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In this component you will learn some of the basic elements in designing a simple part
for an assemble. The piece you need to design is a plate that will be fastened to 4 posts on
an overhead apparatus. The plate needs to run along 2 rods that form a track. Therefore
the plate will need to contain 4 linear bearings that are lightly pressed in. The entire
assemble will weight approximately 100 pounds. You will need to design the plate,
specify which linear bearings and other parts you need to use, provide all the
manufacturing details, and a simple cost analysis. The figure below shows all the critical
dimensions. The following tables provide information related to design specifications.
Major dimensions for track and attachment.
The following table lists different fit classifications. The exact tolerences are not listed
and vary depending on the basic hole or shaft size. The basic size is the nominal size. To
specify a hole 1.5" in diameter with a sliding fit the hole would be sized as 1.5H7.
Remember uppercase letters designate hole sizes and lowercase letters designate
shaft sizes. So the shaft size for the above example would be sized as 1.5g6.
Description of Perferred Fits Using the Basic-Hole System
Type of Fit
Subtype
Description
Symbol
Clearance
Loose running
fit
H11/c11
H8/f7
Subtype
Description
Symbol
Sliding fit
Location
clearance fit
Transition
Locational
transition fit
H7/k6
Locational
transition fit
H7/n6
Locational
interference fit
Interference
H7/g6
Medium drive
fit
Force fit
H7/s6
The following table lists different standard thread sizes. Fasteners of different grades can
be easily found in these sizes. To specify a threaded hole use the size designation
followed by a dash then the threads/inch. An example would be 1/2-20. Also listed is the
drill size for threaded holes. All dimentions are in inches.
Specifications for Unified Screw Threads UNC and UNF.
Size Designation Nominal Major Diameter Threads/inch Drill size
0
0.06000
80
3/64
0.0730
64
53
0.0730
72
53
0.0860
56
51
0.0860
64
50
0.0990
48
5/64
0.0990
56
46
0.1120
40
44
0.1120
48
42
0.1250
40
39
0.1250
44
38
0.1380
32
36
0.1380
40
33
0.1640
32
29
0.1640
36
29
10
0.1900
24
25
10
0.1900
32
21
12
0.2160
24
17
12
0.2160
28
15
1/4
0.2500
20
1/4
0.2500
28
5/16
0.3125
18
5/16
0.3125
24
3/8
0.3750
16
5/16
3/8
0.3750
24
7/16
0.4375
14
7/16
0.4375
20
25/64
1/2
0.5000
13
27/64
1/2
0.5000
20
29/64
9/16
0.5625
12
31/64
9/16
0.5625
18
33/64
5/8
0.6250
11
17/32
5/8
0.6250
18
37/64
3/4
0.7500
10
21/32
3/4
0.7500
16
11/16
7/8
0.8750
49/64
7/8
0.8750
14
13/16
1.0000
7/8
1.0000
12
59/64
1 1/4
1.2500
1 7/64
1.2500
12
1 11/64
1 1/2
1.5000
1 11/32
1 1/2
1.5000
12
1 27/64
Below is a table listing the cost of labor and materials for this part. Assume it takes 2
minutes to remove 1 in3 of material on a CNC machine. When figuring the cost of
material make sure you add in the material that needs to be removed during machining.
For tapped and reamed holes you need to drill the hole first.
Cost of Common Operations and Materials.
Item
Cost
Aluminum
$0.75/pound
Steel(mild)
$0.30/pound
Chrome Moly.
$0.60/pound
Magnesium
$2.25/pound
$35.00/hr
$70.00/hr
Welds
$0.35/inch
$0.40/cut
Tubing bends
$0.75/bend
Non-metallic cutting
$0.20/inch
$0.25/inch
$0.35/hole
$0.35/hole
Tapped hole
$0.35/hole
$0.20/cut
$0.20/hole
$0.05/bend