Jonathan Jones Mae377 Project06 Final

University at Buffalo

2009

Project 06 –

Comprehensive Report MAE377 – Adjustable Wrench

Jonathan Jones - #3451-8370

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Table of Contents 1 Introduction .......................................................................................................................................... 3

2 Problem Statement ............................................................................................................................... 3

3 Results ................................................................................................................................................... 3

3.1 Phase 1: Problem Identification .................................................................................................... 3

3.1.1 List of Inaccuracies in the Adjustable Wrench ...................................................................... 4

3.1.2 List of Changes Made in the Adjustable Wrench .................................................................. 4

3.2 Phase 2: 3D Solid Modeling .......................................................................................................... 5

3.2.1 Part A ..................................................................................................................................... 5

3.2.2 Part B ..................................................................................................................................... 7

3.2.3 Part C ..................................................................................................................................... 8

3.2.4 Part D .................................................................................................................................... 9

3.2.5 Part E ................................................................................................................................... 10

4 Discussion ............................................................................................................................................ 11

5 Conclusion ........................................................................................................................................... 11

6 References .......................................................................................................................................... 11

7 Appendix ............................................................................................................................................. 12

7.1 Question Sheet from Phase 1 ..................................................................................................... 12

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1 Introduction Project 06, being a long and lengthy process, was split into two separate parts, aptly named Phase 1 and

Phase 2. The latter simply being a continuation of the former, Phase 2 expounded upon the problems

we encountered and the recommended changes we made in Phase 1 for the Adjustable Wrench. It

would then take all of my three dimensional Pro/ENGINEER Wildfire 4.0 skills to complete the remainder

of Project 06, as it calls upon the talents taught in Projects 01-05.

2 Problem Statement Taking the problem identification drawings I had made regarding the Adjustable Wrench from Phase 1 of

Project 06, I was tasked with furthering my redesign with a set of challenges. Firstly, I would have to

actually create three dimensional models of the four components of the wrench, all with the

recommended redesigns I had made previously. Secondly, I would have to create a new comprehensive

set of 2D drawings to mend horrific originals (again with the new redesigned dimensions). After such

tasks were complete, I was meant to assemble the four components into one working assembly file, so

that one could see how the wrench was supposed to fit together. One of the easier sections of Project

06 drew on the rendering capabilities I had learned in Project 04, making my wrench appear much more

realistic in still images. Finally, and after a much needed deep breath, I created two animations of the

Adjustable Wrench, showing all of the components and how they were meant to be assembled by

means of rotation and pseudo exploded views. Project 06, to put it lightly, was indubitably quite the

undertaking.

3 Results

3.1 Phase 1: Problem Identification In order to correctly determine which of the wrench’s dimensions were in fact wrong, I started about

attempting to model the wrench in Pro/ENGINEER. Starting with the handle, I was able to model the

basic shape without any major problems. Drawing the thread rack turned out to not even be that bad,

even after spending 45 minutes trying to figure out the Mechanical Engineer’s Handbook that no one

ever bothered explaining to us aspiring engineers. However, the side view of the handle isn’t exactly

right. Following this, I moved on to the housing for the adjustable screw, again finding fault in some of

the dimensions. As far as I can tell, the pin and screw themselves are in perfect order, which comes as

no surprise as the amount of dimensions given regarding those respective components are limited in

comparison to the handle and the housing.

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3.1.1 List of Inaccuracies in the Adjustable Wrench

Component Dimension Problem

Handle 1. In the inside corner edge of the handle, there are no dimensions given for the “blend-like” triangular structure.

2. According to the 2D drawing, the ACME thread rack and the corner triangular structure are flush with each other. However, the radius of the head of the wrench (.875”) minus the height of the handle (.75”) does not equal the height of the threads given in the Mechanical Engineer’s Online Handbook (.0833”).

Housing 3. In the Front View of the housing, the 7/16” dimension from the center of the hole to the base of the bottom cut is not physically possible.

4. In the Side View, the 7/16” dimension from the center of the hole to the bottom of the cut is completely infeasible.

5. The cut into the Side View of the housing cannot be 1” in height, as this cuts into the housing incorrectly.

Pin No problems found.

Screw No problems found.

Misc. 6. No dimensions for any rounds given anywhere. 7. The hole type “NC” should be “UNC.” This is proper form.

Table 1: List of inaccuracies in the adjustable wrench 2D drawings

3.1.2 List of Changes Made in the Adjustable Wrench

Component Problem Solution 2D Drawings of the Solution

Handle 1. Created a triangular extrusion in the corner and added a chamfer of .03” at an angle of 64 degrees.

2. Changed the height of the triangular corner piece to .0833,” the height of the thread.

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Housing 3. Changed the 7/16” dimension to .3825.”

4. Changed the 7/16” dimension to .3825.”

5. Changed the 1” dimension to .9375.”

Pin No changes made. N/A

Scew No changes made. N/A

Misc. 6. Added rounds of appropriate size where necessary.

N/A

Table 2: List of solutions for the Adjustable Wrench Problems

3.2 Phase 2: 3D Solid Modeling

3.2.1 Part A

After the completion of Phase 1, Part A was a relative breeze. This part of the project required us to

model the separate parts of the adjustable wrench and add or alter any changes I had already

suggested.

3.2.1.1 Part 1 – Handle

The handle was relatively easy to fix. Adding a blend to the inside corner of the handle listed in Table 1

and making its height flush with the threading for the screw and it was fixed splendidly. The initial

modeling of the shape was relatively easy as well. The hardest part was correctly modeling the

threading to match the screw and patterning it correctly to match the specifications of the handle.

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(a) (b)

Figure 1: (a) The redesigned handle modeled in Part A (b) different view.

3.2.1.2 Part 2 – Housing

The housing redesign was more of a challenge, as the dimensions I had changed in Phase 1 often

translated to a completely incorrect reshaping of the housing itself. This was not because of the

dimensions I had altered, but rather the order that I was drawing and entering said dimensions.

(a) (b)

Figure 2: (a) The housing modeled in Part A; (b) different view.

3.2.1.3 Part 3 – Screw

The screw was one of the easier parts to model, consisting of a cylindrical extrusion and a helical sweep.

By this point in the process, I had become pretty accustomed to utilizing the helical sweep cut tool, so

this part was quite the breeze.

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(a) (b)

Figure 3: (a) Screw modeling in Part A; (b) different view.

3.2.1.4 Part 4 – Pin

Actually, the pin turned out to be the easiest of the four parts to model. The online walkthrough of the

helical sweep cut actually was in terms of the threading on the pin, so this piece was quite easy.

(a) (b) Figure 4: (a) The screw modeled in Part A; (b) different view.

3.2.2 Part B

So as to avoid the confusion and turmoil brought about by the original 2D drawings given to us that

began this whole redesign process, Part B set about creating a new, correct set of two dimensional

working drawings. With a few clicks of the mouse and a few extra hours in the lab, and the new set of

drawings was all squared away.

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Figure 5: 2D Drawing of the Adjustable Wrench, after changes.

3.2.3 Part C

Part C was actually another facet of the project I basically had to complete in Phase 1, just so I could see

how all of the pieces fit together and if there were any problems with the dimensioning there. Likewise,

in order to show the assembled view in the 2D I had to assemble the actual wrench. Also, this being the

fourth or fifth time I have assembled a product in ProE, I have become fairly adept at the whole

assembly process. Adding an exploded view and Part C was complete.

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(a) (b) Figure 6 (a) Exploded view of the Adjustable Wrench assembly; (b) unexploded view.

3.2.4 Part D

Now that the major parts of the modeling were finished, all that was left to do was to amp up the

aesthetics, making the wrench look realistic and pretty. I added the appearance of blue cast iron to the

handle, brushed iron to the housing, and metallic steel to the pin and screw. Adding a room and scene

to the rendering similar to that of the cell phone we created in Project 03, and touching that up with

some poignant spotlighting, and my rendered JPEG was complete.

Figure 7: Rendered JPEG of the Adjustable Wrench.

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3.2.5 Part E

As the final facet of Project 06, I was tasked with creating a movie that showcased all of the different

views and components of the Adjustable Wrench. I was able to create a video that spun the wrench 360

degrees, individually explode each part to the final exploded view, rotate 360 degrees again, return to

the unexploded view, and finally zoom in for a final close up. Although suffering through the traditional

lengthy pains of creating a rendered MPEG in our labs computers (taking upwards of an hour to finish

the rendering), each movie file was created with success.

(a) (b) Figure 8: Unrendered screenshots of the MPEG, (a) exploded, (b) unexploded.

(a) (b)

Figure 9: Rendered screenshots of the MPEG, (a) exploded, (b) unexploded.

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4 Discussion Project 06 was meant to utilize every tool we have learned in ProENGINEER to this point, and I dare say

it succeeded. We had to go through the problem identification phase that we unknowing had to partake

in during the earliest projects, had to model solid objects using tools ranging from simple extrusion to

blends and helical sweep cuts, had to create a 2D working drawing from our 3D parts, add appearances,

textures, lighting, and environments to create life-like still images, and finally create multifaceted movie

files to show off the finished product. If this sounds like a lot of work, well it was. Project 06 was easily

to most time consuming project to date, totaling approximately 65 or more hours over the course of

two weeks. In a quasi-related issue, I do have a problem with the specified requirements of this project.

In order to create a successful report, I often refer to the project requirements and grading scheme

supplied by our professor. However, in Project 06, there were quite a few discrepancies between the

two documents, as the requirements specifically listed the rendered images and movie files, while the

grading scheme never so much as mentioned them. I daresay an update may be needed.

5 Conclusion Project 06, as it seems to be turning out for the entirety of MAE 377, my engineering 3D CAD class, was

quite the lengthy undertaking. I guess one could say that I have become accustomed to toiling away the

hours in the engineering lab, as indeed I have. Project 06 was a nice comprehensive refresher on all of

the skills I have learned to this point in ProE, and will surely help ease the process of both Project 07 and

our Final Project. I can’t wait.

6 References

1.) Oberg, E.; Jones, F.D. (2000) [Online]. Machinery's Handbook (26th Edition). Available:

https://ublearns.buffalo.edu/webapps/portal/frameset.jsp?tab_id=_2_1&url=%2fwebapps%2fbl

ackboard%2fexecute%2flauncher%3ftype%3dCourse%26id%3d_77303_1%26url%3d

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7 Appendix

7.1 Question Sheet from Phase 1