In this project, my team and I were tasked with accurately measuring a food smasher designed by our professor and then reproducing it both digitally and physically. We began by taking precise measurements of the original part, which we used to create detailed 3D models in SolidWorks. After generating renders of each individual component, we prepared manufacturing drawings and moved into the shop to machine the parts. Using a variety of equipment, we fabricated, assembled, and tested the smasher to ensure it matched the original specifications. This project gave me valuable hands-on experience in the complete design-to-manufacturing cycle, including CAD modeling, technical drawing, machining, and teamwork in a lab environment
Objective:
Our objective coming into this project was to measure a food smasher that was previously manufactured and to replicate it through machining processes. During this project we aimed to refine our skills on the lathe and on the mill. We also exposed ourselves to a lot of different tools that we learned to use.
Raw Materials
- Rod of 6061 Aluminum with diameter of 1 inch
- Circular cut sheet of 6061 Aluminum
- ¼-20 Screw
Equipment/Tools
- Machine Lathe
- Machining Mill/Drill
- Cutting Tool
- Knurling Tool
- Drill Bit
- Screw Tapping Tool
- Calipers
- Rulers
Final/Revised Food Smasher Shaft With Final Dimensions
Process for shaft:
For the shaft we started with a large rod of 6061 aluminum and had to stick it in the lathe and secure it by using the chuck key to tighten the grip. This is where we ran into our first problem of it not being able to be perfectly centered. We solved this by adding a guide hole and the thing at the end that spins with the rod. We realized by still using the machine and cutting off 0.05 inches at a time we shaved off enough to make it centered to the spin. Once we had it to our desired 0.62 inches at the time we drilled our hole into the bottom. We had run out of time and had to take it out but the next class period we spent cutting off our excess metal, knurling and tapping our holes, but this is the day we ran into some big issues. While knurling something was messed up with the tool which made it press too hard onto the rod and caused it to defect where it was clamped. Because of this we had to shave off a little bit under the knurling causing it to be a slightly different size under. We sanded and shined it up as well as added a filet to the top and we were done with the shaft.
Final/Revised Food Smasher Plate with Final Dimensions
Process for the Plate The process of manufacturing a plate for the food smasher started when we received a metal sheet that was cut into a circle. We started by drilling a hole for the screw in the center and adding the taper. Next step was to flatten two of the sides so that we could properly secure it while milling. Once we had done that all we had to do was mark where we were going to mill and start. One of the revisions involved with this project was changing the size of the holes we milled and this was in order to make sure we finished the project on time. You can see this change on the final versus original drawing. Once we milled the holes we were complete with the plate. Conclusion Throughout this project I learned a lot about manufacturing as this was the first thing I have ever made. I learned about patience and how you must have it to preserve your tools life span and to allow your final product to come out perfect. I also learned some specific things along the way like about what I should fix for the knurling next time I use it. I feel that the best way to learn is to fail or to learn from others' failures. This is why for those who may be doing a project like this for the first time I advise you to talk to people like me who have done it and failed at certain things because if you talk to enough people you may be able to avoid all the mistakes before you. Original Drawing with Original Dimensions
