WESTERN CAROLINA UNIVERSITYSCHOOL OF TECHNOLOGY
COURSE SYLLABUS: ET 449 Advanced Rapid Tooling and Prototyping
Email: ballaaron@email.wcu.edu
Web Page: http://www3.wcu.edu/~ballaaron
Course Description
Advanced machining methods and rapid tooling practices
for product fabrication. Emphasis on computer methods, 3D prototyping,
CNC machining and tooling systems.
Pre-requisites: ET-349
Required Text: Required Text: Mastering OneCNC by Bonnie Roskies
Supplemental: Various web sites will be used to supplement the course.
Supplemental Software: ProE; ProD; Excel; MS-Word; OneCNC
Required Materials: Engineer's Pad, 1.44 M Floppy
and flash memory or CD
Three ring binder, plastic sheet covers.
Course Objectives:
The purpose of this course is to provide students a working
knowledge of advanced machining and CAM methods for fabricating new
products by carrying out the following objectives:
1. Develop a knowledge base for steps in the design to manufacture cycle.
2. Provide a knowledge
base for transferring parametric modeling methods and
procedures to the development of product fabrication.
3. Providing a knowledge base for advanced CAM methods and procedures.
4. Develop a knowledge base for rapid manufacturing methods and procedures.
5. Developing skills in part and fixture design and fabrication for productionengineering applications.
Laboratory Sessions:
The course will consist of weekly laboratory sessions
using state of the art technology. These labs will include
but are not limited to the following:
1. Safety and demonstrations of software, CNC machine operations and controllers;
2. Machine tool set-up procedures and fixturing;
3. CAM and CNC operations for tooling and product fabrication.
4. Production machining set-up and procedures.
Safety
Students are expected to maintain an attitude of safety
at all time when working in the laboratory. Special care should
be taken to prevent oil from spilling on the floor. Machines should
be assumed to be ready for operation at MAXIMUM SPEED, and steps must be
taken to properly adjust safe operating settings and parameters. Do not
operate any equipment unless you have been completely checked out and authorized
to do so!
NOTE: You must complete the safety laboratory and
submit a signed statement of acknowledgement and understanding of laboratory
safety and procedures before being allowed to proceed with ANY laboratory
activities. A copy of safety rules for the machining area is provided
in Appendix 1.
Attendance
Attendance of each class period is very important. Students
will sign in to both the lecture and laboratory sessions. Some of
the material that will be presented is not covered in detail in the text.
Students are expected to attend each class session. No make-up tests or
laboratory sessions will be provided except in extreme emergencies or for
extenuating circumstances. Any student missing more than three class periods
may be penalized as follows:
1. A grade of "W" may be
assigned if the infraction occurs prior to
the legal time to withdraw from the course;
2. A grade of "F" may
be assigned if the infraction occurs after the
legal time to withdraw from a course; or
3. Final grade may be
reduced by one letter grade as seen fit by
the instructor.
Evaluation:
Each student will be evaluated based on four areas of
performance. These categories and percentage of the total grade are shown
below:
Category
Percent
Notes
Tests
15%
Midterm (10%), Final (10%)
Labs and weekly assignments
50%
Includes Homework
Semester Project
25%
Team Project (competitive)
Merit
10%
Attendance, safety, clean-up, quality of work
A ten point grading system will be in effect:
A = 90 - 100
B = 80 - 89
C = 70 - 79
D = 60 - 69
F = 0 - 59
Semester Project:
A semester project is required and will consist of producing
either a gear, vane or piston pump. The project will be a group effort
with equal participation from each student. Team members will evaluate
the success of the group and the contribution of each individual team member.
The project will consist of program development for a 3D part/assembly,
production of a working model, and a production plan and production run
for the first proof. A complete set of documentation is required
including but not limited to the following:
1. Set of working
drawings produced to scale on CAD
2. Prototype Development
3. Complete Documentation
of CNC Programs
4. Setup Procedure
for production
5. Program Verification
6. Tooling and fixture
design and fabrication
7. Prototyping
8. Production Plan
including inspection and testing procedures
9. Project presentation.
Requirements and Expectations
All students are REQUIRED to maintain a workbook for
the class including:
notes, quizzes, labs, tests, semester project, and reference
materials. Workbooks
will be collected for grading purposes and used for departmental
accreditation.
Workbooks must be a quality three ring binder with tabbed
dividers neatly maintained.
STUDENTS ARE EXPECTED TO SUBMIT WORK ON TIME! ANY WORK
NOT SUBMITTED ON TIME WILL
BE SUBJECTED TO THE FOLLOWING PENALTY:
1. Late work will receive an automatic 50% grade reduction.
2. Late is defined as any work submitted after the class/lab period due.
3. Any work more than one week late will not be accepted
4. The late work policy will be strictly enforced!
5. If you absolutely cannot attend
class, notify the instructor prior to the absence!
This is the
only way you will be allowed to make up any work!
Students are expected to do their own work! The honor
code will be strictly adhered to. Any student violating the honor code
will be subjected to penalties set forth by the university
academic honesty regulations. Any student in violation of the honor code
will be subjected to the following penalty:
1. A grade of "0" will be assigned to the current work upon the first infraction.
2. A grade of "f" for the course will be assigned upon the second infraction.
Course Topics and Schedule
A weekly schedule of topics and associated lab sessions
is provided in Appendix II.
Note that weeks 10-14 are reserved for project laboratory
work. Each lab section must have their project approved by week 4.
Group project work should begin as soon as possible in
order to maximize the time available in the lab for machine time.
Statement Regarding Accommodations of Students with
Disabilities
Western Carolina University makes every effort to provide
appropriate accommodations for students with documented disabilities in
compliance with the Americans with Disabilities Act. To receive academic
accommodations, students must be registered with the office of Student
Support Services (contact Carol Mellen at 227-7127, Graham Bldg).
The letter received from Student Support Services should be presented as
documentation to the instructor as early in the semester as possible.
Revised by Dr. Aaron K. Ball, Jan 1, 2007
Western Carolina University
School of Construction Management, Engineering & TechnologyMACHINING LAB SAFETY RULES
1. EYE PROTECTION IS REQUIRED WHEN YOU ENTER THE LAB.
WEAR YOUR SAFETY GLASSES! You are required to obtain your own safety glasses.
A limited number is available in the shop.
2. All injuries must be reported to the supervising instructor
immediately.
3. NO BARE FEET OR OPEN-TOED SANDALS ALLOWED IN THE SHOP. Long
hair must be tied back, long sleeves must be cuffed or rolled up, and jewelry
removed when working on machinery.
4. NO FOOD OR DRINK ALLOWED IN THE MACHINE SHOP AREA.
5. DO NOT WORK ALONE. Use the “buddy” or “two-man” system in
order to have someone present in the shop to summon help in case of an
accident.
IN CASE OF AN ACCIDENT OR EMERGENCY, CALL
911 !
6. ENSURE THE SAFETY OF YOURSELF AND OTHERS by being aware of
your surroundings. If you see someone committing an unsafe act, report
it to the
supervisor immediately. As the machine operator
you are responsible for the safety of the people in your immediate area.
It is your responsibility to look around and
be sure that everyone within your range is
wearing safety glasses. Likewise a welder must be sure not to start welding
if people without welding helmets are watching him.
7. IF YOU BREAK A PIECE OF TOOLING, discover broken tooling or
machinery that is not operating correctly; notify the shop supervisor immediately.
Everyone must
comply with this rule in order to prevent
injuries caused by broken or malfunctioning equipment. Hiding or concealing
broken tooling only slows the replacement of that
piece of tooling, so it won’t be there
next time you need it if you didn’t tell the supervisor that you broke
it.
8. YOU MAY NOT WEAR GLOVES while operating machinery. Holding
objects with a rag near moving machinery is also not permitted. Gloves,
rags, etc. can be easily
caught in machines that are in motion,
pulling the operator into the equipment.
9. SECURELY CLAMP DOWN ALL WORK PIECES IN DRILL PRESS AND
MILLING MACHINES. This will prevent work from being lifted up or spun around
with the cutters. Use all guards that
are available and be wary of points of contact with rotating cutters and
chucks.
10. USE PUSH STICKS or some other approved method for keeping fingers
away from moving blades on band saws.
11. USE A VACUUM CLEANER after machining non-metallic substances (e.g.
acetyl, acrylics, phenolics, etc.) This will help control coolant contamination
on machines
with coolant systems.
12. DO NOT MACHINE, GRIND, or CUT ANY RADIOACTIVE OR OTHER SOLID TOXICS
(Beryllium, asbestos) in the shop.
13. DO NOT LEAVE KEYS ON CHUCKS OF LATHES, DRILL PRESSES, AND MILLING
MACHINES. The key can be thrown out with GREAT force when
machinery is turned on. This also applies
to wrenches used to tighten the cutting tools into the spindles of the
milling machines.
14. USE A BRUSH OR WOODEN DOWEL TO REMOVE CHIPS FROM THE MACHINING
AREA. Chips can be very sharp and often very hot.
15. CLEAN UP THE WORK AREA. Part of your grade will be based
on good safety and housekeeping.
16. DO NOT USE COMPRESSED AIR to blow chips off machinery. It drives
chips between the machine ways and scatters them about the shop.
Vacuum the machine and sweep the floor
area of any remaining chips.
17. CLEAN AND REPLACE TOOLS WHERE YOU FOUND THEM. The toolboxes and
cabinets are organized according to the character of their contents.
People expect to find tools in their
‘usual’ locations, so clean and replace everything where it belongs when
you’re finished.
18. DO NOT ATTEMPT ANY UNFAMILIAR OPERATIONS. When in doubt, seek advice
and help from those more experienced in the operation.
19. FOLLOW GUIDELINES POSTED ON THE INDIVIDUAL PIECES OF EQUIPMENT.
20. In order to prevent injury to you and damage to the equipment,
DO NOT ATTEMPT TO OVERLOAD THE CAPABILITIES OF THE MACHINERY.
Appendix II: Course Schedule
WESTERN CAROLINA UNIVERSITY
SCHOOL OF TECHNOLOGY
ET 449: ADVANCED TOOLING AND PROTOTYPING
Week Topic Lab .
1 Optimizing Tool Paths for Production Simple Sub-assembly
2 High Speed Machining Sub-assembly rework
3 Lathe Operations External Threaded Shaft
4 Mill Operations Internal Threads
5 Fourth Axis Machining Positional Indexing
6 Full 4th Axis Machining Impellor or Gear
7 3-D Machining Simple Mold
8 Lazer Machining I.D. Tag or License Plate
9 Semester Project Planning Reverse Engineering and Parametric Design
10 Production Planning Group Project Work
11 Production Machining Group Project Work
12 Advanced CAM Operations Group Project Work
13 Advanced CAM Operations Group Project Work
14 Advanced CAM: Complex Surfaces Group Project Work
15 Final Exam Lab Clean Up