Fabrication for precision mechanisms. Final report

The fabrication of components and assemblies for miniature precision mechanisms provides a variety of exacting manufacturing challenges. Size alone makes many parts hard to pick up, handle, measure, and install. This same small size causes more distortion or bending during machining, assembly, and welding. Some parts even float on the cleaning and deburring solutions. Tools break easily in very small holes, and surface finishes play an important role in part operation. Twenty-five manufacturing operations were studied to improve the precision of existing machining and assembly techniques. The study included the machining of metals and plastics using techniques new to the manufacture of miniature switches, timers, and actuators. Drilling, tapping, and press-fitting miniature features were evaluated. Fixturing and handling techniques, friction reduction, and the forming of ceramic parts were also studied. Many of the new approaches from this study have been incorporated into existing processes and further refined. Detailed observations have been reported in 33 other Bendix reports and the highlights of those observations are summarized in this study