TABLE OF CONTENTS

PAGE

Abstract…………………………………………………………………………….……..…….3(see sample)

Introduction…………………………………………………………………………………….5 In one page briefly describe the principles of CAD/CAM technology and its industrial applications in modern manufacturing. A representative picture from an industry may be included in this section. In the last paragraph of the introduction give the structure of the rest of your project. (see sample)

PART 1: Computer Aided Design (AutoCad)

1.1 Manufacturing drawings …………………………………………..………….……..……8- 2D drawing of the part fully dimensioned, use different colour for dimensions (see sample)

- 2D drawing of the part without dimensions. Name and give details for each feature to be machined. (see sample)

- 3D drawing of the part (see sample)

PART 2: Computer Aided Manufacturing (SURFCAM)

2.1 Cutting Tools……………………………………………………………….……………..12 In a table show the data for the selected tools: Tool type and number, diameter, operation (see sample)

2.2 Tool information and Cut control………………………………………………………...14 Using the SURFCAM NC capability, show the Tool information and Cut control windows for each programming operation. (see sample)

2.3 Presentation of the manufacturing stages using the CAM system…………….…….15 Using the SURFCAM program describe and present graphically, the operations required for complete machining of the part. (see sample)

Surname Name

2.4 Tool path verification ……………………………………………..……….……………26 Using the Toolpath Verification button of the SURFCAM, show the final form of the simulated machined part (see sample)

2.5 Post-processing……………………………………………………………………..…..27 Using the Post button of the SURFCAM, show the postprocessor you used and list part of the generated cnc program, the head and the end, in one page. (see sample)

Concluding Remarks………….……………………………………………….………….33(see sample)

References……………………………………………………………….……….……..….34

(see sample)

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Abstract

The aim of this project is to design and manufacture a mechanical part applying the

Computer Aided Design, Computer Aided Manufacturing and Numerical Control

technology. The project involves understanding of the whole manufacturing procedure from

the first step, the elaboration of the manufacturing drawing until the final, the cutting (or

simulation of the cutting) of the part on a CNC machining center. The whole followed

procedure is given for a representative mechanical part which includes all usually met in

practice, geometric features. Specifically, the part is composed of pockets of various forms,

linear or circular slots, individual holes or array of holes and complex profiles. Also,

respecting accuracy and surface quality requirements, roughing and finishing operation are

applied appropriately. The development of the project offers us the opportunity of gaining

experience in the evolving field of modern manufacturing technology using state of the art

software tools and equipment. (Return back)

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Introduction………………………………………………………………………………………………

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Figure 1: ……………………..

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The rest of the project is organised in two parts. Part 1 describes …………….......... ...

………………………. Part 2 presents………………………………………………...

Finally the project closes with a series of concluding remarks. (Return back)

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PICTURE

1.2 Manufacturing drawings:

(a) Part fully dimensioned

Figure 2: 2D drawing of the part

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Surname Name

(b) Features to be machined

Figure 3: Features to be machined

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(c) 3D Part

Figure 4: 3D drawing of the part

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2.1 Cutting Tools

Tool No Tool type Diameter (mm) Operation

1 HSS End Mill Ø14 Roughing outside profile

2 HSS End Mill Ø10 Finishing outside profile

3 HSS End Mill Ø12 Machining circular pocket

4 HSS End Mill Ø8 Machining inside pockets

5 HSS Drill Ø12 Drilling 2 holes Ø12

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Surname Name

2.2 Tool information and Cut control

Example: Roughing outside profile

Figure 5: Cutting conditions for roughing outside profile

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2.3 Presentation of the manufacturing stages using the SURFCAM system

a. Roughing outside profile

Figure 6: Machining stage 1

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b. Finishing outside profile

Figure 7: Machining stage 2

c. Machining circular pocket

11

Figure 8: Machining stage 3

d. Machining inside pockets

12

Figure 9: Machining stage 4

e. Drilling 12 holes

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Figure 10: Machining stage 5

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2.4 Tool path verification

Figure 11: 3D preview of the part to be machined

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2.6 Post-processing

Surname Name

Figure 12: The Post Process window

The head of the CNC program The end of the CNC program

%

O0

G17 G40 G80 G90

T1 M6

M3 S1592

G0 G54 X51.2 Y106.637

G43 Z25. H1

M8

G0 Z2.5

G1 Z-2.5 F114.592

X53.587 Y109.024 F229.183

X51.2 Y109.95

X48.8 Y106.281

Y100.843

M3 S1592

G0 G54 X17. Y17.

G43 Z25. H14

M8

G81 X17. Y17. Z-10. R2.5 F229.183

X187.

Y187.

X17.

G80

M9

G90 G0 G49 Z0 M5

T1 M6

X0 Y0

M30

Table 1: The codified CNC program for a Milling machine with Fanuc control

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Concluding Remarks

The main aim of this project has been to use some of the latest manufacturing

means which are used in modern mechanical workshops and manufacturing units.

In this direction, a part of moderate complexity but with representative geometric

features was selected. In a first stage, the manufacturing drawings of the specific part

were elaborated with the aid of Autocad design package. In a second stage these

drawings were loaded on the environment of SURFCAM program. In this framework, all

necessary machining operations were defined in the appropriate order. Also, for each

operation the respective cutting conditions were calculated. Finally, after choosing the

postprocessor for our machine control we generated the CNC program for the entire

machining of the part.

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REFERENCES

[1] Computer Numerical Control for Machining, by Mike Lynch, McGraw-Hill, 1992

[2] Manufacturing Processes for Engineering Materials (4th Edition), by Serope Kalpakjian, Steven R. Schmid, Prentice Hall, 4th edition, 2002

[3] Automation, Production Systems, and Computer-Integrated Manufacturing by Mikell P. Groover, Prentice Hall, 2nd edition, 2001

[4] www.cncmachines.com

[5] CNC Machining center – Manual of operation

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