Computer Aided Design and Manufacturing

ME4146 Machining processes

3 hours One requisite

ME4131 Machine Design II

3 hours One requisite

1 Unit 1: Computer Aided Design (CAD) / Geometric Modelling: classifications and properties of 2D and 3D geometric modelling. / Geometrical constraints and parameters of wireframe modelling elements: points, lines, arcs, conics, and splines (Hermite cubie spline curve, Bezier curve, B-spline curve). / Geometric Construction Methods (GCM) for surface modelling: plane surface, ruled surface, lofted surface, revolved surface, extrusion (tabulated) surface, swept surface, Bezier surface, B-spline surface, conic surface, offset surface, fillet surface / Solid Geometric Modelling: Constructive Solid Geometry (CSG), Boundary Representation (B-Rep) and Geometric Construction Methods (GCM) / Solid part specifications: materials and appearances. / CAD Software and file import/export / Geometric Transformation: Translation, Rotation, Scaling and Reflection. / Mathematical geometry in 2D and 3D: Vectors, Lines, Arcs and Circles

2 Lab 1: / Introduction to CAD/CAM. / Machining Operations and Machine Tools / CNC Machines and Programming

3 Unit 2: Computer Aided Manufacturing (CAM) / Overview of manufacturing processes and systems and CAM cycles. / Machining planes selection, cutting tools selection, and toolpath setup / Overview of Computer Integrated Manufacturing (CIM). / CAM Software and file import/export

4 Lab 2: / Introduction to CNC Turning with Sinumerik 802Dsl / Working with SSCNC Simulator using Sinumerik 802Dsl / Home positions, offsets, and work settings / Safety precautions / Transfer and execution of programs in CNC machines

5 Unit 3: Computer Numerical Control (CNC) Systems / Overview of Numerical Control (CNC) Systems / NC, CNC, and DNC machines. / Conventional machines vs. CNC machines / CNC machine coordinates and axes / CNC machine classifications / Components of a CNC system

6 Lab 3: / Introduction to Machine Control Unit (MCU) / G-code and CNC Programming on MCU

7 Unit 4: CNC Machining Operations / Classifications of machining tools and operations: hole machining, turning, and milling. / CNC machining tools Parameters. / Selection of cutting tool and depth of cut / Calculation of cutting speed and feed rate

8 Lab 4: / Introduction to MasterCAM X9 / Importing or Creating CAM Files for CNC Turning using MasterCAM X9

9 Unit 5: CNC Programming / Basics of CNC program and steps to write a CNC program. / Tool list setup and manuscript setup / Tool motion systems and tool mode systems / Codes (words) in CNC program: codes for preparatory functions (G-codes), codes for miscellaneous functions (M-codes), and codes for specific functions (Codes: F, S, D, X, P,…) / Numbers in CNC program: without decimal point numbers and with decimal point numbers. / Special character in CNC program. / An overview of the widely used G-codes: / An overview of the widely used M-codes / Zero Points and Reference Points in CNC machine: Machine zero-point, machine reference, workpiece zero point and too reference point / Subprogram Call M98 / End M99 / Introduction to CNC Canned Cycle

10 Lab 5: / CAM Operations for CNC Turning using MasterCAM X9

11 Lab 6: / Siemens 802Dsl Cycles for CNC Turning

1.1 Mapped to: K1

Explain basic concepts and theories of modeling an engineering geometry using CAD techniques with describing the mechanism of using the model in various engineering applications.

Teaching Strategy Lectures, tutorials, and self-learning assignments. Introductory lecture gives an overview of the content and methods of assessment.

Assessment Methods Homework, project, lab work, assignments, midterm exam and final exam

1.2 Mapped to: K1

Expand knowledge of manufacturing techniques for industrial components using CAM methods.

Teaching Strategy Lectures, tutorials, and self-learning assignments. Introductory lecture gives an overview of the content and methods of assessment.

Assessment Methods Homework, project, lab work, assignments, midterm exam and final exam

1.3 Mapped to: K2, K3

Explain the basic concepts and theories of CNC programming and machining.

Teaching Strategy Lectures, tutorials, and self-learning assignments. Introductory lecture gives an overview of the content and methods of assessment.

Assessment Methods Homework, project, lab work, assignments, midterm exam and final exam

1.4 Mapped to: K1

Understand the relative advantages and disadvantages between different CNC technologies in terms of axis, machining, and programing

Teaching Strategy Lectures, tutorials, and self-learning assignments. Introductory lecture gives an overview of the content and methods of assessment.

Assessment Methods Homework, project, lab work, assignments, midterm exam and final exam

2.1 Mapped to: S1

An ability to use and control the basic tools of computer-aided design (CAD), computer-aided manufacturing (CAM), and computer numerical control (CNC) technologies.

Teaching Strategy Extensive applications of course content and examples provided in lectures and laboratory classes.