AMME5902 Computer Aided Manufacturing
Final Project-Part A
This part of the project consists of setting the manufacturing of the housing that will contain the Arduino Uno and the ultrasonic sensor (HC- SR04) that are used in the part B of the project. The following figure illustrates the design of the housing.
Figure 1: a) Case of the Arduino and Ultrasonic Sensor. B) housing
The CAD model of the housing is available in CANVAS.
The chief aim of the project is to carry out the proposed tasks and arrive at comprehensive answers to the questions noted below. The tasks and the responses to the questions must be presented in a report. The report must include an introduction, contents page, all graphics, Excel spreadsheets, discussion, references and conclusions deemed necessary to convince management that you have a good understanding of the problem (or opportunity!) at hand (presentation: 2 marks)
The following tasks must be carried out:
1. Analise the machining of the housing by using at least 2 different machining patterns (zig, spiral etc). Compare both machining patterns in terms of total toolpath length and total toolpath time. the machining parameters must be specified and justified. These parameters include tool dimensions, feed rates, and spindle speeds. (4 marks)
2. Using Process Engineering methods, analyse an area of machining of the housing (3 marks)
3. Using a combination of CAMWorks and UPG develop a Post Processor for the Mori Seiki NV4000 (3 marks)
The following questions must be answered.
1. Which one of the three CNC machines noted overleaf would you recommend using if your company needed 1200 housings manufactured at the lowest possible price? (2 marks)
2. Which one of the three CNC machines noted overleaf would you recommend using if your company needed 1200 housings manufactured in the shortest possible time frame? (2 marks)
3. Production is scheduled to start on Monday the 3rd of November 2025. What is the first week day (Monday to Friday) that the 1200 housings will be ready? (consider any public holidays) You may work Saturdays but at a 50% overtime penalty. You may not work on Sundays. (2 marks)
4. If all your machinery is purchased new, what is your machinery worth at the end of the project? (2 marks)
5. Which method (i.e. cheapest or quickest) would you prefer to use in your factory and why? (Please discuss this point in great detail). (3 marks)
6. What would be the sale cost of one housing when you need to include a 140% profit ? (2 marks)
Assumptions:
• The stock pieces are made from Stainless Steel and are sized as per the maximum dimensions of the housing.
• All machine cuts are done in one pass.
• Plunge cuts are made at 2/3 of the feed rates that traversing cuts are made.
• Rapid Traverse (G00) moves the tool at 6000mm/min for the Mori Seki, 2000mm/min for the Cincinatti Milacron and 1100mm/min for the TMCMill.
Submission
The submission consists of the following 3 files.
1) The Solidworks/CAMWorks file of the housing that correspond to task 1 (with any of the machining patterns used in task 1) .
2) a video of the CAMWorks simulation of task 1 (with any of the machining patterns used in the comparison) with a maximum duration of 2 minutes.
3) A written report that describe all the tasks and answers to the questions. Your report should be a good, clear presentation on A4 pages and PDF format. All sketches are to be included. The page limit for the report is 25 pages (without including references and appendices).
You must upload the two files of the submission combined as a .zip file into CANVAS. The name of the file should be as per your group number.
THIS ASSIGNMENT SHOULD TAKE EACH AVERAGE GROUP MEMBER APPROXIMATELY 15-20 HOURS TO COMPLETE
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Parameter
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Value
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Comment
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Time
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Cost (ex GST)
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Machine A
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Cincinatti Milacron
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-$85,000.00
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Min Motor Capacity
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1.5 kW
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In X,Y & Z
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Max Spindle Speed
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3,5000 RPM
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Max Feed Rate (SS304)
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390 mm/min
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In X,Y & Z
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Machine Charge Out
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-$165.00/hr
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Operator Charge Out
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-$165.00/hr
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Auto Pallet Changer
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3.0 mins
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Machine B
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TMC Mill
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-$50,000.00
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Min Motor Capacity
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0.85 kW
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In X,Y & Z
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Max Spindle Speed
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4,500 RPM
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Max Feed Rate (SS304)
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75 mm/min
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In X,Y & Z
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Machine Charge Out
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-$98.00/hr
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Operator Charge Out
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-$113.00/hr
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Manual Pallet Changer
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40 mins
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Machine C
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Mori Seiki
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-$345,000.00
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Min Motor Capacity
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1.6 kW x 2
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In X and Y
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Min Motor Capacity
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3.0 kW x 1
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In Z
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Max Spindle Speed
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12,000 RPM
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Max Feed Rate (SS304)
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700 mm/min
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In X,Y & Z
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Machine Charge Out
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-$195.00/hr
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Operator Charge Out
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-$190.00/hr
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Auto Pallet Changer
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1.95 min
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Hardware
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Stainless Steel (Grade 304)
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-$7.00/kg
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ADMINISTRATION
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Infrastructure costs
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37.5 hrs / week
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Rent+Plant Maint. etc.
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37.5hrs / week
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-$3,605.00/week
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Administration costs
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37.5 hrs / week
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Labour
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37.5hrs / week
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-$2,266.00/week
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Overtime
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Labour
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-50%/hr (up to 2hrs)
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Overtime
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Labour
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-75%/hr (2-4hrs)
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Depreciation
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All machines
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Simple
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-30%/year
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Federal Incentive
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Start up grant
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(once only)
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+$200,85.00
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Utilities
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Elect, Water
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-$386.00 / week
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