• A printout/plot of the drawing(s) used in this lab (including the location of all clamps and the drawing origin);
• Setup instructions (in MS Word format) including a screen shot of the ToolPath Output window and instructions on how to properly secure the workpiece stock to the router table); and
• A final part (standard size).

Assignment Notes

• To build this project from one (1) piece of material, the nominal stock size would be ½" thick rectangle approx. 5¾" (X) x 5½" (Y). This size allows for at least ¾" clamping of the corners.
• Choose an inexpensive and soft (i.e., easily routed) material such as plastic, tempered hardboard, MDF, oak, or walnut.
• Appropriate provisions must be made to securely clamp the workpiece to the router table. Allow at least 1" of additional edge for this purpose. The instructor must approve the final setup prior to the student running the program.
• The drawing origin (X0,Y0 ABS) must be located in the parts' upper right corner at least 1 inch from the outside edge of the part.
• The router paths will be generated using the existing AXYZ tooling. For the unscaled part made from ½ thick material, the depth of cuts can be set at either ¼" for thinner sections or ½ for the through cuts. Use the ¼" DIA straight cutting bit (Tool #1) for all cuts including the holes for the 5/16 DIA pins.
• The minimum part thickness would be ½" thick. The thickness of the stock will vary depending upon the final approved material. If the final part is to be over ½ inch thick, use ½ the total material thickness for the thinner section cuts. As the maximum depth of cut of Tool #1 is 0.188 inches, use the multipass option in the Output window for cuts deeper than 0.188".

Hints for making the Geneva Gear Assembly

• The outer circle around the Geneva gear is to be used for setting up a 2D engrave for thinning out the outer part of the gear.
• If the drive pin is to be made from a different material, delete the pin's circle and use a small diameter bit and drill through the material at the designated point.
• If the drive pin is to be made out of the material, create a circle outside the driver geometry and use ToolPath's 2D engrave feature to generate the two bosses.