ME7722A Advanced CAD/CAM Systems.

Assessment - Mould CNC Machining Time Optimisation & Tool Path Verification

Learning Outcome 1: Critically analyse and optimise the machining operations simulation using industrial CAD/CAM package.

Learning Outcome 2: Demonstrate a good understand metal removal methods of complex freeform surfaces using multi-axis computer numerical control part programming and post-processing.

Learning Outcome 3: Develop an extensive knowledge in identifying the capabilities of the virtual multi-axis machining simulation and verification.

Section - A
Mould CNC Machining Time Optimisation & Tool Path Verification

Assignment Brief and assessment criteria: An important part of the CAD process is the development of images in three-dimensional space prior to producing two-dimensional images for manufacturing drawing purposes. In the not too distant future, when computing resources are more readily available, the need for two-dimensional drawings will be eliminated completely as all the generated data sets of co-ordinate points will be held in memory, processed and down-loaded directly to the relevant machine tool prior to manufacture. However, we are dealing with the present day and the need for two-dimensional drawings for manufacturing purposes still exists.

An engineering designer needs to appreciate the advantages and limitations of conventional and computer controlled metal cutting machine tools, to enable products to be economically manufactured. Although the modern trend is towards computer- aided manufacture (CAM) with all the instructions for machine operation fed to the machine as a command signal, each operation has to be broken down and analysed so that the most efficient program can be used by the computer.

Therefore a thorough knowledge of basic machining operations is a pre-requisite before CAM can be efficiently utilised.

The main areas which you should focus on in this assignment are the mould design machining optimisation and verification using the mould designed and validated in the first block of this module.

Core & Cavity Mould Machining
Requirements
In this section the students should demonstrate a good understanding of generative machining using NXCAM module of the Siemens PLM solutions package to do the machining of the mould which was designed and validated in the first assignment.

The manufacturing technique of the proposed design should be optimised by a clear process of selecting the right machining parameters. This process of optimisation is aimed to reduce the machining time in order to achieve a competitive manufacturing cost of the part and the mould. Machining variables which contribute to this task of machining time reduction (for example; machining too path, federates, step-over etc...) should be properly analysed and approved.