(Q1) Develop an optimal process plan to manufacture the widget shown in the following figure. The tools and process capabilities information are provided in Tables 1 and 2. Use the ISE316 Process Plan Template (as shown in Table 3) to create your process plan, and use Table 4 format to systematically present the tool path sketches (at least 2 views) and the machining time calculations for each operation. Assume the loading and unloading times to be 1 minute each. (60 pts.) Raw matl: Al 6061 Blank: 2.00 x 1.00 x 1.00 Blank tol: + 0.01 Qty: 10,000 0.60 0.01 | 1.025 o O - o ) o Q o + o o Ay a W (Q2) Design a Go/No-Go gage to inspect the hole. Discuss the worst case scenarios that will occur at both gage (Go, and No-Go) ends. (20 pts.) Table 1. Tools loaded in CNC M/c Center and suggested cutting conditions Table 2. Process capabilities Tool # of Speed Max. depth of Tool Tool @ ( in) Feed Process Dimensional accuracy Positional accuracy Description teeth it/min) cut per pass (in) + 0.005 0.005 1 End mill (roughing .75 2 006 ipt 25 250 (in Z) Rough End milling 2 End mill (finishing) 750 .003 ipt 400 .100 (in Z) Finish End milling + 0.002 0.005 3 Spot drill (0 = 90") 12 .008 ipr 20 063 (max) + 0.008 Drilling 0.005 .0.001 4 Twist drill (0 = 118") 33/64 .008 ipr 25 (same as preceding 5 Twist drill (0 = 118") 35/64 008 ipr 250 Reaming + 0.0005 operation) Reamer 17/32 003 ipr 50 Semi-finish boring + 0.001 0.001 Boring bar 500 (min) .003 ipr 500 015 Finish boring + 0.0002 0.0001 Table 3. Table for the process plan. PROCESS PLAN NCSU-ISE INC. Part # Part Name: Material: Prepared by: Date: Revision #: 1.0 Approved by: Date : Revision Date: 8/22/2015 OP.# OPERATION DESCRIPTION WORKSTATION/MACHINE SETUP DESCRIPTION TOOL SPEED FEED DEPTH OF CUT OP. TIMETable 4. Use a table formatted like this to show toolpaths and machining time calculations for each operation in the process plan. Op# Toolpath Calculations Op# Toolpath Calculations