Phase 4 Instruction
MECH 323 Machine Design
Appendix: Phase 4 Checklist
* This document (in .doc) must be downloaded from the course website, completed, and
included in the Phase 4 submission package.
Dimensional Rules
Check
Dimension A:
Distance from the base of the gearbox to the center of both the input and the
output shafts should be exactly 41.27 mm (1.625")
Dimension B: Input and output shafts must have a hexagonal length of at
minimum 10 mm while the protruding part of the shaft is greater than or equal
to 15 mm.
Hex couplers have a standard size: 4, 4.5, 5, 5.5, 6, 7, 8, 9, 10, 11, 13 mm
Dimension C: The end-to-end distance between the ends of the input and output
shaft must be exactly 66 mm
Dimension D: The center-to-center distance between the input and output shafts
must be no greater than 65 mm
Dimension E: No part of the gearbox (this includes housing, gears, shafts, tabs
etc) may extend beyond 132 mm along the length of the wooden base
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Phase 4 Instruction
MECH 323 Machine Design
Shafts and Bushings
Check
Shafts have been sized to fit inside bushings
Bushing part numbers have been provided in the McMaster-Carr Order From
(below) and the appropriate bushings present in the CAD model
Shafts provide adequate room for, and a method of transmitting torque to, gears
Shaft design allows for assembly
Input and output shafts are placed on correct sides of housing
Housing
Check
Housing looks robust enough to not break. CAD model is well made and includes
no broken features
Housing provides some method of alignment between the two or more
components
No protrusions from the housing are smaller than 2-3mm (too small features will
not be printed properly.)
Housing includes spots for screws to mount to the wooden base and access room
for tools (if using supplied screws then holes are sized for M6 screws of ½”
length)
Housing can be assembled/disassembled
Housing includes bearing (i.e. bushings in Phase 4) bores, and shoulders to keep
bearings (i.e. bushings in Phase 4) from coming out
Printing Time
Check
Catalyst print time is under 8 hours
Catalyst print time is clearly and explicitly indicated in “Group X Phase 4
Report.PDF” document.
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Phase 4 Instruction
MECH 323 Machine Design
Printing Orientation
Carefully read Phase 4 instructions, and choose one of the two following options.
Option
Check
(1) Standard orientation as specified in Table 1 in Phase 4 Instructions
Do NOT include “Group X Printing Instructions.PDF” document
(2) Custom orientation that is different from the standard in Table 1 in Phase 4
Instructions
You must include “Group X Printing Instructions.PDF” document in your
submission package
McMaster-Carr Order Form
ID
(shaft
diameter)
OD
(outer
diameter)
Length
McMaster-Carr Part
Number
Price/Unit
Quantity
Total Price:
Assembly and Testing of Your 3D Prototype
Carefully read Phase 4 instructions, and choose one of the two following options.
Option
Check
(1) Student Testing
You must sign up for a testing session by sending an email to
bradley.taylor@queensu.ca. (First come, first served.)
(2) TA testing
Further manufacturing processes (e.g. drilling) are not allowed.
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