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Rapid prototyping

Sequence :
1. Draw CAD
2. Convert to STL file
3. Send to Objet Studio software
4. Estimate costing

System :

1. Layer by layer of 28 micron


2. 580 layer
3. Positioning of printing must be optimized
4. Same parts printed in multiples at once
5. Accuracy varies with complexity and size
6. Support material can be removed by peeling, waterjet or NaOH.
7. Status interface on desktop
8. Model RM1200 / kg, support qmaterial RM700/ kg
9. Estimate time should be accurate, but requires recalibration

Operations :

1. Printing
2. After print : remove support
3. Post process : sanding, filing etc

Cost : 180k MYR


Edm wire cutting

Different types of wire :


-coated/non coated
-materials
-0.1-0.3mm thickness

Current : non-coated 0.2mm brass wire

Product type : punch or die

Axis : x and y only. Products are symmetrical in z direction.

Steps :

3 methods to obtain g code :


1. Drawing
2. Use built in CAM
3. Manually write

For drawing
1. Draw model with CAD
2. Draw tool path with CAM
3. Convert to gcode
4. Transfer into machine

Machining operation : cutting only

Cutting speed :
For 3mm steel - 9.1 mm/min
23:48 mins
For 5mm steel - 7-8 mm/min
For 50mm steel - 1.5-1.8 mm/min
125 mins predicted
For 5mm Aluminum - 15.8-17.5 mm/min

Important parameters :

Cutting speed
Workpiece thickness
Workpiece mechanical properties
Wire diameter
Wire mechanical properties
Voltage
Current

Price : 420k MYR


Universal turning

Z axis and X axis


CAD and CAM generate into codings
Motion of machine by numerical coordinates

Spindel holds and spin the workpiece


Spindel is hydraulic
When clamping the workpiece, beware to not put hand in clamping zone
Machine cannot run if clamping not tight (SF)
Machine cannot run if shielding door not shut tight (SF)
Turret/tool magazine has 12 slots
Tetengah support material during machining
Turning machine uses MDI - from drawing dimensions
Workpiece must have extra length than design

Steps:

1. Workpiece shape and dimension is set


2. Coordinate for tool path is set
3. Tool selection and machining parameters is set for each operation
4. Roughing, finishing, undercut threading then grooving sequence is planned
5. Simulate to get expected result and machine time
6. Set datum for tools
7. Run the cnc
5 axis

5 axis :

• 3 translational
• 2 rotational (around x and y)
• To maintain tool being perpendicular to workpiece surface

Sequence :

Placement of solid block


Run the generated codes
Tool selection (by machine)
Start machining with lubricant
1. Facing
2. Drilling
3. Roughing
4. Finishing

Cnc path can be simulated before start process

Flip and fit into jig


Start 2nd machining
1. Facing
2. Roughing
3. Finishing

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