Computer Aided Manufacturing

-Project-

Student: Teacher:
Dragos Muntean Dorel Ananiei
641 DA

2017
1. Model 3D of the part – Short presentation , material
characteristics
 The 3D model in discussion would be the Oscar statue.

Short Presentation

The model for the statuette is said to be Mexican actor Emilio "El Indio" Fernández.
Sculptor George Stanley (who also did the Muse Fountain at the Hollywood Bowl)
sculpted Cedric Gibbons' design. The statuettes presented at the initial ceremonies
were gold-plated solid bronze. Within a few years the bronze was abandoned in
favor of britannia metal, a pewter-like alloy which is then plated in copper, nickel
silver, and finally, 24-karat gold. Due to a metal shortage during World War II, Oscars
were made of painted plaster for three years. Following the war, the Academy invited
recipients to redeem the plaster figures for gold-plated metal ones. The only addition
to the Oscar since it was created is a minor streamlining of the base. The original
Oscar mold was cast in 1928 at the C.W. Shumway & Sons Foundry in Batavia,
Illinois, which also contributed to casting the molds for the Vince Lombardi Trophy
and Emmy Award's statuettes. From 1983 to 2015, approximately 50 Oscars were
made each year in Chicago by Illinois manufacturer R.S. Owens & Company. It
takes between three and four weeks to manufacture 50 statuettes.
In 2016 the Academy returned to bronze as the core metal of the statuettes, handing
manufacturing duties to Rock Tavern, New York-based Polich Tallix Fine Art
Foundry. While based on a digital scan of an original 1929 Oscar, the new statuettes
will retain their modern-era dimensions and black pedestal. Cast in liquid bronze
from 3d printed ceramic molds and polished, they are then electroplated in 24-karat
gold by Brooklyn, New York-based Epner Technology. The time required to produce
50 such statuettes is roughly 3 months. R.S. Owens is expected to continue
producing other awards for the Academy and service existing Oscars.

Material Characteristics

The statuettes presented at the initial ceremonies were gold-plated solid bronze.
Within a few years the bronze was abandoned in favor of britannia metal, a pewter-
like alloy which is then plated in copper, nickel silver, and finally, 24-karat gold. Due
to a metal shortage during World War II, Oscars were made of painted plaster for
three years. Following the war, the Academy invited recipients to redeem the plaster
figures for gold-plated metal ones.

Britannia Metal

Britannia metal (also called britannium or Britannia ware) is a specific type of pewter
alloy, favoured for its silvery appearance and smooth surface. The composition is
approximately and typically 92% tin, 6% antimony, and 2% copper.
Britannia metal is typically spun rather than cast., and melts at 255 degrees Celsius.

Physical Properties Metric

Density 7.30 g/cc

Thermal Properties Metric

Melting Point 255 °C

Component Elements Properties Metric

Antimony, Sb 5%

Copper, Cu 2%

Tin, Sn 93 %

Nickel silver

Excellent corrosion resistance. Excellent cold workability. Fabricated by blanking,

drawing, etching, forming and bending, heading and upsetting, roll threading and
knurling, shearing, spinning, squeezing, stamping and swaging.

Applications: rivets, screws, slide fasteners, optical parts, etching stock, hollow ware,
nameplates, platers' bars.
Available as flat products and wire.

Physical Properties Metric

Density 8.69 g/cc

Mechanical Properties Metric

Tensile Strength, 338 - 896 MPa

Ultimate

Tensile Strength, Yield 124 - 524 MPa

Elongation at Break 50 %

Modulus of Elasticity 120 GPa

Poissons Ratio 0.30

Machinability 20 %

Shear Modulus 46.0 GPa

Thermal Properties Metric

CTE, linear 16.4 µm/m-°C
@Temperature 20.0
- 300 °C

Thermal Conductivity 45.0 W/m-K

@Temperature 20.0
°C

Melting Point <= 1020 °C

Liquidus 1020 °C

Component Elements Metric

Properties

Copper, Cu 63.5 - 68.5 %

Iron, Fe <= 0.25 %

Lead, Pb <= 0.10 %

Manganese, Mn <= 0.50 %

Nickel, Ni 9.0 - 11 %

Other, total <= 0.50 %

Zinc, Zn 25 %

24-karat gold

Gold is a noble metal and does not react with oxygen under ambient conditions.
Therefore gold does not tarnish, leading to its use in jewelry and coinage. The same
resistance to oxidation and other harsh chemical environments leads to its use in
industrial applications such as labware and electrical contacts. Although it does not
typically form oxides, it will form compounds with other metals and is rarely found in
its pure form. It is usually associated with silver and often with mercury. When the
silver content is a high, the metal is called electrum, a naturally occurring gold-silver
alloy. Gold is also found in tellurides and ore containing quartz where it is either
openly visible or enclosed in particles of sulfide minerals such as chalcopyrite,
pyrrhotite, pyrite, and arsenopyrite.
 Physical Properties Metric

Density 19.32 g/cc

Vapor Pressure 0.001013 bar

@Temperature 1770
°C

0.01013 bar
@Temperature 2036
°C

0.1013 bar
@Temperature 2383
°C

1.013 bar
@Temperature 2857
°C

Chemical Properties Metric

Atomic Mass 196.9666

Atomic Number 79

Thermal Neutron Cross 99 barns/atom

Section

X-ray Absorption Edge 0.15344 Å

0.86378 Å

0.90277 Å

1.04028 Å

Electrode Potential 1.68 V

Electronegativity 2.4

Ionic Radius 0.850 Å

1.37 Å

Electrochemical 2.45 g/A/h

Equivalent
Mechanical Properties Metric

Hardness, Vickers 25

Tensile Strength, 120 MPa

Ultimate

Elongation at Break 30 %

Modulus of Elasticity 77.2 GPa

Poissons Ratio 0.42

Shear Modulus 27.2 GPa

Electrical Properties Metric

Electrical Resistivity 0.00000220

ohm-cm

Magnetic Susceptibility -1.42e-7

Thermal Properties Metric

Heat of Fusion 66.2 J/g

Heat of Vaporization 1738 J/g

CTE, linear 14.4 µm/m-°C

@Temperature 20.0
- 100 °C

14.6 µm/m-°C
@Temperature 250
°C

15.2 µm/m-°C
@Temperature 500
°C

16.7 µm/m-°C
@Temperature 950
°C

Specific Heat Capacity 0.128 J/g-°C

@Temperature 25.0
°C

0.133 J/g-°C
@Temperature 227
°C
 0.142 J/g-°C
@Temperature 627
°C

0.159 J/g-°C
@Temperature 1227
°C

0.163 J/g-°C
@Temperature 1027
°C

0.166 J/g-°C
@Temperature 1127
°C

0.170 J/g-°C
@Temperature 1063
°C

Thermal Conductivity 301 W/m-K

Melting Point 1064.43 °C

Boiling Point 2856 °C

Optical Properties Metric

Emissivity (0-1) 0.040

@Temperature 100
°C

Reflection Coefficient, 0.27

Visible (0-1)

0.50

0.85

Component Elements Metric

Properties

Gold, Au 100 %
2 Technological Analyze form CAM point of view

2.1 Surface identification. Color code for surface roughness

The part has 1108 different faces. The full body of the Oscar statue has a roughness
of 1 micrometers, while the stand of the statue has lower roughness of 3
micrometers.
 - 1 micrometers roughness

- 3 micrometers roughness

2.2 Analyze of the geometrical feature

The geometrical shape represent a human body standing on a podium. Thus it can
be divided in 5 different components:

- Head
- Torso
- Arms
- Legs
- Stand

The statue is also symmetrical if cut vertically in half. All the shapes and components
are round the statue not having any straight edges or corners.
The level of details is higher in three different places:
- Where he hold his blazer
- The face
- The feet

Zebra shading analysis

 Direction analysis

2.3 Surface integrity ,Surface angle ,Wall thickness

The surface integrity of a workpiece or item changes the material's properties. The
consequences of changes to surface integrity are a mechanical engineering design
problem, but the preservation of those properties are a manufacturing consideration.

Wall thickness

3. Work piece definition, for each part position.

The initial stock piece is a bounding box.

The dimensions of the bounding box are the following:
X: 26.26 mm
Y: 68.10 mm
Z: 17.39 mm

Initial stock

4. Establish of part positioning

The statue is positioned on X, Y,on the UCS I defined. I also defined another UCS that was on
the same plane with the first one but in an opposite direction.
First of all I created three rectangles in order to divide the statue in three different parts.
Taking in account that there are two UCS, representing the front and the back of the piece,
there is a total of 6 different parts to be milled.
5. Establish the cutting tools
5.1 Geometrical characteristics of the tool, tool body.

For each different process there is a different cutter defined. In total I defined 3
cutters each one with it’s different characteristics.

Cutters and holders list

The geometrical characteristics of the tools

FLAT08-H tool characteristics

 BALL04-H tool characteristics

BALL02-H tool characteristics

5.2 Cutting parameters for each tool for each cutting phase (roughing, and
others) for the part material (formula, values)
 FLAT08-H tool characteristics

The FLAT08-H tool is used for the roughing procedures.

BALL04-H tool characteristics

The BALL04-H is used the re roughing procedures

 BALL02-H tool characteristics

The BALL02-H tool is used for finishing the part.

5.3 Holder definition

I defined two different holders:

 HOLDER1

HODER2

The FLAT08-H and the BALL04-H cutters use the Holder2, while the smallest cutter
used for finishing uses HOLDER1.

6. Machining phase for each part position (detail and justification of

parameters)

6.1 Rough/ rerough

The first procedure is a roughing one using the FLAT08-H tool.

First I selected the boundaries of the procedure as it can be seen in the photo below.

For this procedure I used Volume Milling, Volumill Rough

In the geometry, I selected the boundaries and after I chose the tool.
The second procedure is the rerough using the BAL04-H tool.
6.2 Finishing

The third and last procedure is the finishing using the BALL02-H tool.
For this procedure I changed the main selection to Surface Milling, Finish Mill All
Considering that all the parts have the same type of surfaces the procedures remain
the same for each one of them.

Simulations of the procedures

7. Postprocesing , NC file analysis
8. Reports