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UWS School of Engineering

Engineering Design
EG-165 Engineering Design 1 Casting Machine

Owner: Mike Clee


Date: 14/02/16
Version: 4

Case Study Casting Machine


Introduction
The aim of this design project is to illustrate the importance of Basic Engineering Design considerations such
as design process, dimensional accuracy, tolerances, surface finish and limits and fits. Once more it comprises
an investigation into a specific device a casting machine. Work in groups of four and where possible include
one aerospace and one product student in the group. Ensure that all names are on all work handed in. The
project is to be carried out over the next 3 design sessions as follows.
Session 1

Design Process
Tolerances
Straightness, parallelism and square-ness of machine elements
Design analysis

Session 2

Shaft/hole limits, fits and finishes


Bearings

Session 3

Compilation of designs to CAD drawings

Background to the project


We will once more be using Case Studies in Engineering, it is suggested that you read the enclosed excerpt
now.

Filename: Casting Machine - Ver 4 Ver 4

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UWS School of Engineering


Engineering Design
EG-165 Engineering Design 1 Casting Machine

Owner: Mike Clee


Date: 14/02/16
Version: 4

Session 1 The Design Tasks


Tolerances, straightness, parallelism and squareness
Begin construction of CAD drawings for parts 5,6 and 7 (see figure 6.2). You must carefully consider
tolerances and must ensure holes are straight parallel and square as described in the excerpt. You need to
correctly represent these features on your CAD drawings.
Note: Some of the dimensions on the picture are not quite correct. The pivot pins are 40mm diameter. Link 5
has three holes at 800mm and 220mm spacing. Link 6 has two holes at 800mm spacing. Link 7 has three holes,
equispaced at 260mm. All links are flame cut from 25mm thick mild steel.
Design analysis
Produce a cad drawing of the pivot joints. The best way to do this is a sectional view along the length of the
pin. The design should be such that there is a clearance between the three bars of the joints and they do not rub
against each other in use. Use INA PAP..P10 plain bearings. (see www.ina.co.uk).

Session 2 The Design Tasks

(a)
(b)
(c)

Shaft/hole limits, fits and finishes


Specify a fit for the holes on parts 5,6 and 7.
Add limits and fits and surface finish information to your pivot sketch from last week
Begin construction of a CAD drawing of the pivot assembly

Bearings
Produce a design of the main bearing (spindle 3 bearing). Include in your design the detail of the mounting
structure that connects the whole machine to the base-plate. Two of these structures are required (one at each
end). Describe also the assembly procedure for your design so that the main spindle, main bearings and
mounting structures fit easily together.
Note that the main spindle is fabricated from a 170mm OD, 150mm ID steel tube.

Session 3 The Design Tasks


Compilation of designs to CAD drawings
Complete the 3 Cad drawings to BS PP7308 noting correct representation of tolerances, fits and finishes etc.
Use 1:1 scale wherever possible and use A3 or larger paper (A4 drawings will get half marks). Each member of
the group should take responsibility for one drawing. Make sure all three names are marked on every drawing
and denote the person responsible with a *.
1. Cantilever arms
2. Pivot assembly
3. Main bearing assembly and mounting structure
Deadline: Three CAD drawings to be handed in by 12pm Friday 4th March 2016

Filename: Casting Machine - Ver 4 Ver 4

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