ELEVENTH WEEK

  Eleventh week

For this last week we must fulfill a huge workload. my coworker and I must arrange meeting with other coworkers from Salesianos and get to an agreement to go forward in every single tasks which was assigned through the week. Next a working plan is going to be shown:

Taking a look at the document  on the right side, we can easily notice that there are several milestones which are required to be presented in a specific day or week.

As we can realize there are some quite outstanding tasks to fulfill each day of the week.

On december 17th, We are engaged to provide all blueprints relating to our project.

On december 18th, We are engaged to provide our final technical report which must contain all the stages of the project from the beginning up to the last steps and arragements that my coworkers and I have done. Inside this final document must have all the points that our professors from both schools have assigned.
On december 19th, we will have to speak about our final outcome in from of  both schools (Maristak- Salesianos). To give our final speech, we will use the media or a specific type of telecommunication.
On january 9th, my coworker ( from Maristak) and I will defend our proposal and tell why this should be taken into account to be manufactured. On the other hand, we must explain why we have selected specific heat treatments and their advantages.

Starting the week, my coworkers and I had a big delay linked to the delivery of a specific task from the last week, We could not deliver our 3D pieces on time, because we didn't have a good communication between us. After dealing with this kind of  throubles, we must have gone forward and half part of our group had to draw blueprints and the another one had to carry on writing our final report down and make a small presentation for our final speech. A day before final presentations, we concluded with the majority of our deliveries.  Finally we had to focus on finishing our final report which contained several mistakes.

The last milestone came, all of us were quite nervous about this, We had no clue about how to start giving our speech, and we knew that all professors were engaged to score us. After some minutes all of us organized our turns to provide the speech and finally it turned out quite fine. Most of the group extended their speech, but we decided to provide it to the public in only 5 minutes, perhaps it was not a quite good idea, but our professors told us about it, they said: "Each speech must only last 5 minutes no more because there are a hugh amount of groups", so we fulfilled their requirement.

What has to be presented inside our technical report and final speech?..... Now I am going to make a summary about all aspects that must be presented in the last stage of this challenge:               

1) Descritptive memory
Inside this document we delivered the following points:
- Identification of  troubles to be treated
- Proposal from each one of us in order to solve defined troubles.
- Selection of best proposals among us, or enhance a specific proposal in order to fulfill it with the parameters which were specified beforehand.
- Drawings from the selected sketch and prepare 3D and 2D models by using software engineering applications such CATIA V5 and SolidWork 2019.
- Bill of material (BOM), where the teamwork must specify all elements which were used to complete our project.
- Scheduled and programmed plans which were used to accomplish every single milestone.
- Working plans and documents where must show all agreements that the teamwork has engaged.

1.1) Documents to be presented

On the right side there is a sample of type of documents that must be presented inside the technical report. In this case the document on the right is called " Meeting report", inside this document is registered all activities relating to tasks from each day. It was a completely reliable document to organize our work every single day in this period of time.
On the other side, meeting reports must be included inside our final descriptive memory in the last part of it, specifically in annexes.

As we can see, there is a document which are located below on the right side, and it is named "Working plan", here one member of our group had the mission to complete and register all tasks through the entire weeks. This document was essential to go step by step through all our project. In the first lines it has a summary of all troubles which were treated, and some pictures of it.
On the other hand, this report must have be included by all groups from both schools.This was included in the last chapter of our report which was called "Annexes".

1.2) 3D and 2D models
In this subsection we drew our main ideas to solve all troubles through CATIA V5 and SolidWorks 2019. Fortunately we already have some training using those software so we could accomplish our tasks linked to this subsection. Nex some 3D and 2D models will be described:

1.2.1) Tool holder subassembly

The major function of this element is to hold all cuting elements which count with a hugh amount of differents cross-sections. It is composed of 16 components among scews, springs and solid pieces of metal.

On the left side, we can see the entire body of the assembly, yellow screws (commercial elements) help to press the cutting element through a small rectangular metal plate. When it's needed to return to its original position then we have to unscrew it and some springs help to do it in an easily and constant way.

1.2.2) Turret subassembly

This assembly is composed of 6 components and those are attached mechanically each other. The main purpose of this set is to hold and lock our tool holder which was seen before. There is a handle which is joined to an eccentric bushing which makes possible move 2 drums which are located in the cube sidelong.Two drums are activated by the eccentric bushing when it turns around the axis of the central screw which belongs to the lathe and lock the tool holder by pressing it.

1.2.3) 2D blueprints
In this part we are going to show some samples of  2D blueprints which were drawn by both groups (Salesianos and Maristaks). This point is pretty essential because through these blueprints fabricators will lead themselves to accomplish this purpose. Next some samples of 2D blueprints:

TENTH WEEK

Tenth Week

Nowadays we have a huge workload to do, the scheduled plan for this week has serveral activities to do from mesuaring up to drawing our solution to our current trouble. Our professor gave us new tasks to fullfil this monday.

We have made the pieces in 3D, for this we have used the software program of Catia. Each group, both those of Maristak and those of Salesians, have divided the work to have a good organization. we, Maristak, have made the toolholder and Salesian, the turret. In each sub-assembly, we have many parts that we have to assemble. When assembling the pieces to create or make the assembly, we have not had any problems, since the catia tree is well made

For this we have communicated via whatsapp and via video call.We make video calls twice a week. In this way we communicate and have a greater proximity, in case we have doubts, we have to modify something or just to see the files. Another option would also be to make calls, since seeing or not seeing each other's faces has no impact on anything.

For this Friday we have to deliver, a small explanation of the pieces, because we use them and because we need them, with their respective photos and 3D with their respective format.

On the other side, my teamwork and I have designed a turret, which is composed by six components . All of those components make our turret. Now I will describe a bit each one:


1) Body of the turret
Its main function is to hold the anchor bolt in the middle and other bushings. Its made of A36 which are pretty cheap. It counts with outstanding geometric and dimensional tolerances in order to support the toolhonder.

       

2) Eccentric bushing

Its main fuction is to move the side block drums which constraints any kind of movement from tool holder.

       
                                
3) Quick adjustment lever
This is an element which helpt to activate the side block drums through the eccentric bushing, its quite fundamental at the moment of starting any operation inside the lathe.

4) Side block drums

This element helps to lock the tool holder to be stated in a specific position which mean it makes the tool holder be positioned in one point.

Here there is a sample of our turret in one piece:

NINTH WEEK

Nineth week

This week we were presented with a new challenge. Now, we have to work with students from another center, exactly students of Deusto, from the Salesian Center of Deusto. In this new challenge we have had a problem with the conventional lathe. To be more precise, we have to design or redesign a tool holder and a turret. when we want to cylinder we have to put on chocks or worse, use tools to fit them. For all this, we are taking a planing, communicating with them daily and making two weekly video calls, to follow up equally.

To do a good job, apart from our teacher helping us with the whole challenge, we have a new teacher, who is doing a master. She has studied mechanical engineering and knows the world of work. This has helped us to make some templates to be able to do the work. It has also helped us to follow the deadlines for not arriving in a hurry to the last week of the challenge, which is in January.

At the beginning professors provided us the needed material to proceed to prepare the current challenge solution so students could notice what they were pointing at. Within those steps are included a lots of stages which they named milestones and deadlines.  

The first stage was to recognize the theme or trouble that was needed to solve, once this point was clearly defined then we proceed with the next step which was to collect information about a possible previous solution linked to our touble by other people; my team and I found enough info to begin to create new possible solutions for our challenge.

After doing the first steps we carried out with the next steps. We met up with our new colleagues from Salesianos and clarified ourselves what we need  to solve and how we would do it.  Once we ended this up , each one started to draw proposal to solve the current problem. Before getting to thursday, we have already had all proposals of us. Then one of us wrote the technical report  down for the first milestone which was required to be presented on Thursday 5th.

A new employee indicated us how we must write our  first report down, I mean in a proper way so the judges can get a good presentation in the first milestone. This new employee gave us general highlights or point that must be included inside the report such as titles, logos, index, the current trouble, references, blueprints, descriptions.

Next we show a sample about how we had to provide our technical report to our professors:

Once we ended this up, we must carry on with the selection  of  a best proposal and modify it in order to get a reasonable idea of how to give  a solution to the current trouble. Students from both institutes  organizing all tasks for the next week.

Something that I forgot to say was that new groups were created (mixed groups), a half is from Salesianos and the other half is from Maristak. The major purpose of doing this is to evaluate how we work with other people and develope new abilities related to communication.

Nowadays we are involved in enhancing an unique proposal  so that we can carry out with calculation, type of geometry (dimensions); strength of materials, among others.

EIGHTH WEEK

EIGHTH WEEK

 We started the week on monday, with Julen as always. But it was a little bit different because we read the stories about maleness. And we chose one to be read in Areto nagusia.

We had two exams on tuesday, with Gaizka. The first was about cutting and bending forces and the second was about answering some oral cuestions about our die, and project in general.
 For example:
Where can we find docks, in which catalogue?
What is the measure of the matrix?

Our group answered succesfully most of the questions.
This week is one of the most stressful week of the course because we have to finnish the project and make a presentation about it.

In the current week we must present our final project before a lot of people (Professors, students, and judges). We must explain stuff linked to design process, for instance capacities, weight, length, width, performance, quality of manufactured pieces. However we had to fill our technical support with other subjects such as: Market Study, Analysis and faults and effects and mathematical calculation.

Next, We are going to show some pictures of the final product (Our piece of equipment)

Here now , we are going to make a brief description about how our die works and their main components:

Springs: This component is located between two plates, one is in the top and the second one is located in the medium part. Its principal performance is to separate the cut area from the punches because when the process of cutting happens the sheet metal to be cut and the punch are used to attach each other. Next we can see a commercial spring:

                                             

Spike: This component helps the operator to handle the entire piece of equipment or die, which is very heavy and impossible to remove easily, this way the operator can do inspections and maintenance to the die. This element is bolted in the upper side of the die and next can be moved with a forklift.

                                                     

Eyebolt:  This element is bolted on the die's sideways and owns a high capacity to resist huge loads; it is usually used to handle and lift piece of equipment, machinary in order to offer maintenance, overhalls, inspections and other tasks. 

Matrix: This piece of metal is highly significant at the moment of cutting sheet metals or do other operations like bending, sheet metal forming. It is made of special materials and suffers different treatments in order to harden their structure.

Our die has different dimentions such as: Length_: 500 mm; Width: 350mm ; Height: 245mm. Our die has a height equivalent to 230mm when it is totally close.

 Moreover we had the chance to add the market study to our final technical report, there we talked about the responsabilities of each of us and designed an organigram.

In this organigram we assigned a position to each member of our company within the created areas.

                                               


On the other hand, we remind people of social responsibility and showed our strategy plan to deploy it in every single of our operations. We are engaged with  the ecological caring, responsibility with people because they are the most valuable asset in our operations, and  our relationship with other business located in the place we work.

                                                  

Finally, friday came and we gave our speech to the public  (professors, students, external judges and other people). At first hand one member of our teamwork had to talk about how we created our company , the critiria that we have followed in order to create our company, later another member talked about how important a die can be in our daily basis. The third member of our team had the opportunity to talk about the design of the die in a complete way, giving all details and followed criterias to achieve our goal.

After giving all our speech the judges started to ask lots of questions about the design process , for example: materials, calculations, properties of our die, dimentions. We also had the chance to reply some of them and asked some doubts that we had. The experience was very productive and we obtained more knowledge linked to construction aspects, materials and recommendation at the moment of design this kind of machinary.

SEVENTH WEEK

MONDAY: On Monday we did the three exams, one of English another of Catia and another of Materials. The english exam was about writing a letter and explaining about the course. With Julen we had to make a piece with different parameters. With Gaizka we made a test about materials we use for dies.

TUESDAY: We reconditioned and positioned the punches with new parameters. These parameters were three different levels to be able to assemble the punches. the first level was a offset of 0.1, the second was to 0.2 and third was to 0.5 offset.

WENSDAY: We continue working with the die. Inserting punches and making their acommodation to continue assembling and we continue making commercial alements in Catia.
Also, we have almost finished the project budget.

THURSDAY:

We continued with the assembly of the die, we must have the 95% finnished for next day. We also finnished the budget. The budget is about materials and now we have to do the rest of the budget, salaries and things like that.

FRIDAY:

Today is the "descargo" to present the project. As I said before, we must get the 95% of progress to get a good mark. We also finnished the budget we started yesterday.

SIXTH WEEK

SIXTH WEEK:

Monday:

We started the week with Julen, we designed two pieces to improve our skills with the operations "rib" and "slot".

 

We made a little test with Gaizka about dies and their properties. There we saw questions like: what type of dies do you know? Which are their main features?

We made a reading with Richard about the internet, it was quite interesting.

Tuesday:

We had the whole day to keep on the design of the die. We chose the role of everyone in the group and we kept working on. We chose all the materials that we will use for the die. We finnished the OP 10.

Wednesday:

We kept on with Catia in the first two hours, we used the helix operation.

With Nagore we saw how to make a graphic with the tolerances. And we learnt the % of the tolerances.

Thursday: 

We spent the whole day designing and assemblying the bushes for the die. Even Julen helped us with it. While some of the group were designing, other were searching information about the materials we are using for the die´s components.

This is the excell of materials so far:

Friday:

We measured the "sufridera" (which was machined by 2CMM) in the tridimensional machine.

FIFTH WEEK

FIFTH WEEK

We started the fifth week with Julen as always, he gave us some excercises of Catia. We continued improving our skills with parameters.

With Gaizka we continued designing the die, we insterted columns, seven plates and bushes. Gaizka made a evalution of how the groups are working until now.

The next days, we continued designing the die, we started inserting bushes after drawing them. We also inserted a "tapete".

Gaizka explained us the cutting forces. This way we can search the gravity center of the die and all the plates.

With Nagore, we learned some new things, like the "moda" in a group of numbers. The number which repeats more often, is the moda.

She also teached us the variance of a group of measures. Which are into the tolerances and which are not.

FOURTH WEEK

FOURTH WEEK

We began the week with Julen, as always. He explained us how to create a design table. Here we can choose the parameters for the piece, this way it will be easier to make changes. We use Excel for this.

With Gaizka we started inserting the bushes in the die. For this we made one sketch to draw it. When we finish drawing it, Andrea assemblys it to the die.

Until now, the die is like this:



With Iranzu we continued doing the market study for our company.

We haven´t got any classes with Nagore, because she has been very busy with DFM1 students.

With Richard, we made a listening to improve our skills, we also started preparing for the exam, that will be a letter.

This week was quite short, because we didn´t have class on friday. On thursday we went to Mercedes Benz company in Vitoria-Gasteiz.
We arrived there at 10 am and it lasted 2 hours more or less. There, we saw lot of things about manufacturing of Mercedes cars.
The company was separated in three parts, the first one was the assembly of the external parts of the cars, like the roof, doors...

Then, they carry them to the painting zone, here they use anti corrosives and paintings.

Finally, they carry the cars to the internal assembly zone. Here they put all the components to finnish the car and send it to the customer.

It was a very good day because we learnt lot of things. We think it is possitive to see how they create a car from zero.

THIRD WEEK

THIRD WEEK:

The third week we started making parameters in the tree of catia with Gaizka. Also, we maked sketches in this tree to make ours plates. these plates are: the sufridera, motherboard, top plate and matrix holder.

Gaizka also kept track of how we are working at group level for the challenge.

Nagore's about subject, we continued learning and practicing with tridimensional machine. During one hour, we practice concepts like the point, the plane, points of origin, edge...
Then, we started making AMFE as a group, in this AMFE what we do is an analysis and possible failures of the sufridera and our design band.

With Julen we continued doing pieces in Catia, exactly the piece of the exam that we made on Monday. He began teaching us how to introduce parameters on Catia. This way, when we want to make a change on the piece, we will not lose the form of it.
On Monday, we maked a exam that it lasted an hour.Here I put the piece we did.

With Richard we maked some reading exercises about manufacturing processes as reading and listening.




And finally, with Iranzu we continue doing a market study. The rest is done, like the slogan, logo...then we will think something that differentiates us frome other companies.

This is our DAFO: