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Teaching Multi-axis Complex Surface Machining via Simulation and Projects

Li Qian

Department of Engineering Technology & Management South Dakota State University Brookings, SD 57006

Abstract

Multi-axis Computerized Numerical Control (CNC) machines have become the application of choice for complex sculptured surface machining. Simulation of tool paths and machine operations is desirable for cost and time savings. These advanced technologies are being integrated into a senior Manufacturing Engineering Technology (MNET) curriculum at the South Dakota State University (SDSU).

Seven projects or exercises were assigned to students. A 4-axis HAAS machining center with Direct Numerical Control (DNC) capability was setup by students. 3D complex sculptured surface models were created from 2D drawings at different Z levels for turbine blades. CNC programs were generated for free-form surfaces and 4-axis parts via computer aided manufacturing (CAM) software. Feed-rates were optimized for more efficient machining and improved finish quality. Models of 3 and 4-axis machines in the manufacturing lab were created for simulation. CNC programs were verified by Vericut software prior to actual machining in the lab.

Goals of these projects include: extend students’ knowledge in CNC machines, programming, simulation, verification and optimization; teach students how to model and machine the complex free-form surface; and foster students’ independent learning. This paper will describe the curricular module used in the course in detail and provide simulation demonstrations. Results of simulation and the production lab machining are shared.

1. Introduction

Multi-axis computerized numerical control (CNC) machines have become the application of choice for complex surface machining. These machine tools are widely used in the aerospace, automotive, tool and die making and other industries requiring complex shapes. Collision-avoidance and geometric-error detection are critical issues for multi-axis CNC machining [1]. Simulation of tool paths and machine operations is desirable for cost and time savings. Vericut is a powerful CNC verification software, which detects errors and inefficient motions in CNC programs [2]. Vericut can also perform realistic 3D simulation of entire CNC machines, just like they behave in the shop. Proceedings of the 2005 American Society for Engineering Education Annual Conference & Exposition Copyright © 2005, American Society for Engineering Education

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Qian, L. (2005, June), Teaching Multi Axis Complex Surface Machining Via Simulation And Projects Paper presented at 2005 Annual Conference, Portland, Oregon. 10.18260/1-2--15338