Multi-axis Machining (MFG 568)

2021 Spring
Faculty of Engineering and Natural Sciences
Manufacturing(MFG)
3
10.00
Lütfi Taner Tunç -ttunc@sabanciuniv.edu,
English
Doctoral, Master
--
Formal lecture,Seminar,Recitation,Studio work/practice
Interactive,Communicative,Discussion based learning,Project based learning,Task based learning,Case Study
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CONTENT

Advanced CAD/CAM applications, which are used in metal cutting industry, will be covered with the theoretical and practical aspects. The topics covered during the lectures will be applied through homeworks and a course project. Techniques for analytical surfaces representation and modeling, surface creation techniques in CAD environment, theoretical aspects of toolpath computation for 3 and 5 axis milling, 3 and 5 axis milling toolpath computation operations offered by commercial CAM packages, theoretical and practical aspects of post processing issues for 3 and 5 axis milling will be covered. Process modeling for simulation and verification of 3 and 5 axis milling processes will be covered. Project groups will select sample geometries requiring 3 and 5 axis milling. Then, they will prepare operations for machining of these sample parts using commercially available Siemens NX and CATIA packages to manufacture the selected parts on the 5-axis machine tool available in Manufacturing Research Laboratory or on the 6- axis machining robots available at SU-IMC.

OBJECTIVE

? Represent curves and surface analytically
? Generate curves and surfaces in CAD environment
? Prepare machining tool path operations in CAM environment
? Perform post-processing to the tool path generated in workpiece coordinate systems
? Describe and model generalized milling tool geometry
? Describe and model geometry of a multi-axis ball-end milling process
? Describe the advantages of using computers in NC tool path generation
? Select appropriate milling strategies for a part to be manufactured
? Select appropriate CNC machine tool configuration for a part to be manufactured
? Prepare technical drawings for multi-axis milling processes

LEARNING OUTCOME

-Understanding of the theoretical background of free-form surface representation used in product design.
- Presenting their project work
- Undertake representative machining task as part of their group project. Selection of cutting tools, CNC programming and realizing the required machining process to manufacture a desired part.
- Understanding of the theoretical background of tool path planning for complex parts.
- Understanding of the theoretical background of tool path computation for complex parts.
- Understanding of the theoretical background of tool path computation for post-processing.
- The students will use industrial CAD/CAM software packages. They will learn how to deal with different file formats in CAD/CAM environment.
Understanding of tool selection in multi-axis machining applications.

ASSESSMENT METHODS and CRITERIA

  Percentage (%)
Final 30
Midterm 15
Case Study 20
Participation 5
Individual Project 15
Homework 15

RECOMENDED or REQUIRED READINGS

Textbook

1) Choi, B. K., & Jerard, R. B. (2012). Sculptured surface machining: theory and applications. Springer Science & Business Media.
2) Choi, B. K. (1991). Surface modeling for CAD-CAM. Elsevier Science Inc.
3) Altintas, Y. (2012). Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design. Cambridge university press.
4) Makhanov, S. S., Anotaipaiboon, W., (2007). Advanced Numerical Methods to Optimize Cutting Operations of Five Axis Milling Machines. Springer Science & Business Media