LO2

P2: Plan the production of a CNC machined component.

P3: Produce a CNC part program utilising manual programming techniques.

P4: Use mathematical calculations to produce accurate part programs for use within a CNC machine.

M2: Produce a CNC part program using CAD/CAM software.

D1: Analyse the advantages of the use of CAD/CAM software rather than manual programming techniques for a CNC machined component.

Gantt chart

Here I made a Gantt chart to properly time my actions to finish the project efficiently.

reasorce list

Lathe flow chart

This shows the process that I will take when using the lathe to machine the part, putting this in the form of a flow chart makes it easly readble

3D printing flow chart

This flow chart shows the process I will take when 3D printing the casing for the connector

G-code

G-code is a programming language for CNC machines, G-code stands for Geometric code

G00 - Rapid movement Format G00 X## Y##

G01 - Linear interpolation Format G01 X## Y## F##

G02 - Clockwise circular motion Format G02 X## Y## I## J## F##

G03 - Anticlockwise cicular motion Format G03 X## Y## I## J## F##

XYZ are codinates, F Is the Fill rate and J and F are the offset of the origin

G20/G21 - Units of selection (G20 = Inches, G21 = millimeters)

G17/G18/G19 - G-code plane selection

G90/G91 - Positioning G-code commands

G28 return to original

M06 change tool

T103 Right hand turning tool

T102 Center turning tool

Our stock is a nonferrous material (does not contain iron) this means it is a pretty soft metal so would be easier to cut

When cutting brass it is recommended to use a cutting sped of 90-100

Maths

SFM Surface feet (meters) oer minuts

Vc Curring speed m/min

D Diameter

n(ss) Spindle speed (RPM)

Vf Feed (mm/min)

Fz Feed per tooth (mm/tooth)

Zn Number of teeth

Feed is how far it moved during one revolution

Cutting speed is the linear distance of the tool over a given amount

Our stock is a nonferrous material (does not contain iron)

When cutting brass it is recommended to use a cutting sped of 90-100

Mill

Lower bound: S/n = 90 × 318 / 16 = 1788.75 RPM

Upper bound: S/n = 100 × 318 / 16 =1987.5 RPM

Lathe

Lower bound: S/n = 90 × 318 / 20 = 1431 RPM

Vf = 0.08 × 4 × 1431 = 508.8 mm/min

Upper bound: S/n = 100 × 318 / 20 = 1590 RPM

Vf = 0.08 × 4 × 1590 = 457.92 mm/min

Manually written gcode

This is code that I manually wrote of notepad, I thought using notepad would be better because it can be converted into a ".gcode" file which can then be read by the lathe. Writing manual gcode is dangerous as any mistakes could damage the machine which is why using CAM software that can generate gcode is much safer and more time efficient.

Setup

The first step to making a CAM simulation was creating a new setup. This involved setting the machine, setting the operation type to turning.

In this setup, I also changed the stock to 16mm diameter

Facing

This uses the facing tool to flatten the front of the stock incase the stock was uneven.

Roughing

Here I told the software that I wanted a rough shape, because I was cutting so much I used a thicker tool (8mm) becuse this tool is more durable and won't ware down as quicky as a the thin tool.

Finishing

This tool is much thinner than the rough tool being only 2mm, this allows it to reach further into the corners to get a more defined final shape.

Setting up the perameters for the CAM simulation, here I set things such as: the machine that I will use, the dimentions of the stock and where the origin of teh machine is.

I ran the simulation to make sure that the machine properly faced off the part, when running the simulation it will show any objects that are in the way of the operation but for this operations everything worked as it was expected.

The manufacturer can add radial and axial stock to leave, this leaves space between the the material being removed and the desired part. It calculates the tool path with this in mind

Boxford software

I input the parameters for the brass such as the diameter and length of the part

I used courdinates to determine where the end point of the lines would be so I could create the desired shape.

This is the finished shape with all of the mesurments verified

This is a list of all the tools that the lathe is equiped with

Here the Boxford software simulates the gcode and runs it so that the user can see if it will come out with the desired object.

It shows the gcode that it has written at the top so the user can look for any mistakes that might have been made.

Advantages of the use of CAD/CAM software.

The use of CAD/CAM help the manufacturers greatly when designing and manufacturing. One of the techniques that mechanics use is generating tool paths but first the user must set up the parameters such as the stocks size, the material used, the feed rate, the coolant type being used (if it is being used), and the machine that will be used for the procedure. Once this is done the software can finally generate and simulate the tool paths to create high efficiency movements that the machine would follow to cut out the desired object, the software considers the tool being used as well the manufacturing parameters that the operator set so when the part is being cut it is accurate to what is shown on the software. This essay will be talking about the advantages of using CAM software to aid the manufacturers when creating a product.

The CAM software will have a much greater mathematical accuracy than a worker. Workers can make mistakes for example pressing the wrong operation when doing an equation resulting in a mathematical error, without this human error the machine has a significantly higher chance that the equation is correct. Further more, these equations can be processed at very high speeds depending on the processing power of the computer, It can process multiple equations in fractions of a second. Another benefit of using CAM software is its ability to use more complex machines and applications without making it harder for the manufacturer to program the machine. The software can program more complex machines such as a 5 axis CNC machine which would usually be much harder for the manufacturer to program manually. Additionally, CAM software are much more beginner friendly compared to writing g-code meaning much younger and less experience manufacturers wont have a hard time when learning how to manufacture, this also means that the cost of workers with the same abilities level would be cheaper.

Some CAM software have integrated CAD software as well which means that models won't have to be transfer between apps, this means manufacturers will only need to learn and familiarize themselves with one software which will make working easier and streamline the manufacturing process. Another way that time is saved is that the software can generate and simulate the tool paths, it will try to find a highly efficient path that the tool could take and run a simulation to make sure that it doesn't collide with the model so it runs smoothly and if something wont run for whatever reason it will give feedback on what was wrong or what isn't possible.

One of the major advantegaes of using CAM software is that it can complete difficult calculations to create tool paths for complex geometry that would otherwise take alot of work to complete. It can work on a plethera of different shapes and only take a short amount to time to complete the generation and simulate the machine following the tool path to check if it is clean and efficient, this is more reliable than workers that could make mistakes making doing the calculations or while writing the complex gcode. Furthermore, finding workers that could do the challanging calculating and writing the gcode would be hard as workers of this skill level are very rare and would expect to have a great sallary.

By using the comparison view, the manufacturer can see what stock needs to be removed and what is finished and wont be machined further. While in this view the user can still see the tool path that has been colour coded to make it easy to understand and check for any mistakes

While runing the simulation, it visually shows where the machine collides with the object which tells the manufacturer that they should use a new tool or rethink the process and find a new way to make the whole. The visual feedback that CAM software offeres gives CAM manufacturing a huge advantage over manual programing, It can show collisions and inefficiencys in the process which is not available to anyone doing manual programing. This reduces the risk of the machine or the part breaking which saves money and ensures that the machines can run smoothly.

CAM software has access to many tools and many machines so it can create gcode specifically designed for that specific application, this allows manufacturers to use different machines without having to learn the new language themselfs which could take a lot of time and work. The manufacturer can download these tools from a library so they dont need to store all of the machines on there computer as all of these files would take up alot of space

Using digital software makes it easy for engineers to share models and design and makes it easier for them to work together becuase documents can be shared and edited by multiple parties, this adds a new level of colaboration for engineers as they can easly peer review a model or tool path and share ideas to make more efficient and well made parts.

In conclusion, CAM software is a great tool for beginners and veterans alike with its many quality of life features and easily to understandable UI it can help all manufacturers save time and increase efficiency when working with machines. I think it is very useful for engineers trying to learn how to use the machines because most software is compatible with many machines which reduces the amount of software that workers will need to know how to navigate. CAM software has easy to read UI so that manufacturers can quicky create the tool paths and translate it into any language that the manufacturer desires which allows them to use most machines with little time and effort.

Images taken from Fusion 360 and Boxford CAD CAM design tool

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