Assessment Overview

The assessment consists of three parts: Part Programme, The Component, and a detailed Report. The report should contain explanations of your programmes, including manufacturing details. The explanations should demonstrate your understanding of Hypermill and the related machining processes. The recommended word count for the report is between 2000 and 3000 words, excluding the Safety Statement, Setter, and Operator data sheets. The word count should not exceed 5000 words.

Marks Breakdown:

1. Hypermill programme files with post-processed files: 45% (15% each)
2. Components: 9% (3% each)
3. Report: 46%

CANVAS Upload Instructions:

• The completed Hypermill post-processed programmes (.h, .nc) should be uploaded to CANVAS – 3 files.
• The Hypermill files (.hmc) – 3 files.
• The written report should be uploaded to CANVAS in Word document format.

Report Guidelines

The report should include the following sections:

1. Component Photographs:

• The finished components should be photographed and the images should be included in the report.

2. Datum Selection:

• Explain the datum position and process.

3. Strategies Selection:

• Provide detailed explanations for the following:
  • One 3-Axis milling example
  • One 3+2 milling example
  • One Turning example
• Screenshots may be useful for clarification. Avoid explaining the same item repeatedly.

4. Programme Strategy Selection:

• Justify the selection of three different strategies from each programme (a total of 9 strategies).

5. Project Assistant – Mill and Mill/Turn:

• Discuss the project assistant for both Mill and Mill/Turn processes.

6. Tool Selection:

• Explain the types of tools used, their applications, speeds, feeds, tool life, and any relevant details.

7. Safety Statement – SOPs:

• Provide one main safety statement that applies to all machines, with additional items for any specific machine unique to the task. The SOP files can be downloaded from CANVAS.

8. Sustainability:

• Discuss sustainability considerations relevant to the machining process.

9. Working Holding Methods and Strategies:

• Provide details on the workholding methods and strategies used.

10. Manufacturing Time:

• Discuss the manufacturing time and efficiency considerations.

11. Simulation, Crash Detection, Post Processing:

• Detail the use of simulation, crash detection, and post-processing.

12. Setup Instructions for Tool Setter and Operator – 5-Axis Machine:

• Provide setup instructions specifically for the tool setter and operator when using a 5-axis machine.

13. Part Manufacturer:

• Discuss any errors encountered, sounds/noise/vibration/chatter issues, visual inspection, improvements, suggestions, alternatives, hand finishing, etc.

14. Recommendations:

• Provide recommendations for improvement and optimization.

Part 1: 3-Axis Milling

Material:

• 150mm x 100mm x 50mm free-machining aluminium.

Operations:

• 2 parts: Underside and topside.

Programming Task:

• Create two programmes: one for the topside and one for the bottom side.
• Add a vice when machining the topside.
• Create a programme for the DMG Mori DMC650V for the part.
• Machine the part to an acceptable aesthetic finish. Ensure that the strategies, speeds, and feeds are practical and realistic.
• All surfaces must be roughed and finished using different tools.
• Machine the underside as a separate operation.

Part 2: 5-Axis & 3+2 Milling

Material:

• 100mm x 100mm x 50mm free-machining aluminium.

Programming Task:

• Create a programme for the Hurco VM10ui for the part.
• Machine the part to an acceptable aesthetic finish.
• Ensure that the strategies, speeds, and feeds are practical and realistic.
• The underside must be faced.
• Additional fixture points may be required underneath; these should not be visible from the finished part when viewed from the top.
• Adapt the lettering for a more suitable process (quicker, easier, more defined).
• All surfaces must be roughed and finished with different tools, except for the lettering.
• Use 5-axis strategies for the tapered walls.

Part 3: Mill/Turn

Material:

• Ø50mm x 130mm long free-machining aluminium.

Programming Task:

• Create a programme for the NLX 1500/500 Mill/Turn Lathe.
• Machine the part to an acceptable aesthetic finish.
• The pitch of the single-start thread is 1.5mm.
• Ensure that the strategies, speeds, and feeds are practical and realistic.
• All surfaces must be roughed and finished using different tools, except for the milling operations and thread.
• Use milling strategies where appropriate.