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MIT 2 008 - The CAD/CAM Labs

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2.008 Design & Manufacturing II The CAD/CAM Labs Lab I Process Planning G-Code Mastercam Lathe Lab II Mastercam Mill Check G-Code Lab III CNC Mill & Lathe Machining OBJECTIVE 2 BACKGROUND 2 LAB EXERCISES 3 DELIVERABLES 4 APPENDIX A: PRODUCING THE SAMPLE PART 5 APPENDIX B: PROGRAMMING MACHINE TOOLS 7Labs I, II, III OBJECTIVE These lab exercises will introduce you to process planning and the tools you will need to carry through on such a plan. In the end (lab III) you will produce a machined paperweight with your own unique inscription. You will become familiar with a CNC lathe and a CNC mill, as well as Mastercam, a computer-aided manufacturing software package. You will also learn G-code, the alphanumeric programming language used to control CNC machine tools. BACKGROUND Process planning is an engineering activity that determines the appropriate procedures for transforming raw materials into a final product as specified by an engineering design. Engineering designs are conventionally documented using detailed diagrams indicating important design characteristics such as dimensions, tolerances, materials, and other pertinent specifications. Even though these diagrams convey a large amount of information about a design, they are incomplete in that they do not describe the manufacturing steps necessary to produce the final part. Effective process plans provide this information. In practice, design, process planning, and manufacturing are interrelated since the capabilities and characteristics of available equipment, manufacturing processes, and personnel can have a significant impact on the final design of a product. G-code When the designed product is produced using CNC machine tools, the machine tool controller needs explicit instructions describing the type and order of individual steps required to perform a given task. These instructions are provided to the controller in the form of alphanumeric codes (G-code) and are usually called a part program. A complete listing of G-code commands and a set of example code/part pairs can be found in the appendices. G-code itself can be written with any number of text editors, including the Windows notepad and, of course, emacs. After the code is verified with a simulation, it is loaded into one of the CNC machines. Mastercam Mastercam is a commercial Computer Aided Manufacturing software package. CAM is the process that links CAD (computer-aided design) with machine tools by automatically producing CNC code from a drawing. Mastercam includes a CAD environment, a geometry-to-G-code translator, and a G-code simulator. It is possible to import geometry from other drawing tools like AutoCAD, SolidWorks, or Pro/ENGINEER. 2.008 - Design & Manufacturing II 2 of 8 The CAD/CAM LabsLAB EXERCISES In the next two labs, you will obtain an aluminum disc 3” in diameter and .5” thick (Fig. 1). Inscribe your own unique pattern on the top with the CNC milling machine (Fig. 2), and turn a custom border/facial profile on the remainder of the disk with the CNC lathe (Fig. 3). All exercises will be conducted with a partner - each pair must turn in only one part and will receive a common grade.1 You and your lab mate may need to meet outside of class in order to complete some of these assignments. If you are feeling adventurous, you and your lab mate may produce two different paperweights. They will be graded separately. Fig. 1 Fig. 2 Fig. 3 During Lab I, you and your lab mate will: • learn how to write G-code so that you can manually create your own part programs • run a series of tutorials designed to teach you how to use Mastercam Lathe • see Mastercam create the G-code for a similar profile as shown in Fig. 3 • use Mastercam to draw the lathe profile of your paperweight (the top drawing can be done by hand or any software) • use Mastercam to run a toolpath on the profile • prepare for next week's lab During Lab II you and your lab mate will: • learn how to use Mastercam Mill • check your pre-prepared handwritten G-code program for the mill portion of your paperweight • prepare for next week's lab During Lab III you and your lab mate will: • finalize the drawings (combining top and side views) • finalize your pre-prepared handwritten G-code program for the mill portion of your paperweight • run your program on the CNC mill to inscribe your unique symbol into the center of your disc • use the CNC lathe to run the profile program to turn/face the shape on your paperweight 1 If you feel that your lab mate is not performing his/her fair share of the work please contact the TA to discuss grading arrangements. 2.008 - Design & Manufacturing II 3 of 8 The CAD/CAM LabsDELIVERABLES This page explains what you must have completed by a week after each lab session. See the "Grading Procedures" section of the webpage for more details. DELIVERABLE - Lab I 1) A 2-D drawing of the inscription to be machined on the top of your paperweight. This should be either hand-drawn on graph paper or computer-drawn and dimensioned. 2) A handwritten G-code program of your unique inscription. A Mastercam Mill generated program is cheating! 3) A separate detailed cross-sectional sketch of the side view showing the profile shape that will be machined on the lathe. This should also be properly dimensioned and neat. Things to think about: • You should have the handwritten program on a 3.5” floppy, or a Zip disk, (100MB, or 250MB) if you work on it at home so that you will be ready to debug and run at the beginning of Lab III. • The program should be typed in using Windows Notepad. It must have a filename extension “.txt”. • Keep in mind that your inscription should fit within a 2.0” diameter circle to allow for machining of the profile on the perimeter. • Your milled inscription and profile shape must be unique. • When dimensioning, be sure to reference everything from the center and top of the disk. • Don’t forget Z depths! • Your inscription must have at least one arc or circle - all straight lines are not allowed. • Remember the diameter of the end mill (it must fit between features) before you try anything too fine and detailed. • Remember to consider how the disk will be held in the chuck on the lathe so that you don't machine into the jaws of the chuck - leave at least .200” of uncut material at the


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