Module Title: Smart Manufacturing Technology

Module Code: 212EN

Assessment Type:

Coursework

Assessment Number:

                 1

Study Mode:

     FT

Weighting:

        60%

Submission Date:

01/04/2022

Submission Time:

18:00

Campus:

CUC,CUL,CUSC

Task:

Background

The aim of this assignment is to expose and equip students with theoretical and practical expertise in modern digital manufacturing. This assignment is portfolio-based, comprised of the following components:

• CAD/CAM digital machining supported with demonstration
• Project Report writing on the CAD/CAM digital machining process

This assignment represents 60% of the module grade and will be made available on Aula at the beginning of week 1 (07/03/2022), for a submission due date of (01/04/2022).

Requirement

• Scientific calculator / calculation software (suggested: Excel, Mathcad Prime)
• Knowledge of CAD 3D modelling and interpretation of 2D drawing
• PTC Creo Parametric Educational Edition
• PTC Creo Parametric Manufacturing module

Essential Reading

• El-Hofy, H. A. (2014) Fundamentals of Machining Processes; Conventional and Non-conventional Process. 2^nd ed. CRC Press. ISBN 13: 978-1-4665-7702-2

• Groover, M. P. (2014) Automation, Production Systems, and computer-integrated manufacturing. 4^th ed. Prentice Hall. ISBN - 9789332572492  

Assignment 1 General Instruction

You are a recently integrated manufacturing engineer at DigiMech Manufacturing, a Smart Manufacturing enterprise, which is expanding their business to incorporate multiple machining / manufacturing processes. Due to this, the manufacturing engineers have been divided in two teams, each addressing the planning and development of a product database and its machining processes involved for manufacturing it from a blank piece to the final part. If the last digit of your ID is even, you are part of the turning team; if the last digit of your ID is odd, you are assigned to the milling team. To be able to carry out this task, you must, first, convert the 2D drawing into a 3D model/part. Then, you will plan, elaborate and carry out the required machining processes on the 3D model/part. You are required to carry out the 3D modelling to the required BSI standard using PTC Creo. You are also required to define the conditions, resources and specifications for each of the machining processes deployed in the manufacturing of the part.

Figures 1 and 2 depict the approximate shape of parts that are produced as part of the company portfolio. The operations required have been defined by contractor CAD/CAM engineers of client companies. Irrespective of the part (and, therefore, the team you are assigned to), the operations involve a volume rough machining, drilling, engraving and a finish machining.

You are asked to represent the listed machining processes on your created 3D model/part, which is made of Inconel 718 nickel superalloy:

• Face milling operation – the blank piece has 22.225 mm, or 7/8 inches, height (team milling only)
• Volume roughing
• Drilling of the holes/slots in the specified dimensions
• Grooving (team turning only)
• Engraving using your first name – or surname – and your student ID number as the information to be engraved on the created 3D model/part.
• Finishing (profiling) operation

For each machining operation, you are required to specify:

• Cutting parameters (feed – f or feed per tooth/insert – f_z , depth of cut – a_p , working engagement – a_e , cutting speed – v_c)
• Cutting conditions (use of cutting fluid – specification and justification, tool lifetime, number of tools for completing the operation, total operation time – for each machining operation; total machining cycle time, total production cost per machined part)
• Tool descriptive parameters (tool diameter, cutting edge angle, number of inserts, insert code)
• Tool code (from a  tool supplier’s catalogue)

Figure 1: Part template for the turning team, with the dimensions based on the ID number.

Figure 2: Part template for the milling team, with the dimensions to be based on the ID number.

Very important guidelines that you must remember and adhere to:

• You have to map your ID digits to either Fig. 1 or Fig. 2.
• If working with Fig. 1, the groove width is the same as its diameter. If working with Fig. 2, your extrusion distance/depth for the 3D model/part must be 19.05 mm (3/4 in).

• A zero digit in the student ID number should be replaced by 10 (being, therefore, the highest digit)
• For Fig. 2, choose a magnification factor to multiply your digits, in order to keep the approximate shape of the part (and avoid distortion).
• Figure 1 sections are symmetric.
• For any of the figures, if one dimension yields an inconvenient geometry, feel free to adopt a modification factor (either for amplifying it or decreasing it). In doing so, ensure the steps are appropriately described in your report.
• A batch of 500 units of the part you are designing is required.
• Both parts feature a counter bore hole with the dimensions presented in Figure 3. The placement of the hole is of your choice.
• As an engineer, you will have to define/research a few parameters for providing some of the estimates asked (e.g. CNC mill cost, total working hours per year, average hourly rate of a machinist, etc.).
• You must provide a G-code for the entire manufacturing sequence of operations.
• The word count for the report must not exceed 1500 words. Excluded in this word count are: Title page, List of Figures, Tables, References and Appendix sections.

Figure 3: Counter bore dimensions.

You are required to create a project report on the above contents. You must demonstrate your proposed machining operations by creating a recorded video, expected to last no more than 5 minutes. You are suggested to use one of the following tools:

• Screencast-O-Matic
• Sway
• Power Point
• Adobe Spark
• Prezi
• Microsoft stream
• Tiny take
• Nchsoftware

to illustrate, in brief steps, the digital manufacturing processes adopted in your assignment.

Marks will be awarded for 3D representation, machining process setup in your recorded video demonstration and report:

• 3D Modelling & operation setup

• Correct setup of PTC Creo when creating the 3D model from the 2D drawing using appropriate dimensional unit
• Correct method of generating your dimensions       
• Correct use of extrusion depth                                                   
• Correct representation of all the features in 3D                                                  
• Organisation and neatness of your 3D displayed view in its default format (isometric view)
• Workpiece generation and setup
• Correct selection of the machining operations and setup
• Correct tool selection and setup
• Generation of the material removal process
• Generation of the tool path code
• Generation of the G/M - code

• Recorded video demonstration
  • Quality of recorded video
  • Clarity of voice and content
  • Cohesiveness and consistent of your illustration/demonstration with respect to the above bullet points
• Project Report

• Completeness of the information, neatness and clarity of the contents and abundant use of scientific / technical literature as a basis for the manufacturing plan

Submission Instructions

What you need to submit via Aula – Turnitin submission link:

• 1 x electronic copy of your project report file in PDF or Word format (pdf format is preferred)

What you need to submit as a OneDrive:

• 1 x electronic copy of your work – you may submit the recorded video link (ensure it is accessible by your lecturer) or a PowerPoint, if you have not used any of the suggested video production tools
• 1 x electronic copy of your project report file in PDF or Word format, as a backup (pdf format is preferred)
• 1 x electronic copy of the CAD files of your 3D part/model/component

Completion of this assessment will address the following learning outcomes:

1

Understand and evaluate classic manufacturing and advanced manufacturing techniques and principles

2

Analyse digital manufacturing concepts, cloud manufacturing principles, technologies and application

3

Apply CAD/CAM knowledge in digital manufacturing simulation