Wentworth Institute of Technology

Mechanical Engineering and Technology Department

 

 

Course

MANF2000    Computer Aided Manufacturing

 

 

Instructor

Peter Rourke, CMfgE

 

 

Semester

Spring, 2020  2 hours lecture  2 hours laboratory  3 credits

 

 

Catalog
Description

Students will utilize PC based industrial CAM software and Computer Numerical Control machines to produce machine tool programs and parts.

 

 

Prerequisite

MANF1000 Manufacturing Processes

 

 

Required
Text

     

Kalpakjian, Serope and Schmid, Steven R., Manufacturing Engineering and Technology, 7th ed., Pearson, Boston, 2014,    ISBN-13: 978-0-13-312874-1

 

 

Suggested
Reference

 

Machinery's Handbook (28th Edition) Electronic

 

 

Course
Goals

Students will become competent in applying the design parameters involved in Computer Numerically Controlled (CNC) material removal processes including milling and turning, as well as in rapid prototyping additive processes.

 

 

Objectives

To exhibit proficiency in the fabrication of components using Computer Numerical Control (CNC) equipment, Rapid Prototyping (RP) systems, and matching design criteria to both CAM and RP process capability, each student will: 

  1. Use a 3 dimensional software modeling package to construct simple geometric parts and products.
  2. Build models on a 3-D Systems Rapid Prototyping Equipment
  3. Cut complex, contoured models on CNC lathes and milling machines
  4. Understand machine tool life variables and use Taylor’s Tool Life equation to approximate wear times.
  5. Calculate milling machine cut times used in scheduling and part estimating
  6. Apply correct cutter compensation techniques and calculate tool paths
  7. Understand motor control techniques and use them to calculate machine resolution, repeatability and accuracy
  8. Approximate machine horsepower requirements from data tables

 

 

Grading

·        Laboratories:  30%

·        Attendance / group work:  25%

·        Quizzes and assignments:  30%

·        Final exam: 15%

 

Topic

Topic

Assignment

Laboratory

 

 

 

 

1

Machining Processes: Milling
Work Locating Techniques

Chapter 24 (review)

Technology Database
Shop Safety Review

 

 

 

 

2

Surface Technology
Tribology and Coatings

Chapters 33,34
Chapter 35 (review)

2.5-axis Machine
Laboratory

 

 

 

 

3

Fundamentals of Machining
Mechanics of Cutting

Chapter 21
section 1-4 inclusive

Maze Laboratory Exercise

 

 

 

 

4

Tool Life: Wear and Failure
Machinability

Chapter 21 (cont.)
sections 5-7 inclusive

Plasma Torch 2-axis Laboratory

 

 

 

 

5

Cutting Tool Materials-Fluids
Turning and Hole Making

Chapter 22
Chapter 23 (review)

Lathe Laboratory

 

 

 

 

6

Machining Centers
Advanced Machining Processes

Chapter 25
Chapters 26,27

Conversational

Programming

 

 

 

 

     7

Automation and Operations
Computer Integrated Manufacturing

Chapter 37
Chapters 38,39

Project

 

 

 

 

8

Plastics Manufacturing
Rapid Prototyping

Chapter 19
Chapter 20

Semester Project

 

 

 

 

9

Semester Review

Final Exam

SolidWorks-CAM certification

SolidWorks Certification Exam

CSWP-CAM
SW Professional CAM

 

 

Materials

We use Admiral Metals, Woburn, MA as our supplier of aluminum, stainless, brass and bronze.  If you need a piece of stock for your project, we do not have on campus, try them

 

About the Textbook:

The textbook for this course is Kalpakjian, Serope and Schmid, Steven R., Manufacturing Engineering and Technology, 7th ed., Pearson, Boston, 2014,    ISBN-13: 978-0-13-312874-1.  You must purchase the text.  There is a copy on reserve in the library until you do.

 

Course Notes:

 

1.      Please do not ask me to re-open any quiz for any reason.

2.      All laboratory work and projects become property of Wentworth Institute of Technology.  They will not be returned to you.  If you want a part or project for yourself, you must make multiple copies.  I get the one you wish to submit for a grade.  No exceptions.

3.      Any machined part finished with scotch bright, sandpaper, or polish will automatically receive a score reduction of 50 points.

4.      Please have on your laptop the most current image provided by DTS. The software we will be using includes:

·        SolidWorks

·        Adobe Acrobat (reader)

·        MS Office

5.      If you arrive to class or lab and do not see the electronic attendance sheet I use, it means you arrived late.  You will be marked absent unless you stay at the end of the session and have me change the spreadsheet to mark you as late, rather than absent.

6.      Completed quizzes can be reviewed after they can be taken by clicking on the numerical score for each quiz under "my grades" in blackboard.

7.      If you ask me to help you with CAMWorks you must have a mouse attached to your computer.

8.      The final exam consists of two parts: one is the on-line exam and the other is a display of all your work from the semester to be set out in the lab.

 

Laboratory Notes:

 

1.      Please have your safety glasses with you at all times: lecture and lab. Each time I lend you a pair, or ask you to put them on, reduces your course participation grade.  I will not be the “safety glasses cop”: you will simply receive a lower lab grade.

2.      Always have at the ready your "Best-Practices" notebook. I recommend a cheapy spiral graph paper notebook from Staples ($0.99)

3.      Cell phone use is not permitted in the laboratory.  Please put your cellphone in your book bag.  If you must use the phone for any reason, please tell me so that you may be excused from the lab.

4.      There must be 2 members of a group present when you are running any equipment. Please do not ask me to gain entry to a lab unless there are 2 of you.  Please put effort into making your group a team.  This is part of the “group work: 15%” grade from above.

5.      You are responsible for a thorough clean-up after using any equipment.

6.      There are three “shut-down” emergency buttons on the walls of the lab.  If you see someone in trouble on a machine hit the EMERGENCY STOP button.  This will stop the spindles from turning.  They are a no-harm-no-foul button.

7.      The Tool Tables for the ProtoTRAK mills are saved on each machine.  If for any reason you change a tool let me or Ryan know so that you can correct the tool table.

8.      https://www.lincolnelectric.com/assets/servicenavigator-public/lincoln3/im10197.pdf

9.      To view quiz results, available after the due date and time:
Click name, top right corner
Click the check + icon under the courses dialog    
My Grades will pop up
Pick the quiz, and view attempt
Click on the calculated grade link

 

Learning and Competency Objectives
Engineering and Engineering Technology programs must demonstrate that their students attain the following outcomes listed.  Those that are shown in bold are areas most applicable to this course:

(a) an ability to apply knowledge of mathematics, science, and engineering

(b) an ability to design and conduct experiments, as well as to analyze and interpret data

(c) an ability to design a system, component, or process to meet desired needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and sustainability

(d) an ability to function on multidisciplinary teams

(e) an ability to identify, formulate, and solve engineering problems

(f) an understanding of professional and ethical responsibility

(g) an ability to communicate effectively

(h) the broad education necessary to understand the impact of engineering solutions in a global, economic, environmental, and societal context

(i) a recognition of the need for, and an ability to engage in life-long learning

(j) a knowledge of contemporary issues

(k) an ability to use the techniques, skills, and modern engineering tools necessary for engineering

 

Students will be given project parts to fabricate, and sophisticated CNC tools, equipment and software necessary to complete the work.  Using these modern engineering tools students will demonstrate their ability to design a process proving the manufacturability of the component.  Results will be critiqued and displayed at the front of the laboratory at the end of the semester.

 

DISABILITY SERVICES STATEMENT:

Any student who thinks s/he may require a disability-related accommodation for this course should contact Disability Services in the Counseling Center privately to discuss your specific needs.  Disability Services coordinates reasonable accommodations for students with documented disabilities.  They are located in Watson Hall 003 (the Counseling Center) and can be contacted at 617-989-4390 or counseling@wit.edu.  For more information on acceptable documentation and the Disability Services process, visit the Disability Services website at www.wit.edu/disabilityservices

ACADEMIC HONESTY POLICY:

Students at Wentworth are expected to be honest and forthright in their academic endeavors. Academic dishonesty includes cheating, inventing false information or citations, plagiarism, tampering with computers, destroying other people’s studio property, or academic misconduct.

COLLEGE OF THE FENWAY STUDENTS:

If you are enrolled in this course through COF Cross Registration, notify your course instructor. Please provide her/him with your email address to be sure that you receive course information in a timely way. You should also discuss how to access online applications that might be used in the course.  Please note that cross registered students who wish to drop or withdraw from this course must complete the necessary paperwork according to the Wentworth calendar.

 

LAB GRADING CRITERIA

 

It is my hope that you will find the laboratory projects beneficial in your academic and professional efforts.  Much of the grade for the course is taken from these activities.  It is my experience that students fall somewhere within three categories in the laboratory:

  1. Lacking preparation and confidence the group wants to spend a lot of time with me directly answering each question as it arises. Basically, making me their lab partner. This is not practical or useful at all, and this lab team usually ends up with very poor lab grades.
  2. The team that does their work, and then leaves the lab, or asks me to post more material so that they may move ahead, on their own, at an accelerated pace. This generally ends up with satisfactory lab grades, but not outstanding.
  3. Having completed their work, and helped others in the lab group, this lab group looks to assist other groups with problems they are having. It seems they are around the lab a lot, and are adding to their technical skills, as well as communication, leadership, and team building skills. These students always end up with the highest possible lab grades.

Daily lab grades are recorded.  With the exception of one or two lab periods designated as design sessions (I will be clear when they are coming up) your lab grade is determined by the amount of time you spend cutting and fabricating.  We can do design work anywhere and at any time, however our time on the lab equipment is limited and needs to be maximized.  Grading guidelines are as follows:

·        100-90: All set up ready to go: setup sheets printed, part file on network, spacer heights calculated.  Cutting commences within 10 minutes of class beginning.

·        90-80: All members present at the equipment station, set up sheets printed, and part file ready to be post-processed and put on the network

·        80-70: Last minute tweaking required, part requires last minute post-processing changes, and set up sheets need to be printed, but work commences within 30 minutes of lab start.

·        70-50: Cut strategies finalized and cutting commences within an hour of start of class.

·        50-0: Not prepared and still designing

I will be visiting each group, asking for a set-up sheet.  It must include the spacer calculation.  When you print them, be sure to print two, as I will be keeping one.  Please use the communications tools available to you (Google Docs, Skype, etc.) to do your design work as a team outside of class time.

Note that while machining work done outside of class will almost certainly raise your laboratories grade section (30%), the efficient use of your assigned lab time is also important (25%).

 

Links:

·        Glacern.com

·        To map the network drive that serves the Manufacturing Center open a File Explorer right click on This PC and click as shown below on Map network drive . . .

Add the drive by typing   \\drive.wit.edu\manufacturing
When completed you will see all the information on the drive.

·        https://www.cnccookbook.com/g-code-m-code-reference-list-cnc-mills/

·        The links to have things 3-D printed are:

o   The Print Site

o   The Print Queue