Syllabus

Introduction to CAD/CAM System:
This module introduces students to the fundamentals of Computer-Aided Design and Manufacturing (CAD/CAM) and their integration in modern manufacturing. It covers the role of CAD/CAM in product development, advantages of digital manufacturing workflows, and an overview of CNC technology. Students will understand the structure of CNC systems, coordinate systems, basic machine components, and essential safety practices in a machining environment.

CNC Machines, Tools, and Operations:
Students learn about different types of CNC machines including milling, drilling, and machining centers, along with their construction, working principles, and industrial applications. The module also focuses on tool types, tool selection, tool holding systems, cutting parameters, and standard operating procedures. Special emphasis is placed on machine safety, pre-operation checks, and maintenance guidelines to ensure safe and effective machining.

Introduction to Mastercam and 2D/3D Modeling:
This module provides an introduction to the Mastercam environment and its applications in computer-aided manufacturing. Students learn to create 2D profiles and 3D geometry required for machining processes. They explore the modeling interface, geometry creation, constraints, and the process of preparing CAD models for toolpath generation. Practical exercises reinforce the link between part geometry and machining strategies.

Toolpath Generation and G-Code Programming:
Students develop toolpaths for various machining operations such as facing, pocketing, contouring, drilling, and 3D surface machining using Mastercam. The module emphasizes the process of post-processing toolpaths into G and M codes, understanding CNC program structure, and editing generated codes. Students gain confidence in interpreting and modifying G-code to meet specific machining requirements.

CNC Machine Operation and Workpiece Setup:
This module focuses on transferring NC programs to CNC machines and executing them safely. Students learn machine referencing, tool offset and work offset setting, workpiece clamping, and program execution procedures. They perform machining operations on CNC milling and drilling machines, ensuring correct tool selection, sequence control, and adherence to machining parameters.

Validation, Troubleshooting, and Error Analysis:
The final module deals with validation of machining programs and parts. Students will compare CNC-machined components with CAD models, analyze dimensional deviations, and identify sources of errors related to machine setup, tool wear, or programming. Strategies for troubleshooting, correcting errors, and improving machining accuracy are discussed to develop problem-solving skills relevant to industrial practice.

To introduce students to CAD/CAM integration and CNC machining fundamentals.

To provide knowledge of different CNC machines, tools, operations, and safety practices.

To enable students to model 2D and 3D components using Mastercam software.

To develop competency in generating G-code and executing machining operations.

To train students in validating machined parts and analyzing errors relative to CAD models.

Explain the fundamentals of CAD/CAM systems and CNC machining processes.

Select appropriate tools and operate CNC milling and drilling machines safely.

Create 2D and 3D part models in Mastercam and generate optimized toolpaths.

Produce and interpret G-code programs and execute them on CNC machines.

Validate machining accuracy and troubleshoot errors related to machine, tool, or programming.

John R. Walker, Machining Fundamentals, The Goodheart-Willcox Company, Inc. , 2023

P. N. Rao, CAD/CAM : Principles and Applications, McGraw Hill Education , 2017

Journal of Manufacturing Processes