Holders: Assoc. Prof. Pušavec Franci

Subject description

Course objectives

Within the course students acquire the advanced knowledge and skills that are required to carry out the design, technology setup and analysis of modern machining processes, as well as implement those processes in the whole final product production chain. The student is introduced with in deep features of CAM protocol, where the main focus is placed on the development, choosing of right technology for manufacturing process, optimization of machining/manufacturing parameters, all this with the goal to assure the desired final product quality level.

Presented are basic futures of CAM: CAD – CAM relation, generation of NC code, transfer and manipulation of G-code, usage of it and produce the final product on the CNC machine tool (3, 5, and 6 axes). As an upgrade, the economic aspect of choosing different technologies is presented. Additionally, in the industry more and more important becomes sustainable development, for assuring environmental and employee safer/cleaner production environment. With this novel machining processes are entering the industrial level and are going to be presented in this course (i.e. High pressure jet assisted machining, Abrasive flow machining, Cryogenic machining, Diagnostics of machining processes, etc.).

Thus, as an objective, students will be able to determine attainable tolerances, design necessary machining/manufacturing processes, technologies as well as evaluate the economical limits of selected technology.

Course enrolment requirements

Completed first level studies in mechanical engineering or natural sciences or other fields with knowledge of fundamentals in the field of Machining processes and Computer Aided Manufacturing. The knowledge about fundamental machining principles is asked but not obligatory.

Course contents

Lectures – main topics:

  1. Introduction to the mechanical load in machining processes
  2. Introduction to the CAD - CAM
  3. CAD – CAM steps
  4. Concept of manufacturing systems, programming and geometric relations
  5. CAM for milling (CAM works)
  6. CAM and machining strategies (CAM works)
  7. CAM more axis machining – milling (CAM Works)
  8. Trohoidal machining (Mastercam)
  9. CAM and technological data bases
  10. Flexible robot machining + RE/RP (Sprut CAM)
  11. Economical and technological plan
  12. Final finishing processes
  13. Modern machining processes/strategies
  14. CNC system analysis – machine tools and definition of drives
  15. Sensor assist manufacturing/machining processes – intelligent machining processes

Case Studies:

  • Manual determination of NC-code
  • CAM – turning
  • CAM – milling
  • RP+RE
  • Machining parameters and tools - determination of proper tooling set-up, etc.
  • CAM – Robot
  • Technological and economic plan of manufacturing/machining process 

Objectives and competences

The goal of this course unit is to equip to student with the concepts of modern machining processes, CAD-CAM, the guiding mechanisms for this technology, technology planning, estimation and later exact determination of process limitations, appearing loads, necessary forces and energies. With finished course student is able to select proper machining process, design the technology, and evaluate costs for production.

Intended course learning outcomes

The student will be able to determine the mechanisms guiding the machining processes; to compare different machining technologies under the scope of the course; to select optimal technology and CAM according to various criteria: productivity, accuracy, tool loads, material machining performance, energy used, etc.; to calculate and plan the technology of typical machining processes: milling and turning.

Forms of assessment

Written examination (obligatory), Oral examination (obligatory), Coursework or Project work or Seminar work (optional)

Assigned reading

  1. PUŠAVEC, Franci, KOPAČ, Janez. Sustain ability of modern metal cutting processes: assessment of cryogenic machining. Ljubljana [i. e.] Skofljica: PROFIDTP, 2012. XII, 283 pp., ISBN 978-961-92659-3-2.
  2. Y. Altintas, Manufacturing automation: Metal cutting Mechanics, Machine Tool Vibrations, and CNC Design, Cambridge university press, 2000,
  3. KOPAČ, Janez, KRŽIČ, Primož. CAM algorithm as important element by achieving of good machined surface quality. Journal of Mechanical Engineering, 2008, vol. 54, no. 4, pp. 280-287.
  4. KRŽIČ, Primož, STOIĆ, Antun, KOPAČ, Janez. STEP-NC: a new programming code for the CNC machines. Journal of Mechanical Engineering, 2009, vol. 55, no. 6, pp. 406-417. 

Optional / additional reading

  1. Modern Machining Technology, 1st Edition, J Paulo Davim, 2011, Woodhead Publishing, pp: 412.
  2. CAD/CAM: Concepts and Applications, Chennakesava R. Alavala, 2010, PHI, pp: 564.

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