Conventional Shop Services :
The College of Engineering & Technology houses several areas of technical support. Under the Engineering & Science Research Support Facility the College provides services in:
- CNC & Conventional Machining, Welding, Fabrication and Electroplating/Anodizing
- Foundry and Pattern Shop,
- Computer Aided Design (CAD),
- Computer Aided Manufacturing (CAM), and
- Materials Testing Equipment.
Quality and precision are the primary goals of the ESRSF.
Machined and fabricated parts are inspected for accuracy throughout the machining process. Machinists use sensitive electronic measuring equipment while machining parts to achieve tolerances and specifications of each part. Upon completion, each part is inspected through a series of quality control procedures.
The facility houses a clean room that utilizes high precision measuring equipment and instrumentation, including a high-resolution, computer-controlled vision inspection system. This system is used to inspect, measure and, if needed, reverse engineer work pieces. The vision system performs measurements to .000002 of an inch.
Equipment within the facility's machine shop:
CNC Cincinnati-Milacron 1250 sabre with ab acramatic 2100 control- has four-axis' operation with a maximum of three-axis interpolation. This machine is used to machine a variety of drill system parts and components. Its large capacity allows for work pieces up to 50" x 30" x 26". This CNC machining center utilizes the latest computer technology for the machining of complex contours through paramatric programming (equational programming), solid modeling programming through cam software, and online quick programming of simple geometrys. This feature enhances the technical staff's ability to accommodate a wide range of machining jobs.
BridgePort series 1 CNC Milling Machines (2)- provide additional resources for high volume machining and drastically cut delivery time to the customer. They are capable of machining smaller complex and simple 2-dimensional work pieces. Their converational shop floor programming features allow toolmakers to quickly program and machine the work piece.
CNC BridgePort Interact 412 Machining Center- a three-axis, 12-tool station with a GE Fanuc Series O-Mate control that is available for multiple part production. Off-line part programming using a CAD workstation facilitates part design and production.
CNC Mazak Quick Turn ATC Lathe- has a unique feature of live tooling on the turret. This feature allows the technical staff to perform turning and milling operations in one setup. The result is a high precision machining process that can be performed without ever having to remove the work-piece from the chuck, which eliminates costly secondary machining processes. The Mazak CNC lathe has been used to machine drill system components for the past 8 years.
Engis lapping machine- for precision machining, is used to machine and polish workpieces of extreme tolerances (.000001 inch). Common applications are thin film polishing and material removal, sharpening to razor edges and finish machining of hardened materials. This lapping machine is located in the clean room facility of the engineering machine shop. After and during machining, the work piece is inspected with precision inspection equipment.
25" x 18" Nardini Gap Bed Lathe- where much of the large cumbersome work-pieces that require turning operations are performed. Drill system equipment such as barrels, large pulleys, housings, winch hubs, etc. currently are machined on the Nardini lathe. Other heavy applications include the machining of train axles and wheels for material science research projects.
Conventional BridgePort Milling Machines (3)- used for such applications as milling, drilling, boring, key way cutting, etc.
Conventional 15" x 50" Clausing Lathes (2)- used for turning, threading and boring of cylindrical workpieces. All of the conventional machining equipment contains state-of-the-art digital read outs and tooling.
Kent Automatic Surface Grinder- used for grinding flat and angular surfaces. This grinder has been used for sharpening ice coring cutters, core dogs, reamers and surface grinding precision drill system parts. An Oliver tool cutter grinder is used for the complex geometry grinding on double angle cutters, core dogs and reamers.
Tig, Mig, Gas, and Arc Welders- all have a capacity ranging from very intricate applications to heavy-duty. The Tig and Mig welders can accommodate a wide range of steel and non-ferrous alloys. The shop has an acetylene/oxygen gas torch for brazing and flame cutting, along with a Plasma cutting unit.
Foundry and Pattern Shop- one of the unique features of the ESRSF. The foundry can produce brass and aluminum sand castings. The crucible capacity is approximately 125 lbs. for brass and 20 to 25 lbs. for alumininum. The pattern shop and foundry add versatility to the Engineering shop services by furnishing high quality casings. In the past, the foundry was utilized by the Polar Ice Coring Office Engineers for the production of winch hub and bearing housing castings. The patterns for these winch parts are still in the inventory of the ESRSF.
Betenbender Heavy Duty Shear, Edwards 100 ton Iron Worker, and additional hand brakes and foot shears- turn in-house fabrication and sheet metal work into routine services for the machine shop.
Materials Testing Bay- houses computer controlled testing machines that can perform a variety of material and structural tests. The capacities of thes testing machines is from 0 to 440,000 lbs. A torsion testing machine is available for testing barrels, well screens, drive shafts, gears, and more. Impact testing equipment is also accessible for impact tests on metals, plastic, and other materials.