MANU7015 Advanced Manufacturing Process

Assessment Overview

This assessment is made up of three parts:

1. Part Programmes
2. Manufactured Components
3. Written Technical Report

The Written Technical Report must have detailed explanations of all programmes and manufacturing processes. It must show an understanding of Hypermill software and CNC machining principles.

The report should be around 2000 to 3000 words. It must not be than 5000 words. The Safety Statement, Setter Instructions and Operator Data Sheets are not included in the word count.

Marks Distribution

• Hypermill Programme Files: 45%
• Machined Components: 9%
• Written Report: 46%

To submit on CANVAS you need to upload the following:

• Three Hypermill post-processed programme files
• Three Hypermill project files
• One Written report in Word document format

Report Structure

Your report must have the following sections:

1. Component Photographs
   You need to include photographs of all finished components in your report.
   
   
2. Datum Selection
   Explain how you chose the datum positions and describe the setup procedure used during machining.
   
   
3. Strategy Selection
   Give explanations of the following machining strategies:
   • One example of 3-axis milling
   • One example of 3+2 milling
   • One example of turning
   
   You can include screenshots where necessary.
   
   
4. Programme Strategy Justification
   Justify the selection of three strategies from each programme. Your justification should focus on efficiency, accuracy and machining suitability.
   
   
5. Project Assistant
   Discuss how the Project Assistant is used in both milling and mill/turn operations. Explain how it supports workflow, programming and machining efficiency.
   
   
6. Tool Selection
   Explain the selection of cutting tools used in each process. This includes:
• Tool types and their applications
• Cutting speeds and feed rates
• Tool life considerations
• Suitability for aluminium machining
  
  
7. Safety Statement
   Provide a safety statement applicable to all machines used in the project.
   Include safety considerations for machine-specific risks.
   You should download Standard Operating Procedures from CANVAS. Reference them where appropriate.
   
   
8. Sustainability
   Discuss sustainability factors in machining processes. This includes material efficiency, energy usage and waste reduction strategies.
   
   
9. Workholding Methods and Strategies
   Explain the workholding methods used for each part. Justify their effectiveness in terms of stability, accuracy and safety.
   
   
10. Manufacturing Time
    Analyse production. Discuss efficiency considerations during programming and machining.
    
    
11. Simulation, Crash Detection & Post-Processing
    Describe how simulation tools were used to detect errors avoid collisions and validate toolpaths before generating machine code.
    
    
12. 5-Axis Machine Setup Instructions
    Provide setup instructions for both the tool setter and machine operator when working with the 5-axis system.
    
    
13. Component Evaluation
    Evaluate the manufactured parts by discussing:
• Machining errors or issues
• Noise, vibration or chatter
• Surface finish quality
• Visual inspection results
• Suggested improvements
• machining approaches
• Any required hand finishing
  
  
14. Recommendations
    Provide recommendations for improving machining efficiency, accuracy, surface quality and overall process optimisation.

Practical Tasks

Part 1: 3-Axis Milling

• You will be working with 150mm × 100mm × 50mm machining aluminium.
• You need to do two operations: Topside and Underside.
• You need to make two programmes.
• You will be using the DMG Mori DMC650V machine.
• You need to use a vice for topside machining.
• You need to achieve an aesthetic finish.
• You need to use speeds feeds and machining strategies.
• All surfaces must be. Finished using different tools.
• The underside must be machined as an operation.

Part 2: 5-Axis & 3+2 Milling

• You will be working with 100mm × 100mm × 50mm machining aluminium.
• You will be using the Hurco VM10ui machine.
• You need to produce an aesthetic finish.
• The underside must be faced.
• You can use fixture points underneath. They must not be visible from the top view.
• You need to modify lettering for clearer and more efficient machining.
• All surfaces, except lettering must be. Finished using different tools.
• You need to use 5-axis strategies for wall features.

Part 3: Mill/Turn

• You will be working with Ø50mm × 130mm machining aluminium.
• You will be using the NLX 1500/500 Mill/Turn Lathe machine.
• You need to produce an aesthetic finish.
• You need to make a single-start thread with a pitch of 1.5mm.
• You need to use speeds and feeds.
• All surfaces must be. Finished using different tools except, for milling operations and threading.
• You need to apply milling strategies where appropriate.