Piedmont Virginia Community College
Spring 2019 | Monday: 5:30 - 8:15 PM
Syllabus
Documentation Guidelines
Spring 2019 Open Lab Hours
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IND250 - Introduction to Basic Computer Integrated Manufacturing:
Presents basic principles used in the design and implementation in a computer integrated manufacturing system. Emphasizes team concept and all aspects of a computer integrated manufacturing system to include the following: Robotics, Conveyor Control, Machining Center Integration Quality Control, Statistical Quality Control, and Computer Integrated Manufacturing (CIM) software.
Required Materials:
CNC Trade Secrets - James Harvey
Full Frame Anti-Fog Safety Glasses
Digital Caliper
Software:
Autodesk Fusion 360
Fusion 360 Post Processors
CAMotics - CAM Simulation
Carbide 3D - Software Downloads
Resources:
Fundamentals of CNC Machining - Autodesk
Tormach Machine Code Reference
Course Video YouTube Playlist
Class will meet every Monday afternoon. We will spend the first portion of the semester on the control side of the manufacturing using CAM tools and GCODE. We will build a tool library to prepare us to quickly use the CNC and iterate on our designs for manufacturing. We will move quickly and the CAM portion of the class will require outside practice using simulation. We will be using Fusion 360 as our CAM package and use the Tormach GCODE machine programming reference.
Getting Started:
We are going to practice processes and developing an overarching idea for the class using modeling clay and constrained tools to create certain shapes.
Challenge Slides
Fusion 360 Models
Challenge 1 - Sheet
Challenge 2 - Sheet
Challenge 3 - Sheet
Laser Cut Clay Form - .svg
Supplemental Materials
Master Tool Maker Tom Lie Nielsen - Titans of CNC
CNC Dummies for Routers - This Old Tony
Beginner's Guide to Manual & CNC Machining - NYC CNC
Autodesk Educational Account for Fusion 360
For next class...
Please make sure to watch the above videos to gain some basic understanding of the CNC Machining process, langauge, and context for our future conversations
Create an Autodesk Educational Account if you have not done so already. This will be used to log in to Fusion 360 to perform our CAM operations
Read to page 3-9 in the Autodesk Fundamentals of CNC Machining Book
Getting Started:
Introduction to CNC and CAM tools, while designing small parts for the laser cutter in CAM. We will look at how parts fit together and develop a unique model to be processed by the laser cutter. We will also start talking about tooling for the CNC Milling Machine.
Make sure your account with Autodesk is working...
Basic model in CAM using post processor for Universal Laser
Create a part using the laser cutter...
Change the part based on kerf...
Supplemental Materials:
Caliper Design - .svg
Universal Laser Cutter - Post Processor
Adding a Personal Post Processor - Autodesk
Paper Calipers - duckythescientist - Thingiverse
For next class:
Make sure that your caliper is completed in cardstock, and is scaled to the proper size.
Make sure your Autodesk account is active on Educational Version.
Read 3-10 to 4-13 in Autodesk Fundamentals of CNC Machining Book.
Bring your digital caliper to class! We will be using it extensively.
If you are redoing any of the CAM from class, I will be posting a video on what we did in class for your review.
Getting Started:
We are going to create another simple piece and prepare it for the Carbide3D Nomad 833. We are going to create a reference face, add a tool to the library, and make a simple shape on the machine. You are also encouraged to finalize your caliper from last week, and recut it if need be.
Create a new sketch, extrude with dimensions
Setup your CAM environment, add the Carbide post processor
Add an existing tool to the tooling library for future use
Cut part out of existing stock material and check its dimenions
Supplemental Materials:
Carbide 3D - Post Processor
Carbide Motion v4 - Nomad 833 Control Software
01: Fusion Sketching & CAM Intro, pt. 1
01-1: Fusion Sketching & CAM Intro, pt. 2
Caliper 3D Model - Fusion 360 - .f3d
Caliper CAM - Fusion 360 - .f3d
Wheel 3D Model - .f3d
Wheel Drawing w/ Dimensions - .pdf
02: Fusion Facing Operation
Yonico 1/4" Upcut Router Bit - 31215-SC
Carbide3D #102 .125" Flat Cutter
For next class:
Have your facing operation complete with a 1/4" Spiral Upcut Bit and selected stock, drawings and models are listed above.
Attempt to face your material in the Carbide CNC.
Be prepared to continue with the other operations for next class, review this video for getting setup in Fusion 360.
Getting Started:
We are going to attempt to use our facing operation in the Desktop CNC then finish our other operations.
Face bottom of the part on the Desktop CNC (Carbide 3D)
Create another setup and 4 operations for the remainder of your part
Mill the other side of your part using the Desktop CNC
Supplemental Materials:
Nomad 833 Suggested Speeds & Feeds
Nomad 833 (.25 & .125 - Pine) Tool Library Fusion 360 - .tools
03: GCODE to Carbide 3D Nomad 833
Facing Speeds/Feeds GCODE - .nc
03-1: Facing Speeds/Feeds for Nomad 833 (Pine)
For next class:
Finish CAM from this class, mill your part if you can!
Getting Started:
Discuss your posted GCODE with another student. Try to break down the facing operation, by codes and commands.
Review previous operations in CAM and discuss...
Supplemental Materials:
Final Wheel CAM - .nc
Final Wheel, Model & CAM - .f3d
Speeds & Feeds Cheat Sheet - .pdf
Tormach Machine Code Reference
Wrench Model - .step
Wrench Model Drawing - .pdf
For next class:
Create the CAM for the .step file included above of the Wrench Model. There is also a drawing above to reference.
Make the wrench out of 7.5" x 2" x .2" aluminum in the CAM software.
Export to an NC file and double check your GCODE. Use the Lakeshore Carbide, 3 Flute, .25" Carbide Tool in your setup for all operations.
If you have not created your wheel from last class, make sure you mill your part with lab hours.
Getting Started:
Create the GCODE for the Carbide CNC using the class example and comparing other code. Don't use Fusion to create the GCODE, but you can reference some of your previous examples...
Review any previous class operations and continue to develop your documentation.
Supplemental Materials:
NC Viewer Online
GCODE Class Example - .nc
Tormach TTS Wrench Set - Drawing - .pdf
22mm Flat Wrench Example - .step
30mm Hex Wrench Example - .step
30mm Hex Wrench Example - Speeds & Feeds - Process Sheet
For next class:
Be ready to produce your CAM for the wrench project, either using one of the three provided over the last two weeks, or creating your own.
We will be cutting using the Lakeshore Carbide, 3 Flute, .25" Carbide Tool. Calculate your Speeds and Feeds needed!
Use the Tormach post processor to create your GCODE.
Everything will be cut out of 1/4" Aluminum Plate. If you'd like to add a chamfer around the two edges that would be a bonus!
Getting Started:
Prepare your stock for your 2D operation, cut using the jigsaw and an aluminum blade and a friend.
Make sure you choose .25" thick material
We will be setting up some sacrifical stock to be glue underneath hyour stock material.
Supplemental Materials:
Wrench CAM Simple Process Sheet
Wrench CAM Simple GCODE - .nc
Wrench CAM w/ Finishing Process Sheet
Wrench CAM w/ Finishing GCODE - .nc
Tormach Aluminum Wrench: Tool Library Fusion 360 - .tools
05: Simple Adaptive Clearing - Fusion 360
05-1: 2D Contour Finishing - Fusion 360
For next class:
Be prepared to run your CAM and have your aluminum part ready
We will look at some of the processes and do some review
We will also open up the PCNC440 for use as well
Getting Started:
This class will serve as time to run the machines and continue to build our CAM profiles. We will review our previous examples and allow time for questions about prior operations.
Supplemental Materials:
For next class:
Make sure you are prepared to begin new material! We will move forward from this point. If you need time on the machines, let me know!
Getting Started:
Make sure that you are up to date on your documentation. Please submit a link or your current file here: Submission for Documentation
Please schedule time to work in the lab to continue your projects. This can be with me during office hours or work with the lab techs during lab hours.
Create a new component in Fusion 360 and build a 1" x 2" x 1" rectangular prism, we will use this as a small example for our lesson.
We are going to be creating small holes at different depths, choosing efficient and safe tool paths, and clearing holes prior to milling to make room for clearance and saving our tool life!
Supplemental Materials:
In-class Example
In-class Example - Process Sheet
Class Tool Library - .tools (3.25)
CAM Expression Variables in Fusion 360
Sharpening HSS Drill Bits - This Old Tony
For next class:
Make sure you are up to date with documentation and all your current designs and CAM solutions.
Setup time to utilize the equipment and build your parts.
We are going to keep adding new skills so be prepared! Soon we will talk about our final projects so you haev ample time to prepare.
Getting Started:
We are going to be making our own soft jaws for our final project. This will enable us to make custom projects and manufacture multiple products.
Download and install the soft jaws template for Fusion 360 for the Tormach 5" Vise.
Supplemental Materials:
Class Tool Library - .tools (4.1)
Tormach 5" Vise Jaw Profile - .f3d
05: Soft Jaws - Fusion 360
For next class:
Make sure you are up to date with documentation and all your current designs and CAM solutions.
Setup time to utilize the equipment and build your parts.
Make sure your CAM is complete for your soft jaws. This will most likely be needed for your final project!
Review the introduction to the final project and bring some ideas to class next week. We will deliberate and finalize our thoughts as a class.
Final Project Introduction:
You will design a unique component within Fusion 360 and build the model on the CNC.
You must create an accurate part using the material of your choosing to fit the needs of your design.
The materials include wood, plastic and aluminum, and you must prepare your part on the appropriate machine.
Design a repeatable CAM program that includes workholding, operations, tooling, and finishing.
Getting Started:
We will be finishing the soft jaws from last class. What operations do you think we need to get this part going?
Supplemental Materials:
Class Tool Library - .tools (4.15)
Tormach 5" Vise Jaws - .f3d
06 - Soft Jaws, pt II - Fusion 360
For next class:
Be sure to have your final project idea ready to go. You will have some time next class to work on this!
Finish up the CAM for your soft jaws!
Getting Started:
We are going to utilize today's class to finish any previous projects, build tooling and work on our final projects!
Final Project:
Remember to include all of the elements into a final document that will be shared with the remainder of the class.
The final project will be due at the end of the class on May 6
Getting Started:
We will be modeling the soft jaws in our CAM to create the shape of our project model within them.
Supplemental Materials:
Class Tool Library - .tools (4.22)
Tormach 5" Vise Jaws - .f3d
07 - Soft Jaws Vol. 3 - Fusion 360
For next class:
Be sure to have your final project idea ready to go. Final projects and all documentation are due by May 13 at midnight!
Finish up the CAM for your soft jaws with your part! We will mill these out next class.
Final Project Guidelines:
You will design a unique component within Fusion 360 and build the model on the CNC.
You must create an accurate part using the material of your choosing to fit the needs of your design.
The materials include wood, plastic and aluminum, and you must prepare your part on the appropriate machine.
Design a repeatable CAM program that includes workholding, operations, tooling, and finishing.
Create a PDf of the models, CAM Process Sheets, and any notes your developed during your project.
Getting Started:
Utilize this time to go over all your final CAM processes for your final project. We will talk about any struggles or issues the class is having. The remainder of the class will be used to run parts on the machines.
Supplemental Materials:
08 - Chamfer
For next class:
At the end of next class you will be required to share your CAM and any partsup to this point. Remember that your final project will be due on May 13 at midnight! This will include all files, PDFs and documentation.
Utilize the lab time to work on your projects!
Getting Started:
Utilize this time to go over all your final CAM processes and machine your final project. We will talk about any struggles or issues the class is having.
Supplemental Materials:
Final Project Submission Form
Documentation Submission Form
Last class:
Submit your final project here. Due May 13 at midnight.
Submit your documentation here. Due May 13 at midnight.
Please prepare a few minutes to share what you cut, your CAM, model on Monday, May 13. I will provide some pizza and we can all share some struggles and great moments of the semester.
