CAM Processes Flashcards
Manufacturing Processses
What is a simple definition of CAM?
Downloading completed CAD drawings to machines that will cut and shape materials.
What is laser cutting?
The use of a high energy laser beam to cut or vaporise materials. Compressed gas/air is used to blow the waste material away, leaving a clean edge.
How do laser cutters work?
A 2D CAD drawing is designed and downloaded to the laser cutter by exporting it as a DXF. The laser cutter converts the drawing into a CNC programme, which controls the movement of the laser in the X and Y axes, the power, and the speed.
They can cut and engrave.
What materials can be laser cut?
In schools, polymer sheets (max. 5mm) and MDF.
In industry, some can cut sheet metals aswell.
What is a router and what is it used for?
You can get CNC and manual routers.
They are used to cut sheet materials that are too thick for laser cutting (9mm MDF).
Also used to cut shapes of different depths into a material. E.g. a rebate joint.
CNC routers involve 2D and 3D CAD drawings being downloaded, which cut and shape the material.
How do routers work?
A spindle rotates the cutting tool at high speeds along a path in the X, Y and Z axes.
Can cut wood, plastic and metal.
What do milling machines do?
They work similarly to routers, but instead…
Drill holes
Cut slots
Shape the surface/edges of materials.
The bed can be moved in X and Y axis (up/down or side-to-side) and the cutter is moved in the Z.
What is a 5-axes milling machine?
When the cutting head and machine bed are angled.
Normally used for complex engineering components.
What do modern CNC milling machines do?
They automatically change tools to suit different materials.
They are totally enclosed (safety).
Filled with automatic coolant which floods the tooling and workpiece with lubricant. Increasing tool life and surface finish.
Faster and more accurate.
What is turning?
Involves the use of lathes to machine metals in bar form, or plastic rods.
They reduce length, diameter, and to thread cut.
What is significant about CNC lathes?
They can change tools automatically.
They may form a FMS (Flexible Manufacturing System) with milling machines, laser cutters, etc. by using robot arms to load the material and transport parts.
What is plotter cutting?
The way to cut thin sheet material like self-adhesive vinyl. This would be burnt in laser cutting, etc.
Also cuts paper, fabric and adhesive-backed materials.
Uses a simple blade.
Similarly converts a CAD drawing to a CNC program that used X and Y axes to cut out what’s been drawn.
Used to cut AND mainly engrave e.g. logos. Easy to peel off, doesn’t cut all the way through.
What is virtual modelling and what are its 2 main uses?
A method to test products before they are manufactured.
1. 3D CAD drawings of the product can be put into VR where they can be tested.
E.g. an engine part may be connected to other parts in a virtual engine to check it fits etc.
2. Be used to simulate manufacturing processes and check the product will be machined correctly.
What is Computational Fluid Dynamics? What is it used for?
Tool available in some CAD programmed which is used to simulate the flow of fluids or gases in and around a product.
Saves money from prototypes, failed products and using specialist equipment.
What are some examples of Computational Fluid Dynamic tests?
A car could be tested for aerodynamics in a simulated wind tunnel. Results would help improve the design.
A boat would be tested for how the water flows around its surfaces using a simulated wave tank.
What is Finite Element Analysis?
Using CAD to carry out component stress analysis.
Can simulate vibration or shock loads on drawings. This highlights potential weak points which need developing.
Saves time and a lot of money.
What does Rapid Prototyping do?
A machine that can have a CAD file downloaded to it which will create a 3D, real life model of the design.
E.g. 3D printing.
E.g. subtractive process- using milling machines.
Saves modelling by hand.
What is Fused Deposition Modelling?
A type of 3D printer.
A processing software slices the drawing and guides the paths to build layer by layer, starting at the bottom.
They use less dense support materials so they can break away when finished.
What are some uses of Fused Deposition Models?
Obtain feedback
Save costs
Make moulds for casting
SOME use metal- easily make complex components that don’t need to be joined, don’t waste material, would be stronger, etc.
Either use Electron Beam Melting or Selective Beam Melting- EBM/SBM. These fuse powder layer by layer using an electron/laser.
What is EPOS? What are its uses?
A system that captures data when consumers purchase goods.
- When a barcode is scanned, details are recorded and stock levels controlled.
- Target marketing. Teams can monitor how many items are being sold.
Can change/develop a product that has had a decline in sales. - Email receipts can be used to advertise.
What does a Supply Chain Network (SCN) do?
Ensures the flow of materials/components required is efficient and operated on JiT production.
Its vital.
What is a Master Production Schedule (MPS)?
A plan that determines how many products will be made in a time.
Software networks different parts of the business to plan out the MPS.
e.g. produce to order products will be placed to an EPOS and then in MPS software which will determine time, materials and components needed.
Also schedule AGVs to carry materials around the factory.
What is the Kanban system?
Where small components are poured into reusable plastic bins with barcodes on. When drawn, the barcode (RFID tags) is scanned, and an order is placed to reorder the components.
Its used to achieve JiT production.
What does JiT production do?
Means manufacturers don’t have to carry their stock and aren’t left without unsold products.
Means they don’t need warehouses as materials are only delivered a few hours before manufacture.
