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Purdue School of Engineering and Technology

Purdue School of Engineering and Technology

Engineering Topics: Intro to Advanced Manufacturing

ME 29500 / 3 Cr.

This introductory course covers both theory and practice of Advanced Manufacturing. The course focuses on high-tech machines and processes that are significantly used in the US industry, namely milling, drilling, and turning using Modern CNC (Computer Numerically Controlled) Machine Tools and equipment. The Lab includes training and experimentation on modern CNC milling and turning machines in a virtual reality environment. A physical lab equipped with CNC machine tools is used to provide real life experience as well as test and assess the learned skills. Course outcomes include skills that are critical to the manufacturing industry, in particular the machining sector. Course is offered to major as well as non-major students. High school students can register and earn college credits.

Goals

The objective of this course is to introduce students to advanced manufacturing by using machining as an example. As such, advanced manufacturing is defined as the advanced/optimized way of conducting machining. This typically involves the use of modern CNC machine tools, advanced CAD/CAM (or CAM) systems, software/hardware integration/interfacing, and off-line process optimization.

Outcomes

After the successful completion of this course students should able to:

  1. Compare traditional manufacturing to advanced manufacturing and explain the benefits and importance of the latter [a] [pul 1B]
  2. Define Advanced machining and explain its key elements [a] [pul 1B]
  3. Explain the key elements of a CNC machine tool system (control system, machining process and NC programming) [a] [pul 1B]
  4. Demonstrate a knowledge of machining theory and principles [a] [pul 1B]
  5. Operate safely a typical modern CNC machine tool [k] [pul 3]
  6. Conduct the basic procedures on CNC machine tools [k] [pul 3]
  7. Write sound NC programs for milling, turning and drilling [a, c, e] [pul 1B, 2, 3]
  8. Communicate effectively through written report [g] [pul 1A]
  9. Implement NC verification using simulation tools [k] [pul 3]
  10. Explain the use of CAD/CAM technology in advanced machining [a] [pul 1B]
  11. Demonstrate a knowledge and understanding of machining process optimization [a] [pul 1B]
  12. Follow/use best practice when developing NC programs and/or running cutting operations on a typical CNC machine tool [k, e, c1] [pul 1B, 2, 3]
Topics
  • Traditional manufacturing
  • Advanced manufacturing

NC Programming

  • Basics
  • Programming Tool Motion
    • Programming of Axis Motions
    • Position Offset
    • Tool Radius Compensation
  • Automated programming

Numerical control

  • NC principles
  • NC system classification
  • NC system components
  • Design issues with NC systems

Machining process

  • Introduction
  • Materials Science Basics
  • Fundamentals of Machining
  • Tooling for Machining

Lab (See detailed lecture outline in separate document):

  1. Lab safety guidelines and procedures: Machine shop safety information
  2. Introduction to the following CNC machine tools:
    1. FADAL VMC 3016 (3-axis vertical machining center)
    2. HAAS VF-2 (5-axis vertical machining center)
    3. HAAS SL-20 (2-axis Turning machining center)
  3. Training procedures on FADAL VMC 3016
    1. Starting up machine tool
    2. Setting up workpiece on machine
    3. Defining work offsets
    4. Defining tool offset
    5. Loading NC program (G-code) into machine controller
    6. Machining part by running NC program
    7. Shutting down machine
  4. Projects
    1. Development of NC program to machine a given part
    2. Machining the part on the virtual FADAL VMC 3016