247650-339090 Title

247650-339090
Title: Tool path design for the machining of the dogbone mold plate using Mastercam.

2598420213360
Tutor: Vihtonen MethewSubmitted by: Shiva BhandariDate of submission: 29.4.18
Date of inspection:
ABSTRACT:

Arcada University of Applied Sciences
Degree Programme: Material Processing and Technology
Author Shiva BhandariTitle: Tool path design for the machining of the dogbone mold plate using Mastercam.

Supervisor (Arcada): Commissioned by: Vihtonen Mathew
Abstract:
The main idea of the project is to desingn the dogbone mold plate by using through Mastercam through different steps from 2D design to solid form with different tools and geometry. Throughout the whole path we went through the theory of CAD, CAM and Solid-works by analyzing the manufacturing technologies such as speed, feed rate, and total path time and so on. The main idea was to prepare the dogbone mold design and simulate it to create a mold in Mastercam.
Keywords: Number pages: 10
Languages: English
Date of acceptance:
Table of Contents
Objectives4
Research question 4
Introduction4
CAM (Computer Aided Manufacturing) 4
Equipments5
Working principle5
Simulation…………………………………………………………………………………………………8
Discussion and conclusion………………………………………………………………………………………………….9
References.…………………………………………………………………………………………………9
Objectives
It is aimed to learn the simple knowledge of computer aided design and manufacturing ideas. One can also learn to conversion of 2d and 3d entities such as lines, circles and rectangles into the solid form by using the Mastercam software. Ones can learn several geometric modeling techniques such as solid modeling, surface modeling, etc. Besides; its aim is to learn how to use highly advanced productive tools like simulation and optimization to gain the professional and academic skills.

Research Questions
What are the steps to be taken when designing the 2D model and creating tool paths for given done using Mastercam for milling process?
Introduction
CAM (Computer Aided Manufacturing):
The machining of dog bone mold plate was prepared by using Mastercam 2018 through different steps and technique as per instructed in the lectures. CAM (Computer Aided Manufacturing) is an automatic process that exactly converts the design of product and sketch of an object into a format code and which is measurable by the machine to manufacture the product of an object. The software CAM is applied to design the different parts of mechanism such as manufacture prototypes, completed parts and production parts. The use of CAM is not that old as per we know, for the first time CAM was used in early 1950s. At that time it was just consist of a code instruction on a punched paper tape that could control simple manufacturing functions to be handled at the same instant. There are tremendous benefits of CAM in different field of study such as in mechanical engineering, industrial, fluid dynamics, thermodynamics, etc. After accomplish of CAM one can control the machinery in highly automated environment to produce various items and pieces. ´´Tool selection for rough and CNC milling operation 15, 1, pp 18-26“
Moreover, with the help of this application people can easily measure a plant’s output and production as complete parts to improve efficiently the assembly process. It also increases the utilization of a complete span of production equipments such as speed; electrical discharge machines, etc. so, during the process one can learn how to use the highly advanced productivity tool like simulation and optimization to enhanced professional and academic skills. The system can also be able to create, verify and improvise numerical code program for effective machining productivity and also computerize the creation of shop documentation (Anonymous, 2016).
(Anonymous, 2015) ´´Solidworks plastic for injection molding“
Equipments:
To design the product and simulate Mastercam 2018 was used thoroughly with different steps and process as per the given instructions. Similarly, the HAAS mill was used in a lab to carry out the milling process on plywood instead of aluminum stock as raw materials.
Working principle:
To start the further process obviously we need to make a model or sketch of the design and product what we are intended to manufacture in a lab or in any software. So, firstly we sketched the design in a paper with the dimension of 156mm, 156mm and 30.5mm rectangle with complete model of designed product. Similarly, the same designed was converted in a Mastercam 2018 application. There, the 2D design of dogbane having same dimensions was prepared. During the process different steps were taken to control the tools applications. So, different methods such as drilling, machining, pocketing are carried out by using different machining tools to controls different sizes, holes, ejector, and pin return. Then was finally simulated overall process before it was completed.
During the process several steps and techniques are carried out to complete the product design that are explained below are as follows.

Facing
Drilling
Pocketing
Simulating (simulation)
Facing
Facing is refers to clean or make the object smooth and frictionless from rough phase. So, same step was applied to face the design which was first roughly designed in a Mastercam and was facing was done with facing toolpath. During facing, FlAT ENDMILL with cutting diameter of 5.8 was taken and was faced -1 mm depth in a zizag style.

Figure 1 Facing via Flat-EndmillDrilling
Drilling is to make specific holes which required in a design or any object to complete the product. To make any holes ones need tools with specific sizes and diameter but in this process we need two different sizes tools to drills different sizes whole of the design because here we have two kinds of drillings such as pin guide drilling and dogbane drilling. So, firstly pin guide drilling was done by point drill having total diameter of 24 in specific circles which were made in a Mastercam. The design was drilled with the depth of -30 inches below. There are two types of holes which are pin ejector drills large holes. So, after that again the dogbone drill was done with the same point drill having total diameter having 8 inch with the same depth of -30 inch below.

Figure 2 Pin-guide drilling

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Figure 3 Dog-bone holes drilling

Pocketing
Pocketing is refers to make a space in a designed by using specific tools according to its sizes and shapes. In this design there are different types of pocketing as per the sizes and shapes such as pocket for runners and gate pocketing. So firstly the pocket for runners was done under 5.8 spherical/ Ball-nosed Endmill with total diameter 5.8 and corner radius 2.9 mm and was pocketed -3 inch. Then again gate pocketing was carried out with flat Endmill tool having total diameter of 5.8mm, and corner radius of zero and was pocketed with depth of -3 inch below.

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Figure 4 pocket for runners

Figure 5 Gate pocketing
1130300-419100
Simulation:
The dog bone designed was simulated or visualized by using Mastercam 2018 during the process. Simulation is the wide bunch of computer based application to act the characters of productivity system. It is the availability or a process which is either accurate or planned like workers in a factory which have a specific responsibility to monitor the work such as in a machine also have different tools such as material controlling devices, storage devices and production devices. It is supposed to study the representation of this real world system by numerical valuation by using software like Mastercam, CAD, and Solidworks. However, it is carried to the check the activity of the process, system and product before it is physically built or applied as product. The system of simulation is aimed to minimize the cost, time saving and improving the quality of manufacturing products in the market or factory (P. Radhakrishna, 2008, P. 654).

Therefore, the total path information was stated below table as follows.

Feed length
10645.571
Feed time
4min 51.58s
Min/Max X
-84.380/81.480
Min/Max Y
-77.998/77.998
Min/ Max Z
-35.118/25.000
Rapid length
2466.223
Total length
13111.793
Total time
5min 3.42s
Discussion and conclusion:
The project was aimed to design a dogbone by using CNC milling with the help of Mastercam software. However, the designed was first drawn one the rough paper as a model and then was designed in a Mastercam with different parameters such as rectangles and circles with required dimensions of the model. And was then extruded with extrude toolpath and converted into solid form so, that it can be carried for the machining process with different types of tools with required sizes and shapes. Then, it was gone through the process such as facing, drilling and pocketing. During the process different minor and major error were occurred but then it was done carefully to minimize the percentage error to make the efficient design.
Then finally, the designed was simulated to identify the different data and span time to complete the design so, however, the feeding time was calculated as 4min 51.58s with feed length of 10645.571. So, the total time period to complete the whole process took 5min3.42s.

References:
ONLINE available
Anonymous. 2016 https://www.mastercam.com/en-us/Communities/Blog/Tag/cnc-machining
Accessed 27 April 2018
ONLINE available
https://www.dlib.si/stream/URN:NBN:SI:doc-YB7TF9Y8/3a70b250-08cb-429f-a03c-6476bbc02778/PDF ´´Tool selection for rough and CNC milling operation 15, 1, pp 18-26“ Accessed 27 April 2018
ONLINE available
https://www.creativemechanisms.com/blog/solid-works-plastics-for-injection-molding-prototypes Anonymous. 2015 ´´Solidworks plastic for injection molding“ Accessed 27 April 2018
ONLINE available,
https://ebookcentral-proquest-com.ezproxy.arcada.fi:2443/lib/arcada- ebooks/detail.action?docID=437710 Accessed 27 April 2018
(P. Radhakrishna, 2008, P. 654).