Advanced Manufacturing: Processes & Methods

Unit 1: Intro to Machine Tools

7 Class Sessions, 2 Hour Sessions, 2 Sessions per Week

Essential Objectives Skills

Students will be able to...

Understand the CNC controller on an Successfully load a program and cut a part.
operational level.
Pick up edges to locate a part using a
Why is optimizing cycle time important? wobbler.

What is the importance of proper cutting data

as it relates to machining a part?

Understandings Key Concepts

Students will understand how/why... Students will know...

Loading programs onto the controller

● Controller
Simulating programs correctly
● Work Offset
Properly torquing a part for proper ● Tool offset
workholding
● Coordinate system
Appropriate chipload and surface footage for ● Chipload
a given tool
● Surface Footage
What type of tool to use in a certain ● Endmill
application
● Ballmill
The parts of the CNC machine ● Chamfer mill
● Spot Drill
Why and how to use multiple work offsets
● Drill
How to set tool length offsets
● Face mill
The use of the controller to monitor cutting ● Bull nose Endmill
data and machine performance during the cut
● Feed rate
The importance and directionality of the ● Spindle Speed
Coordinate System in the machine
● Table
How a CAM software will generate G Code ● X, Y, Z Axis
used on the machine
● Workholding
Begin to understand what G-Code values ● Vise
coordinate with certain machine functions
● G-Code
● CAM Software
● Wobbler

Assessments

Cumulative Project Based Assessment

Load and run a part on each applicable CNC machine.

 Advanced Manufacturing: Processes & Methods

Unit 2: 2D Cutting
7 Class Sessions, 2 Hour Sessions, 2 Sessions per Week

Essential Objectives Skills

Students will be able to...

Successfully machine a part using 2D Successfully operate the machines on hand,

toolpaths. without any technical assistance.

How can you use roughing and finishing Successfully post process and demonstrate
strategies to make a complete part? their toolpaths on a machine.

What is the importance of WCS orientation Machine a two sided object.

and position as it relates to the physical setup
of a part?

Understandings Key Concepts

Students will understand how/why... Students will know...

When should you use 2D Adaptive as Face

opposed to another toolpath
2D Contour
Post process toolpaths for the given machine
2D Pocket
Securely hold down a part for the duration of
the cut so that the workholding does not Vise Usage
interfere with the cut
2D Adaptive
Facing toolpath use cases, constraints and
cutting parameters Optimal Load

2D Contour toolpath use cases, constraints Constraining the Toolpath

and cutting parameters including ramping,
cutter compensation and tabbing Rough/Finish Concept

2D Pocket toolpath use cases, constraints Surface Finish

and cutting parameters including
stepover/stepdown, finish passes and entry WCS
types
Orientation
Adjusting toolpaths to achieve higher surface
finish or faster cycle time Validation

The value of using roughing tools for quicker G Code

material removal
 Simulation
The importance of stock setups, model
orientation Two-sided Part

The importance of accurately depicting tools Pickup/probe Location

in the CAM software so that they match their
physical counterparts Digital Twin concept

Post Processing

Step Over

Step Down

Assessments

Cumulative Project Based Assessment

Design and manufacture a flat pack product

Machine a two sided object.

 Advanced Manufacturing: Processes & Methods

Unit 3: 3D Cutting
8 Class Sessions, 2 Hour Sessions, 2 Sessions per Week

Essential Objectives Skills

Students will be able to...

Successfully machine a part using 3D Successfully use 3D toolpaths to machine

toolpaths. parts.

How can you combine 2D and 3D cutting Machine a two sided object with curved or
techniques to reduce machining time? faceted surfaces.

What is the importance of probing surfaces,

as it relates to machining the second side of
an object?

Understandings Key Concepts

Students will understand how/why... Students will know...

When should you use 3D Adaptive as

opposed to another toolpath 3D Adaptive

Post process toolpaths for the given machine Parallel

Securely hold down a part for the duration of
the cut so that the workholding does not Scallop
interfere with the cut
Flow
Parallel toolpath use cases, constraints and
cutting parameters
Blend
Scallop toolpath use cases, constraints and
cutting parameters Morph

Flow toolpath use cases, constraints and

cutting parameters Steep and Shallow

Blend toolpath use cases, constraints and Optimal Load

cutting parameters
Mesh
Morph toolpath use cases, constraints and
cutting parameters
Window Milling
Steep and Shallow toolpath use cases,
constraints and cutting parameters and how
to apply it

Adjusting stepovers to achieve higher surface

finish or faster cycle time

The difference between different finishing

strategies and how to use them

Assessments

Cumulative Project Based Assessment

Design and manufacture a mesh based object.

 Advanced Manufacturing: Processes & Methods

Unit 4: Multi-Axis Machining

9 Class Sessions, 2 Hour Sessions, 2 Sessions per Week

Essential Objectives Skills

Students will be able to...

Successfully machine a part using mulit-axis Successfully use multi-axis toolpaths to

toolpaths. machine parts.

How can you convert a part to a multi-axis Machine a part that has features incapable of
program to save machining time? being machined on a 3 Axis machine

What is the importance of correct workholding

as it relates to the Digital Twin Concept?

Understandings Key Concepts

Students will understand how/why... Students will know...

When should you use a multi-axis toolpath as

opposed to another toolpath ● Swarf
● Multi-Axis Flow
Post process toolpaths for the multi-axis
machine ● Multi-Axis Contour
● Tilt
Integrate higher level workholding into their
CAM programming ● Lean
● Lag
Swarf toolpath use cases, constraints and
cutting parameters ● Tombstone
● Dynamic Work Offset
Multi-Axis Flow toolpath use cases,
constraints and cutting parameters ● Digital Twin
● Zero Point System
Multi-Axis Contour toolpath use cases,
constraints and cutting parameters ● Rotary
● A Axis
Adjusting lead and lean to achieve higher
surface finish or faster cycle time ● B Axis
● C Axis
The difference between different finishing
strategies and how to use them
 Assessments

Cumulative Project Based Assessment

Design and program an object requiring multi-axis toolpahts.