Unit 1 will include history of manufacturing, modern manufacturing, CNC Machining, Autodesk Fusion CAM setup/processes and shop safety.
Autodesk Fusion is a 3D modeling software that include features from many other Autodesk software including design, drawing, animation, manufacturing, and electrical design. In this class we will focus on the manufacturing features as we create NC code to control CNC machines to mill, route, or turn parts. This process is call Computer Aided Manufacturing (CAM).
CNC Machining - Computer Numeric Control (CNC) machines are robots that run a program to control the movement of the machine. Examples of these machines include milling, turning, routing, laser cutting, and water jet cutting. The programs are generally referred to as NC code. This code can be hand typed, or created by a 'post process' from a 3D CAD model and manufacturing setup.
In its Manufacture workspace, Autodesk Fusion can create toolpaths for many common machining operations.
Facing - A face operation removes all material from the top of a stop to top of model. Produces quick part facing to prepare raw stock for machining.
2D Contour - Creates toolpaths based on a 2D countour. Contours can be open or closed and can be on different Z-levels, but each contour is flat(2D). You can choose multiple roughing and finishing passes and multiple depth cuts for any contour.
2D Adaptive Clearing- Roughing operation that uses a more optimized toolpath that avoids abrupt direction changes. taper angles can be defined for any wall or islands.
Parallel - A widely used finishing strategy, the passes are parallel in the XY-plane and follow the surface in the Z-direction. You can choose the angle as well as the stepover in the horizontal direction. The passes can be linked in a zigzag patern, unidirectional, or split in down or up milling sections. Parallel finishing passes are best suited for shallow areas and can be confined to machine only up to a given contact angle.
Flat - Creates a finishing operation that automatically detects all the flat areas of a part that are perpendicular to the tool orientation. Machine the flats with a type of toolpath that resembles either the Pocket or Parallel strategy. Obtain better cutting conditions by optimizing the toolpath over open pockets, as well as finish any nearby walls with the side of the tool by adding a finishing pass.
Scallop - Creates passes at a constant distance form one another by offsetting them inwards along the surface. The passes follow the sloping and vertical walls to maintain the stepover. Although this strategy can be used to finish an entire part, it is most commonly used to machine rest areas of a work piece, folowing a combination of Contour and Parallel Passes.
3D Adaptive Clearing - A roughing strategy available for clearing large quantities of material effectively. It is unique in that it guarantees a maximum tool load at all stages of the machining cycle, and makes it possible to cut deep and with the flank of the tool without risk of breakage. The strategy first makes a series of constant Z-layers through the part, and then clears them in stages from the bottom upwards. Because it can cut so deeply, the first step down at each stage should be the effective intermediate layers proceeds into the shallower layers to maximize the efficiency of the tool use.
Steep and Shallow - Creates a finishing operation that machines steep areas using Contour passes and shallow areas using Parallel and Scallop passes. A threshold angle determines the boundary between steep and shallow areas. Passes in steep areas and shallow areas can overlap and distance to achieve a better surface finish. In shallow areas, Parallel passes are side-by-side whereas Scallop passes are offset inwards.
Flat - Creates a finishing operation that automatically detects all the flat areas of a part that are perpendicular to the tool orientation. Machine the flats with a type of toolpath that resembles either the Pocket or Parallel strategy. Obtain better cutting conditions by optimizing the toolpath over open pockets, as well as finish any nearby walls with the side of the tool by adding a finishing pass.
Drilling - Provides access to a wide range of drilling, tapping and hole making operations, such as counterbores and countersinks.
Hole Recognition - Automate the drilling process by detecting cylinders in the model and creating operations. It evaluates cylinders in any orientation to provide a list of possible operations. They depend on the hole type. Next, you can sellect an operation that you want to apply.
Types of Manufacturing Systems
Custom - Oldest form of manufacturing - one person make something, start to finish. Each product can be custom/unique. Limited by the skills of one craft-person.
Intermittent (Batch) - The start of mass production. Each step is done in bulk (like mixing up a big batch of pancake batter, or cutting parts for 20 products at once). Can be done by one person or by different people who specialize in that process.
Continuous - Exemplified by assembly lines in factories. Many people working together to make many copies of the same product. Each worker trained in their specific job. Workers move from product to product or materials are moved from worker station to station (moving assembly line). Works well when you have a consistent need for a standard product.
Flexible (Automated) - use of reprogrammable machines that might even be able to switch out tools to perform multiple task. Products are mass produced without "retooling" but each product made can be customized to each specific customer.
Classic Manufacturing Principles
Specialization of Labor
Standardization
Mechanization
Moving Assembly Line
Modern Manufacturing Principles
Automation
Push Manufacturing
Pull Manufacturing
Total Quality Management
Efficiency
Inspection
Pilot Run
Kaizen -
Lean manufacturing -
6 Sigma -