manufacturing process article...step downs. end mill 3 bull 2. parallel operation remove stock...

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MANUFACTURING PROCESS

ARTICLE

2019

By: Rino Andias Anugraha and Assistant Team

School of Industrial Engineering

TelkomUniversity

iii

INTRODUCTION

Praise be to Allah Subhanahu wa Ta'ala, because with His grace and mercy, the writer and the

team were given the opportunity to complete the Article Module for the implementation of

the manufacturing process practicum in the 2019/2020 educational year.

In this module the authors and team re-designed our masterpiece of practicum products

namely Stirling Engine, where we added 2 pistons and enlarged the scale of parts that were

made in the previous version for the needs of integrated practicum activities in the Faculty of

Industrial and System Engineering

Prosman Laboratory Adviser

Rino Andias Anugraha, ST., MM

NIP : 99750032

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MANUFACTURING PROCESS LABORATORY ASSITANTS 2019/2020

Aldyan Nurfaizi B. Tau

Alia Agistina

Anak Agung Sri Nandini

Anggit Pratama

Bagas Arganto P.

Bela Pitria Hakim

Damario Haznam

Farras Burhanuddin

Gitanjali Widayu Diatri

Mario Adiprana Muki

Nafisha Herma Hanifha

Pangestu Rizky Purnama

Satria Rahmadani Putra

Sri Yuzarnimar

Tri Maisyah Nugrah Samudro

Zakaria Gunada

Abdurrahman Rashif

Annastasya Septiani

Aquilla Yunma Imaristha

Arief Tri Hendrayanto

Corie Ariesta Arbay

Dhiya Shafa Azizah

Dimas Rayhandika

Elisa Intan Puspitasari

Gamaliel Situmeang

Indah Ekanurhayati

Irfanul Zuhdi Nufrinal

Kholiq Giffari

M. Fachri Husamuddin

M. Arash Arisiah

M. Raihan Arrafi

M. Sohibul Wafa

Nisri Husna Faadhilah

Rafi Pragiwaka Gani

Tirza Ayu Nursazabillah

5

MANUFACTURING PROCESS

LABORATORY

Document

Number

MODULE 3.1 Form

Number

Valid 2019

Module Computer Aided Manufacturing

Labwork CAM Milling

Student Outcomes SO8. Excellent/ Very competent/ Competent in understanding the knowledge of communication techniques and the latest and most up-to-date technological developments

Learning Outcomes LO2. Following the development of technology related to industries such as advanced manufacturing technology, use of information technology to manage companies, green manufacturing, etc.

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A. Tools and Requirements

Tools & Software Requirements

1. Personal Computer

2. Personal Gadget

3. Mastercam 2019

1. Labwork of Module 3.1

2. Personal gadget with internet connection

3. Stationary

B. References

Axsys, Inc. (2018). Retrieved from http://www.axsysinc.com/AxsysSoftwareSolutions.html

CNC Software, Inc. (2018). Retrieved from https://www.mastercam.com/en-

us/Solutions/Milling-Solutions/Multiaxis

CNC Software, Inc. (2018). 2D/3D Mill. Retrieved from Mastercam Web Site:

https://www.mastercam.com/en-us/Solutions/Milling-Solutions/2D-3D-Mill

CNC Software, Inc. (2019). Multiaxis. Retrieved from Mastercam Web Site:

https://www.mastercam.com/en-us/solutions/milling-solutions/multiaxis

CustomPartNet. (2007). Milling Process, Defect, Equipment. Retrieved from

COSTUMPART.NET: https://www.custompartnet.com/wu/milling

CustomPartNet. (n.d.). Milling Process, Defects, Equipment. Retrieved from

CustomPart.Net: https://www.custompartnet.com/wu/milling

In-House Solution, Inc. (2018). Retrieved from

https://www.inhousesolutions.com/mastercam-mill

Manufacturing Process Laboratory. (2018). Modul Praktikum Proses Manufaktur. Bandung:

Telkom University.

Markis, S., Mourszis, D., & Chryssolouris, G. (2012). Computer-Aided Manufactuing.

Mastercam. (n.d.). Retrieved from www.mastercam.com

Milling Process, Defects, Equipment. (n.d.). Retrieved from CustomPart.Net:

https://www.custompartnet.com/wu/milling

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C. Labwork Steps

Flow Process Charts Process Description

1. Read the study case well. Because the

study case contained information that will

be carried out.

2. Do the process settings on Mastercam

2019 according to the tutorial on Labwork

3. Do a facing operation according to the

tutorial on labwork and simulate it.

4. Do a pocket operation according to the


5. Do a circle mill operation according to the


6. Do a drilling operation according to the


7. Do an area mill operation according to the


8. Generate the NC Code. Do it according to

the tutorial on labwork.

END

Generate NC

Code

Area Mill

Operation

Drilling

Operation

Circle Mill

Operation

Pocket

Operation

Facing

Operation

Setting

Process

Read the

Study Case

START

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MODULE 3.1

COMPUTER-AIDED MANUFACTURING (CAM: MILLING)

1.1 Student are able to understand the concept of Computer-aided Manufacturing.

1.2 Students are able to understand the concept of Milling Process.

1.3 Students are able to use Mastercam Milling.

2.1 Introduction Machining Process (Milling Process).

2.2 Computer-aided Manufacturing.

2.3 Mastercam.

2.4 Mastercam Milling Operations

1. OBJECTIVES

2. OUTLINES

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3.1 Introduction to Milling Process

Milling process is removing material from a dedicated workpiece through rotary

cutting. The cutter in a mill often has multiple cutting points, and generally moves

perpendicularly on an axis, cutting with the tool’s circumference into the workpiece.

The milling process can produce shaping as well as details in a piece there are shapes,

slots, holes, notches, grooves, pockets, and specialty faces are all results of custom

millwork. In milling process, the tools move in rotational motion while the workpiece

moves in translation motion.

Figure 3.1.1 Milling Process. Retrieved from (Milling Process, Defects, Equipment, n.d.)

3.2 Computer-aided Manufacturing

Computer-aided Manufacturing (CAM) can be defined as the use of computer

systems to plan, manage, and control the operations of a manufacturing plant

through either direct or indirect computer interface with the plant's production

resources. In other words, the use of computer system in non-design activities but

in manufacturing process is called CAM. (Elanchezhian et al. 2007).

3. BASIC THEORY

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In Computer-aided Manufacturing there are input, process, and output. To

understand more of that, we presented a flowchart which shows input, process, and

output of Computer-aided Manufacturing. Important things to know is the output of

CAM (NC code) will be input for the CNC Machine.

Figure 3.1.2 Processes Flowchart

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Figure 3.1.3 The Use of CAM’s Output

The example of CAM software are Solid CAM, Rhino CAM and Mastercam. The

output from CAM software is NC code, this code will be inputted for CNC (Computer

Numerical Controlled) machine for further processing into the machine. In this

module, we focused on using Mastercam software.

3.3 Mastercam

Mastercam is a software used to describe or plan the process of machining

virtually through a computer screen. The result of machining process planning is then

used as a guideline on CNC machine programming.

Mastercam’s comprehensive set of predefined toolpaths-including contour, drill,

pocketing, face, engraving, surface high speed, advanced multiaxis, and many more-

enable machinists to cut part efficiently and accurately. Mastercam users can create

and cut parts using one of many supplied machine and control definitions. There are

some advantages of using Mastercam:

1. Program will perform faster dan more accurately.

2. The completed program can be executed and simulated on a computer.

3. Simulation at the computer allows collisions to be detected between the CNC

machine and the part and work holding in a virtual situation versus actual

machining.

NC Code

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3.4 Mastercam Milling Operations

The following types of operation process in Mastercam software are:

a. Mastercam 2D Milling Operation

Mastercam’s 2D toolpath deliver easy and optimized pocketing, contouring,

drilling, facing, and much more. 2D operation is used if the feeding area is clear

(view from top) and the surface of the feeding area is flat so that it can be feed

from above. Examples of products that use 2D Milling Operation is arm balancers.

Figure 3.1.4 Mastercam 2D Milling Operation

Table 3.1.1 Mastercam 2D Milling Operation

No. Operation Explanation Tools

1.

Dynamic Mill

Operation

Utilize the entire flute length of

the cutting tools to efficiently mill

pocket, open pocket, standing

cores or material left from

previous operation.

End Mill 3 Bull

2.

Swept 2D

Create a toolpath by sweeping

one boundary (the across

contour) along a second contour

(the along contour). End Mill 3 Bull

3.

Swept 3D

Create a toolpath by using a set-

boundaries, such as one across

boundary and one along

boundary, one across boundary

and two along boundaries, or two

across boundaries and one along

boundary.

End Mill 3 Bull

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Table 3.1.2 Mastercam 2D Milling Operation (cont.)


4.

Contour Operation

Contour toolpaths remove

material along a path defined by

chain of curves. Flat End Mill

5.

Dynamic Contour

Operation

Utilize the entire flute length of

the cutting tool to efficiently mill

material off walls supporting

closed or open chains. Flat End Mill

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6.

Peel Mill Operation

Mill between two selected

contours or along a single

contour. Flat End Mill

7.

Area Mill Operation

Machine pockets, material that

other toolpaths leave behind, or

standing bosses and cores. Flat End Mill

8.

Blend Mill Operation

Morph smoothly between two

open chains. Create the toolpath

along or across the selected

chains.

Flat End Mill

9.

Slot Mill Operation

Efficiently machine around slots.

The slots must be closed and

include two parallel, straight

sides.

Flat End Mill

10.

Circle Mill

Mill circular pockets based in a

single point. Select either point

entities or center points of arcs. Flat End Mill

11.

Helix Bore

Machine a hole using helical

motion based on a single point.

Roughing passes are created as

cut down the hole.

Flat End Mill

12.

Pocket Operation

Clean out material from an

enclosed boundary in a finishing

or roughing operation. Flat End Mill

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13.

Drilling Operation

Create holes from selected point.

Drill

14.

FBM Drill and FBM

Milling Operation

Detect holes in a solid based on

the specified criteria and generate

complete series of drilling and

chamfering options.

Drill

Center Drill

Spot Drill and

optional depends

on the object

15.

Auto Drill

Create a complete series of drill

operations for a set of arcs or

points.

Drill

16.

Start Hole

Automatically create drill

toolpaths at the plunge points of

one or more toolpaths.

Drill

17.

Face Operation

Clean the stock from the top of a

part and create an even surface.

Face Mill

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18.

Engrave Operation

Machine letters and design using profile geometry.

Engrave Tool

19.

Revolved

Create a toolpath by revolving a curve around an axis of rotation.

Ball Nose Mill

20.

Lofted

Create a smooth, curve blend between chains of curves.

Ball Nose Mill

21.

Ruled

Create a linear blend between chains of curves

Ball Nose Mill

22.

Thread Mill

Create a series of helixes for machining a thread-mill or other suitable tool

Thread Mill

23.

Model Chamfer

Machine safe horizontal chamfers on solid model.

Chamfer Mill

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b. Mastercam 3D Milling Operation

Mastercam provides unsurpassed control on surface cuts, delivering superior

finishes and optimized cycle times our refined 3D toolpaths give you a smooth,

and precision finish. 3D Milling Operation is used if the feeding area is not clear

(view from top) and the surface of the feeding area is terraced but can be done

from top.

Figure 3.1.5 Mastercam 3D Milling Operation

These are the advantages of 3D milling operation:

1. More efficient.

2. Constant scallop machining maintains a consistent finish on sloped and flat

surface.

3. Constant-Z rest milling (re-machining) identifies machines areas and critical

depths that need to be cut with a smaller tool.

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Table 3.1.3 Mastercam 3D Milling Operation


1.

OptiRough

Operation

Remove the maximum amount of

material with the minimum number of

step downs.

End Mill 3 Bull

2.

Parallel

Operation

Remove stock quickly by using constant

Z depth cut at a specified angle in the

tool plane.

End Mill 3 Bull

3.

Area Roughing

Operation

Machine standing bosses and cores,

cavities and pockets, or material that

other toolpaths left behind.

End Mill 3 bull

4.

Radial

Create cutting passes that radiate

outwards from a central point.

End Mill 3 Bull

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5.

Hybrid

Machine steep and shallow areas by

utilizing both scallop and constant Z

approaches.

End Mill 3 Bull

6.

Pocket

Operation

Remove a lot of stock quickly by

creating a series of planar cuts (or

constant Z).

Flat End Mill

7.

Plunge

Operation

Rough a part quickly by using a drilling-

type motion.

Flat End Mill

8. Multisurfaces

Pocket

Operation

Remove a lot of stock quickly by

creating a series of planar cuts (or

constant Z).

Flat End Mill

9.

Waterline

Machine a set of profile curves along

the cut surfaces.

Flat End Mill

10.

Horizontal Area

Machine the flat areas of the surface

model, creates cutting passes at the Z

height of each area.

Flat End Mill

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11.

Equal Scallop

Create a toolpath with consistent

scallop motion relative to the stepover

distance.

Flat End Mill

12.

Project

Operation

Project geometry or toolpath from an

earlier operation onto surfaces.

Ball Nose Mill

13.

Raster

Suited for shallow surfaces or steeper

surfaces that are perpendicular to the

angle of the passes.

Ball Nose Mill

14.

Pencil

Clean out material by driving the cutter

tangent to two surfaces at a time.

Ball Nose Mill

15.

Blend

Create a toolpath along a surface

between selected chains.

Ball Nose Mill

16.

Scallop

Machine the surface model with a

constant stepover.

Ball Nose Mill

17.

Spiral

Create cutting passes where the tool

feeds into the part.

Ball Nose Mill

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Table 3.1.2 Mastercam 3D Milling Process (cont.)


18.

Contour

Create constant Z cuts around the

steep walls of the part.

Radius Mill

19.

Flowline

Follow the shape and direction of the

surfaces and creates a smooth and

flowing toolpath motion.

Lollipop Mill

c. Mastercam Multiaxis Operation

Multiaxis machining can intensely increase a company’s competitiveness.

Mastercam’s multiaxis interface is simple and intuitive to use. Mastercam has

complete control over the three crucial elements of multiaxis machining, which

are cut pattern, tool axis control, and collision avoidance. Multiaxis operation is

used when there are parts that can only be formed by side-feeding or cannot be

feed from top. An example of product that uses a multiaxis operation is a turbine.

Figure 3.1.6 Mastercam Multiaxis Milling Operation. Retrieved from

(CNC Software, Inc., 2019)

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Table 3.1.4 Mastercam Multiaxis Milling Operation


1.

Swarf Milling

Operation

Create multiaxis motion that keeps

the side of the tool in contact with

selected surfaces or surfaces or solids

Best suited for roughing blades.

Flat End Mill

2.

Flow Operation

Best suited on a single surface or a

row of surfaces (oriented in the same

manner and direction).

Flat End Mill

3.

Triangular Mesh

Operation

Create a toolpath where the tool is

always in contact with the machining

surfaces.

Flat End Mill

4.

Project Curve

Project defined curves or patterns

onto the selected surface to be

machined.

Flat End Mill

5.

Circle Mill

Mill circular pockets based on a single

point.

Flat End Mill

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Table 3.1.3 Mastercam Multiaxis Milling Operation (cont.)


6.

Blade Expert

Cut simple, split or multi-bladed

impellers.

Flat End Mill

7.

Curve Operation

Machine a 3D chain or surfaces

edges.

Ball Nose Mill

8.

Parallel Operation

Create a toolpath that cuts in slices

that are parallel to each other.

Ball Nose Mill

9.

Along Curves

Operation

Machine orthogonal to the selected

drive curve.

Ball Nose Mill

10.

Morph Operation

Machine between two leading

curves.

Ball Nose Mill

11.

Multisurface

Operation

Machine based on the selected

pattern options (like cylinder, sphere

or box).

Ball Nose Mill

12.

Swarf

Create multiaxis motion that keeps

the side of the tool in contact with

the selected wall geometry.

Ball Nose Mill

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Table 3.1.3 Mastercam Multiaxis Milling Operation (cont.)


13.

Rotary Advanced

Create a 4-axis rotary toolpath that

allows for more control over tool

motion.

Ball Nose Mill

14.

Deburr

Create a toolpath that break edges

and removal burrs.

Ball Nose Mill

15.

Port Operation

Create a roughing or finishing

toolpath for port geometry,

machining from top to bottom.

Lollipop Mill

16.

Port Expert

Cut a port or internal chamber of a

part.

Lollipop Mill

17.

Drill Operation

Drill holes by using the selected arcs.

Drill

18.

Rotary

Create a toolpath along or around

the selected rotary axis.

Drill

19.

Roughing

Rough out pocket geometry by

selecting the floor, wall or ceiling

surfaces to automatically generate a

toolpath.

End Mill 3 Bull

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Axsys, Inc. (2018). Retrieved from

http://www.axsysinc.com/AxsysSoftwareSolutions.html

CNC Software, Inc. (2018). Retrieved from https://www.mastercam.com/en-

us/Solutions/Milling-Solutions/Multiaxis

CNC Software, Inc. (2018). Retrieved from www.mastercam.com:

https://www.mastercam.com/en-us/Solutions/Milling-Solutions/2D-3D-Mill

CustomPartNet. (2007). Milling Process, Defect, Equipment. Retrieved from

COSTUMPART.NET: https://www.custompartnet.com/wu/milling

In-House Solution, Inc. (2018). Retrieved from

https://www.inhousesolutions.com/mastercam-mill

Manufacturing Process Laboratory. (2018). Modul Praktikum Proses Manufaktur.

Bandung: Telkom University.

Markis, S., Mourszis, D., & Chryssolouris, G. (2012). Computer-Aided Manufactuing.

4. REFERENCES

manufacturing process article...step downs. end mill 3 bull 2. parallel operation remove stock...

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