Gear Clock Project

Overview
For our Catia Final project we worked on the magnetic gear clock. Our main tasks
consisted of redesigning and machining some parts as well as creating a base that
could hold the computer components and have and aesthetically pleasing look.

Redesigning in CatiaV5
For this part of the project we had to redesign the gears to contain a spiral look as
can be seen below. It was a challenge as we were provided with the new design but
no dimensions. We solved this by figuring out the main angles and using pure
constraints and relations as can be seen in the picture below.

Rotor Spoke Plate

24 Magnet Wheel B &C

24 Magnet Wheel
D

Great Wheel

Base

Lessons Learned

When it comes to altering parts to contain the same design but being of
different sizes, finding the main constraints and relations for the design, will

help to make the change faster and easier.

Master Cam
We started out be trying to complete the Master Cam tutorial but the part file was
missing so we dove right in using the modified Catia parts. We learned a lot about
how to use the program to create pocket, contour, and drilling operations as well as
how to transfer files into and out the program. Below are the final machining
process lists for all the parts as well as the lessons learned.
Rotor Spoke Plate

24 Magnet Wheels B & C

24 Magnetic Wheel D

Rotor Spoke Plate

Base

Lessons Learned

How to create contour, pocket, and

operations.

drilling

We learned how to import files into Master Cam making sure that the wire
frame is activated.
How to determine the speed of the different tools.
Setting the overall operation parameters.
When to have coolant on and when not to.
Maximizing the choices in our operations to produce a quality part in minimal
time.
Taking into consideration all the machining aspects.
Climb cutting vs conventional cutting.

Hass Mill Machining

To machine the parts we used the Hass mill. We first learned the basics such as
how to start the mill and how to maneuver the different axis. Below is a brief
description of our process for machining the different parts.
We began by cutting out a stock piece from a 1/8 in aluminum piece.

We then found its center and marked it.

After clamping down the part, we loaded all the different tools into their assigned
number. We then used one of them to zero-in the center of our stock piece. Having
done that we proceeded to zero in all the different parts with respect to the Z-axis.
We then verified the code and uploaded
it to the mill. The machining process
could now begin.

In order to machine the parts we had to

find a way to unclamp the stock piece
from the fixture as the cutting tool would

otherwise be running into the clamps. To do this we found that the best method
was to either pick three available locations in the design to tap and screw into.
Once that is done and the screws have been added we simply stopped the
operation to add the screws and unclamp the stock piece and then proceeded with
machining, as can be seen in the picture.

Below are the finished products.

Rotor Spoke Plate

Great Wheel

24 Magnetic Wheels B & C

24 Magnetic Wheel D

Base

Lessons Learned

How to zero-in parts in the Hass Mill

Loading code into the Hass
Properly mounting tools into the holders
Loading and Unloading tool holders in the Hass
Calibrating the tools for the operations.
How to initiate as well as pause operations
Manually turning coolant on/off
Always keep an eye on the milling operations