Course syllabus
IMS025 - Manufacturing processes, machines and CAM
IMS025 Tillverkningsteknik och digitala tillverkningsmetoder lp2 HT21 (7,5 hp)
Examiner |
Peter Krajnik (PK) |
| 031-772 1311 | |
| peter.krajnik@chalmers.se | |
| Course responsible | Philipp Hoier |
| hoierp@chalmers.se | |
| Lecturers | Peter Krajnik (PK) |
| Gustav Holmqvist (GH) | |
| Philipp Hoier (PH) | |
| Guest instructor | Seyed Hosseini (SH) - RISE Research Institutes of Sweden |
| Assistants | Daniel Gren (DG) - PhD Student |
Aim
This course is concerned with the basics of material conversion and machining processes, along with their practical applications to solve problems encountered in manufacturing. The subjects of materials, machines, computers, and software are discussed in light of manufacturing processes. The course begins with the fundamentals of industrial production, followed by lectures on material-removal and material-conversion, as well as introducing novel manufacturing processes, such as additive manufacturing. A special feature is the coverage of machining, one of the most widely used methods of producing the final shape of manufactured products. The essential topics of programming, design, and automation of CNC (Computer Numerical Control) machines; NC (Numerical Control) programming; and CAD/CAM technology are introduced. Lectures includes case-studies drawn from both industry and research. With this course, the undergraduate Mechanical Engineering students will learn the basic principles of manufacturing processes, machines, CNC design, and CAD/CAM technology.
Intended learning outcomes
After completion of the course the student should be able to:
- Appreciate the basics of manufacturing, materials processing technology, and novel paradigms such as additive manufacturing.
- Recognise diverse machining operations and gain insight into their industrial applications.
- Learn the basic concepts of machine tools and machining systems.
- Obtain fundamentals of programming, design, and automation of CNC machines.
- Gain a hand-on experience on NC programming with CAD/CAM systems.
- Discover methods to test machine accuracy and performance.
Content
- Manufacturing technology fundamentals.
- Material-conversion processes: casting, forming, additive manufacturing.
- Fundamentals of material-removal processes: turning, drilling, milling, grinding, abrasive fine finishing; non-conventional processes.
- Machine tools and systems: evolution of machines; metal-cutting machines, machining centers, cells, FMS.
- Machine tool accuracy/performance testing and error budgeting.
- Fundamentals of programming, design, and automation of CNC (Computer Numerical Control) machines; virtual machines and digitalization trends.
- NC (Numerical Control) programming with CAD/CAM systems.
Organization
The course includes lectures, case studies, and tutorials/lab exercises. A typical case study will examine scientific development and industrial end-use of manufacturing processes and machines. The course has strong links with the Chalmers Centre for Metal Cutting Research (MCR) and is designed to usefully propagate the current "State-of-the-Art" in manufacturing technology. The lectures will be given in English and Swedish.
Course home page
PDF handouts from lectures, screencasts, latest version of the course handbook, notifications about lectures as well as literature can be found on the Canvas course homepage. Registration for assignments as well as hand-in of reports is facilitated by Canvas as well.
Assignments & lab exercises
The following compulsory assignments & labs (3 credits) are included in the course:
Machine-tool assignments
Questions: Peter Krajnik, krajnik@chalmers.se
In this series of three remote assignments you will be (individually or in groups) exercise with the aspects of machine-structural loop, machine-tool spindle design and machining dynamics depending on the frequency response function of the machine.
Feedback: Passed/Rework
Cutting calculation exercise
Questions: Philipp Hoier, hoierp@chalmers.se
In this home-assignment a number of calculations regarding turning and milling are to be done and submitted in groups of two.
Feedback: Passed/Rework
Computer lab: CAM
Questions: Philipp Hoier, hoierp@chalmers.se
The goal of this on-campus exercise is to become familiar with the CAM software Creo and the methods required to carry out simple machining sequences such as face milling, volume milling, profile milling, drilling, and turning. The exercises are conducted in small groups and are spread out over three separate occasions on campus (see schedule).
Feedback: Passed/Rework
NC-programming
Questions: Philipp Hoier, hoierp@chalmers.se
In this home-assignment the students need to write a G-code for a selection of parts that are to be machined in a lathe and/or milling machine. The assignment is done in groups of two and will need to be submitted online via Canvas.
Feedback: Passed/Rework
Deep Drawing
Questions: Gustav Holmqvist, gustav.holmqvist@chalmers.se
In this home-assignment, calculations about a drawing sheet metal into the shape of cups need to be done. Students will work in groups of two and submit the solutions they obtained via Canvas.
Feedback: Passed/Rework
Literature
There are no textbooks required for this course. For each lecture there will be teaching material made available on the course home page in Canvas. Presentation/lecture handouts and instructions will provide the necessary insight into the state-of-the-art of the manufacturing methods.
The course material is also covered in most parts in these books, but reading the books are not required:
- Elshennawy, Ahmad K. Weheba, Gamal S.. (2015). Manufacturing Processes and Materials (5th Edition). Society of Manufacturing Engineers (SME) –
Computer-Aided Manufacturing is very brief in the above book, so if you want to learn more in-depth about CAM, you can try this book:
- Radhakrishnan, P.. (2015). Computer Numerical Control Machines and Computer Aided Manufacture (2nd Edition). New Academic Science.
Both books are available as e-books through Chalmers Library by going to, knovel.com (via Chalmers network) and searching the book title using advanced search.
Examination including compulsory elements
- To obtain a final grade in the course, a written exam is required + approved assignments + approved computer lab(s).
- Final grade is based on the exam.
- Oral re-exam is optional in case of small number of registered students.
- The exam gives 4.5 credits and is assessed against 100 points in total with the following grading:
- Fail – 0-39 points
- 3 (Passed) – 40-59 points
- 4 (Passed with credit) – 60-79 points
- 5 (Passed with distinction) – 80-100 points
- The assignments/labs do not grant extra/bonus points for the exam
Lecture schedule
(Lecture slides can be found under "Files")
| Week | Day | Date | Start | End | Room | Topic |
Teacher |
| 1 | Måndag | 2021-11-01 | 15:15 | 17:00 | Delta | Intro & Principles of Manufacturing | PK |
| 1 | Tisdag | 2021-11-02 | 15:15 | 17:00 | Beta | Machine tools I | PK |
| 1 | Onsdag | 2021-11-03 | 13:15 | 15:00 | Beta | Machine tools II | PK |
| 2 | Måndag | 2021-11-08 | 15:15 | 17:00 | Beta | Machine tools III - Part 1, Part 2 | PK |
| 2 | Tisdag | 2021-11-09 | 13:15 | 15:00 | Alfa | Material removal processes 1 - cutting technologies I | PH |
| 3 | Måndag | 2021-11-15 | 15:15 | 17:00 | Beta | Computer Aided Manufacturing I | PH |
| 3 | Tisdag | 2021-11-16 | 08:15 | 10:00 | Delta | Material removal processes 1 - cutting technologies II | PH |
| 4 | Måndag | 2021-11-22 | 15:15 | 17:00 | Beta | Material removal processes 1 - cutting technologies III | PH |
| 4 | Tisdag | 2021-11-23 | 13:15 | 15:00 | Delta | Material removal processes 2 - abrasive technologies | PK |
| 5 | Måndag | 2021-11-29 | 13:15 | 15:00 | Själv-studier | Material-processing technologies - casting and forming I; Del_1 Del_2 | GH |
| 5 | Tisdag | 2021-11-30 | 10:15 | 12:00 | Själv-studier | Material-processing technologies - casting and forming II; Del_1 Del_2 | GH |
| 6 | Måndag | 2021-12-06 | 15:15 | 17:00 | Beta | Manufacturing processes in the automotive industry | PK |
| 6 | Onsdag | 2021-12-08 | 10:15 | 12:00 | Zoom |
Material-processing technologies - casting and forming: Frågor/Repetition |
GH |
| 7 | Måndag | 2021-12-13 | 08:15 | 12:00 | Delta | Additive Manufacturing | SH |
| 7 | Tisdag | 2021-12-14 | 13:15 | 15:00 | Alfa | Summary and Exam info | PK |
Link to map of campus Lindholmen
Computer lab schedule
| Week | Day | Date | Start | End | Room | Topic | Teacher |
| 3 | Tisdag | 2021-11-16 | 13:15 | 17:00 | Jupiter044 | CAM tutorial 1&2 Group1 | PH/DG |
| 3 | Onsdag | 2021-11-17 | 13:15 | 17:00 | Jupiter044 | CAM tutorial 1&2 Group2 | PH/DG |
| 4 | Onsdag | 2021-11-24 | 13:15 | 16:00 | Jupiter044 | CAM tutorial 3, Group 1 | PH/DG |
| 4 | Torsdag | 2021-11-25 | 09:15 | 12:00 | Jupiter044 | CAM tutorial 3, Group 2 | PH/DG |
| 5 | Fredag | 2021-12-03 | 09:15 | 12:00 | Jupiter024, Jupiter025 | CAM tutorial 4, Group 1 | PH/DG |
| 5 | Fredag | 2021-12-03 | 12:30 | 15:30 | Jupiter024, Jupiter025 | CAM tutorial 4, Group 2 | PH/DG |