DIY

# Plug instead of a socket

At work, an electrician asked me: can I make a couple of stubs in glasses instead of dismantled sockets. Can I do it?!!! Let's see)))
First, I asked to give me exactly the same glass as installed. I will take off the dimensions for the manufacture of plugs from it. Well, he immediately brought me a piece of plywood. He says he just found such a piece (10). Tolstish, but oh well.
To create a stub model, I will use my favorite SolidWorks. A simple caliper is suitable for removing the required glass dimensions.
I measure inner diameter of the glass. It turns out that it is oval, not round !!! The size jumps between 63-65 mm. I'll take the average – 64 mm.
The basic dimensions are known. Create New part in the program.
Next with Extruded Boss/Base first I will draw a sketch, having previously selected the desired plane for it. In principle, in this case, it does not matter which plane will be used, it is more for rendering the file in the folder where it will be stored.
I draw a circle with a diameter of 64 mm.
When When you exit the sketch, you will be prompted to set the thickness of the part. I have a piece of plywood 10.5 mm. You can set any desired thickness, but then you will have to perform unnecessary steps when cutting. I'll leave it as it is.
< a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627303302_020-0012-zaglushka-09.jpg" rel = "prettyPhoto"> The distance between the edge of the glass and the inner stops is 4.5 mm. I will make cutouts in the details, leaving this size. That is, 10.5 mm – 4.5 mm = 6 mm. The depth of the cutouts is 6 mm. I will not bother with the form of these deprecations, the main thing is that they are no less than the glass stops.
In the program, the function Extruded cut I select the plane of the part and create a sketch on this plane.
First, I will set the axial lines, and, accordingly, I will draw the places of the depressions. The stops at the glass are 6 and 20 mm wide. I'll add a little, let the pockets be bigger. The main thing here is to leave the thickness so that the plug would turn out when installed “flush” with the edge of the glass.
I will add a couple of holes for self-tapping screws, so that they coincide with the holes on the stops. When measuring the distance between the holes of the narrow stops, I got 58 mm between the centers. Back diameter 3 mm.
Well now, the model of the future part is ready. I actually spent 5 minutes on design!
Next I will use SolidCam to create a control program for a CNC milling cutter. In SolidWorks, it is considered an add-on, although I think that it is a standalone program that works in the SolidWorks environment.
I will not describe each of my movements, I will just lay out the screenshots in order to understand the actions. If you have any questions, ask, I will be happy to answer.
< a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627303922_020-0012-zaglushka-17.jpg" rel = "prettyPhoto"> < a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627303923_020-0012-zaglushka-19.jpg" rel = "prettyPhoto"> < a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627303923_020-0012-zaglushka-21.jpg" rel = "prettyPhoto"> < a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627303923_020-0012-zaglushka-23.jpg" rel = "prettyPhoto"> Manager the program is created, I send it to the machine, fix the workpiece, install the cutter, set the zeros along the XYZ axes relative to the workpiece, and start the machine.
< a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627304173_020-0012-zaglushka-26.jpg" rel = "prettyPhoto"> < a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627304211_020-0012-zaglushka-28.jpg" rel = "prettyPhoto"> < a href = "https://usamodelkina.ru/uploads/posts/2021-07/1627304237_020-0012-zaglushka-30.jpg" rel = "prettyPhoto"> Here is the first detail cut out.
Worth check how she sits in the glass. In my opinion, perfect. The photo shows that it protrudes 0.3-0.5 mm above the edge of the glass. This is due to the burrs on the glass itself from the casting. Corrected by Z-0.3. So be it. An uneven gap is also noticeable in the photo. This is exactly the ovality of the glass.
If everything went well, I'll start the program further. Let the machine finish cutting the workpiece. As a result, you get 4 stubs. It's not difficult for me, but my colleague will be satisfied.
the photo below it is noticeable that due to the fact that he slightly lowered the “0” of the cutter along the Z axis, the plug falls flush with the upper edge of the glass.
It remains to wait for Monday and mount the received stubs in place. For painting or other coating, let the (electrician) decide the issue. I did what I was asked))
I have everything. All good!

Source:

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