Simple Design

In this component you will learn some of the basic elements in designing a simple part
for an assemble. The piece you need to design is a plate that will be fastened to 4 posts on
an overhead apparatus. The plate needs to run along 2 rods that form a track. Therefore
the plate will need to contain 4 linear bearings that are lightly pressed in. The entire
assemble will weight approximately 100 pounds. You will need to design the plate,
specify which linear bearings and other parts you need to use, provide all the
manufacturing details, and a simple cost analysis. The figure below shows all the critical
dimensions. The following tables provide information related to design specifications.
Major dimensions for track and attachment.

The following table lists different fit classifications. The exact tolerences are not listed
and vary depending on the basic hole or shaft size. The basic size is the nominal size. To
specify a hole 1.5" in diameter with a sliding fit the hole would be sized as 1.5H7.
Remember uppercase letters designate hole sizes and lowercase letters designate
shaft sizes. So the shaft size for the above example would be sized as 1.5g6.
Description of Perferred Fits Using the Basic-Hole System
Type of Fit

Subtype

Description

Symbol

Clearance

Loose running
fit

for wide commercial tolerances or allowances on

external members.

H11/c11

not for use where accuracy is essential, but good for

Free running fit large temperature variations, high running speeds, or H9/d9
heavy journal pressures.
Close running fit for running on accurate machines and for accurate

H8/f7

Description of Perferred Fits Using the Basic-Hole System

Type of Fit

Subtype

Description

Symbol

location a moderate speeds and journal pressures.

where parts are not intended to run freely, but must
move and turn freely and locate accurately.

Sliding fit
Location
clearance fit

Transition

provides snug fit for location of stationary parts, but

H7/h6
can be freely assembled and disassembled.

Locational
transition fit

for accurate location, a compromise between

clearance and interference.

H7/k6

Locational
transition fit

fit for more accurate location where greater

interference is permissible.

H7/n6

Locational
interference fit
Interference

H7/g6

Medium drive
fit
Force fit

for parts requiring rigidity and laignment with prime

accuracy of location but without special bore
H7/p6
pressure requirements.
for ordinary steel parts or shrink fits on light
sections, the tightest fit usable with cast iron.

H7/s6

suitable for parts which can be hightly stressed or for

shrink fits where the heavy pressing forces required H7/u6
are impractical.

The following table lists different standard thread sizes. Fasteners of different grades can
be easily found in these sizes. To specify a threaded hole use the size designation
followed by a dash then the threads/inch. An example would be 1/2-20. Also listed is the
drill size for threaded holes. All dimentions are in inches.
Specifications for Unified Screw Threads UNC and UNF.
Size Designation Nominal Major Diameter Threads/inch Drill size
0

0.06000

80

3/64

0.0730

64

53

0.0730

72

53

0.0860

56

51

0.0860

64

50

0.0990

48

5/64

0.0990

56

46

0.1120

40

44

0.1120

48

42

0.1250

40

39

Specifications for Unified Screw Threads UNC and UNF.

Size Designation Nominal Major Diameter Threads/inch Drill size
5

0.1250

44

38

0.1380

32

36

0.1380

40

33

0.1640

32

29

0.1640

36

29

10

0.1900

24

25

10

0.1900

32

21

12

0.2160

24

17

12

0.2160

28

15

1/4

0.2500

20

1/4

0.2500

28

5/16

0.3125

18

5/16

0.3125

24

3/8

0.3750

16

5/16

3/8

0.3750

24

7/16

0.4375

14

7/16

0.4375

20

25/64

1/2

0.5000

13

27/64

1/2

0.5000

20

29/64

9/16

0.5625

12

31/64

9/16

0.5625

18

33/64

5/8

0.6250

11

17/32

5/8

0.6250

18

37/64

3/4

0.7500

10

21/32

3/4

0.7500

16

11/16

7/8

0.8750

49/64

7/8

0.8750

14

13/16

1.0000

7/8

1.0000

12

59/64

1 1/4

1.2500

1 7/64

Specifications for Unified Screw Threads UNC and UNF.

Size Designation Nominal Major Diameter Threads/inch Drill size
1 1/4

1.2500

12

1 11/64

1 1/2

1.5000

1 11/32

1 1/2

1.5000

12

1 27/64

Below is a table listing the cost of labor and materials for this part. Assume it takes 2
minutes to remove 1 in3 of material on a CNC machine. When figuring the cost of
material make sure you add in the material that needs to be removed during machining.
For tapped and reamed holes you need to drill the hole first.
Cost of Common Operations and Materials.
Item

Cost

Aluminum

$0.75/pound

Steel(mild)

$0.30/pound

Chrome Moly.

$0.60/pound

Magnesium

$2.25/pound

Labor (all activities)

$35.00/hr

CNC machine (time)

$70.00/hr

Welds

$0.35/inch

Saw or tubing cuts

$0.40/cut

Tubing bends

$0.75/bend

Non-metallic cutting

$0.20/inch

Edge preparation for welding

$0.25/inch

Drilled holes < 1" in diameter

$0.35/hole

Drilled holes >= 1" in diameter $0.35/inch/hole

Reamed hole

$0.35/hole

Tapped hole

$0.35/hole

Sheet metal shearing

$0.20/cut

Sheet metal punching

$0.20/hole

Sheet metal bending

$0.05/bend