Manufacturing the Camera

1
Camera Lab 5
Manufacturing Field Trip
2
Camera Systems Reverse Engineering

• Shutter
• Mechanical
• Flash
• Electrical Mechanical
• Case
• Manufacturing Materials

3
Camera Systems Reverse Engineering

• Shutter
• Mechanical
• Flash
• Electrical Mechanical
• Case
• Manufacturing Materials

4
Some things to think about, and who might think
about them

• Materials (MSE, Chem E)
• Processes (ISE, WE, Chem E, ME)
• Tooling molds and dies (ME, ISE)
• Production setup and plant layout (ISE)

5
Some questions a designer might ask

• Whats the best material for this part?
• Given the best material, how do I form it?
• How will my design affect how the part is
  manufactured?
• How does the manufacturing process affect my
  design?
• Can I make this using fewer parts?

6
Some things a manufacturing engineer might think
about

• How can I make this component most efficiently?
• How can I make it with the least amount of
  material, energy, and labor?
• What manufacturing process is best suited to this
  component?

7
Today well look at three important manufacturing
processes

• Thermoplastic injection molding
• is used for almost every part of the camera,
  except the circuit board, shutter, and springs.
• Sheet metal forming
• is used to make the shutter, springs, contacts
• Machining
• is used to make the molds for injection molding,
  and the dies for metal forming.

8
Injection molding

• Injection molding is a widely used process used
  for forming the groups of polymers known as
  thermoplastics.
• Thermoplastics undergo a physical change during
  molding, and can be remelted and reused.
• The other group of polymers, thermosets, change
  chemically when processed, and cant be reused.

9
To form polymer resin into components, we need to

• Bring it to a liquid state
• Inject it under high pressure into a mold
• Let the resin cool and solidify
• Open the mold and eject the part
• Close the mold and start again

10
The injection molding machine

• Heats the polymer until its liquid
• Clamps the mold shut
• Injects polymer into the mold cavity
• Holds it under pressure until its cool enough to
  retain its shape, and
• Ejects the part and starts the process again...

11
The injection molding machine
chemical
chemical
12
The injection molding machine
13
The injection molding machine
14
If we look at injection pressure vs. time
15
Some problems

• Filling the mold before the plastic freezes
• Designing the mold so that the part can be
  ejected easily
• Designing the part and mold so that we can
  produce the parts and make a profit.

16
What about the metal parts?

• There are several different ways of forming
  metal
• forging
• extruding
• drawing (the aluminum can!)
• bending
• rolling

17
Today, well look at blanking

• Blanking occurs when we punch a hole in a sheet
  of metal, and keep the piece (blank) that we
  punch out.
• When we punch a hole and keep the hole, then
  the process is called piercing.

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The blanking process
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The piercing process
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The punch press
21
How do we make the tools that form the metal and
plastic?

• By machining
• Milling
• Turning
• Grinding
• Sawing
• Electric discharge machining

22
Probably the most important machining process is
milling.

• Milling machines
• Can make a variety of complex shapes
• Can machine essentially any material
• Can be computer controlled
• Are widely used to make molds and dies
• Use a rotating cutter to machine a fixed work
  piece.

23
A CNC vertical milling machine
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Machining parameters
25
What well do today

• Form into supergroups of 12
• Go to Baker Systems 090 (basement)
• Your supergroup will move through four different
  stations injection molding, sheet metal
  forming, machining, and fixed-assembly.
• See handout for memo discussion questions.