Description
This unit introduces students to all the stages of the CAD/CAM process and to the process of modelling components using CAD software specifically suitable for transferring to CAM software. Among the topics included in this unit are: programming methods, component set-up, tooling, solid modelling, geometry manipulation, component drawing, importing solid model, manufacturing simulation, data transfer, CNC machine types and inspections.
On successful completion of this unit students will be able to illustrate the key principles of manufacturing using a CAD/CAM system; produce 3D solid models of a component suitable for transfer into a CAM system; use CAM software to generate manufacturing simulations of a component; and design a dimensionally accurate component on a CNC machine using a CAD/CAM system.
Learning Outcomes
By the end of this unit students will be able to:
1. Describe the key principles of manufacturing using a CAD/CAM system.
Hardware:
CAD workstation, printers, USB flash drives and network cables
Software:
Operating systems, hard disk requirements, processor, CAD software e.g. SolidWorks, Autodesk Inventor, CATIA; CAM software e.g. Edgecam, Delcam, GibbsCAM, SolidCAM
Inputs:
CAD model, material specifications, tooling data, spindle speeds and feed rate data calculations
Outputs:
CAM files, program code and coordinates, manufacturing sequences, tooling requirements, auxiliary data
Programming methods:
CAD/CAM, manual programming, conversational programming
Component set-up:
Zero datum setting, tool set-up and offsets, axis of movements
Work-holding:
Machine vice, chuck, fixtures, clamping, jigs
Tooling:
Milling cutters, lathe tools, drills, specialist tooling, tool holders, tool turrets and carousels
2. Produce 3D solid models of a component suitable for transfer into a CAM system.
Solid modelling:
Extrude, cut, fillet, chamfer, holes, sweep, revolve, lines, arcs, insert planes, properties of solid models e.g. mass, centre of gravity, surface area
Geometry manipulation:
Mirror, rotate, copy, array, offset
Component drawing:
Set-up template, orthographic and multi-view drawings, sections, scale, dimensions, drawing
Attributes e.g. material, reference points, tolerances, finish
3. Use CAM software to generate manufacturing simulations of a component.
Import solid model:
Set-up, model feature and geometry identification, stock size, material
Manufacturing simulation:
Operations e.g. roughing and finishing, pockets, slots, profiling, holes, tool and work change positions, tool sizes and IDs, speeds and feeds, cutter path simulations, program editing
4. Design and produce a dimensionally accurate component on a CNC machine using a CAD/CAM system.
CNC machine types:
Machining centres, turning centres, MCUs e.g. Fanuc, Siemens, and Heidenhain
Data transfer:
Structured data between CAD and CAM software e.g. datum position and model orientation; file types e.g. SLDPRT, parasolid, STL, IGES, DXF; transfer to CNC machine e.g. network, USB, Ethernet
Inspection:
Manual inspection e.g. using Vernier gauges, bore micrometres
Automated inspection e.g. co-ordinate measuring machine (CMM), stages of inspection throughout manufacturing process