Spring 2012
Phillip Daniel
Surface Grinder Analysis and Build Log
Here is a copy of the reports that I wrote to keep track of my analysis and the deterministic design of the machine tool.
Kinematic Coupling
Designed, modeled, built and tested a kinematic coupling.
Elastically Averaged Coupling
Designed an elastically averaged coupling to support the lead-screw in my T-Base machine tool. Completed a unit test to verify that the design will perform as intended.
Carriage Assembly - Part 1
Describe the functional requirements, design parameters, analysis, resources, risks, and countermeasures associated with designing a surface grinding machine. I also build and test a sketch model to help design the linear motion modules (carriages) for the machine.
Carriage Assembly - Part 2
I finalized the design of the linear motion module as well as the geometric and load induced error budget. I also analyze the propensity of the design to jam, describe some of the design decisions for the LMM, and begin manufacturing the assembly.
Carriage Assembly - Part 3
Finished fabricating all of the parts for the first carriage and potted the bushings in place. I then measure the stiffness, accuracy and repeat-ability of the assembly.
Spindle Assembly- Part 1
Began the design of the rotary motion module (spindle) and modeled the geometric error of the surface grinder assembly. I also build a sketch model for the lead-screw and analyze its stiffness, accuracy,and repeat-ability.
Spindle Assembly- Part 2
Finalized the design of the spindle, began fabrication, and estimated the load based errors of the assembly
Spindle Assembly - Part 3
Selected fits for the Rotary Motion Module, fabricated the parts, and assembled the unit.
Started fabrication for the second carriage and completed testing for the spindle.
I finished assembling the surface grinding machine. Here I describe my testing and how the measured performance matches my design criteria.