our parts have a really nice finish on them, thanks to the care we took in manufacturing the molds. We saved a lot of time by die cutting the white disk out instead of injection molding the part. The Bugs Bunny part was a great success because of the complexity of the design. We carefully designed the shape of the mold such that the tools would be able to trace out the curve. We were really happy that the mold was successful at making the Bugs Bunny disk. Steve also perfected the technique of thermoforming the parts without bubbles and dust contamination, which was a great success for our team because we had great thermoform parts.

A couple opportunities for improvement for our mold would be to make the size of the Bugs Bunny tail a little smaller to prevent the deformation of the part during ejection from the injection molding machines. We would also try to design the ring such that the ejector pin holes would align with the dimensions of the rings. This would reduce the amount of time that would be needed to cut off the additional runners. We would also like to add ball bearings to the design to allow for more fluid motion while sleeping. We could also reduce the weight of the yoyo, to allow for an easier return of the yoyo to the hand. This could be done by using a metal ring that had a larger inner diameter. Lastly, we would want to change our molds to make them smaller so that our parts would actually fit within the specifications we set.



Tuesday, December 3, 2013

ALL THE YOYOS! (Finally!)

Today we finished assembling all of our yo-yos.
 In order to get into assembly mode, we prepared by watching Space Jam.