辅导案例-MMAN2130

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.


欢迎咨询51作业君
51作业君 51作业君

Email:51zuoyejun

@gmail.com

添加客服微信: ITCSdaixie