ENG08027 2016 Advanced Manufacturing Technologies and CAM

Model complex geometries, surfaces, 3D solids and design intricate precision components using industry standard CAD/CAM software for CNC Machining applications.

Select and specify appropiate machining processes, suitable machine types, workholding solutions and tooling requirements for a range of CNC applications, including high-speed, 5 axis machining.

Use a CAD/CAM programing system to design CNC programmes, generate tool paths, simulate the machining process and output NC code for a range of complex machine tools.

Understand the scientific principles and the complete process chain of additive manufacturing processes

Recognize the fundamental differences between non-conventional machining processes that can be used for creating very accurate free-form intricate micron-scale shapes and features with very hard materials that can be very difficult and costly to machine using conventional technologies.

Develop an understanding of the principles of Industry 4.0 for advanced manufacturing processes and the interrelationships between Internet of things and services, Cyber Physical Production Systems (CPS) and Smart Factories.

Aquire basic knowledge and skills to design, build and operate industrial robotic systems and to understand the advantages and disadvantages of their deployment.

Understand systems behaviour and analytical modelling methods that can be deployed for discrete manufacturing process simulation and optimisation for different production scenarios and be able to apply statistical and analytical tools for simulation experimentation. 

Advanced Manufacturing Technology 

Advanced Manufacturing Technology will be taught through a combination of theory classes, computer labs, and relevant equipment laboratories/workshops.

CAM:

Computer Aided Manufacture will be taught using the lastest version of CAM software in a Practical based lab. Students will get hands on experience of using software and be shown real life Machine set-ups in state of the art facility.

Advanced Manufacturing Technology

Advanced Manufacturing Technology will be assessed through a combination of continuous assessment (20%), practical work(20%), and final exam (60%).

CAM:

Computer Aided Manufacture will be assessed through continous assessment on an on going basis. Students will have to complete assignments on a weekly basis and also have an Assessment on the final week.

Advanced Manufacturing Technologies and CAM:

Advanced Manufacturing Technologies and Computer Aided Manufacture will have a repeat attend, repeat assignment and repeat assessment depending on failure.

Advanced Manufacturing Technologies:

Students will be introduced to a range of different Additive Manufacturing (AM) processes including FDM, SLA, SLS, LOM and DMLS. They will gain knowledge on resultant material properties of produced components in addition to design process considerations required for AM process efficiencies. Students will become familiar with selecting appropriate additive manufacturing process for a particular need based on technical, economic, quality and time considerations.

Non-conventional machining processes such as ECM, EDM, LBM, AJM, EBM, and USM will be introduced to students. They will become familiar with the advantages, disadvantages and machining characteristics of non-conventional machining processes. Students will be taught about machine set up, machining process variability and optimization, and material removal rate calculations.

Industry 4.0 concepts will be explained and demonstrated to students. The role of Internet of Things and Services, Manufacturing Data Analytics and Cyber Physical Production Systems for Smart Factories will be examined. Impact of Industry 4.0 on areas such industrial value chains, IT security, product lifecycles, reliability and continuous productivity and new emerging service and business models will be presented and critically discussed with students.

Student will be able to demonstrate basic knowledge and understanding in industrial robot types, tooling design for robotic systems, robotic system integration with other production equipment via SCADA, and robot safety and the design of safe working environments.

 Student will understand the role of modeling and simulation in the development and improvement of discrete manufacturing processes and systems. They will learn about analytical techniques of systems, statistical aspects of modeling and system dynamics. Students will use modeling and simulation tools such as ProModel and Simul8 for implementing and validating different production scenarios.

CAM:

Geometry creation & 3D Solid/surface creation

Define geometry using lines, circles, arcs, fillets, chamfers etc. Use of geometry modifiers, trim, break, join, explode etc. Use of geometry translations, offsets, mirror image, rotations etc. Create 3D solid/surface creation; extrude, extrude cut, revolve, sweep, shell etc. Import solid models from other CAD applications.

CNC Machining Centres

High speed Machining Centre, 5 axis Machining Centre, Muti-axis Turning Centre, EDM Machining centre, CNC machine selection, Machine capacity, Machine accuracy and repeatability, Tooling capabilities, Coolant application, Workholding capabilities.

Tooling

Tool type selection; Turning tools, Milling tools, EDM tools, Tool material selection, Tool holding, Tool geometry, Feed & Speed Calculation.

CAM

Creation of High speed tool paths, multi axis tool paths, 3D surface tool paths, Graphical Simulation of machining process. Milling; 2D high speed, Surface rough & finish, Surface high speed, Multi-axis. Turning; High speed rough & finish, C & Y axis, Multi-axis, Stock Manipulation. EDM; Contour, 4 axis.