Date: November 4, 2022

Lab Section Number: 006 19932

Lab Day and Time: Friday 11:00 am – 12:50 pm
Lab Instructor: Alexander Hoang

MET 245 Manufacturing Systems

Project 2 Hammer Project
Report

Team Members:
Siqi He
Connor Harris

Introduction:

The purpose of this project is to learn about material removal processes and get an understanding
of machine tools and handling in a group setting. As a group of two, students learned about
machine tool handling on hammer heads and handles by using the lathe, cutting cools and surface
grinders to produce a functional hammer from metal blocks/ cylinders.

Process Routing Sheet

Operation Detail Sheet
art: Hammer Head
Material: 1018 steel, hot rolled, 1” hexagonal bar
 Cutting Tool Parameters
Op Operation Machine Workhold Tool
Mat Spee
r. # Description Tool ing Holder Type Size Feed DoC
er. d
Saw to rough length
band saw
of 3¾ inches.
MetalMizer blade with 250 -
Workpiece: 1" 1”
10 vertical vise N/A kerf 0.055”, N/A 275 varies N/A
hexagonal 1018 steel wide
band saw high-speed fpm
bar.
steel (HSS)
Mill the workpiece to
3.5” length. Two
workpieces will be
Cincinnati
cut in the same 0.100
horizontal milling 6" diameter 6"
time. 46 1.0 ’’ for
20 milling vise machine with 24 diamet N/A
Workpiece: 1'” rpm ipm each
machine arbor teeth er
hexagonal steel bar cutter
(arbor mill)
stock sawed to 3.75”
length

Slab milling of one

side of the chisel (20º
Cincinnati
bevel surface). Two 12 tooth
horizontal Fixture milling 3"
workpieces HSS plain 102 2.0 0.100
30 milling with 20º machine diamet N/A
will be cut at the milling rpm ipm ” max
machine angle arbor er
same time. Operation cutter
(arbor mill)
40 may be performed
before this one.
Run existing program
to face mil one side of
Hurco 0.100
the chisel (20º bevel
VM10U milling 7 teeth, face ” max
surface).
5-axis machine milling 4.5" rough
Only one workpiece 609 14.6
40 vertical vise with N/A cutter (shell diamet cut
will be cut at a time. N/A rpm ipm
CNC 20 degree milling er 0.200
This operation may
milling jig cutter) ” first
be performed before
machine cut
Operation 30.

cross
Surface grind two
feed:0
sides of the hammer
1/2" wide .050”
head to produce the
grinding infeed
correct grinding 7”
Surface magnetic wheel with 3450 : TBD
50 workpiece width of wheel diamet N/A N/A
grinder table ceramic rpm traver
0.985±0.005 inches. arbor er
(Al2O 3 ) se
Two workpieces will
grit feed:
be ground at the same
hand
time
feed
Run existing program Hurco #6 HSS center center
to: VM10U center drill drillin drillin
milling 3
Centerdrill to prevent 5-axis 7/16" g g:
machine differe
60 the drill from vertical collet diameter N/A 978 0.002 N/A
vise with nt
walking. CNC two flute rpm ipr
locator tools
Drill the hole to milling twist drill drillin Drilli
depth. machine (HSS) g: ng:
 Counterbore a flat 5/8" 698 0.006
area for the handle to diameter, 2 rpm ipr
seat toothed Count Count
counterbore erbori erbori
cutter ng: ng:
2750 .004
rpm ipr
Cut internal threads
using hand tap. This guide rails
H
operation can be done of 1/2-inch 13
70 and-tapping tap collet ½” N/A Hand operated tool
after hand-tappi TPI NC tap.
station
chamfering ng station
(Operation 80)
Chamfer end of the
workpiece to remove 1.25×1.25
Monarch 80° parallelogram-shaped
sharp edges. This 3-jaw inch right 350 Hand
80 engine with 1/2" inscribed circle, 0.08”
operation can be chuck hand rpm feed
lathe. uncoated carbide.
done before holder
Operation 70.
stamp end of
90 workpiece for none N/A
identification
Degrease the
10 workpiece, black
none N/A
0 oxide dip, wash, dip
seal, and dry.
 OPERATION DETAIL SHEET
Part: Hammer Handle
Material: 6061-T6 aluminum, 1” round bar

Cutting Tool Parameters

Op Operation Machine Workhold Tool
Mat Spee
r. # Description Tool ing Holder Type Size Feed DoC
er. d
band saw
Saw the bar stock to
MetalMizer blade with 250-2
97 1"
10 vertical vise N/A kerf 0.055”, N/A 75 varies N/A
/ 8 ” (9.875”) length wide
band saw high-speed fpm
steel (HSS)
0.100
"
Face one end of the max.
532 Hand
hammer handle to 80° (
rpm feed
9.625" length. parallelogra rough
(roug (roug
Workpiece: 1'' 1.25×1.25 m-shaped 1/2" cut, to
h cut) h cut)
diameter aluminum Monarch 3-jaw inch right with 1/2" inscrib be
20 N/A 700 0.005
bar stock sawed to engine lathe chuck hand inscribed ed calcul
rpm ipr
approximately 9 7 / holder circle, circle, ated)
(finis (finis
8”(9.875”) uncoated 0.010
h cut) h cut)
length carbide "
(finis
h cut)

Center-drill one end

of the hammer to
accept the live center. 60º center
Monarch Jacobs
Workpiece: 1" 3-jaw drill, high #4 700 Hand
30 engine drill N/A N/A
diameter aluminum chuck speed steel size rpm feed
lathe. chuck
bar stock faced on (HSS)
one end

0.100
Turn the 0.875" body
"
diameter. The length 80° 532 0.015
max.
of cut should be at parallelogra rpm ipr
(roug
least 6", taking m-shaped (roug (roug
h cut,
care not to hit the 1.25×1.25 with 1/2" 1/2" h h
3-jaw to be
spindle at the end of Monarch inch right inscribed inscrib cuts) cuts)
40 chuck and N/A calcu
the cut. engine lathe hand circle, ed 700 0.005
live center alted)
Workpiece: 1" holder uncoated circle rpm ipr
0.010
diameter aluminum carbide (finis (finis
"
bar stock - faced on h cut) h cut)
(finis
one end
h cut)

Chamfer the end of

80°
the workpiece to
1.25×1.25 parallelogra 1/2"
remove the sharp 3-jaw
Monarch inch right m-shaped inscrib 700 Hand one
50 edge. chuck and N/A
engine lathe hand with 1/2" ed rpm feed cut
Workpiece: 1" live center
holder inscribed circle,
diameter aluminum
circle,
bar stock processed
 with operations 10 uncoated
through 40. carbide

Workpiece: 1"
diameter aluminum
3000
bar stock processed
rpm
with operations 10 0.015
CW
through 50. ipr
(roug
This CNC lathe is a (roug
h
rear type lathe so the h
turnin
tools are mounted turnin
80° g and
upside down. g and
parallelogra facing
The CNC Lathe will facing
m-shaped 1/2" ) 0.125
perform the )
special with 1/2" inscrib 3500 ”
following: 1×1 inch 0.005
center tool inscribed ed rpm (roug
- Face the handle to right hand ipr
adapter circle, circle, CW h cut)
the finishal length. Hurco CNC holder. (finis
60 for the uncoated N/A (finis 0.005
- Center drill the lathe h
turret. carbide #4 size h ”
remaining end of Collet and turnin
60 turnin (finis
hammer to accept the live center g and
#4 size 60º degree g and h cut)
live center facing
center drill, center facing
- R ough turn and )
high speed drill )
finish turn the major 0.006
steel (HSS). 1800
thread diameter ipr
rpm
0.005" smaller than (cente
CW
the r
(cente
nominal major drill)
r
diameter.
drill)
- Rough and finish
turn the 2.5º taper.

This thread relief

groove will create a
zone for disengaging
the cutting tool
during the subsequent 0.125” wide
1.25×1.25
operation of thread 3-jaw grooving to be
Monarch inch 532 Hand
70 cutting. chuck and insert, 0.125” N/A calcul
engine lathe grooving rpm feed
Workpiece: 1" live center uncoated ated
holder
diameter aluminum carbide
bar stock processed
with operations 10
through 60.

Cut a thread 0 .055 to

0.057 inch deep using
the compound infeed 60 degree
13 11
method 1.25×1.25 threading
3-jaw thread passe
Workpiece: 1" Monarch inch insert, 1/2" ½” 98
80 chuck and N/A s per s@0
diameter aluminum engine lathe threading wide, wide rpm
live center inch .005"
bar stock processed holder. uncoated
(TPI) depth
with operations 10 carbide
through 70.
 stamp end of
90 workpiece for none
N/A
identification

Comparison of Recommended and Used Machining Parameter

PROCESS OUR PARAMETERS RECOMMENDED

PARAMETERS*

MILLING HAMMER HEAD TO 46 rpm speed at 1 inch per minute 65-110 feet per minute
LENGTH feed

DRILLING HAMMER HEAD 698 rpm with a feed rate of 0.006 60-100 feet per minute
inches per revolution

MILLING HAMMER HANDLE 532 rpm filled 165 feet per minute
TO LENGTH

TURNING THE BODY DIA. OF 532 rpm with a feed rate of .015 2820 feet per minute
THE HAMMER HANDLE inch per revolution then 700 rpm
with a feed rate of 0.005 inch per
revolution to finish

DRILLING HAMMER 700 rpm fed by hand 350-400 feet per minute
HANDLE FACED END

*all feed rates relative to recommended rpm

Cost Calculation:
Calculate estimated price of one hammer head if you make a) one (1) part, b) two thousand (2,000)
parts.
From the process routing sheets, we know that it takes 0.792 hours to finish one hammer head. Hourly
wages of a machinist in the U.S. is $23.67, the labor cost would be $18.74 per hammerhead.

1) Estimated material cost is $1 per hammerhead. $1+$18.74 = $19.74

2) For 2000 hammerhead: 2000*19.74 =$39,490.65

Conclusion:
Overall, this lab was a positive and valuable experience useful in learning and understanding a
spread of processes used to manufacture products. In this lab, most of it seemed to go according to
plan: all but one of the processes were able to be executed by all of the groups. One of the processes
some groups were unable to perform on their hammer handles as there were either issues with the CNC
or the program that it was running. When working on the handle, it didn't pass the go no go gauge, the
problem was fixed after we trimmed the diameter down with the lathe. The great things about this project
are that we were able to have hands-on experience with the machines and were able to gain a minor
amount of machining knowledge through completing this lab. Something that might make this project
better would be if a knurling process could be added to the hammer handle so students could learn
about another manufacturing related process relevant to metals in addition to having a hammer with
better grip and overall usability.