ADVANCE WORKSHOP

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 MODULE # 1

SAFETY IN LABS

Prepare from class notes.

 MODULE # 2

BASIC CONCEPTS

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 Fixed vs variable cost

• Fixed Costs – incurred in a predetermined amount, regardless of number of units

produced (i.e. setting up the factory work area or cost of an injection mold)

• Variable Costs – incurred in direct proportion to the number of units produced

(i.e. cost of raw materials)

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 Fail safe and ease of assembly

• Part is inserted from the top of the assembly

• Self-aligning

• Does not need to be oriented

• Part requires only one hand for assembly

• Part is assembled in a single, linear motion

• Part is secured immediately upon insertion

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 Design for Production

• Just-in-time (JIT) concept

• Standardization

• Modular Design

• Interchangeability

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 Module 3

• Measurements Techniques and Errors in Measurements

• Standardized Patterns and Calibration Issues

• Accuracy and Precision

• Tolerances and Clearances 3+.001,

• 3.010, 3.0091, 3.004, 3.0014, 2.9989, 2.9991, 3.0005, 3.001, 2.999

• Quality Inspections and Corrections

• Wastage Control
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 Tolerances and Clearances

CLEARANCE is the distance between the adjacent surfaces

of mating parts (how much the mating parts CLEAR each

other), while TOLERANCE is the allowable variation of a

dimension from its nominal (desired) value ( the amount of

error one will TOLERATE)

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 Tolerances and Clearances

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 Accuracy and Precision

Precision refers to the closeness of two or more

measurements to each other, Whereas Accuracy

refers to the closeness of a measured value to a

standard or known value.

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 Accuracy and Precision

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 Quality Inspections and Corrections

• If your team cannot produce defect-free goods or services in

the first instance, inspection is too late.

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 MODULE # 4

CONVENTIONAL MANUFACTURING
PROCESSES

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 CONVENTIONAL MANUFACTURING

• Casting

• Forming

• Machining

• Joining (welding, brazing, soldering, adhesive)

• Moulding

• Labelling and Painting

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 Casting

• Centrifugal casting
• Die casting
• Full-mould casting
• Lost-foam casting https://www.youtube.com/watch?v=npHQPXGGkgI

• Investment casting (Lost-wax casting)

• Counter gravity casting
• Sand casting
• Shell moulding https://www.youtube.com/watch?v=hCiqoFBh_DA

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 Forming

• End Tube Forming

• Forging
• Rolling
• Extrusion
• Bending
• Pressing
• Shearing https://www.google.com/search?q=shearing+manufacturing+process&sxsrf=ALeKk01ZUxRXOawrkP1-i6T3MnfVFGmISw:1607684839942&tbm=isch&source=iu&ictx=1&fir=Q7dq8QKWX3Z1pM%252CZAZF3MroQ7SphM%252C_&vet=1&usg=AI4_-
kT0xo8YimNsazAKBuF_rTloAFrjmg&sa=X&ved=2ahUKEwjYia7e5MXtAhXxURUIHYV4BJAQ_h16BAgHEAE#imgrc=K89mp7Fnb66SoM

• Other types of Forming

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 Machining

• Turning Many machines can perform multiple machining processes. For Example: Lathe
machine can perform Turning, facing, cutting, drilling, boring, Reaming, Honing,
Surface finishing
• Boring

• Drilling

• Honing https://www.youtube.com/watch?v=TyZL90po6bg

• Milling https://www.youtube.com/watch?v=oJPGioHgNjU
https://www.youtube.com/watch?v=Chs55TQZOSk A planer is a type of metalworking machine tool that uses
linear relative motion between the workpiece and a single-
point cutting tool to cut the work piece. A planer is similar
• Planing / Shaping to a shaper, but larger, and with workpiece moving,
whereas in a shaper the cutting tool moves.
• Cutting / Sawing (Shear cutting, Cutting disc, Turning, Welding, Water jet Cutting,
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Laser Cutting, wire Cutting, plasma Cutting) https://www.youtube.com/watch?v=9qXja6MEsdE
 Machining
Electrochemical machining (ECM) is a method of
• Grinding removing metal by an electrochemical process. It
is normally used for mass production and is used
for working extremely hard materials. Its use is
• Buffing limited to electrically conductive materials. ECM
can cut small or odd-shaped angles, intricate
• Polishing https://www.youtube.com/watch?v=k1Ng9RhSstE contours or cavities in hard materials such as
titanium aluminides, Inconel, Waspaloy, and high
nickel, cobalt, and rhenium alloys.
(Electroplating https://www.youtube.com/watch?v=OxhCU_jBiOA) Electrical discharge machining (EDM), also known
as spark machining, spark eroding, die sinking,
wire burning or wire erosion, is a metal fabrication
• ECM https://www.youtube.com/watch?v=b1nX7WVIN7U process whereby a desired shape is obtained by
using electrical discharges (sparks)

• EDM https://www.youtube.com/watch?v=kh4DSOtef4k The broaching process, similar to shaping with multiple

teeth, is used to machine internal and external surfaces
such as holes of circular, square, or irregular shapes,
• Broaching keyways and teeth of internal gears. A broach is a long
https://www.youtube.com/watch?v=rAJx-6SLdP0
multi-tooth cutting tool with successively deeper19cuts.
 Machined Parts Examples

• Gears https://www.youtube.com/watch?v=XZgsV0AZJJ0
• Crankshaft https://www.youtube.com/watch?v=mj8leWsB4w4

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 MODULE # 3

MANUFACTURING PROCESSES LAYOUTS

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 TYPES OF MANUFACTURING LAYOUTS

• Process Layout / Job shop

• Product Layout / Assembly Line

• Project Layout

• Others incl Modular Layout, Mixed Layout

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 MODERN MANUFACTURING CONCEPTS

• Computer Integrated Manufacturing (CIM)

• JIT

• Subletting the work in modular fashion

• Flexible Manufacturing Organizations

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 MODULE # 4

3D PRINTING / ADDITIVE MANUFACTURING

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 3D PRINTING / ADDITIVE MANUFACTURING

Steps:
• Geometric Modeling
• Tessellation of the Geometric Model
• Slicing of the model into layers
Channel Modes:
• Moving point
• Moving Line
• Layer Mode 25
 3D PRINTING / ADDITIVE MANUFACTURING

Process Types:
• Liquid Based
• Powder Based
• Molten Material
• Fused Deposition Modeling (FDM)
• Droplet Deposition Manufacturing(DDM) / Ballistic-Particle Manufacturing

• Solid Sheets
• Laminated-Object Manufacturing (LOM)
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 3D PRINTING / ADDITIVE MANUFACTURING

Problems:
• Part Accuracy
• Limited Variety of materials
• Mechanical Performance
• Multiple Error Sources
• Heat Plate Issues
• Size Limitations
• Manufacturing Time vs Density 27
 3D PRINTING / ADDITIVE MANUFACTURING

Cycle Time and Cost Analysis:

Ti=(Ai/(v*D))+ Tr
Where
• Ti =Time to complete layer i (secs)
• Ai =Area of layer i (mm2)
• v=speed of moving spot on surface (mm/s)
• D=Diameter of the spot (mm)
• Tr =Repositioning Time between layers (s)
Ref: Chapter 29, page 764-765, example 29.1 28
Principles of Modern Manufacturing 5th Edition by Mikell P. Groover
 MODULE # 5

CNC MACHINING

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 THE CNC CODES

N: The N value gives the line number.

G: The G number tells when the tool to move and stop.
X, Y, Z: These values indicate the position of the tool in three dimensions — X for
horizontal, Y for vertical and Z for depth.
F: F relates to how quickly the machine feeds the piece.
S: S tells the machine how quickly to move the spindle.
T: The T tells the machine which tool to use.
M: M values give miscellaneous functions or machine functions, telling the device how
to act by giving on and off directions.
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 THE CNC CODES
I and J: These values indicate the incremental center of any arcs the machine makes.
R: R gives the radius of arcs made by the machine.
A: A values direct the tool around the x-axis.
B: The number with B shows the rotational value around the y-axis.
C: An auxiliary axis that rotates around the z-axis gets its positional value from the C
value.
D: This number shows how much the system offsets the tool diameter.
L: L gives the system a value to indicate repeating operations and how many times they
need to loop.
P: The program jumps in time or a delayed time with the P command. 31
 THE G CODES
• G01 X247.951560 Y11.817060 Z-1.000000 F400.000000
• G01 which means “move in straight line to a specific position”.
• We declare the position or the coordinates with the X, Y and Z values.
• Lastly, with the F value we set the feed rate, or the speed at which the move will
be executed.
• To wrap up, the line G01 X247.951560 Y11.817060 Z-1.000000 F400.000000
tells the CNC machine to move in a straight line from its current position to the
coordinates X247.951560, Y11.817060 and Z-1.000000 with speed of 400
mm/min.
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 THE G CODES
• The unit is mm/min with command G21 which sets the units to millimiters. If we
want the units in inches, we use the G20 command instead.
• G00 – Rapid Positioning

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 THE G CODES

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 THE G CODES

• Example:
Y
Y

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 THE G CODES

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 THE G CODES

• Plane Selection: G17 is generally the default plane.

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 THE G CODES

• G28 Return Home:

• In order to avoid collision,
we can include an
intermediate point with X, Y
and Z parameters. The tool
will pass through that point
before going to the reference
point. G28 X## Y## Z##

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 THE G CODES
• G00 Moves the tool in rapid travel (not necessarily a straight line)
• G01 Moves the tool using a set feedrate
• G02 Moves the tool along a clockwise arc path
• G03 Moves the tool along a counter-clockwise path
• G04 Sets a dwell time in seconds or revolutions of the spindle
• G10 Data setting
• G11 Data setting mode cancel
• G17 Establishes axis movement in the X and Y axis planes
• G18 Establishes axis movement in the X and Z axis planes
• G19 Establishes axis movement in the Y and Z axis planes 39
 THE G CODES

• G20 Values are in Inches

• G21 Values are in millimeters
• G28 Return to reference position
• G30 Second reference position
• G33 Thread cutting
• G40 Cancel cutter compensation
• G41 Cutter compensation left
• G42 Cutter compensation right
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 THE G CODES
• G43 Tool length compensation positive
• G44 Tool length compensation negative
• G49 Tool length compensation cancel
• G90 Absolute measurements
• G91 Incremental measurements
• G94 Feed per minute
• G95 Feed per revolution of the spindle
• G96 Constant surface speed control
• G97 Constant surface speed control cancel
• G98 Return to initial point in canned cycle 41
 THE G CODES
• G43 Tool length compensation positive
• G44 Tool length compensation negative
• G49 Tool length compensation cancel
• G90 Absolute measurements
• G91 Incremental measurements
• G94 Feed per minute
• G95 Feed per revolution of the spindle
• G96 Constant surface speed control
• G97 Constant surface speed control cancel
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 THE M CODES

• M values give miscellaneous functions or machine functions, telling

the device how to act by giving on and off directions.

• M00 Program stop

• M01 Optional stop

• M02 End of program

• M03 Spindle on Clockwise

• M04 Spindle on Counter-clockwise

• M05 Spindle stop

• M06 Tool change 43

 THE M CODES

• M08 Coolant on

• M09 Coolant off

• M10 Clamp

• M11 Unclamp

• M30 End of program and rewind to beginning of program

• M98 Call subprogram

• M99 End subprogram

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 Example

G91

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 Description of the G-code program example:
• Code initialization. This character (%) is always present at the beginning and at the end of the program.
• Safety line: Set metric system (all dimensions in mm), XY plane, absolute positioning and feed rate of 100 inches/min.
• Spindle on clockwise at speed of 1000 RPM.
• Rapid positioning to B(5,5).
• Controlled motion on the same position, but lowering the tool to -1.
• Linear cutting movement to position C(5,15).
• Clockwise circular motion to point D(9,19), with center point at (9,15).
• Linear cutting to point E(23,19).
• Linear cutting to point F(32,5).
• Same straight cutting to point G(21,5).
• One more straight cutting to point H(21,8).
• Counterclockwise circular interpolation to position I(19,10), with a center point at (19,8).
• Linear cutting to point J(13,10).
• Counterclockwise circular cutting to position K(11,8), with a center point at (13,8).
• Linear cutting to position L(11,5).
• Final linear cutting movement to position B(5,5).
• Rise up the tool.
• Go to home position.
• Spindle off.
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• Main program end.
 How it Works

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  Useful Links:
• https://www.slideshare.net/snakeaye/g-and-m-codes
• https://www.youtube.com/watch?v=jlhjrMKiZfo
• https://www.youtube.com/watch?v=0yU-U9Hc-M4
• https
://howtomechatronics.com/tutorials/g-code-explained-list-of-most-
important-g-code-commands/

• https://www.cnccookbook.com/g-code-m-code-reference-list-cnc-
mills/

• https
://roboticsandautomationnews.com/2018/01/26/how-to-become-a
-g-code-master-with-a-complete-list-of-g-codes/15807/
• https://www.youtube.com/watch?v=rWXVq0y5QIk
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