ME 548 Numerical Control of Machine Tools, Fall 2018
University of Waterloo, Department of Mechanical & Mechatronics Engineering
|| Jim Baleshta (MasterCAM), Robert Wagner (NC Machining) (DC-1705), Jason Benninger (NC Machining)
|| CPH - 3679, Tue: 02:30 - 04:30 pm; CPH - 3679, Thu: 10:30 - 11:30 am
|| Lever Lab (E2 - 1306), CIM Lab (DC - 1709). Precision Controls Lab (DC - 1708).
Lab projects will require the use of MasterCAM, MachPRO, MCOSMOS, MATLAB, NC programming, and machining.
Please check regularly for updates and announcements.
There will be a help session on Thursday, November 29th from 11:30 am to 12:20 pm in CPH 3679.
Lab 3 submission deadline has been extended to Friday, November 30th at 5:00 pm. There will not be any further extension.
Lab 1 timeline:
Oct 18: Industrial guest lecture on 5-axis machining
Lab 2 timeline:
- Sep 6-14: Engraving pattern has to be presented to the course TA for approval.
- Oct 5: Initial CAM program - MachPRO tutorial, Lever Lab (E2-1306), 1:30-3:30 pm
- Oct 8-12: Shield machining CMM, DC 1708, 15-18
- Oct 9: MachPRO optimized CAM program
- Oct 9 – Oct 18: Machined part
- Oct 15- Oct 26: CMM inspection report
- Oct 29: Submission of the final report and the machined part
Lab 3 timeline:
- Oct 26: Milling force measurement labs, DC 1709, 1:30-3:30 pm
- Nov 19: Submission of the final report
- Nov 16: Modal testing lab, DC 1708
- Nov 29: Submission of the final report
CNC contouring demo (link)
Shear angle analysis (link)
Lead/lag controller demo (link)
Welcome to ME 548. This course aims to provide students with a background in
the operating principles of CNC machine tools, NC part programming, CAD/CAM software,
mechanics of metal cutting operations (such as turning, milling, and drilling), and the
dynamic behavior of machine tools under the influence of cutting forces originating from the machining process.
- Altintas Y., 2012, Manufacturing Automation: Metal Cutting Mechanics,
Machine Tool Vibrations, and CNC Design, 2nd Edition, Cambridge University Press, ISBN 978-0-521-17247-9. (required)
- Tlusty J., 2000, Manufacturing Processes and Equipment, Prentice Hall, ISBN 0-201-49865-0. (recommended)
- Technology of Manufacturing Automation (~12 hr):
Every student will design a part with their own engraving in MasterCAM, automatically generate the NC code, optimize it using MachPRO, and machine their part on a three-axis CNC milling machine. Afterwards, they will write a CMM inspection program and use the CMM to measure the errors in their part.
Project 1 (18%): CNC Programming, Machining and CMM Inspection of a Shield
- NC part programming
- Operating principles, components, and control of CNC machine tools
- Automatic NC code generation with CAD/CAM software (MasterCAM)
MACHpro: Manual, Project files.
CMM: Manual, STEP file.
- Mechanics of Metal Cutting (~12 hr)
Students will measure actual cutting forces during a milling operation using a dynamometer.
They will also write a program to simulate the machining forces and compare their
simulations to the experimental results.
Project 2 (10%): Measurement and simulation of cutting forces in milling
- Orthogonal and oblique cutting
- Mechanics of milling, turning, and drilling
- Tool wear and breakage
- Selection of optimum machining conditions
Matlab: Project 2 files
- Static and Dynamic Deformations in Machining (~11 hr)
Students will measure the accelerance frequency response function (FRF) of a linear motion
stage at 5 different points. They will identify modal parameters for 3 modes using the 'Peak Picking'
method. They will also sketch the mode shapes.
Project 3 (7%): Modal testing and analysis of a linear motion stage.
- Dimensional form errors in turning, boring, and milling
- Structural vibrations of machine tools
- Forced and self-excited (chatter) vibrations in machining
Modal Testing: Manual ,Matlab File ,Report Template
Student Setup: Assembly Instructions
Marking Scheme: Final (%45), Midterm (%20), Laboratory projects (%35).
Project reports need to be prepared as individual work and submitted on time.
Academic integrity is expected of all students. Offenses, including plagiarism, will not be tolerated.
For further information, please see: http://www.eng.uwaterloo.ca/~ugoffice/html/course_responsibilities.html.
10% reduction per day will be applied to late submissions.
Prerequisites: ME 262, ME 360 or MTE 360.