Acrylic Clock Process Design

Adrian AllenSteven LonaNicholas Tracy

Ideas-Unlimited

PROCESS SUMMARY FOR BASE 

Set Up Number Operation Description

Machine Tool Description

10 Cut-off 0.75 in. x 2.0 in. cross sections of cast sheet acrylic stock to a length of 5.75 .015 in.

Cut-off Saw

20 Fabricate background housing on the planar surface opposite datum feature A

4 axis horizontal machining center

30 Polish all surfaces of the base Propane torch or buffer with finishing compounds

 

B

5.75

2.00

0.25

A

Set Up 20 SketchScale: 1:1Units: Inches

0.50

0.75

Set Up 20 Descriptionfor Clock BaseREQUIRED TOOLS

MACHINE TOOLS: Horizontal Machining Center, HS 1

FIXTURE: Chick Vise Attached to Tombstone

CUTTING TOOLS: 0.5 Inch Double Flute End Mill

MISCELLANEOUS TOOLS: Edge Finder, Dial Indicator

 

Operation Number

Operation Description

Tool Number Tool Description

Important Process Parameters

1 Slot mill opposite datum feature A in one pass 

1 0.5 inch end mill

d = .25 in.w = 4.25 in.V = 314 fpmF = 0.0042 in/th

 

Process 20 Description for Base

PROCESS SUMMARY FOR BACKGROUND 

Set Up Number Operation Description Machine Tool Description

10 Cut-off a 0.75 in. x 5.5 in. cross section of cast sheet acrylic stock to a length of 8 .015 in.

Cut-off Saw

20 Fabricate clock housing, PSU logo, and circular contours on the planar surface opposite datum feature A. End mill side and upper notch required for base union on datum feature C.

4 axis horizontal machining center

30 Polish all surfaces of the background

Propane torch or buffer with finishing compounds

 

5.1

25

0 in

.1

.87

50

in.

5.2500in.

Diameter = 3.75 in.Hole Diameter = 2.3125 in.Hole Depth = 0.5625 in.

7.0

0 in

.

Set up 20 Description for Clock BackgroundREQUIRED TOOLS

MACHINE TOOLS: Horizontal Machining Center, HS 1

FIXTURE: Chick Vise Attached to Tombstone

CUTTING TOOLS: 0.5 Inch Double Flute End Mill, 1/32 Inch Double Flute End Mill, and a 1/8 Inch Double Flute End Mill

MISCELLANEOUS TOOLS: Edge Finder, Dial Indicator

Process 20 Description Clock Background

Operation Number

Operation Description

Tool Number

Tool Description

Important Process Parameters

1 End mill circular contours on the planar surface opposite datum feature A.

1 0.5 inch end mill

d = 0.800in.V = 314 fpmF = 0.0042 in/th

2 End mill clock housing on the planar surface opposite datum feature A.

2 0.5 inch end mill

d = .5625 in.V = 314 fpmF = 0.0042 in/th

3 End Mill PSU logo on the planar surface opposite datum feature A.

3 0.5 inch, 1/8 inch, and 1/32 inch end mill

d = .02 in.V = 314 fpmF = 0.0042 in/th

4 End mill side and upper notch required for base union on datum feature C.

4 0.5 inch end mill

d = .25 in.w = 5.25 in.V = 314 fpmF = 0.0042 in/th

Assembly for Acrylic Clock

Join the base and the background using a acrylic adhesive as the final step

Product Cost

¾” Acrylic Sheet = $260 (96”x 48”) Clock Insert = $5.90/piece + Shipping Batteries = $.55/piece Adhesive = $25.00 License = $350 Labor Costs = $.90/clock Machining Costs = 7.50/clock Cost per Clock = $23.78

3 Scenarios

If we use a selling price of $25, Then our break even point is 62 clocks

If we use a selling price of $30, Then our break even point is 34 clocks

If we fully utilize one acrylic sheet (78 clocks) and use a selling price of $25, Our profit will be approximately $446