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Board # 148 : MAKER: Generations of NC Machining through Laboratory Work

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2017 ASEE Annual Conference & Exposition


Columbus, Ohio

Publication Date

June 24, 2017

Start Date

June 24, 2017

End Date

June 28, 2017

Conference Session

Make It!

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Sangarappillai Sivaloganathan United Arab Emirates University

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Dr Sangarappillai Sivaloganathan – Siva is a Srilankan by birth and a citizen of the United Kingdom. His experience in Sri-lanka started with an year’s post-graduate apprenticeship in the manufacturing shops of the Government Railway and nine years in the Cement Industry. He graduated as a Mechanical Engineer from University of Srilanka, and obtained his Masters from the University of Aston and PhD from City University of London, both in the UK. He started his career in the UK as the Senior Research Assistant at the SERC Engineering Design Centre. He joined Brunel University in 1995 where he worked for 18 years before joining United Arab Emirates University in August 2011. During his stay at Brunel he has worked with many British industries. Dr Sivaloganathan is a keen researcher in Design and was the Convenor for the International Engineering Design Conferences in 1998 and 2000. He has been a regular participant of the ASEE annual conference during the past few years. He has published more than 85 papers in reputed journals and conferences.

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Rajesh Ganithi The Petroleum Institute

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Mr. Rajesh Ganithi started his career in engineering with a diploma in tool-and-die making from NTTF, India in 1995. Over the next 20 years, he gathered enormous amounts of experience while working for a variety of companies in various capacities. He started with IRS Singapore Pte Ltd as mold maker for five years from 1995. He then joined Meridian Automotive systems, Canada in 2001 as a tool and die maker. In 2005, he joined ATS Automation Tooling Systems, Canada as a tooling engineer and then joined Prolink Molds Canada in 2008 as a manufacturing engineer. Training students in CNC applications was part of his work in the past few years in Canada. In 2012, he joined UAE University as the engineer in charge of the CNC lab. The lab was completely rejuvenated by Rajesh and he plays an active role in teaching and researching CAM and its applications. Coming from a practical background, Rajesh has research interests in strategies for machining-time reduction and material saving. At present working in Petroleum Institute, Abu Dhabi.

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Yusuf Khan Airani P.E. United Arab Emirates University

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Yusuf Khan Airani is a lab engineer at the United Arab Emirates University. He graduated as a Bachelor of Mechanical Engineering from the Pune University, India in 2011. He also has earned an Advance Diploma in Tool Design & Manufacturing from Nettur Technical Training Institute in 1994. He initially worked in Sasib Moulds, Dies & Spare Parts. He subsequently moved to Canada in 2002, where he worked for Clover Tool Manufacturing Ltd until he joined United Arab Emirates University in August 2016. Mr Airani has in depth knowledge of machining & manufacturing processes reinforced with over 20 years of experience in the industrial sector. He is interested in exploring the shortest and easiest machining processes for any given component and in teaching machining processes for students.

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NC machining has grown through several stages before it came to its present level. At the beginning with no Computer Aided Design to assist, the geometric nature of components was inputted through codes. This took the beneficial practices in programming such as loops. During this time a challenging and lucrative job is code proofing where the codes were checked and proved to be correct, manually. This demands a command in NC programming. This ability to detect any errors in the code is valuable even now. CAD in the meantime was developing faster and methods to define complex curves and surfaces, for example the Bezier curve and surface, were developed. The next generation of CNC machines took advantage of these developments and provided for the inclusion of these at what can be called the low level CAM packages. They generated codes for few defined curves and surfaces. As CAD continued to develop and the power of computers became available at comparatively low cost the next generation of sophisticated CAM packages that can generate NC codes for complex curves and surfaces started to appear at a very rapid rate. MasterCAM is a typical example of this kind of CAM package that can take a CAD model as the input to generate the code. As CAD continued to develop with feature based modelling, feature based CAM has been developed. Thus one can see four generations (i) code based CNC (ii) Low level CAM based CNC (iii) high level CAM based CNC and (iv) feature based CAM and CNC in the development path. Each has its strength and it was felt that students who are familiar with all four can easily gain command in their professional lives. At X university the students are exposed to the first generation work with bench-type MTAB turning machines that require code to be keyed in. They are then exposed to the second-generation low level CAM through the BOXFORD bench-type milling machines. Here they could use Bezier curves and other geometries as input. They are then moved to the advanced CAD based CAM package generation, with a CNCINNATI arrow 2 machine. This is a powerful industry type machine that can machine complex surfaces with the help of the MasterCAM package. After this they move to the DMG turning center that permits feature based inputs. By following this passage the students learn the strengths and difficulties of each generation. This paper will discuss examples from each of the four generations. Samples and a short presentation will be produced at the poster session.

Sivaloganathan, S., & Ganithi, R., & Airani, Y. K. (2017, June), Board # 148 : MAKER: Generations of NC Machining through Laboratory Work Paper presented at 2017 ASEE Annual Conference & Exposition, Columbus, Ohio. 10.18260/1-2--27768

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