Benjamin Banneker - roboticsengineeringcte502.com€¦ · Web viewAll deliverables must be word processed with the required student ID information ... report it to your instructor

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Robotics EngineeringDoDEA - Career and Technical Education

Identifying Elements of Structural DesignExercise 1 – The History of Engineering

Objective: You will research the origin of mechanical engineering and create a detailed timeline of ten (10) significant accomplishments in mechanical engineering throughout history. You will also research one of many famous engineers and inventors and describe their contributions to mechanical engineering and the impact their work has had on society.

Deliverables: Copy and paste the required deliverables to another document for submission. All deliverables must be word processed with the required student ID information in the footer of the document. The header of the document should contain the title of the assignment. Both the question and answer must be included in the deliverable with the answers highlighted. All work must be complete and accurate to receive credit. 1. Graphic timeline of ten significant events in engineering history from the dawn of civilization up to present day.2. Detailed definitions for each of the terms found in the Nomenclature section.3. An original 200 to 300 word composition identifying one engineer/inventor and describing their contributions and impact

upon our civilization. See the list of recommended individuals in Information section of this document.

Information: Cultures and societies have flourished as the result of key inventions that have reduced our burden, increased productivity, or enriched our lives. History is built upon the people and their innovations and there have been many contributions recognized as milestones during the history of mechanical engineering.Milestones are placed upon timelines to mark significant events. Timelines help us realize the relationship between as well as the sequence of these milestones. Timelines lend a greater appreciation of these accomplishments over time. Milestones representing significant accomplishments in engineering are many. From the abacus, horse collar, and movable type to the invention of the clock, automobile, and International Space Station there are many contributions that engineers have made throughout time. Engineers such as:

Ada Byron Al-Jazari Archimedes Benjamin Banneker Bonnie Dunbar Dean Kamen Erna Schneider Hoover Leonardo da Vinci Charles Goodyear

Frederick McKinley Jones Garrett A. Morgan Hedy Lamarr Hertha Ayrton Jacques de Vaucanson Karl Benz Alexander Parkes Ole Kirk Christiansen Kenneth J. Dunkley

Lillian Gilbreth Lonnie G. Johnson Marie Curie Mark Dean Nikola Tesla Philip Emeagwali Robert Fulton Leo Baekeland

…and many others have all placed their milestone upon the timeline of innovation and service to this important career field.

Research Resources: The www changes all the time. If you find a dead link, please report it to your instructor but you should also use a search engine to find the information in another site.Web Site Descriptionhttp://www.history-timelines.org.uk/ Timelines of People, Places and Events. http://office.microsoft.com/en-us/templates/timeline-TC001016265.aspx Templates to produce timelines in MS Word.http://www.black-inventor.com/ Famous Black Inventorshttp://www.women-inventors.com/ Famous Women Inventorshttp://en.wikipedia.org/wiki/List_of_inventors List of inventors

Nomenclature: Research and develop a detailed (two to three sentences) definition for each of these terms. It’s important to realize that many words have multiple definitions. Some of which may have nothing to do with this course of study. Make sure your definitions fall within the context of this lesson.

Innovation Milestone Timeline Mechanical Engineering Invention Inventor

Conclusion: Understanding how far civilization has come through the actions of innovative minds is nothing short of remarkable. Regardless of nationality, race, gender or socioeconomic standing the power of innovation has brought about marvelous inventions that have contributed to the quality of life around the globe. Innovation is a skill within all of us that must be exercised to become practical. Through practice, you may become the inventor who finds a cure for cancer, designs an engine that doesn’t pollute or solve the world’s energy crisis.

Robotics Engineering – DoDEA Career and Technical EducationIdentifying Elements of Material and Structural Design – The History of EngineeringRevised 9 May 2023

http://en.wikipedia.org/wiki/List_of_inventors

http://www.women-inventors.com/

http://www.black-inventor.com/

http://office.microsoft.com/en-us/templates/timeline-TC001016265.aspx

http://www.history-timelines.org.uk/

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Identifying Elements of Materials and Structural Design

Exercise 2- MaterialsObjective: At the completion of this exercise, you will demonstrate your knowledge of the properties of various materials, how they are manufactured and then converted into the products we use.

Deliverables: Copy and paste the required deliverables to another document for submission. All deliverables must be word processed with the required student ID information in the footer of the document. The header of the document should contain the title of the assignment. Both the question and answer must be included in the deliverable with the answers highlighted. All work must be complete and accurate to receive credit. 1. Detailed definitions for each of the terms found in the Nomenclature section.2. Detailed answers to the queries listed in the Questions section.3. Completed table from the Materials Lab.

Information: Closely examine the display that you’re reading this document from. What is it made of? Undoubtedly, you’ll recognize a type of plastic, some metal and perhaps glass. You may also notice a bit of paint here and there. Although you cannot see inside the device, it’s pretty clear that this display was manufactured from a variety of materials using processes that compress, stretch, mold, separate, fasten and coat the component parts needed to construct it. Of course, this would be true for any modern product. Identifying these materials, their characteristics and applications, as well as how they’re processed into a useable forms allow us to understand how stuff is actually made.

Materials science is a field of study that applies the properties of matter to the areas of science and engineering. Scientists that design new materials and discover their applications investigate the relationships between the atomic structures within materials to better understand their properties and invent new materials.

Materials fall into the following broad categories: Biomaterials Ceramics Composite Materials Metals Polymers Semiconductors

Mechanical properties of materials include: Strength Elasticity Plasticity Hardness Toughness Fatigue

Normally, materials are first considered for their mechanical (or physical) properties. However, some materials have other traits that could benefit or even interfere with a product’s manufacture or usefulness. Electrical properties identify the degree of the material’s ability to conduct or oppose the flow of electricity. Optical properties rate the materials ability to transmit light. Some materials are transparent while others are translucent or opaque. Patterns in the material may also distort or diffuse light while pigment may be added to change the color. Chemical properties determine how materials react with other materials. This includes oxidation or rusting. Thermal properties determine how materials respond to forms of energy like heat and types of light. Researchers, scientists and engineers must be knowledgeable of all these characteristics if they are to successfully design new materials for the companies that make stuff.

Primary manufacturers process raw (natural) materials like wood, ore, minerals, natural gas and petroleum into industrial materials also called standard stock. The company that built the display that you’re studying purchased Robotics Engineering – DoDEA Career and Technical EducationIdentifying Elements of Material and Structural Design – The History of EngineeringRevised 9 May 2023

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the standard stock like sheet metal, circuit boards, plastic graduals and semiconductors from primary manufactures. The display’s manufacturer processed the standard stock into the shapes and forms needed to assemble and test the end product. The process of converting industrial stock into a finished product is called secondary manufacturing and there are six methods involved in this process: Casting and Molding Forming Separating

Conditioning Assembling Finishing

The materials and manufacturing industry is incredibly vast and provides many opportunities for careers in Science, Technology, Engineering and Math (STEM). For right now, let’s focus on just

Plastic is a generic name sometimes given to a category of materials more precisely known as polymers. The word “polymer” is derived from the Greek word polumerēs, which means consisting of many parts or segments. These segments are actually replicating molecules called monomers (mono means "one"). Polymerization is the process by which monomers react (combine) to form long chains that link to other polymer chains forming the material we know as plastic. It’s these linkages and the molecular structure of the polymer that determines the material’s properties. Polymers can be synthetic but are common in nature as well. While hair, fingernails, feathers, cellulose, proteins, rubber and starch are all naturally occurring polymers, synthetic polymers are typically made from chemicals refined from petroleum oil.

Partially synthetic polymers (like gum elastic) have been around since 1832 but it wasn’t until 1907 that fully synthetic polymers made the scene. Because plastic from synthetic polymers is easier and cheaper to manufacture and much lighter than metal, the polymer industry has become larger than the steel, aluminum and copper industries combined. In fact, polymers have a range of uses that substantially surpass that of any other category of material. Applications include adhesives, solvents, coatings, and foams. Packaging, textiles, industrial fibers, composites, electronic devices, biomedical devices, and optical devices have also been born from advances within this industry. Polymer research has also led to the spectacular innovations in the emerging field of high-tech ceramics. Considering the impact, polymers have upon modern life, it’s important to understand how plastic is produced and applied in the manufacturing process.


“I was trying to make something really hard, but then I thought I should make something really soft instead, that could be molded into different shapes. That was how I came up with the first plastic. I called it Bakelite.” Leo Baekeland - 1907

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Acrylonitrile (C3H3N) Butadiene (C4H6) Styrene (C8H8)Let’s examine just one type of synthetic polymer in greater detail. It’s the familiar material that LEGO™ uses to make all those plastic bricks, beams, plates and wheels. It’s a polymer commonly called ABS plastic which stands for the three monomers used to construct the material; Acrylonitrile, Butadiene and Styrene. ABS is a thermoplastic and its molecular formula is (C3H3N · C4H6 · C8H8)n That’s a lot of carbon, hydrogen and nitrogen atoms to figure out how to put together. The diagrams above may provide a clearer understanding of the molecular structure of the monomer components and how they might fit together to form the small polymer chain of ABS plastic also shown above.

ABS plastic is a common thermoplastic used to make lightweight and rigid products such as pipe, musical instruments, automotive body parts, helmets, and toys. Thermoplastic melts to liquid when heated and typically hardens to a strong, glasslike material when it’s cooled. Polymers are broken down by breaking the intermolecular bonds between them. This can be done by either heating the material or introducing other monomers (like solvents) to substitute existing reactions in the material. The result is a reshaping or disintegration of the polymer chains in the polymer material.

It’s all about how the monomer molecules are structured and how they react to produce polymer chains. Engineers can choose the characteristics of the materials they develop by tweaking the monomers used to build the material. The longer the polymer chains and increased intermolecular bonding between the chains… the stronger the material becomes. Also, the closer the chains are packed together the more rigid the material becomes. The polymerization of Acrylonitrile, Butadiene and Styrene creates a tough and safe material suitable not just for LEGO™ but for many consumer products we use today. Heated thermoplastic can be blow and vacuum formed, extruded, as well as injection, thermo-set, compression, insert, and transfer molded into a wide variety of objects that serve a multitude of applications.

Research Resources: The www changes all the time. If you find a dead link, please report it to your instructor but you should also use a search engine to find the information in another site.Web Site Descriptionhttp://science.howstuffworks.com/plastic.htm How Stuff Works - How Plastics Workhttp://entertainment.howstuffworks.com/lego.htm How LEGO™ Bricks Workhttp://www.youtube.com YouTube - How do they do it? LEGOhttp://www-materials.eng.cam.ac.uk/mpsite/default.html Univ. Cambridge - Materials Selection and Processinghttp://pslc.ws/ PSLC - Polymer Science Learning Centerhttp://www.pbs.org/wgbh/buildingbig/lab/index.html PBS - Information about force/load upon materials/shapes. See Instructor for Document ITEA – HITS Manufacturing Processeshttp://www.materialsworldmodules.org/modules/polymers.shtml Materials World Modules - Polymers Modulehttp://www.wolframalpha.com/ Wolfram Research - Computational Knowledge Enginehttp://www.sciencegeek.net/eChem/eChem.html eChem - 3D Molecule Model Builder


Secondary manufacturing Primary manufacturing Industrial Stock Casting/Molding Processes

Forming Processes Separating Processes Conditioning Processes Assembling Processes

Finishing Processes Monomer Polymerization Composite Materials

Questions:

1. Partially synthetic polymers (gum elastic) have been around since 1832, but there wasn’t a strong interest to move away from natural polymers until the 2nd World War. Why?

2. How would you categorize the mechanical properties of a pencil eraser?3. How does the choice of materials affect the usefulness of an object?4. Using terms from the Nomenclature section of this lesson… From nature to your book bag… Describe the

manufacturing process and life cycle of a pencil.5. From the video, “How do they do it? LEGO™”… In 1999, when the video was produced our planet had 6 billion

people on it. At that time there were 62 bricks for every man, woman and child on Earth. Assuming the number of bricks per person is the same… Calculate the approximate number of LEGO™ bricks that are on our planet today. How many towers could you build to the Moon with that number of bricks?


http://www.sciencegeek.net/eChem/eChem.html

http://www.wolframalpha.com/

http://www.materialsworldmodules.org/modules/polymers.shtml

http://www.iteaconnect.org/Publications/HITSKITS/PH31D.PDF

http://www.pbs.org/wgbh/buildingbig/lab/index.html

http://pslc.ws/

http://www-materials.eng.cam.ac.uk/mpsite/default.html

http://www.youtube.com/

http://entertainment.howstuffworks.com/lego.htm

http://science.howstuffworks.com/plastic.htm

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Procedure: Materials Lab In this activity, you’ll closely examine and then categorize various materials according to their mechanical properties. Each sample that you’ll evaluate is identified with a number. Complete the table below rating each material from 0 to 3 (3 being the highest) and identify the name and type for each material sample.

Required Materials and Equipment: Volt-Ohm-Milliammeter (Multimeter)

Get the following samples from your instructor:

Particleboard Wood Plywood Aluminum Plastic (PVC) Brass Fiberglass Steel Glass Ceramic Rubber Cotton Cardboard Plastic (Acrylic) Wax

SampleID # St

reng

th

Elas

ticity

Plas

ticity

Har

dnes

s

Toug

hnes

s

Fatig

ue

Con

duct

ivity

Opa

city

Material Name Material Type123456789

10111213 1 1 2 1 1 2 0 3 Cardboard Biomaterial1415

Conclusion: Our stuff is made from the raw materials harvested from our Earth’s natural resources. Primary manufacturers convert these natural supplies into industrial materials or standard stock. Standard stock like sheet metal, thread, wood, fibers, plastic granules, and other materials are purchased by secondary manufactures where it’s casted, molded, formed, separated, conditioned, assembled and finished into the products we purchase from stores. Knowing the characteristics of these materials, how they’re produced and processed helps engineers realize the limitations of materials as they design solutions to modern engineering problems.


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Exercise 2b – Making Plastic From MilkObjective: At the completion of this experiment, you’ll demonstrate the polymerization process using the monomer called casein that’s found in milk. You’ll create an organic plastic and mold it into a pair of dice.

Deliverables: Copy and paste the required deliverables to another document for submission. All deliverables must be word processed with the required student ID information in the footer of the document. The header of the document should contain the title of the assignment. Both the question and answer must be included in the deliverable with the answers highlighted. All work must be complete and accurate to receive credit.

Detailed definitions for each of the terms found in the Nomenclature section. Detailed answers to the queries listed in the Questions section. Completed casein dice project. eChem – 3D molecular model of:

a. Acrylonitrile (C3H3N) Molecule (Required)b. Casein (OH)C18H14N2O3C(=O)x Molecule (Optional) This is Extra Credit

because it’s a difficult task and will take a significant amount of time to build the molecular model. You’ll need to use carbon rings and you may have to experiment with different starting points for the model to fall into place.

Information: Casein plastics have been around since Leonardo da Vinci’s time. He used the material to gesso his canvas before painting a masterpiece. The first plastic buttons for clothing were made of casein, but the milk based plastic had not been considered for large scale manufacturing until 1897 in an attempt to manufacture white chalkboards. The raw materials (milk) used in the process were expensive compared to synthetic polymers. So when polymers from petroleum were invented, the production of casein plastic was mostly abandoned. It’s still used today to make paper glossy and glues stronger for bookbinding.

Casein Formula: (OH)C18H14N2O3C(=O)x

Structural Diagram 3D Structure (Ball and Stick)

Robotics Engineering – DoDEA Career and Technical EducationIdentifying Elements of Material and Structural Design – MaterialsRevised 9 May 2023

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Milk is colloid, or globs of the protein casein suspended in water. Doesn’t that sound yummy? In this state, the casein is essentially a monomer that can be processed to make plastic, but only if the molecules could get close enough to combine. This process is called polymerization. Polymers are formed by combining (associating) small molecules or monomers into long chains of molecules. Although most plastics are produced from petroleum products and natural gas, plastic from casein is just one of thousands organic polymers that exist in nature. Since most of cow milk is made up of the protein casein under the right conditions this protein can be processed into a natural form of plastic. Adding an acid like vinegar to milk causes the casein molecules to unfold freeing the monomers to replicate and produce long chains of the polymer. This process is called denaturing. Adding heat speeds up the reaction and causes a more complete separation of the casein molecular chains from the water.

Research Resources: The www changes all the time. If you find a dead link, please report it to your instructor but you should also use a search engine to find the information in another site.Web Site Descriptionhttp://www.youtube.com Making Plastic From Milk Easyhttp://www.sciencegeek.net/eChem/eChem.html eChem - 3D Molecule Model Builderhttp://www.wolframalpha.com/ Wolfram Research - Computational Knowledge Engine


Gesso Colloid Denaturing Casein Acid Associating

Questions: 1. What are the differences in casein content between 1%, 2% and whole milk?2. What other foods could be used as an acid to perform the denaturing process in this activity?3. What atoms are represented by the grey, white, red and blue balls in the 3D structure of the casein model?

Procedure: Pair of Dice Lost? Pair of Dice RegainedRequired Materials and Equipment: This experiment can be performed at home.

9 Ounces of 2% milk 4 Tablespoons of White Vinegar Small Mixing Bowl (Microwave Safe) 1” x 4” Cardboard Strip, 2 Each

Steps: Complete each of the following steps in this order:1. Study the video, “Making Plastic from Milk –Easy” listed in the Research Resources section.2. Pour the milk into a microwave save bowl and heat in the microwave on high for two (2) minutes.3. Pour the vinegar into the heated milk and stir until the casein finishes polymerization.4. Strain the casein and knead the material into a ball while mixing it into a smooth consistency.5. Set it aside on a paper towel to drain for about 30 minutes or more. The material should not be watery.6. Fold and tape the two cardboard strips into forms to make two separate cubes.7. Allow the cubes of casein to dry for a day or two.8. Remove the casein cubes from the forms and mark them as dice.

Conclusion: Knowing what polymers are and making them yourself are two distinct learning experiences. In this activity you applied your knowledge of polymerization and created plastic from the casein in milk. You also used a CAD program to design a polymer molecule. In doing so, you learned that monomers can be made to recombine in long molecular chains by changing the molecules’ shape through the process of denaturing. You also learned that thermal energy can speed up the reaction process. It may be interesting to note that we ingest polymers every day. Cheese makers use a similar process to produce some of world’s finest cheeses. There may not be much difference between those single slices of cheese you find in the grocery store and the plastic that keeps them separated.


http://www.wolframalpha.com/

http://www.sciencegeek.net/eChem/eChem.html

http://www.youtube.com/

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Worksheet 3 – Fasteners, Fastening and BondingObjective: After completing this exercise, you’ll demonstrate your knowledge and the proper use of fasteners and fastening. You’ll model various types of fastening systems using our robotics trainer. You’ll also become familiar with other methods the manufacturing industry uses to fasten materials together.


1. Detailed definitions for each of the terms found in the Nomenclature section.2. Detailed answers to the queries listed in the Questions section.

Information: Temporary and (various degrees of) permanent are the two basic types of fastening methods to consider during product assembly. The method best chosen is determined by many factors. You certainly wouldn’t want to weld or glue parts of an assembly together that may need to be taken apart later for maintenance or repair. The same is true for using nails when the design specifically calls for woodscrews and glue. It’s very important to follow the design specifications when selecting the fastener that’s appropriate for the work being done. The application and types of materials being fastened together often determine the kind of fasteners that are used.

There’s one final distinction regarding the types of fasteners and fastening methods in regards to permanence… No fastening method is actually permanent. Even welds and adhesives can be removed if there’s no regard for the components that are fastened by them. When materials are fastened together, their joining is designed to form continuity between the components. The goal is to make the components act as one. Therefore, it’s important to consider the various mechanical stresses that manufactured products must endure without deformation or failure. These forces are:

1. Compressive Stress results when an object is squeezed along the same axis. 2. Tensile Stress occurs when an object is being pulled along the same axis.3. Shear Stress can be related to the stress caused by a pair of scissors as they cut through an object. Shear

stress is a sliding force represented by one material moving in parallel along another object.4. Torsion Stress represents a twisting motion applied to an object.

It’s important to remember that the strength of joining materials together is only as strong as the fastener and material that’s being joined. Bolting cardboard together seems inappropriate when you consider the metal fastener is thousands of times stronger than the material surrounding it. Although the bolt itself may stronger, glue may be the better fastening method in this situation.

Threaded Fasteners – These are pretty common fasteners that are available in a variety of sizes and are made from array of materials including steel, stainless steel, brass or plastic depending on the application of the fastener. These are temporary fasteners that are manufactured in the Imperial and Metric measurement schemes. Screws have external threads and nuts have internal threads. The thread can be course or fine, but the actually thread sized is standardized based upon the screws diameter and the pitch of its threads. It’s important for you to know the names of these screws as well as their proper application. Caution: Most threaded fasteners use a right-hand thread meaning the fastener will tighten if it’s turned to the right (clockwise) and loosen if it’s turned to the left (counter clockwise). The old axiom is, “Righty Tighty… Lefty Loosey.” Over tightening any fastener can strip its treads. Some specification require fasteners be tightened to a specific torque. In addition, using the wrong tool or the wrong size tool can damage the head of the fastener making it difficult to install or remove.


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Socket Cap Screw

The Socket Cap Screw typically features a Hex or Torx head socket allowing for a greater transfer of power during tightening. This type of fastener is also tamper resistant.

Tapping Screw

The Tapping Screw is sometimes called a sheet metal screw and has sharp threads for cutting into the material it’s securing. The threads run completely up to the head of the screw.

Cap Screw (Hex)

The common Hex Cap Screw features a hexagonal head that can be gripped with either a box-end, open-end, adjustable, or socket wrench. Add the corresponding nut and it becomes the common bolt.

Wood Screw

Wood Screws can have pan, flat, round or oval heads with either a slotted or Phillips recess for driving the screw. The shaft of the screw is partially threaded so the fastener can draw the materials closer together when the screw is tightened. They’re not just for wood.

Machine Screw

Machine Screws are available in flat, pan, oval, round and button head varieties using either slotted or Phillips driving systems. They are the most common type of screw used in manufacturing coming in a vast array of sizes. Some even come complete with a built in lock washer.

Hex Standoff

Hex Standoffs are a nifty little invention that allows the designer setup a platform that’s stood-off from another surface. They’re frequently used with printed circuit boards (PCB) to keep the PCB solder joints on the bottom of the board safely away from a metal chassis or case. They can be made of insulating plastic (Nylon) or conductive metal.

Set Screws

Set Screws do not have a head. They’re used in situations where a head would interfere with the product’s function. The top of setscrew has a hexagonal socket that fits an Allen Wrench or Hex Key. The other end typically comes to a dimpled point and usually tightens so the point drives into a recess or keyway.

Hex Nut

The Hex Nut is the female counterpart to the screw or more accurately, the bolt. It has internal threads that match the diameter and threads per inch (TPI) of the mated screw. Nuts must be started at a right angle to the screw otherwise they’ll cross-thread and bind damaging both the nut and screw. Some hex nuts include built-in lock washers.

Is it called a bolt or is it a screw? It’s not a settled argument, but essentially a screw becomes a bolt when it’s used with a matching nut. Why? It’s due to U.S. trade and tariff laws. It’s actually cheaper to import and export bolts when they’re called screws. Lock Nut

Locknuts are used to secure the nut on to the bolt to keep it from coming loose. The cap of the nut is constricted requiring more torque to tighten and loosen the nut. Some locknuts are split while others use a plastic insert to secure the nut in place.

Drive Styles Head Styles Tip Styles

PhillipsSocket Cap

Round Cup

Slotted Pan Low Profile Cone

Hex Flat (Countersunk) Hex Flat

Torx Oval

Note: It’s always best to turn the nut while holding the screw instead of the other way around. The nut requires less torque to tighten than the screw giving more accurate torque readings.


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Unthreaded Fasteners are permanent fasteners that require special tools for installation. Actually, these types of fasteners can be removed but they often require cutting or drilling to do so. Unthreaded fasteners work by shortening and deforming one end of the fastener to cinch the materials together. Although they require effort to install and remove their degree of permanence and low cost may be most desirable for specific applications. Aircraft manufactures prefer rivets over threaded fasteners because they are permanent, low cost, light weight, easy to inspect and install.

Blind Rivet

Blind Rivet Nut

Blind Rivet Gun

Blind Rivets The term “Blind” means that one end of the rivet is not accessible during installation. To install a Blind Rivet, a hole is first drilled through the materials being fastened. The rivet is inserted into the hole and the Rivet Gun onto the shank of the blind rivet. As the handles of the rivet gun are squeezed, the shank of the blind rivet is drawn up through the rivet body as its mandrel head deforms the rivet body and draws the materials closer together. After a prescribed force is applied to the rivet gun, the shank of the blind rivet will break at the break notch and eject the remaining shank making the popping sound. The Rivet Nut can be installed just like a blind rivet, but this device leaves behind a threaded hole that accommodates a machine screw. It’s a very cool way to add a nut to a fastener point. To remove blind rivets, you simply drill off the head and punch the rivet out with a drift punch and hammer.

Domed Head Solid Rivet

Flat Head Solid Rivet

Flat (Countersunk) Solid Rivet

Solid Rivets work like any unthreaded fastener. It has a smooth shank and a manufactured head. They can be made from aluminum, brass, copper or steel and may be solid or hollow tipped. The manufactured head can be either domed, flat or countersunk, but regardless of the rivet type or style, solid rivets require a punch (setter) and anvil to install them.The anvil is used to form the tail end of the rivet. The anvil is rigidly held in place while the rivet is driven into a recess on the surface of the anvil. The shape of the recess determines the shape of rivet’s tail. The punch is used to drive the rivet through a hole in the joined materials and then into the recess on the anvil. The punch (Setter) is struck with a hammer to deform the tail of the rivet and in-turn bind the materials together.

Rivet Anvil Rivet Punch or Setting Tool Fabric Snap

Fabric Snaps are installed essentially the way rivets are set. There is a male and female part of the snap assembly and they both require different punches and anvils for installation. Otherwise, the mating parts of the snap will become deformed and will not be able to snap together.

Application Note: It’s not a good idea to mix materials when using fasteners. Regardless of the type of fastener, all materials expand and contract with variations in temperatures. If you use a brass nut with a steel bolt the fastener will tighten or loosen with changes in temperature. Copper and aluminum fasteners can also deteriorate due to electrolysis if they are used with another metal or alloy.

Miscellaneous Fasteners include hardware and other devices that are either used as or used with other fasteners. There are nearly as many types of fasteners than there are things to fasten and more are being invented every day. The purpose of this exercise is to expose you to the fasteners and fastening methods predominately used in robotics engineering and technology.

Washer

Standard Washers are most often used with screws or bolts. They are designed to protect the materials that are being fastened together by distributing the crushing force of the screw-head or nut. They also provide a slipping surface for spinning fasteners so they don’t damage the joined material as they twist and tighten.

Split Lock Washer

External Tooth Lock Washer

Internal Tooth Lock

Washer

Lock Washers are used to make it more difficult for the nut or screw to work its way loose through vibration or stress. The lock washer creates friction that works to keep the fastener stationary. There are many different types of lock washers and they’re made of the same materials that many nuts and screws are made of.


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Shim

The Shim is more than just a thin washer. Shims are added or taken away from an axle to change the distance between two surfaces while still allowing them to rotate on the axel. The height of a room door is a good example. The door that swung freely before the room was carpeted can swing freely again when shims are added to the door’s hinge to lift the door.

External Retaining Ring

Internal Retaining Ring

E-Ring

Retaining rings are used to secure wheels and bearings to shafts or in bores. Special tools called (oddly enough) retaining ring pliers are used to expand or compress retaining rings for self-lock installation into groves carved onto shafts or in bores or housings.There are three basic types of retaining rings. The External Retaining Ring is spread apart, slipped over a shaft or axle and then locked into a grove on the shaft. E-Rings are shaped like the letter “E” and are also external retaining rings. They’re pushed onto shafts or axles and self-lock into grooves carved onto the shaft. Internal Retaining Rings are compressed and inserted into a bore (hole) or housing and locked into place as it’s released to expand into a groove.

Thrust Washer

The Thrust Washer is more than just a thick washer. It’s designed as part of a drive system for a wheel or gear to keep it spinning without wobbling when it’s under angular stress. The thrust washer is sandwiched between a drive gear or hub and the wheel or gear it’s trying to turn. The trust washer typically turns with the drive system.

Cotter Pin

Cotter Pins are easily replaceable fasteners that are passed radially through holes in a wheel hub and axle to hold the wheel in place. The end of the pin is split and bent out to keep the pin from sliding back through the pin hole. The cotter pin also acts as a safety device called a shear pin. If the wheel jams and the drive continues to turn, the cotter pin with shear off and protect the drive from binding.

External / Internal Ring Pliers

E-Ring Installation Tool

Clevis Pin

The Clevis Pin is a smooth pin that’s passed through holes in joining materials or assemblies to make a temporary joint. The clip on the end of the pin keeps the clevis pin from falling out of the hole. Pull the clip and then the pin and the assembly can be quickly disconnected.

Push Nut

Push Nuts are designed for specific diameter shafts or axles. They’re made of hardened spring steel and are pressed onto the ends of axles to keep wheels on the shaft. The teeth of the push nut bite into the shaft to keep it in place. You can use a nut driver and hammer to tap the push nut into place.

Spring Pin

Spring Pins are a more permanent and low profile adaptation of the cotter pin. It’s installed the same way with matching holes in the wheel (or gear) hub and axle except the diameter of the pin is somewhat larger than the hole in the hub and axle. The spring pin is driven through the holes with a hammer and drift punch. It’s held in place by the friction of the expanding pin. The head and tail of the spring pin does not extend beyond the outer diameter of the wheel hub hence… low profile.

Adhesive Tape

Adhesive Tape comes in a wide variety of materials, adhesives and applications. Most adhesive tapes are named appropriate to their application. Masking tape is most often used to mask off areas where paint should not go. Electrical tape is used to isolate and insulate electrical connections. Duct tape is used to seal the air-duct joints used in heating and air-conditioning systems. Whether it’s packaging, carpet, anti-seizing, or sealing tape there is a tape for nearly every fastening requirement.


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Quick-Release Pin

The Quick-Release Pin works precisely like a clevis pin except there is no clip to keep it in place. Instead there is a spring loaded ball bearing at the end of the pin. When the pin is pushed into its hole, the ball bearing locks into a groove holding it temporarily in place. A good pull on the ring pulls the ball bearing out of the groove and the pin pulls easily out of the hole.

Cable Tie

The Cable Tie or Zip Tie was invented as a low-cost and disposable method to organize and bind cables. They’ve become a simple way to bind nearly anything together and come in many sizes and colors. Cable ties have a one-way locking mechanism that prevents the tie from loosening. They are simply cut-off to remove them. Never use a cable tie on a body. Since they can only tighten, they have caused serious injuries

Machine Key

Machine Keys are used to transfer torque between a shaft and a wheel hub or gear. The key locks the wheel hub to the shaft and is sometimes held in place with a set screw. Machine keys are inserted into a lateral notch in the hub and shaft called a key-way. If the machine key is not installed or falls out, the wheel would simple free-wheel. They come in standard sizes and lengths and are made of hardened steel.

Hook and Loop

Hook and Loop fasteners are sometimes known by the trademark name, Velcro. Lots of companies now manufacture Hook and Loop fasteners providing the material in various sizes, shapes, colors and strengths. It comes in self-adhesive and sewn applications. One side of the fastener is covered with rows and columns of tiny, stiff, plastic hooks. The other side is covered with fabric loops. The sides interlock when pressed together but can be pulled apart with some effort.

Adhesives – Glues have been around for thousands of years. Initially, adhesives were sticky biomaterials like beeswax, tree sap, and tar, as well as animal hides and bones. As technology and materials manufacturing evolved, other adhesives were created to meet the emerging needs of industry. From beeswax to superglue, adhesives are fastening methods that are vitally important to the manufacturing process.

Glues have two properties; How well it sticks to materials (adhesion) and how well it sticks to itself (cohesion). When a glue bond breaks at the surface of the material, it’s due to a failure in adhesion. When the bond breaks in the glue itself, it’s due to a failure in cohesion. There are two prominent explanations describing how glue works. The Van der Waals Forces describes how molecules in the adhesive align observing polarity to create a strong molecular bond while Mechanical Bonding describes how glue fills even the tiniest nooks and crannies in the material to get a better grip on the materials surface.

It’s important to note that some adhesives work better with specific materials. Matching the type of adhesive to a particular material is an important consideration. However, the key to a successful adhesion and cohesion is the same regardless of type of adhesive being used. Remove any interference to the Van der Waals Forces or Mechanical Bonding affect. Note: The following images do not represent an endorsement for a specific product or brand name.

Material surfaces need to be clean before adhesive is applied. Adhesives need to be used under the conditions prescribed by the manufacturer (Material, Temperature and Humidity). The glue joint can’t be moved until the adhesive has fully cured.

Thread-lockThread-lock is designed for the locking and sealing of threaded fasteners which require normal disassembly with standard hand tools. The product cures with or without air. It prevents loosening from shock and vibration. Thread-lock comes in a variety of colors indicating its strength and durability. Blue is particularly suited for applications where disassembly is required for servicing. Red thread-lock requires heat to disassemble the fasteners. Don’t have thread-lock, nail polish will work in a pinch.

Safety

Precautions: Keep out of reach of children.


Feature BenefitProtects threads Prevents rusting of threadsMedium strength Can be removed with hand toolsLocks threads Prevents loosening of metal fasteners caused by vibrations

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Preparation: Protect work area. Parts to be sealed must be clean and dry. Shake the product thoroughly before use. Note: To prevent the product from clogging in the nozzle, avoid touching the bottle tip to the metal surface.

Application: For Thru Holes - Apply several drops of the product onto the bolt at the nut engagement area. For Blind Holes - Apply several drops of the product down the internal threads to the bottom of the hole. For Sealing Applications - Apply a 360° bead of product to the leading threads of the male fitting, leaving the first thread free. Force the material into the threads to thoroughly fill the voids. For bigger threads and voids, adjust product amount accordingly and apply a 360° bead of product on the female threads also. Assemble parts and tighten as required. Sets in approximately 10 minutes and fully cures in 24 hours.For disassembly, shear with standard hand tools and remove with methylene chloride. In rare instances where hand tools do not work because of excessive engagement length, apply localized heat to nut or bolt to approximately 482°F (250°C). Disassemble while hot.

Cleanup: Clean adhesive residue immediately with a damp cloth. Cured product can be removed with a combination of soaking in methylene chloride and mechanical abrasion such as a wire brush.

Contact CementContact Cement is a versatile high-performance adhesive sealant formulated for all-purpose projects and repairs. This semi-flexible crystal-clear adhesive is designed to address the daily needs of the homeowner, both indoor and outdoor.

Safety Precautions:

Wear gloves. Wash hands after use. For interior applications, use in a well ventilated area.Preparation: Protect work area. Surfaces to be sealed or bonded must be clean and free from grease. For improved

adhesion, roughen very smooth surfaces. Pre-fit all materials before applying product. Application: As an adhesive - Apply adhesive to both surfaces to be bonded. Wait for 5 minutes until adhesive is

tacky and then press surfaces together. Clamp if necessary. Sets in approximately 10 minutes and dries in 24 hours. Dry time is dependent upon temperature, humidity and amount of adhesive used. As a sealant - Apply a layer 1/4' (6 mm) thick bead over the area to be sealed. Tool if desired. Let dry for 24 hours. If necessary apply a second coat.

Cleanup: Clean tools and uncured product residue immediately with mineral spirits or acetone. Cured product may be carefully cut away with a sharp-edged tool.

Spray AdhesiveSpray Adhesive is an aerosol version of Contact Cement. It dries clear and has strong adhesive and cohesive characteristics. It dries quickly and is ideal for a wide range of projects including photo and art mounting. Spray Adhesive will work on a variety of porous and nonporous substrates. It is recommended for bonding paper, wood, metal, acrylic, foam, fabric, polyethylene and polypropylene, PVC, cardboard, leather, felt, carpet, corkboard, glass, foil rubber and most plastics. Certain plastics and elastomeric substrates can exhibit bond failure due to plasticizer migration. High humidity and high temperature can also promote bond failure.

Feature BenefitRepositionable or permanent bonding Variety of applicationsDries clear and will not yellow with age Invisible bondCan apply multiple coats Increases bond strengthDoes not bubble No reworkingAcid Free Will not damage photographs

Safety Precautions: Apply in a well-ventilated area, wash hands after use.Preparation: Apply adhesive between 65°F (18°C) and 95°F (35°C). Shake can well before using. Surfaces must be

clean, dry and free of foreign materials. Protect finished surfaces. Pre-fit all materials. Testing of substrates for compatibility is recommended. Turn spray tip so that the black dot is aligned with the nozzle.

Application: Hold can in a vertical position. Point valve towards surface and spray from a distance of 8' to 10' (20 to 25 cm). Keep the can moving to create an even coat and avoid build-up on the surface. Start and stop


Feature BenefitAll-purpose adhesive Great for everyday projects and repairsDries crystal clear Eliminates obvious bond lines achieving invisible repairsThick gel-like consistency Will not run or drip; Reduces clean-upWaterproof Forms a tight, waterproof, weatherproof bond for a superior seal;

Great for plumbing repairsDries to a semi-flexible bond Ideal for bonding flexible materials such as fabric or leatherGap filling Will fill and seal uneven surfaces

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the spray just off the work to prevent runs and sags. For repositionable/temporary bonds: Apply a very light even coat to one surface. After 15 seconds, join with light pressure only.For a permanent bond: Apply a medium coat to one surface. Allow to dry to tack and join.For stronger permanent bonds: Apply a medium coat to both surfaces. Allow to dry to tack (1 to 10 minutes). Porous surfaces will require more than one coat.

Cleanup: After use, invert spray can and spray for approximately 2 seconds (or until spray is free of adhesive) to clear valve and spray tip. Clean spray tip with turpentine or mineral spirits. Note: When using solvents for cleanup, use proper precautionary measure.

Rubber CementRubber cement is a latex polymer combined with a solvent like acetone. It’s well suited for applications that prefer relatively weak adhesion and cohesion. It’s predominantly used in graphic arts for positioning and repositioning paper flatwork. Rubber cement is inexpensive and easy to use. Excess glue or drips can be easily peeled away leaving no sign of the adhesive.

Safety Precautions: Apply in a well-ventilated area. Do not use near an open flame. Some rubber cement uses benzene, a cancer causing agent.

Preparation: Protect work area. Surfaces to be bonded must be clean and free from grease. For improved adhesion, roughen very smooth surfaces. Pre-fit all materials before applying product. Use the applicator brush to apply the adhesive.

Application: Apply adhesive to one surface for a repositionable bond and on both surfaces for a more permanent bond. Wait for 1 or 2 minutes until adhesive is tacky and then press surfaces together. Sets in approximately 10 minutes and dries in 2 hours. Dry time is dependent upon temperature, humidity and amount of adhesive used.

Cleanup: Excess glue and drips can be peeled away.

Glue StickThe glue stick is a solid Polyvidone adhesive that is delivered in a twist up or push-up applicator. The Polyvidone adhesive has high adhesion and moderate cohesion affect well suited for paper and paper products. The glue can be applied smoothly and evenly, and allows sufficient time to reposition the object. The applicator helps keep fingers clean. An airtight cap+tube-system, the glue stick keeps fresh and can be used for several years.

Feature BenefitTwist-up or push-up applicator Clean and hands-off applicationRepositionable or permanent bonding Variety of applicationsNon-toxic adhesive Well suited for school and office use

Safety Precautions: Wash skin with soap and water.Preparation: Surfaces to be bonded must be clean and free from grease.Application: Apply adhesive to one surface for a repositionable bond and on both surfaces for a more permanent

bond. The adhesive sets in approximately 10 minutes and dries in 2 hours. Dry time is dependent upon temperature, humidity and amount of adhesive used.

Cleanup: Excess adhesive on work surfaces or clothing can be cleaned up with soap and water.

Super Glue (Cyanoacrylates)Cyanoacrylates can bond just about any plastic, metal and wood project. Because it bonds in seconds it is well suited for impatient craftsmen that would normally have to use clamps. Super Glue is not recommended for use on cloth, Styrofoam, vinyl or CLEAR PLASTIC parts. Super Glue can ignite cotton, dissolve Styrofoam, and fog clear plastic. Super Glue bonds instantly to skin. Super Glue has a similar molecular structure of the same adhesive that mussels use to cling to rocks in the ocean. Scientists synthesized the natural protein and learned how to mass produce it for commercial use. Its first uses were in medicine as a skin and organ adhesive for field surgery during the Vietnam conflict. It had great tensile strength but can be easily twisted or sheared to break the bond. Baking soda can be added to it to make it a filler.

Feature BenefitRobotics Engineering – DoDEA Career and Technical EducationIdentifying Elements of Material and Structural Design – MaterialsRevised 9 May 2023

Feature BenefitApplication Brush In Cap No additional tools required for useRepositionable or permanent bonding Variety of applicationsCan apply multiple coats Increases bond strength

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Gel formulation No mess, no drip formula; Ideal for vertical applicationsDries transparent Invisible repairsSets in seconds No clamping required

Safety Precautions: Wear gloves (non cotton). Protect work area.Preparation Surfaces to be bonded must be close fitting, clean, dry and free from oil, wax and paint. For best

results, lightly roughen smooth surfaces. Pre-fit parts to be joined as you won’t have much time to set them.

Application: Puncture the nozzle and squeeze the bottle to dispense the adhesive. Only one drop of adhesive per square inch of surface is required. Excess glue may take much longer to dry. Press surfaces together immediately and hold for 60 seconds. Do not attempt to reposition the parts. Immediately after use, clean tip with tissue and replace cap. For increased strength, leave the parts undisturbed for at least 10 minutes. Full cure in 24 hours. Note: Cure time is dependent upon temperature, humidity, porosity of surfaces and amount of adhesive applied.

Cleanup: Cured adhesive may be cut away with caution using a sharp blade, removed with mineral spirits or with boiling water.

Epoxy and Epoxy Putty (5 Minute)Epoxy and Epoxy Putty is a two-part adhesive consisting of an epoxy resin and a hardener. When mixed in equal amounts resin and hardener react to produce a tough, rigid, high strength bond, which starts to set in 5 minutes and reaches handling strength in 1 hour. The resin and harder must be uniformly mixed for proper bonding. It’s a great adhesive for a wide range of materials or for a versatile filler (Putty), gap bonding, surface repairs and laminating. Epoxy does not shrink during hardening and is resistant to water and most common solvents. It can be tinted

with earth pigments, cement or sand for color matching and can be sanded and drilled. Feature Benefit

Can be drilled Will not crack when drilledCan be tinted Matches surrounding materialsWater resistant Can be used outdoorsDoes not shrink One-time applicationSets in 5 minutes Quick completion of project

Safety Precautions: Mix and use in a well-ventilated area using gloves.Preparation: Protect work area. Surfaces must be clean, dry and free from oil, wax and paint. For better adhesion,

roughen smooth surfaces prior to cleaning. Pre-fit parts to be joined. Application: Dispense equal amounts of hardener and resin directly onto surface to be filled or bonded. Putty can

be cut into equal amounts and kneaded together to mix. Place objects together within 4 minutes of adhesive application. Bond sets in 5 to 7 minutes at 68°F (20°C) to 77°F (25°C). For best results in butt joints, apply adhesive as a reinforcing fillet or splint over the joint for additional support. Remove any excess adhesive immediately with mineral spirits. Usable strength is obtained within 1 hour. Warmer temperatures will shorten the set time and cooler temperatures will lengthen it.

Cleanup: Clean excess glue immediately with mineral spirits or acetone. Cured adhesive may be cut away with caution using a sharp blade. Prolonged immersion in paint stripper will soften the cured adhesive to aid removal.

Acrylic Solvent CementUse on Polystyrene and ABS plastic. Bonds plastic by dissolving and cementing. Precision plastic needle, dropper, and brush applicator makes easy work of gluing even small intricate detailed parts. Application can be drawn into seams through capillary action to make and clean and neat bond.

Safety Precautions: Keep out of the reach of children. Keep away from heat, spark, open flame and other sources of ignition. Contact with hot surfaces may produce toxic effects. Keep container closed when not in use. Store in the shade below 80ºF. Use only in adequate ventilation. Avoid breathing of vapors.


Feature BenefitClean and seamless adhesive method Smoother and more complete bondingLow viscosity Small amounts provide for strong bondsNearly instant and strong bond Quick and clean assembly

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Preparation: Preassemble parts without cement to insure proper fit. Trim or file where necessary so parts meet without a gap. When cementing painted or plated parts, scrape away paint or plating from surfaces to be joined.

Application: Apply cement sparingly with a syringe, dropper or brush to one surface and press firmly together. Avoid cement of finger tips, as glue smudged on areas not to be joined cannot be removed. It will also discolor or “cloud up” clear parts. Do not use on clear parts.

Cleanup: Wipe solvent from work surface. Allow extra adhesive on bonded materials to cure. Do not wipe excess.

Model CementCement for plastic models is specially formulated polystyrene cement for joining all polystyrene and ABS plastics. Cement for wood models is better choice for wood models. Cement for models can be used in the construction of model kits and may also repair many common household products.

Safety Precautions: Keep out of the reach of children. Keep away from heat, spark, open flame and other sources of ignition. Contact with hot surfaces may produce toxic effects. Keep container closed when not in use. Store in the shade below 80ºF. Use only in adequate ventilation. Avoid breathing of vapors.

Preparation: Preassemble parts without cement to insure proper fit. Trim or file where necessary to insure a gap free interface.

Application: Use solvent cements sparingly. Too much glue will dissolve plastic. When cementing painted or plated parts, scrape away paint or plating from surfaces to be joined. Apply cement sparingly to one surface and press firmly together. Avoid cement of finger tips, as glue smudged on areas not to be joined cannot be removed. It will also discolor or “cloud up” clear parts. Do not use on clear parts.

Cleanup: Cement can be cleaned from work surfaces with acetone or mineral spirits.

White / Wood GlueToday’s white glue is primarily made from polyvinyl acetate latex (PVA), water and some “Elmer”. Wood glues are made using a slightly altered formula called Aliphatic Resin. When the water in the adhesive evaporates, the bond is made. White glue is sometimes called “Craft Glue” and is well suited for crafts (Duh) while wood glue is primarily used in carpentry. These adhesives are recommended for use on porous materials -- wood, cardboard, cloth, porous pottery, and wood-to-wood bonds. It is not water resistant. Because of wrinkling, it is not suitable for bonding light weight paper. Do not allow these adhesives to freeze. Store them in a tightly closed container in a cool and dry place.

Precautions: Some types of wood glue contain formaldehyde. Don’t use them if possible. Work in a well ventilated area and avoid getting the glue on your skin. Wash away with soap and water.

Preparation: Use above 40°F (4°C). Surfaces must be clean, dry and free of frost, grease, dust and other contaminants.

Application: Apply the adhesive evenly to both surfaces to make a more secure bond. Clamping is required for 30 minutes to 1 hour to set the glue; curing time is 18 to 24 hours. PVA glue dries clear.

Cleanup: Cleanup with soap and water.

Construction AdhesivePolyurethane construction adhesive is a one component, polyurethane based, moisture-curing

adhesive. It can be used for interior or exterior projects and is also waterproof, paintable and cures in cold or warm temperatures. It is a strong adhesive and is


Feature BenefitStrong adhesion and cohesion Strong bondingPolystyrene solvent Welds plastics together

Feature BenefitNon-Toxic Safe for children to useEasy Cleanup Use water for cleanupGood construction adhesive Resists solvents, heat and moistureGood adhesion Works well on porous materials

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ideal for wide range of construction projects including sub floor installations.

Safety Precautions: Wear gloves. Cured adhesive on bare skin will not come off immediately with washing and will cause skin to darken. Cured adhesive and discoloration will come off in about 3 days.

Preparation: Use above 40°F (4°C). Surfaces must be clean, dry and free of frost, grease, dust and other contaminants. Pre-fit all materials and protect finished surfaces. If using cartridge format, cut nozzle at a 45° angle to desired bead size and puncture inner seal. Be very careful not to allow construction adhesive to cure on a finished (painted) surface.

Application: Apply adhesive to one surface of the material being bonded. Press the surfaces firmly together. Materials may be repositioned within 45 minutes after applying the adhesive. If bonding two non-porous surfaces (such as foam, metal and fiberglass), add water in the form of a very light or atomized spray from a plant mister bottle to the extruded adhesive. The repositioning time will then be reduced to less than 30 minutes. Use mechanical support or clamps for 24 hours while the adhesive cures.

Cleanup: Clean tools and uncured adhesive residue immediately with mineral spirits in a well-ventilated area. Remove cured adhesive by carefully scraping with a sharp-edged tool.

SiliconeSilicone is a multipurpose adhesive and sealant which creates a waterproof, protective seal that is ideal for metal, glass, rubber, tile and porcelain. It is designed to be used indoors and outdoors to repair everything from electrical connections to seams on boots to stop leaks in wet weather. Silicone can be used to bond or repair saltwater or freshwater aquariums.

Feature BenefitExtreme temperature resistance All-season useWaterproof Indoor and outdoor useNo cracking, peeling or shrinking One-time applicationGap filling Excellent for imperfect surfacesFlexible bonds Impact resistant and flexes with materials

Safety Precautions: Wear gloves. Respiratory, skin and eye irritation possible.Preparation: Use between -35°F (-37°C) and 140°F (60°C). Protect work area. Surfaces must be clean, dry and

free of old adhesive, grease, dust and other contaminants. Note: Paint will not adhere to silicone. If desired, paint items prior to gluing. Remove cap. Puncture inner seal with other side of cap. Attach nozzle and cut to desired bead size.

Application: As an adhesive: Apply to one of the surfaces to be bonded. When bonding rubber or plastic surfaces, lightly roughen surface for best results. Press materials together. If possible, clamp parts together for full cure time of 24 hours. As a sealant: Apply with a steady pressure, forcing sealant into the joint. Tool within 5 minutes. Do not use in joints deeper than 12 mm (1/2") without the use of a backer rod. Use in joints between 1/4" and 3/4" wide. For aquariums: Apply a 1/4" bead to the edge of glass, covering the thickness of the glass edge. Set glass on base and repeat procedure for all sides. All joints must be glass to sealant to glass with no entrapped air bubbles. Apply additional sealant to inside joints. Do not use in aquariums larger than 30 gallons (114 L) and/or aquariums containing water greater than 18" (46 cm) in height.

Cleanup: Clean tools and adhesive residue immediately with mineral spirits. Cured sealant may be carefully cut away with a sharp-edged tool. There is no solvent for silicone.


Feature BenefitWaterproof Great for interior or exterior applicationsLow odor No strong solvent odor; Great for interior useStrong and versatile Permanently bonds together almost any substrateHigh strength Stronger than many substrates it joins together.Broad Service Temperature Suitable for use in hot and cold environments

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Hot-Melt Adhesive (Hot Glue)Hot glue is a thermoplastic adhesive typically provided in solid cylinders which are commonly referred to as glue sticks. Glue sticks come a few diameters and lengths designed to fit a specific type of hot glue gun or pistol. The glue gun houses a heating element that heats the glue stick to a liquid while a trigger mechanically advances the glue stick through the heater and out the nozzle of the gun. The temperature required to prepare the glue depends on the makeup of the polymers in the glue stick. Adhesion also varies depending on the materials being bonded. Cohesion can be strong, but some brands and types of hot-melt adhesives are brittle in certain applications. Glue guns and adhesive come in low-temperature and high-temperature varieties. Low temperature glue guns operate at 250°F (121°C) while high-temperature versions operate at 380°F (193°C).

Safety Precautions: The temperature of a hot glue gun and the glue out of the nozzle is hot enough to cause serious burns. Use leather gloves to protect hands and never touch the glue unless it has cooled. Do not leave the hot glue gun plugged in for a prolonged period of time. Don’t use any electrical device with a damaged power cord. Keep glue guns out of reach of children.

Preparation: Protect work area. Surfaces must be clean, dry and free of grease, dust and other contaminants.Application: Insert a glue stick and plugin the hot glue gun allowing it to heat-up for about five minutes. Place the

glue gun on a non-combustible surface while plugged in. Place something under the nozzle to catch the oozing adhesive. Place the nozzle on the surface being bonded and squeeze the trigger for the desired amount of glue. Quickly press the materials together to make the bond.

Cleanup: Hot glue can be removed with scraping. Heat from a hot air gun can make the job easier.

Research Resources: The www changes all the time. If you find a dead link, please report it to your instructor but you should also use a search engine to find the information in another site.Institution Web Site DescriptionIndustrial Press http://buku-ku.com/machinerys-handbook-27th-edition/ Machinery’s Handbook – Hardware Specifications Gesipa USA Fasteners http://www.gesipausa.com/blind_rivets_basics.html Online lesson on how blind rivets work.YouTube http://www.youtube.com/watch?

feature=player_detailpage&v=9aoXmzdSf_I Video - How Do Blind Rivets Work?Valley Fastener Group http://www.valleyfastener.com/solid-rivets.html Online lesson on how solid rivets work.Mlevel3.com http://www.youtube.com/watch?

v=1hB3rIECtxM&feature=player_detailpage Aircraft riveting video lesson YouTube http://www.youtube.com/watch?

v=wvL0AC37NOw&feature=player_detailpage Glues for Plastic Models Parts 1 and 2 – Videos describe how to properly use modeling adhesives.

HowStuffWorks.com http://home.howstuffworks.com/plastic-glues.htm Online tutorial regarding plastic glues and cementsGrainger http://www.grainger.com Industrial supplier of hardware, tools & materialsMcMaster http://www.mcmaster.com Industrial supplier of hardware, tools & materials


Screw Nut Retaining Ring Rivet Bolt Punch Lock Washer Pin Keyway Adhesion Cohesion Cyanoacrylates Polyvinyl Acetate Bead (of glue)

Questions:1. Research and develop a detailed definition for each of the terms found in the Nomenclature section of this

document. Many words have multiple definitions. Some of which may have nothing to do with the field of Robotics Engineering. Make sure your definition falls within the context of this lesson.

2. Name three examples of threaded and non-threaded fasteners. Include images in your answer.

3. What’s the difference between a bolt and a screw?

4. Match the following action and bicycling activity with the appropriate terminology to describe the type of stress:Robotics Engineering – DoDEA Career and Technical EducationIdentifying Elements of Material and Structural Design – MaterialsRevised 9 May 2023

Feature BenefitHeat from hot air gun softens glue Disassembly and reassembly possibleQuick hardening Fast assemblyInsulator Safe for electrical stress relief

http://www.mcmaster.com/

http://www.grainger.com/

http://home.howstuffworks.com/plastic-glues.htm

http://www.youtube.com/watch?v=wvL0AC37NOw&feature=player_detailpage

http://www.youtube.com/watch?v=wvL0AC37NOw&feature=player_detailpage

http://www.youtube.com/watch?v=1hB3rIECtxM&feature=player_detailpage

http://www.youtube.com/watch?v=1hB3rIECtxM&feature=player_detailpage

http://www.valleyfastener.com/solid-rivets.html

http://www.youtube.com/watch?feature=player_detailpage&v=9aoXmzdSf_I

http://www.youtube.com/watch?feature=player_detailpage&v=9aoXmzdSf_I

http://www.gesipausa.com/blind_rivets_basics.html

http://buku-ku.com/machinerys-handbook-27th-edition/

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Action Activity StressPulling or Stretching Cranking Peddle ShearingTwisting or Turning Sitting on Seat TensileSqueezing or Pressing Rolling Tires CompressiveSliding or Cleaving Using Hand Brake Torsion

5. Examine the inventory card that’s found in the cover of the Tetrix Robotics Parts Kit. Create a table listing the correct names and quantities of the fasteners included with the kit. Include an image from this lesson identifying the fastener into the table you created.

6. Describe three methods or fasteners used to keep a nut from vibrating loose.

7. Describe three methods or fasteners used to keep a wheel on the end of a shaft or axle.

8. Generally speaking… What three conditions must be met to insure the best possible adhesive bond?

9. Indentify three adhesives that are best suited to bonding a paper poster to a cardboard placard.

10. Describe the difference between adhesion and cohesion.

11. How do solvent and plastic cements work differently than adhesives?

12. What is the origin of Super Glue?

13. What types of adhesive are not appropriate for bonding clear plastic?

14. How do you remove silicone from a work surface or joint?

15. What type of adhesive will most rapidly lose cohesion when exposed to hot sunlight?

Conclusion: Assembly is one of the final stages of the secondary manufacturing process. Complex manufactured products are typically comprised of lots of individual components or parts that must be fastened together to build the final product. Wheels and gears may need to be bolted or pinned onto shafts while electronic circuits may need to be soldered together. Ultimately, covers and cases may have to be glued in place or perhaps they simply snap together to make the final product safe and presentable for sale. Whether it’s bolting, screwing, pegging, pinning, gluing, soldering, or welding knowing the proper fastener or fastening method can make component assembly safer for you and provide a quality product to the customer.


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Identifying Elements of Structural DesignExercise 3 – Fasteners and Fastening


1. Each Study Model should be constructed, tested and then presented to the instructor for inspection.2. Analysis of each Study Model regarding its Strength Rating and type of stress weakness.

Required Materials and Equipment: Get these materials and tools from your instructor.Mindstorms Lego Kit Mindstorms Resource Kit

Steps: Build and evaluate each of the following models. Rate the strength of the fastening method from 1 to 5 with 5 being the strongest. You’ll also need to identify if the fastening method is most susceptible to Compressive, Tensile, Shear or Torsion stress. Using the online image gallery of the fasteners will provide for greater detail and may better help you properly assemble these joints. You may have to retrieve some special parts from the Mindstorms Resource Kit.

Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5Weakness: Weakness: Weakness:


Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5Weakness: Weakness: Weakness:Robotics Engineering – DoDEA Career and Technical EducationIdentifying Elements of Material and Structural Design – MaterialsRevised 9 May 2023

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Conclusion:

By design, the types of fasteners that are used with the Lego modeling system are essentially limited to snap together pins or pegs. Regardless of their combination and configuration, Lego components are held together by simple friction. This is intentional and because of this design Lego models are temporary constructions which easily fall to pieces under the most moderate forms of stress. Despite this limitation, clever use of fasteners and fastening methods can make even Lego machines as strong as the ABS plastic they’re made of. Keep this sheet for future reference as you use the Lego system of components to design various robots using your imagination and an ever expanding knowledge of engineering.


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Identifying Elements of Structural DesignExercise 4 – Trusses in Chassis Design

Objective: Students will investigate various methods of reducing the weight of a robot chassis while maintaining function. They will construct and evaluate models of various trusses and construct study models of a swing as a proof of concept for various fasteners, fastening methods and truss designs.


1. Each Study Model should be constructed, tested and then presented to the instructor for inspection.

2. Analysis of each Study Model regarding its Strength Rating and type of stress weakness.3. Working Study Model of the Swing.4. Tetrix Mantis (Indirect Drive) or Ranger Bot Chassis

Information: One of the major components of a robotics system is its chassis. Although the chassis is much more visible in mobile robots, practically every robotics system requires something to hold motors, wheels, actuators and circuitry as well as control and power systems. This is essentially what the chassis does. It’s a platform for robot operations and an important consideration in any robot design.

The professional goal of any engineer is to create designs that take into consideration not only function, but the type and amount of materials (and in turn the cost) used to develop the product. This is a balancing act where changes in one characteristic will certainly affect the other. Generally speaking, the goal in

chassis design is to get the best bang for the buck or… Producing the most cost effective and efficient design to solve the problem at hand. Often, the solution is the

strongest of all geometric shapes… The common triangle.

Closer examination of these CAD drawings and the truss bridge designs reveal the

triangle as their fundamental design element. Structures are strongest when stress is equally

distributed throughout the structure. When members of a triangle are of equal length it is called an equilateral triangle.

Since the member lengths are the same, so are the angles where the members join. The equilateral triangle is the strongest of the triangles because stress is equally distributed throughout the structure. Other types of triangles are strong, but it’s a good rule that no angle should be less than 30° or greater than 60°.


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When triangles are combined with straight members to build structures they are called trusses. Truss designs are common in bridges, roofs and towers. Although truss designs vary, they are cost effective structures that deliver strength while reducing the material required to build them. The same concept is true for a robot chassis design. The triangular cut-outs in the robot chassis deliver suitable strength while reducing weight by eliminating excess material. Bends in the material also add to the strength of the structure by distributing stress to other members in the structure. Those stresses are most often referred to as compressive or tensile stress. It’s also important to remember that most materials are stronger under compression than they are under tension.

Research Resources: The www changes all the time. If you find a dead link, please report it to your instructor but you should also use a search engine to find the information in another site.Institution Web Site DescriptionGarretss Bridges http://www.garrettsbridges.com/design/trussdesign/ Information on model bridge designTetrix Robotics http://www.tetrixrobotics.com/Downloads/default.aspx?moid=560 Tetrix Mantis Robot InstructionsTetrix Robotics http://www.tetrixrobotics.com/GettingStartedGuide/ Tetrix Ranger Bot Getting Started Guide


Equilateral Triangle Truss Chassis Compression Tension Stress



2. Copy and paste the truss bridge diagrams from the previous page to a new document. Identify five of the designs.

Procedure: Exercise InstructionsRequired Materials and Equipment: Get these materials and tools from your instructor.

Mindstorms Lego Kit Mindstorms Resource Kit Tetrix Robotics Kit

Build and evaluate each of the following models. Rate the strength of the fastening method from 1 to 5 with 5 being the strongest. Using the online image gallery of the structures will provide for greater detail and may better help you properly assemble these models. You may have to retrieve some special parts from the Mindstorms Resource Kit.

Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5

Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5 Rating: 1 – 2 – 3 – 4 – 5


http://www.tetrixrobotics.com/GettingStartedGuide/

http://www.tetrixrobotics.com/Downloads/default.aspx?moid=560

http://www.garrettsbridges.com/design/trussdesign/

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Tetrix Chassis Build

You’re going to have to choose between the Mantis (Indirect Drive) and Ranger Bot models for the Tetrix Robotics training system. Both models work with the same tutorials and courseware and can be used to complete all the activities slated for the remainder of this course. The Mantis robot platform is pretty robust, but it takes longer to build. The Ranger Bot is an easy build, but it’s not as stable or maneuverable as the Mantis. Regardless of the model you choose, once selected you cannot change your mind. Equally important is that you follow the assembly instructions correctly and completely. There are no alternate parts nor are there optional ways to put the chassis together. Follow the instructions carefully using the correct components and fasteners.

Important: Encoders are fragile and expensive. Your instructor will install the encoders on each DC motor before you install them on your chassis. Do not remove the encoders once they’re installed.

You are not going to completely assemble the models at this point. You will stop at the point where the instructions ask you to install the wiring. This should be after the motor and wheel installation. This completes the chassis portion of the assembly. STOP when you’re asked to install wiring.

Mantis - Tetrix Platform Ranger Bot - Tetrix Platform

Assessment Rubric:Assessment

Item Criteria Student Instructor

Prototype – Robot Chassis Design1 Are all fasteners of the correct type and positioned correctly? Yes/No2 Are all members of the correct type and positioned correctly? Yes/No3 Is the model assembled correctly? Yes/No

Conclusion: In completing this exercise you have recognized the importance of triangles to the design of sturdy structures. You’ve learned that triangles and trusses are integral to the design of cost effective yet strong bridges, roofs, towers and even robot chassis. Although the presence of triangular components is not always obvious, structures that incorporate them into their design are strong. Materials are more often stronger under compression than tension and good truss designs take this into consideration before construction or assemble starts.


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Identifying Elements of Structural DesignExercise 5 – Designing and Analyzing Virtual Structures

The goal of the West Point Bridge Designer Challenge is to design a structurally sound bridge that costs the least amount of money to construct. Before you start this competition, each team must login to a computer workstation and create a folder for your team named “C:\Temp\WPBD”. Next, launch the West Point Bridge Design Software. Each team must also maintain a design log. This will be your deliverable and evidence of completion of this task. As you complete each new successful bridge ask for the instructor to validate the load test and initial next to the new bridge name on your design log. Save each bridge with a unique file name into your folder into the “C:\Temp\WPBD” folder. Files should be named bridge1, bridge2, and bridge3 in order as each new successful bridge is saved. Again… Your bridges will be saved to the C:\Temp\WPBD folder.

1. Fill out the top of the “Design Log” with your name(s) and team name.2. Start the West Point Bridge Designer software3. Select “Create New Bridge Design” and use the design Wizard.

1—Read only2—No3—Deck Elevation = 20 meters; standard abutments; no pier; no cable anchors4—Medium strength; standard5—Suspension6—Enter team name; designer: team member initials (ex. jk/rb)7—Read, then select finish

4. Begin designing! 5. Save each design to the proper folder with the proper name.6. Have a monitor initial each successful design.

Good luck! You have 60 minutes.


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WEST POINT BRIDGE DESIGNER COMPETITIONDesign Log

Official Rating Sheet

Team:Final Ranking:

Entrant Init: # 1 #2

Bridge New Cost Monitor’s Initials Bridge New Cost Monitor’s Initials

1. 26.2. 27.3. 28.4. 29.5. 30.6. 31.7. 32.8. 33.9. 34.

10. 35.11. 36.12. 37.13. 38.14. 39.15. 40.16. 41.17. 42.18. 43.19. 44.20. 45.21. 46.22. 47.23. 48.24. 49.25. 50.

I certify these results to be true and accurate to the best of my knowledge and ability.

Judge’s Name (Print) Judge’s Signature


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Robotics EngineeringDoDEA - Career & Technical Education


Exercise 5b – Using the EDP to Build a Support StructureObjective: At the completion of this exercise, you will demonstrate your knowledge of the engineering/design process along with forces, materials, loads, and the structure of bridges to design and build a model bridge that will support a weight designated by your teacher while utilizing the minimum amount of resources to maintain fiscal integrity.

Information: One of the problems that engineers face today is to build a structure that is safe, aesthetically pleasing and provides function. Prototypes are often used in the design process to test strength; the shape of the structure is the most important feature for supporting its load.


Load Force ResistanceTension Compression ShearArchitectural structure Civil structure SteelReinforced steel Reliability

Research Resources: The www changes all the time. If you find a dead link, please report it to your instructor but you should also use a search engine to find the information in another site.Institution Web Site DescriptionPBS http://www.pbs.org/wgbh/buildingbig/ Information regarding building various structures on

large and small scales.

US Military Academy at West Point

http://bridgecontest.usma.edu/manual.htm Manual and lesson plans for file folder bridge design activities.

US Military Academy at West Point

http://bridgecontest.usma.edu/index.htm Provides virtual software for bridge building as well as a physical bridge model for construction using simple materials.

About.com http://architecture.about.com/od/greatbuildings/Great_Buildings_and_Structures.htm

Excellent source of information for a wide variety of architectural structures.

Institute of Structural Engineers

http://www.istructe.org/Pages/default.aspxProvides information on a career in structural engineering.



2. Analyze the changes in structures from the ancient Egyptians to today. What differences and similarities do you see between then and now?

3. What shapes provide more support for load bearing structures? Why?Robotics Engineering – DoDEA Career and Technical EducationIdentifying Elements of Material and Structural Design – MaterialsRevised 9 May 2023

http://www.istructe.org/Pages/default.aspx

http://architecture.about.com/od/greatbuildings/Great_Buildings_and_Structures.htm

http://architecture.about.com/od/greatbuildings/Great_Buildings_and_Structures.htm

http://bridgecontest.usma.edu/index.htm

http://bridgecontest.usma.edu/manual.htm

http://www.pbs.org/wgbh/buildingbig/

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4. Differentiate between tension and compression and explain how these forces are balanced on a bridge.5. How does the choice of materials affect the structure? Give examples throughout history.6. Why are trusses frequently used in the construction of bridges and skyscrapers? 7. What are the advantages and disadvantages of the truss design?

Procedure: File Folder Bridge Construction

Required Materials and Equipment: Get these materials and tools from your instructor.File folders Cardboard base Wood gluePins Ruler ScissorsWax paper

Steps: Complete each of the following steps in the assigned order:1. Refer to the Manual and Lesson Plans for file folder bridge design activities. From the USMA – West Point

website.2. Use the Engineering& Design Process worksheet to design a model bridge that will support a designated load. 3. Document each stage of the process fully.4. Build your model.5. Perform mathematical computations to predict load bearing ability.6. Weigh your model.7. Test your structure by adding weights incrementally. If time allows, refine and retest.8. Perform destructive testing for maximum efficiency.9. Report results.

Conclusion: In completing this exercise you will be able to recognize the importance of triangles related to structural engineering. You will see that triangles are the basic geometry involved in building structures like bridges. A truss is a structure made of one or more triangles built using straight members connected by joints. Tension and compression are forces that act on a truss. The forces of tension and compression must be balanced for a bridge to be stable. Different situations require different materials based on their properties. When using members to build a truss, it is important to identify whether the member will be subject to more tension or compression as to what type to use. Hollow members have different characteristics than solid and steel acts differently than carbon-steel and the thickness makes a difference in terms of support but also adding load to the structure. Combining the right elements to produce a safe, reliable structure within the budgetary requirements is not an easy task.


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