the who’s final production presentation “better than the last one” paul freund mark radio chad...

The Who’s Final Production Presentation

“Better than the last one”Paul FreundMark Radio

Chad Swanson

Previous Prototype

•Single Dovetail•Solid Base•2.5” x 4.5”•Oval Wood Base

Final Product• Double Dovetail• Box Tubing for Base• 3” x 5”• Rectangular Wood

Base• “Trademarked” Logo

Resources and Tooling• Haas Vertical

Machining Center• Router• Cut-off Saw• Fixtures

• ¾” Dovetail Cutter• ¾” Spot Drill • ¾” Flat End-mill• 3/8” Flat End-mill• 6” Face-mill

Wood Base• Walnut• 4 ½” x 6 ½” x ¾”• Rectangular groove cut

in to house Al base• Routed Edges• Natural Walnut Stain

Wood Base Process PlanSet Up

NumberOperation

DescriptionMachine

DescriptionTool

DescriptionProcess Parameters

10End mill 0.125 in groove into wood base

3-Axis Vertical Machining Center

0.125 in HSS flat end mill

Spindle Speed: 4037 rpm Feed: 6.8 in/min

The Aluminum Base• 3” x 5” x 1/8” Al Box

Tubing• 4 “male” dovetail

ends cut into top• Bead blasted

Set Up Number

Operation Description

Machine Description

Tool Description Process Parameters

10

Cut-off a 5 in. X 3 in. cross section of 6061 AL stock box tubing to a length of 2.0 +/- .015 in.

Cut-off saw

20 Face mill box tubing 3-Axis Vertical Machining Center

4 in. Face mill 1000 rpm

30 End mill box tubing 3-Axis Vertical Machining Center

0.75 in HSS end mill


40 Dovetail Box tubing3-Axis Vertical Machining Center

0.75in, 60 degree dovetail cutter


Set Up Number


Machine Description


10


Cut-off saw









Set Up Number


Machine Description


10


Cut-off saw









Aluminum Base Process Plan

The Top• 3” x 5” x 3/8”• Double Dovetail• Bead Blasted • Field Feature• “Trademarked” Logo• Alternate Oval Logo

Top Process PlanSet Up

NumberOperation

DescriptionMachine

DescriptionTool


10

Cut-off a 3 in. X 0.5 in. cross section of 6061 AL stock to a length of 3.2 +/- .015 in.

Cut-off saw

20 Face mill sides of top piece


4 in. Face mill Spindle Speed: 1000 rpm Feed: 15 in/min

40 Face mill top of top piece



50 Face mill bottom of top piece



60 End mill bottom of top piece




70Dovetail bottom of top piece




Top Process Plan (con’t)Set Up

NumberOperation

DescriptionMachine

DescriptionTool


10Engrave field design into bead blasted top plate


0.75 in HSS spot drill

Spindle Speed: 2037 rpm Feed: 34 in/min

The Fixture: The Pinball Wizard

Estimated Work Content (Time)50 Pieces

• Dovetail Top ~ 3 Hours• Dovetail Base ~ 5 Hours• Machine Field ~ 5 Hours• Bead Blast ~ 5 Hours• Wood Bases ~ 3.5 Hours• Miscellaneous Filing ~ 2 Hours• Assembly ~ 1.5 Hours• TOTAL HOURS ESTIMATED ~ 25

Status of Materials, Tooling, & Fixtures• Materials

– All Aluminum arrived 11/14/2001– Have 10 Wood Bases, 2-Day Lead Time for

more• All tooling currently on hand, may need

extra dovetail cutters• Either fixture modifications or new

fixture to be machined for Aluminum bases

Gantt Chart

Costs• 3 x ½” Aluminum Stock—32’ = $181.54• 3 x 5 Al Tubing = $182.88• Shipping = $20.00• Wooden Base = $75.00• Miscellaneous = $75.00• Machining/Resource Costs = $450.00• Licensing = $350.00• Personalization

TOTAL = $1334.42 or $26.69/unit ($19.69/unit without licensing)

QUESTIONS??????

the who’s final production presentation “better than the last one” paul freund mark radio chad...

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