2. Sophomore Project – Spring 2014/15: Chess Set
ABSTRACT
The project for this year’s sophomore class was to design and manufacture a complete
chess set with board. The class as a whole had to determine a style for the chess set to provide
an overall guidance for the design of our pieces. The intent was having the pieces looked to
compliment the other pieces and complete the set. The board should have a distinct look. It
should not overpower or conflict with the look and feel of the chess pieces, but rather
compliment the set. Designs should also take into consideration the manufacturing process;
i.e. scale of material, material properties, and machining limitations. The latter being the big
concern for our piece, the knight. The initial goal was to produce twenty-five complete chess
sets. There is also an element to this chess set that makes it unique. What makes this set
unique is the chess pieces will sit atop a removable checker piece. A small magnet mounted
inside the checker hold the two pieces with together.
The initial thought when designing the knight was, the sky is the limit. We soon
realized there were going to be restriction on our design. First of all we wanted to break from
the traditional look of a knight piece, the horse figure. We wanted the look of an actual knight
in armor or at least the helmet portion of a knight in armor. This was our main consideration
when designing our knight. We considered and designed numerous concepts around this idea.
The school’s CNC lathes and mills are limited in their capabilities. This was a major facture in
coming to our final design. We still had a number of details in our final design that required
some challenging milling operations after the lathe operations were completed. The lathe
operation had some challenges of its own. The conversion of our DXF on the CNC Lathe was
not a smooth transition. Overall the final design turned out to be a terrific final product. We
are happy with our knight.
3.
4. Tooling & Fixture for Knight Piece
1 Tooling
1.1 LATHE TOOLING:
T0101 General turning tool
LH General turning tool
T4141 Grooving tool
Cutoff tool
1.2 MILL TOOLING:
½” End Mill for plume and helmet shape
1/8” End Mill for face
1.3 DRILL & TAPPING TOOLING:
Counter sink tool
Number 7 drill
¼”-20 UNC tap
2 Fixtures
2.1 ALUMINUM SOFT JAWS FOR LATHE CHUCK
2.2 LATHE CHUCK INSTALLED IN VERTICAL MILL FOR DRILL & TAP OPERATION
2.3 CUSTOM SOFT JAW MOUNTED IN JERGENS-BOCK BRAND QUICK CHANGE SYSTEM VISE THAT IS
MOUNTED ON THE HAAS 5-AXIS TRUNNION TABLE
2.4 CUSTOM ALUMINUM HANDLES WITH ¼”-20 BOLT FOR BUFFING OPERATION
5.
6. Knight Inspection Sheet
To be within tolerance, +/- 0.025”, of the knight specifications the diameter of the base
has to be around 1.25” to be able to fit in the checker base to complete the knight assembly.
Then the height has to be around 2.81” from base to the top of the plume or head gear. Along
with the face of the knight has to be on the center datum inside the mill operation, as well as
the taper to be in tolerance in ordinance with datum A and manufactured in the lathe process.
Measurement Description True Measurement Actual
Measurement
Critical Measures
Height of the part
(plume Included)
2.81” +/- 0.025
Diameter of The Base
(Checker Insert)
1.25” +/- 0.025
Diameter of Ribbon Base 1.48” +/- 0.25
Depth of The Face 0.206 +/- 0.025
Noncritical Measurements
Width of Plume 0.25” +/- 0.025
Height of the head 0.09” +/- 0.025
7. Purchase Order
Knight Tech
Mark Storms
Jesse Jacobs
Date: 1/28/2015
PO # 1
VENDOR Michael Paul
K & J Magnetics
18 Appletree Ln.
Pipersville, PA 18947
1-888-746-7556
Customer ID N/A
SHIP
TO
Dexter Hulse
University of Cincinnati
East Campus
1981 James Sauls Sr. Dr.,
Batavia, OH 45103
(513) 558-0008
Customer ID
Shipping Method Shipping Terms Delivery Date
Qty Item # Description Job Unit Price Line Total
1600 D41 $0.20 $320.00
D41
1/4" dia. x 1/16"
thick
Nickel Plated
Axially Magnetized
Subtotal $320.00
Sales Tax
Total $320.00
1. Please send two copies of your invoice.
2. Enter this order in accordance with the prices, terms, delivery method, and specifications listed above.
3. Please notify us immediately if you are unable to ship as specified.
4. Send all correspondence to:
Dexter Hulse
1981 James Sauls Sr. Dr.
Batavia, OH 45103
Phone 513-558-0008
Fax [000-000-0000]
Authorized by Date
8. Cost Breakdown
for Knight pieces
Material Cost Material
used
$53.61/144"x1.5"
dia.
330"= $124.91
Machine Cost Machine
hours
$25.00/hr 43hrs= $1,075.00
Total Cost $1,199.91
Total
Pieces
110
Cost per
piece
$10.91
Team Knight
Mark Storms
Jesse Jacobs
15. Sample of Weekly Report
Soph. Project
Weekly Report
Project: Knight Chess Piece
Week Ending: 1/23/15
Team Member: Mark Storms
Worked on the knight piece design and collaborated with team
member Jesse Jacobs. Awaited on class to design and share
base design.
Team Members: Jesse Jacobs
Mark Storms
Description
16. Sophomore Project – Spring 2014/15: Chess Set
SUMMARY
This year’s project seemed simple enough in the beginning, but once the semester got
rolling you soon realized how challenging the project was actually going to be. The semester
has come to a close and the project is just about complete. All the main chess pieces have been
produced, the checkers are about done, and the boards still have some work to be done. It will
still be a little while before we’ll see a finished and complete chess set, but not from a lack of
trying. I believe that once everything is done they will look AWESOME when put together!
I learned there is a lot that goes in to designing and manufacturing any kind of product.
There are all kinds of things that need to happen for a project to be successful. I believe that
the main things for any project to be successful are the people involved with the project. That
can make or break your project. For the most part our class had some good people that helped
make this project fun and worthwhile. Teamwork is another must in manufacturing. The
teams have to be on the same page when working towards a common goal. Communication is
very important, but when is it not.
If we were to do it all over again what should we do different? That is the million dollar
question. I believe that a definitive time table should be established in the first class of the
semester. The Gantt chart should be produce as a class no later than the second class meeting.
The design time table should be set in stone and picking of a final design should conclude by
the third class meeting. Get materials ordered early and double check that the required
quantities are correct. Another consideration would be to have people assigned to more than
one team. They could be assigned to a primary team and a secondary team. This could be
helpful when teams have absences during a particular week. That about sums up the
recommendations.
