Course syllabus
IMS026 - Manufacturing processes, machines and CAM
IMS026 Tillverkningsteknik och digitala tillverkningsmetoder lp2 HT22 (7,5 hp)
Examiner |
Peter Krajnik (PK) |
| 031-772 1311 | |
| peter.krajnik@chalmers.se | |
| Course manager | 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, material-conversion technologies and 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:
- Describe the basics of manufacturing, materials processing technology, and novel paradigms such as additive manufacturing
- Differentiate diverse machining operations and recognize their industrial applications.
- Explain the basic concepts of machine tool design and machining systems.
- Apply fundamentals of CNC programming and automation of CNC machines by writing and testing G-codes for machining of simple parts.
- Execute the common steps during CNC programming of more complex parts using CAD/CAM systems.
- Discuss methods to test machine tool accuracy and performance
Content
- Manufacturing technology fundamentals.
- Material-processing technologies: casting, forming, additive manufacturing.
- Fundamentals of metal cutting (machining): turning, drilling, milling, grinding, finishing; non-traditional machining.
- Machine tools and systems: evolution of machines; metal-cutting machines, machining centres, cells, FMS.
- 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, 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 (1.5 credits) are included in the course:
Assignment 1: Machine-tools
Questions: Peter Krajnik, krajnik@chalmers.se
Students will 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
Assignment 2: Cutting calculations
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
Assignment 3: 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
Assignment 4: 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
CAM lab exercises
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
Grinding laboratory exercise & tour of workshop
The materials processing laboratory of the Department of Industrial and Materials Science (Campus Johanneberg) are visited. Students will get the chance to see the facilities with its available manufacturing processes. Particular focus will be placed on the latest machine tool, a high performance surface grinding machine. A number of dressing and grinding trials will be executed to demonstrate the grinding process.
Feedback: Attendance required to pass.
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
Lectures
| Week | Day | Date | Start | End | Room | Topic |
Teacher |
| 1 | Måndag | 2022-10-31 | 15:15 | 17:00 | Delta | Intro & principles of manufacturing | PK |
| 1 | Tisdag | 2022-11-01 | 15:15 | 17:00 | Beta | Machine tools & manufacturing systems I | PK |
| 1 | Onsdag | 2022-11-02 | 13:15 | 15:00 | Beta | Machine tools & manufactuing systems II | PK |
| 2 | Måndag | 2022-11-07 | 15:15 | 17:00 | Beta | Machine tools & manufacturing systems III | PK |
| 2 | Tisdag | 2022-11-08 | 15:15 | 17:00 | Alfa | Material removal processes 1 - Cutting technologies I | PH |
| 3 | Måndag | 2022-11-14 | 15:15 | 17:00 | Beta | Computer aided manufacturing I | PH |
| 3 | Tisdag | 2022-11-15 | 08:15 | 10:00 | Delta | Computer aided manufactuing II | PH |
| 4 | Måndag | 2022-11-21 | 15:15 | 17:00 | Beta | Material removal processes 1 - Cutting technologies II | PH |
| 4 | Tisdag | 2022-11-22 | 15:15 | 17:00 | Delta | Material removal processes 2 - abrasive technologies | PH |
| 5 | Måndag | 2022-11-28 | 13:15 | 15:00 | Beta | Material- processing technologies - casting & forming I | GH |
| 5 | Tisdag | 2022-11-29 | 08:15 | 10:00 | Babord | Material- processing technologies - casting & forming II | GH |
| 6 | Fredag | 2022-12-09 | 08:15 | 12:00 | Beta | Additive manufacturing | SH |
| 7 | Måndag | 2022-12-12 | 10:15 | 12:00 | Delta | *Bonus: Manufacturing technology in the automotive industry | PK |
| 7 | Tisdag | 2022-12-13 | 15:15 | 17:00 | Alfa | Summary & exam info | PK |
| 7 | Fredag | 2022-12-16 | 08:15 | 12:00 | Beta | Additive Manufacturing | SH |
Link to map of campus Lindholmen
Exercises & labs
| Week | Day | Date | Start | End | Room | Topic | Teacher |
| 3 | Onsdag | 2022-11-16 | 13:15 | 17:00 | Jupiter044 | CAM tutorial 1&2 Group1 | PH/DG |
| 3 | Fredag | 2022-11-18 | 08:15 | 12:00 | Jupiter044 | CAM tutorial 1&2 Group2 | PH/DG |
| 4 | Onsdag | 2022-11-23 |
13:15 12:30 |
16:00 15:00 |
Jupiter044 Jupiter 308 & 309 |
CAM tutorial 3, Group 1 | PH/DG |
| 4 | Fredag | 2022-11-25 | 09:15 | 12:00 |
Jupiter044 Jupiter 308 & 309 |
CAM tutorial 3, Group 2 | PH/DG |
| 4 | Onsdag | 2022-11-30 | 13:15 | 15:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 1 | PH |
| 4 | Onsdag | 2022-11-30 | 15:15 | 17:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 2 | PH |
| 5 | Fredag | 2022-12-02 | 09:15 | 12:00 |
Jupiter024, Jupiter025 Jupiter 308 & 309 |
CAM tutorial 4, Group 1 | PH/DG |
| 5 | Fredag | 2022-12-02 | 13:15 | 16:00 |
Jupiter024, Jupiter025 Jupiter 308 & 309 |
CAM tutorial 4, Group 2 | PH/DG |
| 6 | Måndag | 2022-12-05 | 10:15 | 12:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 3 | PH |
| 6 | Måndag | 2022-12-05 | 13:15 | 15:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 4 | PH |
| 6 | Måndag | 2022-12-05 | 15:15 | 17:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 5 | PH |
| 6 | Onsdag | 2022-12-07 | 10:15 | 12:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 6 | PH |
| 6 | Onsdag | 2022-12-07 | 13:15 | 15:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 7 | PH |
| 6 | Onsdag | 2022-12-07 | 15:15 | 17:00 | IMS labb Johanneberg | Lab tour & Grinding lab, Group 8 | PH |
Course summary:
| Date | Details | Due |
|---|---|---|