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ISE 370 MANUFACTURING

ISE 370 MANUFACTURING TERM PROJECT: “GO DAWGS” Numerical Control (NC) is the basis for many manufacturing processes in today’s industry. NC is the operation of machine tools and other processing machines by a series of coded instructions. CNC or computer numerical control systems include a built-in computer to support the machine and process. The main objective of this project was to simulate how a CNC machine is used in industry to facilitate a process and fabricate a designed part. In this course the importance, uses, and limitations of CNC machines when applied to the industrial world have all been learned. This assignment offered the opportunity to experience and evaluate the effects of a CNC machine on a process and vice versa. This is most important in the fast paced, changing world of industry we now live in. The goals of this project were to design a part, write a code for the Fadal CNC machine, learn how to enter the code and operate the machine, and effectively fabricate the object from a block of wax. A University of Georgia “G” was to be the designed (Figure 1). The most difficult aspect of this project was determining how to make the CNC draw an ellipse. Because of this problem, the team wasn’t sure if they would be able to draw the appropriate design. There was discussion of making changes, in order to simplify the program. The adversity was met head on, however, and the original design was ultimately kept. The first step after determining what was to be cut by the CNC was to design the part using a CAD program. Due to the familiarity of the team with AutoCAD, this was the program of choice to draw the “G”. It became immediately apparent upon drawing the object, that this could be a very challenging design due to the inclusion of ellipses. The CNC codes supplied as reference material included how to draw arcs, but there was no information on drawing an ellipse. The team attempted to use I and J coordinates to create an ellipse. This proved to be an incorrect approach. When the program was entered into the machine the picture drawn on the machine did not at all resemble a “G”. The team went back to the drawing board with another idea at hand. It is also possible to draw arcs using RF coordinates, which required finding radii. An ellipse is drawn with four circles with different radii. Therefore, if the radii of each circle could be determined, then the ellipse could be drawn, using the intersections of each circle as the endpoints of each arc. A problem arose, when it was discovered that AutoCAD uses many more than four circles to draw an ellipse. Consistent intersections could not be found in order to determine the radii and arc lengths. We were left with only two options; first the team could draw an ellipse on AutoCAD using four known circles and construction lines, automatically giving the radii and obviously showing the proper arc endpoints. If this didn’t prove effective, the last resort would be to interface the drawing with the CNC machine, using the computer in the lab, let the software write the program, and look at it to determine how it is done. The program was written using the fundamentally drawn ellipse with construction lines, shown in Figure 2. After entering the program into the machine, a few errors were brought to our attention, and it also gave us gouge warnings at certain lines. Upon the approval of Dr. Radha, however, the program was run and a “G” was fabricated. The following is the Program written to create the design shown in Figure 1. The program starts with tool number 10. This is the 1/8” mill. We used an rpm of 1200, a feed rate of 20.0, and a depth of cut at 0.50. The mill starts by cutting the inside ellipse (path noted by the blue lines). When it reaches the underside of the “G” in the inner ellipse, labeled #? In Figure 3, the cutter compensation is turned off and a linear move is done to mill that straight edge. The 1/8” mill then moves to cut out the outside ellipse. This will probably prove to be the most difficult area to fabricate. In order to remove the rest of the inside and to complete the design, a tool change to a Ľ” mill was necessary. The first path of this mill follows the first path of the 1/8”, except that it stops short on the underside so as not to gouge the straight edge. The mill then moves linearly following the red line in Figure 3, to remove the remaining wax on the inside. The dimensions to the design can be viewed in figure 4. The resulting fabrication shows some room for improvement, but is drastically better than the first dry run shown by the CNC machine. The 1/8” mill didn’t come all the way around the outside ellipse, leaving some wax to be milled at the opening of the “G”. The underside of the design held true as the trickiest part of the fabrication. It looks as though the Ľ” mill was too large for the area we allowed it and the 1/8” didn’t quite react as we planned it to. A slight gouge was created in the last counter clockwise move of the 1/8” mill on the inner ellipse. Another gouge occurred as the Ľ” came around to the underside of the inner ellipse and hit the straight edge. Overall, the fabrication is good. With the exception of those two small areas, the result looks exactly as it was designed. The group would still like to interface the design with the computer and have it draw the part as well. Perhaps this will show what errors in the program the team can avoid and even a better way to fabricate the part altogether. All in all this was a great project for the team to undertake. The group learned a lot about not only the CNC machine, its capabilities and incapacities, but also about problem solving and using resources to create this design. The team chose a difficult project and stuck to the original design despite suggestions otherwise. A great sense of accomplishment was felt when the result turned out positive! Bibliography:

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