MMAN2130 – Design and Manufacture CNC Machining Assessment Peer review files submitted: Week 7 Friday, 09:00am Peer review submissions due: Week 8 Tuesday, 09:00am Finalised CAM files are due: Week 8 Thursday, 09:00am Weighting 25% Task You will be utilising all the skills you have learnt so far to manufacture two components using CNC Milling machines located on campus. You will create 3D CAD models from an engineering drawing customised to your zID. You will then generate the necessary milling processes required to manufacture these components. The stock dimensions for manufacturing your components are 50 x 50 x 12 mm. These components will then be compliance tested in terms of dimensional accuracy as well as functional performance (do they fit together?). Computer-aided Design You will need to complete the following tasks for the CAD component of this assessment. 1. You must produce a CAD model based off the engineering drawing in Teams titled “CNC Machining Assessment Primary Component” using Solidworks. a. Save this file as “zID_Primary_Model”. 2. You must then design a complementary CAD model based off the provided engineering drawing such that the two components fit together as best as possible (see Figure 1). Some features will be more difficult to design and subsequently manufacture than others. You will need to make a decision about what you feel comfortable achieving. Note, these two components are required to have a “clearance fit” during assembly. a. Save this file as “zID_Complementary_Model”. Failure to use your zID specific dimensions when creating the 3D models will result in a 50% penalty to your overall CNC Machining Assessment grade. Figure 1. The provided primary component and designed complementary component are required to fit together. Hints when creating the CAD in preparation for manufacture!! There are a few key things that we need to keep in mind when designing parts for manufacture. We are leaving behind the virtual world of perfect dimensions and need to consider tolerancing systems for critical features. The Tormach typically has an accuracy of ±0.05 mm when machining. This means that rather than creating CAD files with nominal (perfect) dimensions, you will need to dimension features to account for required clearance considering worst-case scenarios. For example, let’s assume that you have a 10mm hole that needs to accept a 10mm circular shaft. In a worst-case scenario, the 10mm hole will measure at 9.95mm and the 10mm circular shaft will measure at 10.05mm after machining. As a result, these parts will most only fit under interference fit conditions, perhaps they won’t even fit at all. They will definitely not be a clearance fit. After you have designed and modelled your complementary component, you can check how well they fit together using the Assembly feature in Solidworks. You can also modify the transparency of the components to visualise features that may not easily be seen once the two components are mated. Computer-aided Manufacture Once you have your two components modelled in Solidworks, it is time to begin preparing them for manufacture. There are two different CNC machines on campus that will be utilised to manufacture your components. Depending on the machine, it will contain a tool library with the same tools BUT differing feeds and speeds compared to the other. It is very important that you check which machine you are allocated to and ensure you are working with the correct tool library. Surname Tormach Machine Allocation Tool Library Abood - Long Kirby Makerspace Kirby Tool Library Luo - Zuo Design Futures Lab DFL Tool Library A video tutorial of how to import your Solidworks CAD models into the Fusion360 fixture file has been uploaded to Teams and is titled “CNC Machining Assessment Setup”. You will need to complete the following tasks for the CAM component of this assessment. 1. Open up the Fusion360 file titled “CAM_ASSEMBLY.f3z”. 2. Import the two CAD files and mate them to the correct position in the fixture plate as per the video tutorial. 3. IMPORTANT: Rename the CAM file as zID_CAM_Programming by clicking on “File” - > “Save as”. 4. Using Fusion360, generate the necessary milling operations and tool pathways. 5. Using the simulate feature, ensure that your parts are able to be manufactured within 14 minutes. Note, the most efficient machining time is desirable. 6. Once your CAM file is ready for submission, export it as a “.f3z” file named zID_CAM_Programming. Don’t forget to delete the v1 that appears during the export process. Things to check during simulation: • There are no tool collisions with the fixture, other student’s stock pieces, etc. • You are spot drilling before drilling operations. • The endmill operations are complying with the cutting rule, % ∗% = 0.2. • The time limit has been met. Manufacture of Your Components and Compliance Testing Before manufacture of your components can commence, your Fusion 360 files will undergo a manufacturability review by staff. This is a very important check that ensures we will be able to manufacture everyone’s components in the timeframe whilst preventing downtime and expensive equipment failure. Common issues that prevent manufacture are choosing the wrong tool for an operation (e.g. face mill for adaptive clearing) and violating the endmill cutting rule by not carefully checking the simulation. The manufacturability review will be completed by 18:00 on Monday, Week 9. Students that have manufacturability issues will be contacted via their student email the following day. Manufacturing of components will be live-streamed and will begin on Tuesday, Week 9. If your CAM file is found to have violated the manufacturing requirements, you will be allowed to fix the issues and resubmit for a 20% penalty applied to your total mark. The deadline for re-submission will be 09:00 on Monday, Week 10. You don't have to re-submit but we won't be able to manufacture your part, and subsequently we won't be able to perform compliance testing. Compliance testing will be live-streamed and is currently scheduled for Thursday and Friday of Week 11. (Optional but Recommended) Peer-Review of CAM Simulation You have the option to participate in a peer review of your Fusion360 files. By submitting your files to the Peer Review tool on Moodle, you will be allocated 3 students CAM simulations to peer-review as well as receiving feedback from 3 other students. This is an opportunity to improve your simulation AND minimise the chance that an incorrectly generated CAM file will break the fixture, tool or machine. You will also be checking that their simulation time is within the 14-minute constraint.
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