| Course Unit Code | 346-5011/01 |
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| Number of ECTS Credits Allocated | 4 ECTS credits |
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| Type of Course Unit * | Choice-compulsory type B |
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| Level of Course Unit * | Second Cycle |
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| Year of Study * | Second Year |
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| Semester when the Course Unit is delivered | Winter Semester |
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| Mode of Delivery | Face-to-face |
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| Language of Instruction | Czech |
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| Prerequisites and Co-Requisites | Course succeeds to compulsory courses of previous semester |
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| Name of Lecturer(s) | Personal ID | Name |
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| SAD76 | prof. Ing. Marek Sadílek, Ph.D. |
| Summary |
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| Learning Outcomes of the Course Unit |
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This subject is for 3. semester of magister study, specialization mechanical technology. Students will study theory and practice of machining technology (3axis milling, 3+2axis milling (indexing machining) and 5axis simultaneous by means of CAM system. Contents of this subject including: creation and edition of CAD geometry, setting cutting conditions, creation of technological process (strategy of cutting – tool paths, setting cutting tools, tool holders, fixtures of workpiece, instruction - G, M code etc.), cutting simulation, NC code generation for cutting machine.
The subject includes two practical demonstrations of 5axis machining in the CNC machining laboratory of the department.. Practical demonstration include setting the 5axis milling center (machine tool setting, clamping of a cutting tools into a suitable tool holders, setting cutting tools, demonstration of different types of fixtures of workpiece, workpiece zero point setting using the workpiece probe, loading, editing, simulation, verification NC program in machine control system and real cutting.
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| Course Contents |
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Syllabus of lectures:
1. Introductory lecture. Software product options for computer aided manufacturing (CAM systems) - examples.
2. Importing geometric data into the CAM system - modifying and positioning the geometric data (model of part, workpiece, fixtures and other geometry). Possibilities of creation and modification of fixtures, modification of technological parameters.
3. 3axis milling-roughing strategy.
4. 3axis milling-finishing strategy.
5. 3+2axis milling.
6. Problems of Tool overhang - types of cutting tool clamps. Advanced simulation and verification, practical demonstration of machining.
7. Kinematics of machining centers. Graphics configuration for simulation of a real CNC machine tools with a defined machine 3D model.
8. Multi-axis milling - 3axis conversion to 5axis machining.
9. Multi-axis milling - 5axis machining strategy.
10. Tool flow in practice. Database of cutting tools. Defining graphics of special shape of tools.
11. Application of workpiece probes - creation of NC program for automatic measurement on the machine tools.
12. Postprocessing. The setup sheet creation.
13. Multi-axis milling. Modification of the CAM program according to the tolerated dimensions.
14. Advanced methods of CNC machine tools programming.
Exercise content:
1. Introductory lecture. Software product options for computer aided manufacturing (CAM systems) - examples.
2. Importing geometric data into the CAM system - modifying and positioning the geometric data (model of part, workpiece, fixtures and other geometry). Possibilities of creation and modification of fixtures, modification of technological parameters.
3. 3axis milling-roughing strategy. Project assignment.
4. 3axis milling-finishing strategy.
5. Work on the project + practical demonstrations of machining in the CNC laboratory when setting 5axis milling center - 3axis milling (using the workpiece and tool probe, simulation, verification and modification of the NC program in the machine control system).
6. 3+2axis milling.
7. Advanced simulation and verification, Graphics configuration for simulation of real CNC machine tools with defined model of machine.
8. Multi-axis milling - 3axis conversion to 5axis machining.
9. Multi-axis milling - 5axis machining strategy.
10. Work on the project + practical demonstrations of setting the 5axis milling center - 5axis simultaneous milling, practical demonstration of kinematics of the 5axis milling center.
11. Defining graphics and simulation of special shape tools (tooth mulling cuter and shape cutters).
12. Postprocessing. Creation of setup sheet.
13. Work on the project + practical demonstrations of machining in the CNC laboratory when setting 5axis milling center - 5axis milling (using the workpiece and tool probe, simulation, verification and modification of the NC program in the machine control system). Using of a workpiece probe for measuring the dimensions of the machined part, possibility of editing the NC code according to the resulting measured dimensions.
14. Completion of projects. Test. Evaluation. |
| Recommended or Required Reading |
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| Required Reading: |
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[ 1 ] APRO, K. Secrets of 5-Axis Machining, Industrial Press, Inc. 989 Avenue of the Americas, New York, NY 10018, First Printing, August, 2008, pp. 172. ISBN 978-0-8311-3375-7.
[ 2 ] SANDVIK Coromant, Technical Editorial Deartment. Modern Metal Cutting – A Practical Handbook. Tofrers Tryckery AB, Sweden, 1994, 927 p. ISBN 91-972290-0.
[ 3 ] Electronic support: Student version of EdgeCAM and SolidCAM software, User guide EdgeCAM: beginning in EdgeCAM, turning, milling, EDM cutting- wire cutting, postprocessor, technology assistant, and others.
[ 4 ] Electronic support: Student version of SolidCAM, SolidCAM software, User guide SolidCAM: beginning in SolidCAM, 2.5 axis milling, HSM milling, 5 axis milling postprocessors, and others.
[ 5 ] http://www.edgecam.com – web pages, supplier of CAM system EdgeCAM.
[ 6 ] http://www.solidcam.com - web pages, supplier of CAM system SolidCAM.
[ 7 ] http://www.mastercam.com - web pages, supplier of CAM system MasteCAM.
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[1] SADÍLEK, M.; SADÍLKOVÁ Z. Počítačová podpora procesu obrábění. VŠB – TU Ostrava, 2012, 100 s., Dostupné na: http://vyuka.fs.vsb.cz/. Součástí této výukové opory je také 14 animací.
[2] SADÍLEK, M. CAM systémy v obrábění I. - II. doplněné vydání. VŠB – TU Ostrava, 2010, 138 s., ISBN 978-80-248-2278-5. Dostupné v knihovně VŠB – TU Ostrava.
[3] SADÍLEK, M. Počítačová podpora výroby. VŠB – TU Ostrava, 2011, 80 s., Dostupné na: serveru katedry + http://www.346.vsb.cz/studijni_literatura.html. Součástí těchto výukových opor jsou také animace.
[4]http://www.mastercam.com - stránka výrobce CAD/CAM systému Mastercam.
[5] Elektronická podpora dostupná na serveru kat 346: výukové opory, studijní verze softwaru, manuály, příklady a další.
[6] APRO, K. Secrets of 5-Axis Machining, Industrial Press, Inc. 989 Avenue of the Americas, New York, NY 10018, First Printing, August, 2008, pp. 172. ISBN 978-0-8311-3375-7.
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| Recommended Reading: |
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[ 1 ] SHAW, Milton C. Metal Cutting Principles. Oxford, Clarendon Press, 1984
[ 2 ] Handbooks of cutting tools - WIDIA, SANDVIK, ISCAR, PRAMET TOOLS.
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[ 1 ] HILDER, Terry. CNC-mozek stroje. MM Průmyslové spektrum, 2003, č.5, s.
38-39. ISSN 1212-2572.
[ 2 ] http://www.frezovani-5os.cz – webové stránky o víceosém obrábění, citováno 19.7. 2010.
[ 3 ] SOLIDCAM. Průvodce uživatele modulem souvislého víceosého frézování, SolidCAM + SolidWorks, 1995-2008, s 241.
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| Planned learning activities and teaching methods |
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| Lectures, Tutorials, Experimental work in labs |
| Assesment methods and criteria |
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| Task Title | Task Type | Maximum Number of Points
(Act. for Subtasks) | Minimum Number of Points for Task Passing |
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| Graded credit | Graded credit | 100 (100) | 51 |
| Písemný test | Written test | 30 | 11 |
| Projekt v CAM systému | Project | 70 | 40 |