Blog 26: Senior Project Reflection

(1) Positive Statement


What are you most proud of in your 2-Hour Presentation and/or your senior project? Why?
How much information I had learned because I didn't know how much till I presented.




(2) Questions to Consider


a. What assessment would you give yourself on your 2-Hour Presentation (self-assessment)?


AP


b. What assessment would you give yourself on your overall senior project (self-assessment)?


CR


(3) What worked for you in your senior project?

mentorship and research


(4) (What didn't work) If you had a time machine, what would have you done differently to improve your senior project if you could go back in time?
being late on deadlines

(5) Finding Value


How has the senior project been helpful to you in your future endeavors? Be specific and use examples.

Helped me with gathering information

Mentorahip Log

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Mentor: Danny King (909)7025493






Interpretive
What is the most important thing you gained from this experience? Why?
the most important thing i've gained was the skill to use a CAD/CAM program properly. I didn't know how before and it is a skill that will help me later if I choose to continue in this profession

Applied
How has what you’ve done helped you to answer your EQ? Please explain.
It helped answer my EQ because it provided proof to my best answer by allowing me to get better at a CAD/CAM program simply by using it in a real environment. By thinking that my program may be used at some point in time, i was able to take it seriously and improve myself

Exit Interview Questions

(1) What is your essential question? What is the best answer to your question and why?

My essential question is how can a machine programmer best produce quality parts in the aerospace industry? The best answer for this would be to have a working knowledge of CAD/CAM systems because through my interviews, personal experience and research, I found that not only is it much easier to learn the program through actually using it in a real situation, but people who have experience with the program are more desirable because they have the knowledge on how to properly adjust programming for parts due to constantly changing factors rather than someone just out of a class with no skill in that area.

(2) What process did you take to arrive at this answer?

 From the very beginning I knew that my first answer would be my best answer, this was how all the programmers and my mentor learned the program, and all of them never had trouble finding a job even when their company would go down and there were people freshly out of classes to compete with. Senior Project was mostly there for me  to find solid ways to back it up. 

(3) What problems did you face? How did you resolve them?

Problems I faced were finding out ways to actually teach the information to other people, I've grown up with basic knowledge of machine programming, but it was hard to find a way to sort out what was basic important knowledge over what was basic and not really needed knowledge. Also finding out possible activities was also challenging because i felt so limited in what i could do. These problems were solved by asking for help from my peers and brainstorming with them

(4) What are the two most significant sources you used to answer your essential question and why?

The two most important sources for answering my EQ would be my fourth interview and and article about how successful a certain school's programming curriculum was. The latter hadn't really applied till i had connected the dots after my first interview where i read it again to discover the reason why these students never had trouble finding a job was because part of their learning was participating in an actual machine shop . My forth interview, basically provided proof from an expert for my best answer.

(5) What is your product and why?

My product from senior project was for me to develop the appropriate use of the CAD program to create objects that could conceivably be manufactured. I previously did not have this knowledge, I could create images, but I couldn't actually program. Through senior project, i was able to create an actual, functional program.

Updated 3 Column

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Independent Component 2

a) Statement saying: “I, Ariana King, affirm that I completed my independent component which represents 30 hours of work.”
(b) Cite your source regarding who or what article or book helped you complete the independent component
For my second independent component, I spent 30 hours doing basic quality checks on parts. The tools that i frequently used were calipers and small hand CMMs. I would check the part as it was a chunk of metal and then after it was cut. I only did basic size and depth measurements.

3/02/13 8:00 A.M.-3:00 P.M

Learned the basics of what I should be doing when measuring parts. Calipers are used for length and width, and depending on how big or small the cut is, depth. These are mostly used for general estimates and help provide a reference more than actually measure. The actual CMMs do the accurate measuring and i would watch the machines to make sure they were running smoothly and would record any error the machine detected. While not exactly slow, the process isn't quick either which is why only a few out of a batch was tested at a time,

3/09/13 8:00 A.M.- 1:00 P.M.

Tested to see if work holdings were keeping the metal at the required depth. This manual CMM was set to the desired depth previously and was moved to where a placeholder block was being held. The CMM was placed closer and closer to the block till it touched and if programmed correctly, hit zero on the dial.

3/16/13 8:00 A.M.-4:00 P.M.

Rather slow day as I pretty much measured with calipers and the manual CMM as required. It wasn't that not many parts were made at the shop that day, but rather they took a very long time to make and were full of details. I wasn't able to use the actual CMM at the shop due to the fact they needed to be as fast and accurate as they could since the parts were taking so long. I simply did the easy "grunt work" part of measurement. Since I couldn't take a picture of the part or machine as it was a prototype, I decided to examine the warnings of the machines while i was waiting for the parts to finish.

The blood was a nice touch.

4/06/13 8:00 A.M.-1:00 P.M.

Same generic measuring. By now i was getting faster at it, being able to produce results fast without screwing up on a measurement. (My work is always checked by someone in quality.) I also helped clean up the shop that day, by taking out bins of metal chips and wiping the floor and tables free of coolant.

4/13/13 8:00 A.M.-1:00 P.M.

Did the last few hours with some calipers and examined "scrapped" parts in the CMM. Also painted red rejected parts where the mistakes were made to show the programmers where things went wrong.

APPLIED
How did the component help you answer your EQ or support one or more of your answers. Please include specific examples to illustrate how it helped.

This helped me answer my EQ by letting me both experience quality work and cleanliness. While I was mostly focused on measurement checks, Briefly I did do some cleaning one day, and I always had to make sure i put everything back right where i got it from that way other people could use it when needed. While this did teach me not to cheat with measurement, it mostly provided proof for my 3rd answer which is to have a clean shop floor. When the floor would start to get too dirty, i would notice that my feet would either be slippery or stuck based on what coolant was used and metal chips would embed themselves in my shoe. Whenever something I, or someone else was using was moved out of it's intended place, no one would know where it was and productivity wouldslow down.

Current Mentorship Hours

1/12/13 8:00 A.M.-1:12 P.M.: Programmed part number 53002668

8:00-10:00 Created a solid model from a blueprint supplied by a customer

10:00-11:45 Generated tool paths in MasterCam

11:45- 1:12 Created set-up sheets for operator

2/3/13 7:43 A.M.-1:00 P.M.: Set up and first articled part number 53002682

2/17/13 8:15 A.M.-2:30 P.M.:Programmed part numbers 0507222 and 69000629

2/23/13 8:00 A.M.-1:30 P.M.: Designed and programmed fixture for vacuum base

3/3/13 9:00 A.M. 1:15 P.M.: set up 1st articled part number 0511425

3/9/13 8:00 A.M.- 2:00 P.M.: Designed fixtures part number "food tray"

WB

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Blog 19

1. Effective User of Technology
2. I have been further understanding a program called MasterCAM which is used in the CNC machining industry. I have also been able to work with some quality testing machines which were machines I had never used before.

3. Finished box and lid from independent component 1:

20 Questions

1. How can a machine programmer best produce quality airplane parts in the aerospace industry?

2. How do different types of metal effect the way you program a specific airplane part?

3. Why is it so important to track a heat lot on material used for these parts?

4. What types of coatings and paints are commonly used and how does this affect close tolerances?

5. What are some of the tolerancing differences between commercial airplane parts and government airplane parts?

6. What other outside processes are most commonly used and why can't we accomplish those with a CNC machine?

7. How do you determine what goes on a CNC mill and what goes on a CNC lathe?

8. On a part that has multiple operations, how is quality sustained throughout each operation?

9. What is the process used when quoting a new job? 

10. What are some examples of various types of workholding?

11. What is the protocol when a part has changed revision?

12. How do you determine what is the most efficient machine, be it a mill or a lathe, to make a specific part?

13. Some metals can be cut without the use of coolant. What are those metals and what kind of tools are used to cut them?

14. When making a set up sheet for the machinist to use, what kind of information is important to have on it?

15. What are some programming techniques used to achieve a good surface finish? How do these techniques differ from material to material?

16. When running a job, what is more important? Tool life, or run time?

17. All these cutting tools are extremely sharp and when cutting metal, sharp chips are flying out at high speeds. Also, the part itself has corners that are razor sharp. How can a program minimize work related accidents?

18. How important is it to have a clean and tidy shop floor? How do you sustain a tidy shop floor? How does this tie into making quality parts?

19. In what ways does production work with quality from start to finish on each job?

20. What is the best way to learn CNC programming using a CAM system?

3rd Interview Questions

1. How can a machine programmer best produce quality airplane parts in the aerospace industry?


2.How many CMM machines is average to have in a standard Machine Shop?


3. What are the other ways to ensure quality other than a CMM machine?


4.What percent error is allowed for a part to be "okayed"?


5.What is done with parts that aren't approved?


6. What are ways to test a part for stress?


7. What type of debarring method do you use?


8. What does debarring do?


9. Does type of coolant affect quality?


10. Is every part checked, or only a sample?

Independent Component 1

Step 1:

02/14/2013 6:00 P.M.-6:20 P.M.
I created two dimensional lines to create the shape of my solid model.

Step 2:

02/14/2013 6:20 P.M.-7:20 P.M.
I used my two dimensional lines to extrude my box and create a cavity for the box.

Step 3:

02/15/2013 8:30 A.M.-10:30 A.M.
I added details to make the part machinable. By adding Fillet radii, it creates a shape that will allow me to create machinable tool paths.

Step 4:

02/15/2013 10:30 A.M.- 12:30 P.M.  5:00 P.M.-7:30 P.M.
02/16/2013 8:30 A.M.- 10:30 A.M.  2:00 P.M.- 5:30 P.M.
02/17/2013 9:00 A.M. - 10:00 A.M.  12:00 P.M.- 1:00 P.M.
 Determined material stock size that part will fit in and be able to be machined from. Material needs to be over sized in order to be held in a vise. I then started creating tool paths for the first operation.

Rough periphery cut:

Roughed out pocket:

Finished inside pocket and periphery. Also drilled and tapped cover mounting holes:

Step 5:

02/17/2013 4:30 P.M. - 7:30 P.M.

I then flipped my model over to complete the second and final operation. I milled off the excess material and created a deburring operation to eliminate all sharp edges. I also personalized the box by engraving my name to the bottom. This took 3 hours.

Step 6:

02/18/2013 8:30 A.M. - 11:30 A.M  6:00 P.M.- 9:00 P.M.

 I followed the same steps (drew solid model and created tool paths) to create the cover for my box

Here is the view of my box with the cover on it.

Testing to see if it could be made, no errors were shown on the program.

All this is to create NC coding that the CNC mill can read.

LITERAL
“I, Ariana King, affirm that I completed my independent component which represents 30 hours of work.”
(b) Cite your source regarding who or what article or book helped you complete the independent component
My mentor was the best in helping me complete this component.
(d) Explanation of what you completed.
I created a 2D image of a box with a lid and holes for screws in MasterCam which generated the NC coding after both the model and tool paths were completed.
APPLIED
By better understanding the program, I can better handle the program itself,reducing mistakes, and increasing the speed in which I can generate a program. This helps provide validity to my first answer, which was having a sound understanding of how the specific program a machine programmer is using works. Creating this box allowed me to become familiar with some of the tools of the program as well as how tool programming works.

Independent Component 2 Plan Approval

(1) Write a description of what you plan on doing for your independent study component.


     I plan to do both in process inspection as well as final inspection of machined parts. I will be working with various inspection instruments designed to check  the tightest tolerance of a part.

(2) Describe in detail how you think your plan will meet the 30 hours work requirement.

I will be doing the job of a quality inspector which will include using various type of inspection equipment on various types of parts.
(3) How does your independent study component relate to your working EQ?


 Since my second answer is value machine tool quality over price, doing quality checks will help me better understand as to why tool quality is so important.

Independent Component 1 Plan Approval

CONTENT:

(1) Write a description of what you plan on doing for your independent study component.

Make a few programs in MasterCAM to better aquatint myself with the program

(2) Describe in detail how you think your plan will meet the 30 hours work requirement.

Multiple programs will be made ranging in various difficulties and therefore ranging in times taken to make them

(3) How does your independent study component relate to your working EQ?  

It helps me better understand what program a machine programmer has to work with.

Blog 16

1. How can a machine programmer best produce quality airplane parts in the aerospace industry?
2. Devote himself more to quality than price efficiency.
3.  CMM machines ensure quality, but cheap ones aren't useful at all. Using tools that are made to handle the proper metal. Run proper maintenance on work holdings.
4.  How to select a CMM
5.  I plan to further pursue my second answer by talking to the people in charge of quality in the shop.

On Friday February 8th, you will be going into 2-Hour houses.   In your 2-Hour house, each student will be presenting the following:

• Introduction:  Hello, my name is Ariana King my senior project topic is machine programming and my essential question is How can a machine programmer best produce quality airplane parts in the aerospace industry?
• Sponge: What do you know about machine programming?  
• My first answer is by understanding the programs they use and my second one is by valuing quality over price.
• "According to "How to select a CMM", a proper CMM machine is key in ensuring quality.
• I plan to understand how a CMM machine determines quality by spending more time in the quality department of the shop.

Blog 13

30 Minute Lesson Plan

Name: Ariana King
Date:
House:North

Essential Question: How can a Machine Programmer best produce quality airplane parts used in the aerospace indusry?

Objectives: Properly setting a starting point in CAD/CAM systems, Learning how to understand the genreal coding of a program

CategoryGuide

Introduction: My name is Ariana King and I based my senior project on machine programming with CAD/CAM software. In this presentation, I hope to give a basic understanding on how CAD/CAM helps produce airplane parts while showing how important CAD programs are in the manufacturing field.

Verification: Does anyone know anyone who works in the manufacturing field? Does anyone have an idea how airplane parts are made? Does anyone know what a starting point is for in design programs? Has anyone worked with coding before?

End: Define what a starting point is used for in CAD programs. What do certain letters in the machine coding mean? How does CAD/CAM software help aid the manufacturing industry, or more specifically, the Aerospace industry?

Body

• Literal: The starting point oddly enough is not where the first line is drawn, but is where the tool is told to start. CAD/CAM software speeds up the production of airplane parts by removing almost all excessive prototypes. Some of the most important parts of coding in CAD/CAM software is stored in just one or two letters.
• Interpretive: Most important was to familiarize myself with the program so that i could further understand when my mentor was demonstrating how he created certain parts.
• Applied: How may this topic help you in the future? This will help me in the future by providing me with an "edge" should I choose to pursue this career in the future. There is never a shortage of jobs for programmers.

Visuals Items used for the Body of presentation. Visuals must enhance learning experience for audience members. I will have a Basic, pre-made program to give a rough idea how a machine would understand a program.

Activity (Describe the independent activity to reinforce this lesson)• What is the activity: I will have a simple match game where I offer a letter used in coding, and ask for someone to match what the letter means in the code.
• What materials will be used: Computor and a projector

Three Important SourcesThree Important Sources
1. (Source and justification. Minimum speaking length: 30 seconds.)

2. (Source and justification. Minimum speaking length: 30 seconds.)

3. (Source and justification. Minimum speaking length: 30 seconds.)

Conclusion: Thank you for your time and I hope you were able to better understand the basic workings of my project.