February 25th 2008

Overall views and concepts

◦Adam Stagnaro (Machining)◦Stephen Steger (FEA)◦Karina Pikhart (Solidworks)◦Sarah Cooper-Davis (MathCAD )◦Tess Veuthey

WBS Tasks Task LeadStart End Dur

atio

n (D

ays)

% C

ompl

ete

Day

s C

ompl

ete

Day

s R

emai

ning

1 Fabrication John 2/11/08 4/11/08 60 20% 12 48

1.1 Spindle shaft 2/11/08 2/25/08 14 100% 14 0

1.2 housing 2/25/08 3/07/08 11 0% 0 11

1.3 housing end caps 2/25/08 3/07/08 11 0% 0 11

1.4 cross-feed flexure 3/17/08 4/01/08 15 0% 0 15

1.5 lead screw flexure 3/17/08 4/11/08 25 0% 0 25

2 Error model task Jane 2/11/08 5/14/08 93 0% 0 93

2.1 list of spindle error sources 2/11/08 2/25/08 14 0% 0 14

2.2 model individual spindle errors 2/11/08 3/10/08 28 0% 0 28

2.3 finish full spindle error sources 2/11/08 5/14/08 93 0% 0 93

2.4 list of flexure error sources 3/03/08 3/17/08 14 0% 0 14

2.1 model individual flexure errors 3/03/08 3/17/08 14 0% 0 14

2.2 finish full flexure error model 3/10/08 4/07/08 28 0% 0 28

2.3 list of drive error sources 3/31/08 4/07/08 7 0% 0 7

2.4 model individual drive error 3/31/08 4/28/08 28 0% 0 28

2.5 finish full drive error model 3/31/08 4/28/08 28 0% 0 28

2.6 HTM-based lathe error model 2/11/08 5/14/08 93 0% 0 93

3 Measurement task dates Bill 3/07/08 4/28/08 52 0% 0 52

3.1 CMM training 3/07/08 3/21/08 14 0% 0 14

3.2 Spindle error motions 3/07/08 3/17/08 10 0% 0 10

3.3 Cross Slide error motions 3/19/08 4/07/08 19 0% 0 19

3.4 Carriage error motions 4/07/08 4/28/08 21 0% 0 21

4 Report results and Conclusions Bill 2/11/08 4/28/08 93 0% 0 93

4.1

Outline (text, table & figure placeholders) 3/31/08 4/07/08 7 0% 0 7

4.2 images 2/11/08 4/30/08 79 0% 0 79

4.3 tables 3/10/08 4/30/08 51 0% 0 51

4.4 1st draft in separate modules 4/07/08 4/30/08 23 0% 0 23

4.5 integrated, final draft 2/28/08 5/14/08 76 0% 0 76

4.6 design notebooks 2/11/08 5/14/08 93 0% 0 93

5 / 5

/ 08

5 / 1

2 / 0

85

/ 19

/ 08

4 / 2

1 / 0

84

/ 28

/ 08

3 / 1

0 / 0

83

/ 17

/ 08

3 / 2

4 / 0

83

/ 31

/ 08

2 / 1

1 / 0

82

/ 18

/ 08

2 / 2

5 / 0

83

/ 3 /

08

4 / 7

/ 08

4 / 1

4 / 0

8

n=σyield / σ max

Chosen Safety Factor: n=3

Worst Case Scenario Tool Hits Chuck

NEF

sT

MkgEI

Idot

T

T

TFWP

MN

srad

WP

P

tool

impact

tool

tool

41.1

033.0

36.1

/

/

)(0

375

21.4

/89

375

*

2

@

Production and Calculations

Fcutting

RA RB

RA = -0.5 Fcutting

RB = 1.5 Fcutting Fcutting

-0.5 Fcutting

-1.5 Fcutting

Determined that bending stress is greatest at D (σd = 10.5 kpsi)

For 12L14 steel:

◦ Sy = 60 kpsi

◦ Se = 31.1 kpsi (calculated)

With given load, the part has infinite life (σd< Se) and does not yield (σd < Sy)

Safety Factor 2.96 for endurance limit Safety Factor 5.7 for yield

Using σm = σa = 10.5 kpsi, plotted data on Goodman diagram. Well within acceptable range Calculated cycles to failure: N = 1.81*1010 cycles

Manufacturing Thermal Material Bearing Deflection Vibrations

Shaft fabrication