12/12/2014

Corner Drill
Professor:RonGriswald

MET4820CapstoneFall2014
Authoredby:NickBoyer,Rick Girt,DaveHendricks,JeffKalina,
KeithPovec

MET4820CapstoneFall2014

The Problem
Each custom ATA (Airline Transit Authority Specification) case produced by LM
Engineering requires the use of multiple 4 hole tapered clamps (Figure 1.1 & 1.2).
Depending on the style case there are 4 to 16 clamps on a case with 4 holes per
clamp, this translates to 16 64 holes (#8 drill bit) that need to be hand drilled
throughthealuminumtongueandgroove.
Currently astandard drill is used however the operatorexperiences fatigue by the
endoftheshiftbypressingthedrillintothematerial.Additionallywhenacaseisset
on a table, the drill handle is placed at a 90 angle creating a nonergonomic
position.

Figure1.1FourHoleTaperedClampFigure1.2FourHoleTaperedClamp

Design Process
ThedesignprocessbeganinSeptemberfirstbyvisitingLMEngineering.
Observingtheircurrentprocessofmountingthecornerbracket.Testsweredone
tomeasurethecurrentspeed,forceandtimingtodrillthefourholesmanually,
asiscurrentlydone.
Inclassthegroupdiscussedthecriteriafortheproject.

MET4820CapstoneFall2014

Goals:

Designfixture/jigmachinetodrillclampsoncases(lid/tray)
Minimizeoperatorefforttoincreaseproductivityanddecreasefatigue,
Decreasecycletime
Increaseproductivity
Safety
Productrepeatability
Quality
Eliminatorerror
Repeatability
Keepcasesquare,willmakedividerinstalleasier(improvement)

Design parameters:

Lightweight25lbmax
Ergonomics
Rigidity
Sturdy(impactresistance)
Takelesstimethandoingitbyhand(20seconds)
Portability
Easeoftoolchange
Easeofmaintenance
Costeffective(LookatROI)
Existingpowersources(airand110v)
needtoaccommodatedifferentthicknesscasesandfortongueandgroove.
needtolocatethepartconsistently
Getquotedatafabshop.
Lookalistofwearablepartsandwhatwewouldkeepinstock.
Documentationforhowtouse

Constraints:
6wx6dx3.5h
Notmorethan100psiairpressure
110v15amp
Accommodatefordifferentsizedtongueandgroove
#8drillbit

Desirable Features:

Balancedsymmetricallysothatitiseasytolift(lookatcenterofgravity)
Rubber
Lightaspossibly
Rubberpadsforclamping
Eliminatesplintering

MET4820CapstoneFall2014

Operatingbytrigger(maybesomethingelsetoeliminatetriggerfinger)

How to improve from here

Someimprovementsthatmadefoundalongthewaywereasfollows:

Findingamotorthatcancarrytheloadfoundanairdiegrinder
MachiningpartsImprovedourmachiningskillstocorrectthebadparts
TimingissueswithgettingpartsWorkedonotheritemsuntilpartscamein
Some3DprintedpartsdidnotcorrectlyReconstructwithwood.Itwouldbe
betterifmoretimewasallowedfortheprintingsothatcorrectionscouldbe
madeifnecessary.
WeightalittleontheheavysideFindmaterialsthatcouldreducetheweight
howeverthisisdifficultasthemotoranddrillspindlewerethebulkofthe
weight.

Credits
ThankstoProfessorCostarellandYSUSTEMdepartmentforallowingustoworkonthis
RealWorldproject.
ThankstoProfessorGriswoldforTeachingthisclassandhelpingusalongtheway.
ThankstoLandMCasesforhavingtheneedfortheprojectandfundingtheproject.
ThankstoProfessorConnerfordoingthe3Dprintingforthisassignment
JohnDodsonforallowingtheteamtousethemachineshopforlatehours.