UNIVERSITY OF PORT HARCOURT

FACULTY OF ENGINEERING
DEPARTMENT OF MECHATRONICS ENGINEERING

A
PRESENTATION
ON
CAD/CAM APPLICATION IN TURNING PROBLEMS,
SURFACE MILLING, MACHINING OF CURVED SURFACE
SUBMITTED BY:
GROUP FIVE (5)

IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE

AWARD OF AUTOMATION AND ROBOTICS
FACULTY OF ENGINEERING,
UNIVERSITY OF PORT HARCOURT,
RIVERS STATE, NIGERIA
COURSE TITLE: AUTOMATION AND ROBOTICS
COURSE CODE: MTE 502.2
COURSE LECTURER: PROF. T.A. BRIGGS

July 7, 2024
NAMES AND MATRIC NUMBER OF GROUP MEMBERS
MANGIBO LASBURY TEKENA U2018/3035009
SULE MERCY OYIZA U2018/3035025
ORDU KINGSLEY NYEBUCHI U2018/3035026
OKEKE CHINECHEREM U2018/3035027
OSANEKU DESTIN U2018/3035034
BADUME JESSICA U2018/3035044
OKULU HANSON U2018/3035048
 TABLE OF CONTENT
 CHAPTER ONE: INTRODUCTION
 WHAT IS CAD/CAM
 THE HISTORY OF CAM
 CHAPTER TWO
 CAD/CAM APPLICATION IN TURNING PROBLEM
 HOW TO OPRATE A CNC TURNING MACHINE
 PREPARING THE CNC TURNING MACHINE
 PRODUCING THE CNC TURNED PART
 TYPES OF CNC TURNING OPRATIONS
 COMPONENTS OF A CNC TURNING MACHINE
 ADVANTAGES AND DISADVANTAGES
 APPLICATIONS OF CNC TURNING MACHINE
 CHAPTER THREE
 CAD/CAM APPLICATIONS IN SURFACE MILLING
 WHAT IS CAM MILLING
 HOW DOES CAM MILLING WORKS
 Why Is CAM Milling Advantageous in Modern
Manufacturing?
The factors to consider when selecting materials for CAM milling
include:
 Challenges in CAM Milling Operations and How Are They
Solved?
 How Does Computer-Aided Design (CAD) Enhance CAM
Milling?
 What Safety Protocols Are Essential in CAM Milling?
 Why Is CAM Milling Important for CNC Manufacturing?
 CHAPTER FOUR
 CAD/CAM APPLICATIONS ON MACHINING OF CURVED
SURFACES
 Fundamentals To Profile CNC Milling in curved surfaces.
 General Tips For CNC Milling Curved Surfaces
 INTRODUCTION

Today’s CAD/CAM capabilities are part of a long history of innovation and

development. As design and manufacturing method evolves, so too have its uses
expanded. This articles explains the history of computer-aided design and
computer-aided manufacturing, including its milestone development and current
uses.
WHAT IS CAD/CAM?
CAD stands for ‘computer-aided design’ CAM stand for ‘computer-aided
manufacturing’. CAM preceded CAD by some years.
CAM is based on Computer Numerical Control (CNC) where pre-programmed
computer software dictates the movement of factory tools and machinery. The
most widely used CNC programming language in CAM is G-code.
CAD is the software used to create electronic files for printing, machining and
other manufacturing operations. CAD arrival increased the productivity of
designers and improved the quality of design amongst other benefits. The software
CAD is used to support both engineers and designers across a range of industries,
architecture, automotive and aviation.
THE HISTORY OF CAM
Computer-aided manufacturing was also developed in the 1950s when computers
were used to create G-code which was in turn translated into punched cards that
could control machines. Punch tapes were produces through computer control
which could then increase the speed of both instruction creation and
manufacturing.
The tools and machines directed by these codes vary, from plasma cutter to water
jets. The earliest commercial applications of CAM lie in the automotive and
aerospace industries
A REVIEW OF CAD/CAM APPLICATIONS (turning problems, surface milling, machining of cur surface)

CHAPTER TWO

CAD/CAM APPLICATIONS IN TURNING PROBLEM

WHAT IS CNC TURNING
CNC turning is a subtractive machining process that removes material from a
workpiece that spins at a high speed. The workpiece is attached to a chuck that
makes a varying number of revolutions per minute. As the cutting tool comes in
contact with the rotating workpiece, it removes material and sculpts the desired
shape. CNC turning machines work with mainly cylindrical or oblong
components. It can also be used to manufacture other shapes such as discs, picture
cones, hexagons, or a mix.
HOW TO OPERATE A CNC TURNING MACHINE
The turning manufacturing process is straightforward. It occurs in 4 stages.
CREATING A CAD MODEL
The first step of CNC turning is to prepare a 2D or 3D model of the final design
using CAD software. There are many types of software one can use.
SOLIDWORKS, Fusion 360, and AutoCAD are the most common. It is easy to
prepare CAD models for simple designs. However, more complex designs will
require the services of an expert.
CONVERSION TO CNC COMPATIBLE FORMAT
The next stage is to convert the electronic design to a language the machine
understands. You do this using CAM software such as Mastercam, solidCAM, or
CAMWorks. The CAM software checks if the model has any mistakes, makes
directions for the turning tool, and sets necessary machine parameters.
PREPARE THE CNC TURNING MACHINE

Before carrying out the turning operation, you must set up and configure the
machine. Despite the automation, an operator plays a crucial role in preparing the
CNC turning lathe. To do this,
.Put off the machine and load the workpiece onto the chuck.
.Thereafter, select the tools and secure them on the tool turret.
.Calibrate by setting the tools and workpiece correctly.
.Check and optimize necessary parameters.
.Upload the CNC code and prepare for the turning operation.

PRODUCE THE CNC TURNED PARTS

Now, it’s time to bring your idea back to life. There are many turning operations
one can use. As soon as you execute the program, the machine runs continuously
till the program ends or it is switched off. The loading, cutting, and idle time
determines the turning cycle time. You may need to run the machine more than
once. This depends on the complexity of the part.
TYPES OF CNC TURNING OPERATION
CNC lathe machining operations can either be internal or external. External
operations act on the outer diameter of the workpiece while internal operations
work on the internal diameter. However, it is more difficult to carry out internal
operations. It causes more chips to build up and requires longer tools.
THERE ARE FEW EXAMPLES WE CAN EXAMINE

EXRERNAL TURNING OPERATIONS (SPECIFIC) TURNING

In the turning process, the tool gradually removes material along the side of the
workpiece intending to reduce the outer diameter. This operation can either be
rough or finish. In rough turning, the final parts are accurate with a rough surface
finish. However, the surface of the final part in the finish turning is fine and glossy.
Furthermore, the turned part’s surface can have several features. It can range from
steps and tapers to chamfers and contours.
FACING.
Many times, a workpiece is usually longer than how it should be. Face turning
aims to reduce a part’s length. In facing, the end of the workpiece is located
perpendicularly to the rotating axis and moves against the tool. This process
smoothens the part as it produces the desired length.
GROOVING
The grooving operation involves creating a narrow cut in a workpiece. The size of
the cut is related to the width of the cutting tool. The wider the tool, the larger the
groove it can produce. Very large grooves require multiple passes and a longer
time. Note that the groove can either be located externally or on the surface of the
workpiece.
INTERNAL TURNING OPERATIONS (NON-SPECIFIC)
BORING
Boring involves rotating a predrilled workpiece over an insert. As the part spins,
the insert cuts into the edges of the hole to create a variety of features. Boring
operations help to expand smaller holes, straighten holes, and mask die casting
defects.
REAMING
Reaming uses specialized tools to enlarge pre-drilled holes and improve their
surface finish. It is similar to boring and drilling. However, it removes a smaller
amount of material and acts mainly as a post-processing technique.
TYPES OF CNC TURNING MACHINES
 HORIZONTAL TURNING CERTERS
 VERTICAL TURNING CERTERS
 HORIZONTAL LATHES
 VERTICAL LATHES

COMPONENTS OF CNC TURNING MACHINE

It is important to understand how each part of a CNC turning machine works to
achieve the greatest outcome. The following are list components that makes up a
CNC machine.
1,HEADSTOCK, 2,TAILSTOCK,
3,SPINDLE, 4, CHUCK, 5,LATHE BED,
6,CARRIAGE, 7,TOOL TURRET,
8,CONTROL PANEL.
ADVANTAGES OF CNC TURNING
There are many advantages of the CNC turning process which include.
 CNC turning produces accurate parts as it eradicates human errors by using
CAD and CAD software
 Turning centers offer flexibility in manufacturing as it is compatible with
many materials and different sizes of parts.
 CNC lathes are efficient and fast allowing parts to get to market on time
without compromising quality.
 Additionally, CNC turning is a precise method as it ensures consistency in
production batches.
 Turning machining is a safe process because it is fully enclosed and prevents
materials from flying away and around.

DISADVANTAGES OF CNC TURNING

Despite the numerous benefits, CNC has some shortcomings.
They are as follows
 The cost of setting up and maintaining a CNC turning machine is high.
 CNC lathe machining comes with size restrictions and may not be able to
accommodate very large workpieces.
 Because the turning process is a subtractive method, it generates a
considerable amount of waste.
There are materials that are most appropriate for CNC turning
They are as follows
1, metals 2, plastics 3, woods 4, glass 5, wax
APPLICATIONS OF CNC TURNING
 AEROSPACE COMPONENTS
  AUTOMOTIVE PART
 ELECTRONICS INDUSTRY
 OIL AND GAS INDUSTRY

CHAPTER THREE
CAD/CAM APPLICATIONS IN SURFACE MILLING
WHAT IS CAM MILLING
CAM milling, a pivotal manufacturing method, synergizes milling and Computer-
Aided Manufacturing (CAM) software for precision engineering. In milling,
material subtraction occurs as a spinning tool shapes the workpiece. CAM software
automates this on CNC machines, translating CAD designs into machine-readable
code. CAD and CAM can be effortlessly integrated with technologies like
Mastercam®. This dynamic combination guarantees accurate and economical
production of finely designed components by optimizing the manufacturing
process and improving precision.
How Does CAM Milling Work?
CAM milling transforms traditional manufacturing by automating processes
through software. Designers create intricate 3D models with CAD software, while
CAM software converts these designs into exact instructions for automated tools
and machinery. Because the program interfaces directly with the manufacturing
machinery, there is no longer a requirement for manual jig setups. Many thousands
of identical models can be produced accurately and efficiently thanks to the
streamlined method, which also drastically cuts down on labor and time.
Productivity, consistency, and overall quality of manufactured goods are improved
in a variety of industries by this CAD/CAM integration.
Why Is CAM Milling Advantageous in Modern Manufacturing?
CAM milling offers several advantages in modern manufacturing as listed below :
1. Decreases the likelihood of mishaps and injuries on the work floor using
automated CAM systems.
2. Guarantee high machining accuracy, meeting stringent tolerances.
3. Automated processes decrease manual labor, enhancing overall production
efficiency.
4. Facilitates the creation of complex and intricate shapes with ease.
5. The automated nature of CAM milling ensures uniform outcomes, minimizing
variations.
6. CAM machines operate at high speeds, contributing to swift production cycles.
What Factors Should Be Considered When Selecting Materials for CAM
Milling?
The factors to consider when selecting materials for CAM milling include:
1. Material Requirements: Consider functionality, strength, and operating
conditions.
2. Part Application: Tailor material choice to the specific needs of the
application, such as weight requirements for aerospace parts.
3. Environment of Operation: Ensure the material can withstand
environmental conditions and machining heat.
4. Stability in Dimensions and Tolerance: Choose materials with good
stability and machinability for precise dimensions.
5. Machinability: Factor in ease of machining, especially for large production
batches.
6. Physical Appearance: Consider aesthetics if important for consumer
products.
7. Material Costs: Balance functionality with costs, exploring viable
alternatives when needed.
8. Availability: Ensure selected materials are readily available for efficient
CAM milling.
How Do Precision and Accuracy Impact CAM Surface Milling?
Precision and accuracy are important in CAM milling to guarantee the creation of
high-quality products. Precision is required throughout the whole machining
process, from programming the machine to milling the pieces. Any departure from
the intended level of precision may lead to defective products. This may render the
finished item unsuitable for its intended purpose, and in doing so may damage the
reputation of the maker. Excellence in CAM milling demands a steadfast
dedication to upholding the highest level of accuracy at every step of the
procedure.
What Makes CAM Milling Different From Other Milling Techniques?

1. Computer-Aided Control: With CAM milling, precision is increased

through automated control systems that are directed by digital data.
2. Integration with CAD: CAM milling seamlessly integrates with Computer-
Aided Design (CAD), allowing direct translation of design data into
machining instructions.
3. Efficiency Emphasis: Through automated toolpath development and
numerical control software, CAM milling puts efficiency first by optimizing
the production process.
4. Complex Geometries: CAM milling outperforms traditional milling
processes in its ability to machine complicated shapes and elaborate designs
with ease.
What Are the Challenges in CAM Milling Operations and How Are They
Solved?
1. Costly Implementation: Invest in software, hardware, and machine tools
while considering maintenance expenses.
2. Training Requirements: Provide staff training for software and machine
operation, ensuring skill updates.
3. Data-Security Concerns: Safeguarding valuable data and designs from
cyber-threats, theft, or corruption.
4. Tool Wear: Implement regular tool inspections and replacements to
maintain efficiency.
5. Compliance: Adhere to legal and ethical standards in the industry and meet
customer expectations for responsible CAM milling practices.

How Does Computer-Aided Design (CAD) Enhance CAM Milling?

CAD models, created in software like Autodesk Fusion, serve as the foundation for
CAM operations. CAM software utilizes these models to generate toolpaths,
instructing machine tools on how to transform digital designs into physical
components. The seamless integration between CAD and CAM ensures accuracy,
efficiency, and the translation of intricate designs into precisely machined
products, optimizing the overall manufacturing process.

What Safety Protocols Are Essential in CAM Milling?

1. Personal Protective Equipment (PPE): Mandate the use of safety gear
like: goggles, gloves, and ear protection.
2. Emergency Stop Mechanism: Implement easily accessible emergency
stops for immediate halting of the milling process.

3. Tool Inspection: Conduct regular inspections of cutting tools to identify

wear or damage, ensuring replacements are timely.
4. Ventilation: Maintain well-ventilated workspaces to mitigate exposure to
fumes or vapors generated during milling operations.

Why Is CAM Milling Important for CNC Manufacturing?

For CNC manufacturing to function well and save manufacturing costs, CAM
milling is necessary since it speeds up the creation of assembly line equipment.
With the help of CAD/CAM software's customization features, tabletop CNC mills
may produce extremely specialized designs that guarantee accuracy and
adaptability when fabricating components. The use of CAM enhances the
efficiency of workflow, enables economical mass production, and highlights its
vital role in propelling contemporary manufacturing capabilities.
 CHAPTER FOUR
CAD/CAM APLLICATIONS OF MACHINING OF CURVED SURFACE
Milling a curved surface falls under the umbrella of profile/ contour CNC milling.
It involves machining irregularly shaped profiles or continuous curves with various
degrees (either slanted, concave, or convex). This is a crucial process in getting
most of the uniquely shaped bespoke parts done, which requires the CNC
machining services providers to have advanced knowledge of the fundamental
machining principles and programs.
Fundamentals To Profile CNC Milling in curved surfaces.
Before arriving at the final machined part, it will be first subdivided into different
categories: roughing/ semi-roughing, semi-finishing, finishing, and super-
finishing. The larger the component, the more operation types will be involved. It
is important to sub-categorize the operations in machining a work part so that you
would be able to maximize the full potential of the tooling and parameters you will
be using.
Roughing- This operation is always the first stage of machining and usually
begins with cutting the raw material block to shape the part approximately near the
desired shape or profile, leaving enough metal stock for further operations.
Semi-finishing- This process involves machining the part as per dimension
requirements or removing the remaining stock on the part. Semi-finished parts may
also be subjected to further processing to achieve a specific requirement for surface
finish.
Finishing- This process comes after the semi-finishing operation. Finishing is
done to improve the part’s surface finish by removing obvious burrs and other
surface flaws. In this operation, it is essential to use high-performing tools because
this will significantly affect the work part’s final appearance.
Super-finishing- the operation goes further until super-finishing if the parts
require a mirror finish or a super smooth profile. For this to be achieved, high-
speed machining techniques and high-precision tools are used.
Get to Know the Tools Used in CNC Milling Curved Surface
To come up with smooth-curved surfaces on a part being fabricated, different
variations of rounded end mills are used. These include rounded inserts, ball nose
indexable end mills, and ball nose solid carbide. Round-profiled toolings are
preferred for contouring applications because it does not leave evident marks of the
tool path.
Insert-type end mills with rounded inserts- These tools often come in large
tooling diameters. Rounded insert type end mills are well suited for roughing
operations due to their high stability and impressive productivity.
Solid ball nose end mill- These end mills can leave a very nice surface finish on
a machined part. They may have low stability due to their structure. That is why
they are more commonly used for finishing than for roughing operations.
Indexable head ball nose end mills- Indexable head end mills are similar to
solid carbide end mills but have exchangeable heads. These special toolings have a
detachable end which may be replaced when needed.
General Tips For CNC Milling Curved Surfaces
1. Necessary Preparations
Before deciding to fabricate your custom parts through profile milling, it is also
essential that you become aware of the various factors that may affect the whole
CNC milling process. In addition to this, there are specific things you need to
identify so that you can properly choose the suited machining technique. Below are
some of the things you need to be prepared about:
1. Be mindful of the cavity depths of your part designs- This plays a significant
role in helping you choose the right cutting tools to use and how long will be
the gauge length you will be needing.
2. Know how much material will be subtracted from the raw block- This will
help you plan for the operations required in fabricating your work part,
whether you will need additional procedures after semi-finishing and semi-
roughing.
3. Consider how you will clamp the workpiece in place- This will help you
prepare for the necessary fixtures you will be needing.

2. The Old And Classic: Get Your Feeds And Speeds Right
Feeds and speeds determine the rate of material subtraction on the parts, which is
why they have a significant impact in achieving an excellent surface finish. For
this, calculations are needed to be followed. Feed rates to be used may also be
dependent on the depth of cut, the tooling used, the material to be cut, the profile of
the part being machined, and the accuracy required.
We will not mention actual values for the speeds and feeds in this article because
these values may vary depending on multiple factors. It is still recommended to
refer to trusted references for the actual speed and feeds. Nevertheless, here are the
basic rule of thumbs:
The depth of cut and feed rate varies depending on the hardness of the materials
being machined. Take note that for harder materials, the feeds and depth of cut are
much lower than that of softer materials like aluminum. Furthermore, the harder
the material to be cut, the faster the cutting speed should be.
Feed rates and depth of cut for roughing operations are much more aggressive than
finishing operations. It is the combination of using high-speed techniques and the
right tools that make an excellent surface finish.
3. Tooling Utilization
There are many variations of tools available in the market nowadays. For roughing
operations, tooling rigidity should be prioritized to withstand the aggressive cut
depth and feed demands of roughing. On the other hand, for finishing operations,
the end mills should be very sharp not to leave any evident trace of the tool path.
Another difference is the tool diameter used. Typically, roughing tools have larger
diameters than that of the finishing tools.
4. Minimize Vibration In Your CNC Milling Processes
Vibration is one of the major causes of undesirable surface finish, chatter, and
cutting tool damage. During a milling operation, the vibrations may be coming
from multiple sources, including clamping stability, tool rigidity, material
hardness, and inaccuracies in the machine spindle. Below are some of our tips to
minimize this machining obstacle:
 Use tools with good runout accuracy
 Avoid having too long overhang in your end mills during roughing
operations. Instead, use extension bars or extension tool holders
 Secure your work holding fixtures by ensuring that proper grip and balance
are maintained during the cutting operations.
 Avoid aggressive cuts when dealing with hard metals.
CONCLUSION
CNC turning is crucial in the manufacturing business, providing precision and
versatility for a wide range of components. This article has explained the different
turning machine types available, CNC turning operations, and their pros and cons.
This article presented CAM milling, explained it, and discussed its process and
materials used.
CNC milling curved surfaces are usually subdivided into different operations
(roughing, semi-finishing, finishing, and superfinishing) so that the desired profile
is achieved gradually. The toolings used for this type of milling typically have
rounded profiles or what is commonly called ball nose end-mills. In summary,
CNC milling a curved surface involves doing the necessary preparations, getting
the feeds and speeds right, being mindful of the tools you will be using, and
minimizing vibrations.

REFERENCES
ZTLTECH (2024): “WHAT IS CNC TURNING, PROCESS, ADVANTAGES
AND APPLICATIONS”.
XOMETRY (2024): CAM MILLING: “PROCESSS MATERIALS USED,
ADVANTAGES AND CHALLENGES”.
WAYKEN RAPID MANUFACTURING: “A GUILD TO CNC MILLING
CURVED SURFACE” (2024).