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The Clock Project consists of 5 hand machined parts. An aluminum base, brass pen holder, brass nut, steel pencil holder, and a polycarbonate clock face. The clock is then completed with a pre-bought mechanism and hands. This project was graded under tight tolerances, some as small as 0.005".

Clock Project

Lessons Learned

In this project especially, I learned the importance of time management. Along with a strict deadline, limited machine time meant every student was pressured for time. With 140 students and only 6 machines, being efficient with your time was critical. Correctly managing your free time meant the difference between a polished finished product and a failing grade.

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My advice for future students is to start NOW. The earlier you start, the more time you have to fix mistakes. As novice machinists, these mistakes happen often, so give yourself a buffer. Your grade will thank you.

Cost Estimation

The cost breakdown for each of the machined parts are shown below:

  • Brass Round Stock (5/8" C360) - $3.95

  • Steel Round Stock (5/8" 1018 Cold Rolled) - $1.49

  • Aluminum Stock (2"x0.375" 6061-T6) - $3.96

  • Brass Hex Stock (9/16" C360) - $3.28

  • Polycarbonate Stock (5"x8") - $5.24

  • Clock Mechanism - $6.00

  • Labor - $960

    • $24/hr average machinist pay​

    • 32 hours of labor spent machining, sanding, and finishing

This results in a total estimated cost of $983.92.

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If I were to make 10,000 clocks by hand, this would take around 13,000 days and cost $9,839,200. Obviously, this is not cost effective or time efficient.

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If we assume a largely automated system and no labor costs, these 10,000 clocks would cost $295,700 and take 417 days to produce. Each clock would be then worth around $29.57. This is under the assumption that a robot costs 6$/hr and can produce one clock per hour.

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Clock Manufacturing - Automation

Automating both the brass and steel pieces can be accomplished with a CNC lathe. Turning, facing, drilling, and tapping can all be accomplished with this machine. A machinist would be needed to write G-code and to load/remove parts.

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A CNC mill can be used to automate the entirety of the aluminum base. All of the complex operations like chamfers and countersinks can easily be accomplished with the CNC mill. Once again, this would have to be run under a machinist's supervision.

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The clock face could be automated with a robot, but these cutting and drilling operations are easy to get in tolerance by hand.

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Finishing and sanding processes can be automated with a robot, yet these processes are also easy to complete by hand.

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