MANU2518 - Assignment 1

Advanced Manufacturing and Mechatronics MANU2518
Assignment 1 - Semester C 2022

Course code: MANU2518
Group: 2
Lecturer: Dr. Son Vu Truong Dao
Assignment due date: November 27, 2022
Page number: 12
"I declare that in submitting all work for this assessment I have read, understood and agreed to the
content and expectations of the Assessment declaration."
Student Name: LE HUY

Student Number: S3915144
Student Name: NGUYEN THONG LINH
Student Name: LUU NGUYEN BAO TRAN
Student Name: NGUYEN BUI HUY HOANG
Student Name: LO KA KIU
1
2
Table of Contents
Question 1 [2 pts]: 3
Bonus Question 5 [1 pts] (you do NOT have to complete this question): 10
Bonus Question 6 [1 pts] (you do NOT have to complete this question): 11
References: 11
3
Question 1 [2 pts]:
Estimate peripheral milling time for the initial machining operation.
Enter your student number and calculations for the estimated machining time in the table below.
Show all working out.
X digit: 2
Firstly, we need to machine the top and the bottom surface each with 1 mm.
We were given:
Cutting speed of the tool:
v=32 m/min=32000 mm /min

Feed or chip load:
f =0.25 mm /tooth
Depth of cut for cutting tool:
d=1mm
Diameter of cutting tool:
D=40 mm
Width of cutting tool:
w=50 mm
Number of teeth of cutting tool:
nt =8
Length of workpiece:
L=200 mm
Total machining time of workpiece:
T M =?
For total machining time of the plate, it is known that:
L+ A V
T M= = [1, p.57]
fr R MR
For the workpiece cutter offset of peripheral milling, the formula will be:
A=√ ❑ [1, p.57]

A=√ ❑
4
For the rotational speed of the cutter, the formula will be:
v 32000 800
N= = = rev /min [1, p.57]
π D π × 40 π
For the feed rate of the cutter, the formula will be be:
f r=nt fN [1, p.57]
800 1600
f r=8× 0.25 × = mm /min
π π
With the workpiece cutter offset, spindle speed and feed rate found, the total machining time will
be:
T M =π ¿ ¿
However, this total machining time of the plate is only for one surface with the part width of 50
mm. We need to machine 200 mm of each surface. This implies that for the total machining time
for the top and bottom surface will be:
T M =0.40496 ×8=3.23968 min
Question 2 [1 pts]:
Calculate the required spindle RPM for the recommended linear cutting speeds for both tools in the
table below.
Enter your calculations for the spindle speed below. Show all working out.
Tool 1 spindle RPM
For Tool 1, End mill type, we were given:
Diameter of the Tool 1:
D=10 mm
Length of the Tool 1:
l=100 mm
Recommended feed rate of the Tool 1:
f r=300 mm /min
Recommended linear cutting speed the Tool 1:
v=36 m/min
We know that:
5
Linear cutting speed formula:
“ v=π DN ” [1, p.57]
Using the formula of the linear cutting speed (peripheral speed), the spindle speed of the Tool 1 in
revolutions per minute will be:
v 36 × 1000
N= = =1145,9156 rev /min
πD π ×10
Therefore, the spindle speed of Tool 1 will be:
N 1=1145,9156 rev /min
Tool 2 spindle RPM
For Tool 2, Twist drill type, we were given:
Diameter of the Tool 2:
D=6 mm
Length of the Tool 2:
l=100 mm
Recommended feed rate of the Tool 2:
f r=150 mm /min
Recommended linear cutting speed the Tool 2:
v=48 m/min
We know that:
Linear cutting speed formula:
“ v=π DN ” [1, p.26]
Using the formula of the linear cutting speed (peripheral speed), the spindle speed of the Tool 2 in
revolutions per minute will be:
v 48 ×1000
N= = =2546,4791 rev /min
πD π ×6
Thus, the spindle speed of Tool 2 will be:
N 2=2546,4791 rev /min
6
Question 3 [2 pts]:
Determine the X and Y coordinates of each of the holes which require drilling in the plate as per
Figure 1(d). Assume that the bottom left corner of the plate is the origin of the X and Y axes. The
origin of the Z axis will be the top surface of the plate.
X digit: 2
Table 3.1 - Table of X digit
Note: X digit is the last digit of your assigned group number (for example, if your group number is
18, your X digit is 8)
Enter the coordinates of your hole locations below. The hole locations in the inner arc correspond
to time on a standard wall clock.
Hole location X coordinate Y coordinate
Top outer right 175 175
Bottom outer right 175 25
Top outer left 25 175
Bottom outer left 25 25
Centre 100 100
Inner arc 12:00pm 100 141
Table 3.2 - Table of X and Y coordinates of Hole locations
Note: The data on the parameters of holes and cuts have low amplitudes in the range below ± 0.01
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Question 4 [14 pts]:
Develop the G-code required to machine the plate.
Enter your G-code here including comments to describe what the program is doing.
Also, save out your project file from CAMotics and submit it along with your report.
% - Program flag (starting)

O01 - Program name
N10 G90 G21 G40 G49 - Set the metric system and the absolute positioning system.
transparent tool compensation
N20 G28 Z0 - Send the machine home in the Z-axis

N30 G28 X0 Y0 - Send the machine home on the X and Y axes
N40 G90 G54 - Change to absolute position and load G54 work offsets
N50 T2 M06 - Load TooL2: 6x100mm Cylindrical

N60 G43 H1 - Load Tool2 length compensation
N70 G00 X100. Y100. Z12. - Move to the point (100, 100, 12)
N80 M03 S600 - Spindle on clockwise to 600 rpm
N90 M08 - Coolant on
N100 G01 Z0. F100. - Cut down Z = 0mm, and set feed to 100mm/min
N120 G01 Z-12. - Cut down to Z = -12mm (Linear Interpolation)
N130 G00 Z12. - Lift tool to Z= 12mm (without cutting)
N140 G00 X25. Y25. - Move to the point (25, 25, 12)
- OUTER HOLES CUTTING
- SMALL HOLES CUTTING (ø6MM AND 12MM DEPTH)
- BIG HOLES CUTTING (ø10MM AND 6MM DEPTH)
N260 T1 M06 - Load Too1: 10x100mm Cylindrical
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- BIG CIRCLE CUTTING (ø170MM AND 10MM THICKNESS
AND 6MM DEPTH)
N400 G00 Y185.Z-6. - Move to the point (100, 185, -6)
N410 G02 I0. J-85. - Circle cutting: ø170mm, 10mm thickness and 6mm depth
(Circular Interpolation, CW)
- 4 ARC CUTTING (ø170MM AND 10MM THICKNESS AND
12MM DEPTH)
N440 G03 X40. Y160. I0. J-85. - Start cutting from (100, 185, -12) to (40, 160, -12) with
ø170mm and 10mm thickness (Circular Interpolation, CCW)
N480 G03 X40. Y40. I85. J0. - Start cutting from (15, 100, -12) to (40, 40, -12) with
N500 G00 X100. Y15. Z12. - Move to the point (100, 15, -12)
N530 G03 Y40. X160. I0. J85. - Start cutting from (100, 15, -12) to (160, 40, -12) with
N570 G03 Y160. X160. I-85. J0. - Start cutting from (180, 100, -12) to (160, 160, -12) with
- SMALL CIRCLE CUTTING (ø82MM AND 6MM THICKNESS
AND 6MM DEPTH)
N610 G01 Y141. Z-6. - Linear cut to the point (100, 141, -6) (Linear Interpolation)
N620 G02 I0. J-41. -Circle cutting: ø82mm, 6mm thickness and 6mm depth
(Circular Interpolation, CW)
- INNER HOLES CUTTING ((ø6MM AND 12MM DEPTH)
N660 G00 Y129. X71. Z12. - Move tool to the point (71, 129, 12)
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N690 G00 X59. Y100. Z12. - Move tool to the point (59, 100, 12)
N780 G00 X129. Y71.Z12. - Move tool to the point (129, 71, 12)
- CUTTING THE RADIUS OF THE CIRCLE (10MM THICKNESS)
N880 G00 X100. Y100. Z12. - MOVE TO THE CENTRE OF THE CIRCLES (100, 100, 12)
N890 G01 Y185. Z-6. - Linear cutting from (100, 100,-6) to (100, 185, -6)
N900 G00 Y100. - Move to the point (100, 100, -6)
N910 G01 X185. - Linear cutting from (100, 100,-6) to (185, 100, -6)
N920 G00 X100. - Move to the point (100, 100, -6)
N930 G01 Y15. - Linear cutting from (100, 100,-6) to (100, 15, -6)
N940 G00 Y100. - Move to the point (100, 100, -6)
N950 G01 X15. - Linear cutting from (100, 100,-6) to (15, 100, -6)
N960 G00 X100. - Move to the point (100, 100, -6)
N970 G01 X40. Y160. - Linear cutting from (100, 100,-6) to (40, 160, -6)
N980 G00 X100. Y100. - Move to the point (100, 100, -6)
N990 G01 X40. Y40. - Linear cutting from (100, 100,-6) to (40, 40, -6)
N1000G00 X100. Y100. - Move to the point (100, 100, -6)
N1110G01 X160. Y40. - Linear cutting from (100, 100,-6) to (160, 40, -6)
N1130G01 X160. Y160 - Linear cutting from (100, 100,-6) to (160, 160, -6)
N1150M05 - Stop spindle

N1160M09 - Stop coolant
N1170G49 - Cancel tool length offset
N1180M30 - End program
% - Program flag (stopping)
Table 4.1- G-Code and Comments of the Injector Plate
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Figure 4.2 - Camotics
Picture 1 information:
1. Tool table:
a. Tool1: 10x100mm Cylindrical
b. Tool2: 6x100mm Cylindrical
2. Workpiece:
Dimension Offset
X 200.00mm 0.00mm
Y 200.00mm 0.00mm
Z 12.00mm -12.00mm
Table 4.3 - Dimensions and Offsets of Three Axis
3. Time: 41.63 secs Triangles: 7118640 Triangles/sec: 171008.73
4. GCode: Tool Path bounds ((0,0,-12), (185,185,12)) dimensions (185,185,24)
5. Computing surface bounded by ((-0.1875,-0.1875,-12.2125), (200.188,200.188,0.2125)) at

0.175 grid resolution
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Figure 4.4 - NCViewer - GCode
Bonus Question 5 [1 pts] (you do NOT have to complete this question):

One of the goals is the rapid colonisation of Mars which will require many rockets to be built quickly.
As such, the chief engineer is trying to make sure that the time to make each rocket is minimised. Use
CAMotics to help estimate the total machining time. In order to help her reduce the total rocket build
time, suggest how the machining time could be reduced. Comment on any business consequences
associated with your suggestion
In order to minimize machining time, the simplest way of accomplishing this task is to determine
an optimal method of holding the workpiece so that the machine can perform as many machining
operations as possible in a single allocation of the workpiece. This will effectively reduce the total
machining time since there will be less effort required to rearrange the location of workpieces. In
addition, it is also crucial to find a way to simplify the G-code as much as possible so that the
loading time for the controller can be reduced and if possible, use G81 for canned cycles for any
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repetitive drilling operations as it requires less lines of code. Furthermore, the sequence of
operations can be wisely arranged which in turn reduces the time for machining. From those
suggestions above, reducing the machining time directly increases the productivity of any
products as more products will be produced in a certain amount of time. As productivity
increases, the price per product will be reduced significantly. This can lead to a higher demand
for the products, which in turn, will benefit the company producing them. To keep up with their
competitors, other rival companies will have to discover different strategies to develop a more
effective way of production to prevent their product sales from declining. In conclusion,
minimizing the machining time will lead many corporations into a more challenging economic
scenario. In that way, some of them will quit producing any products which they may not be as
competitive enough. However, this will boost the development of mass production as a whole.[1]
Bonus Question 6 [1 pts] (you do NOT have to complete this question):

The Chief also asks that you find a method to inscribe identifying information on the plate such as the
part ID, material, date of manufacture, and which specific engine assembly the part will be
assembled with. He would like to do this for most other metal parts of the Titan engine, so a fast,
and repeatable method is required. Suggest a method which could be used to quickly inscribe
identifying information with minimum labour
In order to inscribe the part details such as: part ID, material, manufacture date and which engine
assembly that part can be assembled with, using a laser engraving technique can help engrave
the details listed above in a quick and efficient manner. For instance, with a fast and repeatable
approach, using a hand held laser marking device can be beneficial in inscribing letters, numbers
and important information [2]. Specifically, for the injector plate material called Inconel 625 Nickel
Superalloy, a laser can carve deep engraving marks depending on the laser power, leaving a clean
result that can reduce the time needed to refine the surface [3]. To inscribe the essential details,
the user simply transfers the file containing the information (part ID, material, manufacture date,
and part assembled for engine assembly) into a USB [4]. Afterwards, users insert the USB into the
device to transfer the file needed into the device [4]. The handheld laser marking device will then
display the graphics of the file onto the screen to which the user can then adjust the layout of the
font, size and position of the text [4]. The graphics will then be selected and chosen in the settings
to be filled [4]. Users can pick the settings of the parameters, speed and power of the laser to start
the engraving process [4]. Finally, to start marking, confirm the graphics by selecting the start
button and holding the button of the hand held laser to mark the surface of the product [4]. The
laser marking system not only provides an effective and fast paced approach but also provides a
simplistic and repeatable method of inscribing the details needed onto the plate.
References:
[1] M. Mazur. “MANU2488: ADVANCED MANUFACTURING & MECHATRONICS: WHAT WE MAKE AND
HOW WE MAKE IT LECTURE 2 - MACHINING OPERATIONS AND MACHINE TOOLS.”
rmit.instructure.com. https://rmit.instructure.com/courses/114466/pages/week-2-lecture-slides-
and-supporting-documentation?module_item_id=4544614 (accessed Nov. 26, 2022).
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[2] Pryor Technology Inc. “Laser Marking 150,000 Names on 1138kg Superalloy Heart Made Easy.”
Pryor Marking Technology. https://www.pryortechnologie.fr/knowledge-centre/blog/laser-
engraving-150000-names-on-1138kg-superalloy-heart-made-easy (accessed Nov. 25, 2022).
[3] Keyence Corporation. “Fiber Laser Marking.” Laser Marking Central.

https://www.keyence.com/ss/products/marking/laser-marking-central/basics/fiber-laser.jsp
(accessed Nov. 25, 2022)
[4] YouTube. “How to operate Portable Handheld Laser Engraver Machine For Metals? Check Now!.”
YouTube. https://www.youtube.com/watch?v=faf2Kn6bO4U (accessed Nov. 25, 2022)
14

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Advanced Manufacturing and Mechatronics MANU2518

Assignment 1 - Semester C 2022

Student Name: LE HUY

Question 4 [14 pts]: 6

Bonus Question 5 [1 pts] (you do NOT have to complete this question): 10

Bonus Question 6 [1 pts] (you do NOT have to complete this question): 11

Cutting speed of the tool:

v=32 m/min=32000 mm /min

For total machining time of the plate, it is known that:

A=√ ❑ [1, p.57]

f r=nt fN [1, p.57]

T M =0.40496 ×8=3.23968 min

Tool 1 spindle RPM

For Tool 1, End mill type, we were given:

Diameter of the Tool 1:

Recommended linear cutting speed the Tool 1:

“ v=π DN ” [1, p.57]

N 1=1145,9156 rev /min

Tool 2 spindle RPM

For Tool 2, Twist drill type, we were given:

Diameter of the Tool 2:

Recommended linear cutting speed the Tool 2:

Linear cutting speed formula:

“ v=π DN ” [1, p.26]

N 2=2546,4791 rev /min

Table 3.1 - Table of X digit

Hole location X coordinate Y coordinate

Top outer right 175 175

Bottom outer right 175 25

Top outer left 25 175

Bottom outer left 25 25

Centre 100 100

Inner arc 12:00pm 100 141

Inner arc 1:30pm 129 129

Inner arc 3:00pm 141 100

Inner arc 4:30pm 129 71

Inner arc 6:00pm 100 59

Inner arc 7:30pm 71 71

Inner arc 9:00pm 59 100

Inner arc 10:30pm 71 129

Table 3.2 - Table of X and Y coordinates of Hole locations

% - Program flag (starting)

N20 G28 Z0 - Send the machine home in the Z-axis

N50 T2 M06 - Load TooL2: 6x100mm Cylindrical

N1150M05 - Stop spindle

Table 4.1- G-Code and Comments of the Injector Plate

a. Tool1: 10x100mm Cylindrical

b. Tool2: 6x100mm Cylindrical

3. Time: 41.63 secs Triangles: 7118640 Triangles/sec: 171008.73

4. GCode: Tool Path bounds ((0,0,-12), (185,185,12)) dimensions (185,185,24)

5. Computing surface bounded by ((-0.1875,-0.1875,-12.2125), (200.188,200.188,0.2125)) at

Bonus Question 5 [1 pts] (you do NOT have to complete this question):

Bonus Question 6 [1 pts] (you do NOT have to complete this question):

[3] Keyence Corporation. “Fiber Laser Marking.” Laser Marking Central.

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