Introduction to Process Planning
Choice of the process parameters
Clamping
Introduction to CNC
Manual programming
Automatic programming
Milling basics
High Speed Milling
5 axis milling
Milling of die and models
Milling of aeronautical and automotive parts
Milling of turbine,impellers, turbochargers
G. Halevi, R.D. Weill, Principles of Process Planning, Chapman & Hall
Gerald Farin, Curves and surfaces for CAGD, Academic Press
Piegl-Tiller, The NURBS book, Springer editions
Karlo Apro, Secrets of 5-Axis machining, Industrial Press
Learning Objectives
General objective:
to provide to the students the competencies to realize a process plan and use proficiently a CAM system
With reference to the knowledge (CC) identified for the course, reference is made to the following descriptors:
- cc10: knowledge and understanding of applicable engineering techniques and methods (and their limitations) in non-technical fields.
- cc12: knowledge and understanding of the most suitable production process for the realization of mechanical components, and definition of process parameters able to meet the requirements of product feasibility.
With reference to the competences acquired (CA) identified for the Course reference is made to the following descriptors:
- ca10: applying knowledge and understanding problems related to the choice of the most suitable production process for the production of mechanical components, and to define the process parameters able to satisfy the product feasibility requirements.
Prerequisites
Mechanical Technology
Mechanical Design
Teaching Methods
50 hours of In-class lesson
4 hours of practical exercise with CAM
Visit to manufacturing companies to view the productive processes
Further information
The dates of the examinations are available using the CSIAF booking system
Type of Assessment
The level of knowledge acquired by the student will be evaluated by an oral examination provided by both teachers on process planning and manufacturing process, including the technical and technological tools for its implementation.
The student must prove the competences acquired on manufacturing process selection and process parameters definition to obtain a sufficient grade. Complementary competences are related to multidisciplinary approach to design and manufacturing process.
With reference to the knowledge (cc) and competences acquired (ca) identified for the course, oral examination aims at highlighting the acquired knowledge c10 and cc12, and verifying the competences ca10.
Course program
Introduction to process plan:
- semi automatic development of a process plan
- optimization of process plan
Choice of the optimal process parameters:
- selection of the optimal setup
- optimization considering costs and time
Clamping:
- theory of clamping
- examples of clamping
Introduction to CNC:
- closed loops, CNC
- reference system
- horizontal and vertical machines
- CNC milling machines
Manual programming:
- ISO language
- zero reference point
- trajectory
- compensation of the tool
Automatic programming:
- role of CAM
- input to CAM
-mathematical model: IGES format
- Curves and surfaces: NURBS, Bezier, B-splines, Coons
- Poliedric model
- CAM auxiliary functions
- tools definition
- processors and postprocessors
- realistic simulation
High Speed Milling (HSM):
- interaction of tool-machine tool-CNC-CAM
- role of tool in HSM
- role of Machine tool in HSM
- role of CNC in HSM
- role of Cam in HSM
5 axis milling:
- 5 axis machine structures
- mill turn machine with 4 or 5 axis
- CAM for 4 or 5 axis
- RTCP function with NC
- post processor differences with 3 and 5 axis
- alternative solution for the calculus of machine axis
- Euler angles to define the working zone
Milling of die and models:
- example of programming with CAM
Milling of aeronautical/automotive parts:
- example of CAM
- milling of inlet hoses
Milling of turbine/impeller/turgochargers:
- example of multiblade turbine
- note for the milling of thin walls