212EN - Smart Manufacturing Technology Assignment

Assignment Task

Background

The aim of this assignment is to expose and equip students with theoretical and practical expertise in modern digital manufacturing. This assignment is portfolio-based, comprised of the following components:

• CAD/CAM digital machining supported with demonstration
• Project Report writing on the CAD/CAM digital machining process

You are a recently integrated manufacturing engineer at DigiMech Manufacturing, a Smart Manufacturing enterprise, which is expanding their business to incorporate multiple machining / manufacturing processes. Due to this, the manufacturing engineers have been divided in two teams, each addressing the planning and development of a product database and its machining processes involved for manufacturing it from a blank piece to the final part. If the last digit of your ID is even , you are part of the turning team; if the last digit of your ID is odd , you are assigned to the milling team. To be able to carry out this task, you must, first, convert the 2D drawing into a 3D model/part. Then, you will plan, elaborate and carry out the required machining processes on the 3D model/part. You are required to carry out the 3D modelling to the required BSI standard using PTC Creo (or equivalent). You are also required to define the conditions, resources and specifications for each of the machining processes deployed in the manufacturing of the part.

Figures 1 and 2 depict the approximate shape of the parts that are produced as part of the company portfolio. The operations required have been defined by contractor CAD/CAM engineers of client companies. Irrespective of the part (and, therefore, the team you are assigned to), the operations involve a volume rough machining, drilling, engraving and a finish machining.

You are asked to represent the listed machining processes on the component assigned to your team. The axisymmetric part family is made of 316H stainless steel , while the plate part family is made of carbon fibre reinforced polymer (carbon-carbon CFRP) :

Face milling operation – the blank piece has 25.4 mm, or 1 inch, height (team milling only)

• Volume roughing
• Drilling of the holes/slots in the specified dimensions
• Grooving (team turning only)
• Engraving using your first name – or surname – and your student ID number as the information to be engraved on the created 3D model/part.
• Finishing (profiling) operation
• For each machining operation, you are required to specify:
• Cutting parameters (feed – f or feed per tooth/insert – f _z , depth of cut – a _p , working engagement – a _e , cutting speed – v _c )
• Cutting conditions (use of cutting fluid – specification and justification, tool lifetime, number of tools for completing the operation, total operation time – for each machining operation; total machining cycle time, total production cost per machined part)
• Tool descriptive parameters (tool diameter, cutting edge angle, number of inserts, insert code, tool code)

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