UNIVERSITI TUNKU ABDUL RAHMAN

Sungai Long, Kajang

LKC FES
UEME3223 Computer Aided Design and Manufacture
INDIVIDUAL ASSIGNMENT : CAD/CAM

Name : LEE PIN YANG

ID: 1203864
COURSE : MECHANICAL ENGINEERING
LECTURER NAME: MR. WONG HONG MUN

1.0 Introduction
Computer Aided Design ( CAD ) is done by using computer softwares such as Autodesk
Fusion 360 to help user create, modify and visualize a design. Through the computer software,
the design is able to translate into a language that the computer is able to process such as
mathematical and graphical model. Computer Aided Design ( CAM ) is the use of computer to
allow user to plan and control plant production through the computer interface. For example, to
control the operations of a CNC machine on how to cut and how to cut a particular material into
some useful final product.
By combining both CAD and CAM, we have a powerful computer system which comprises
of hardware and the software tool that helps in visualizing, designing and finally producing the
product.
In this machine component that we chose, it is a basic two and a half axis CNC part.
Basically there is an open pocket in the middle of the component with a protruding cylinder
island with tapered threads on the inside. This is to facilitate fastening of the component on the
machine. There are four holes surrounding the open pocket with two type of diameter, the large
diameter then followed by small diameter to the bottom of the component.

2.0 Computer Aided Design

We are going to design a product that looks like this:

2.1 Construct Rectangle block and Counterbore holes

The first step that we have to do in CAD is create this rectangular brick-like object. First,
draw a 200mm100mm rectangle and then extrude it by a height of 40mm. To get the four holes,
simply draw a smaller rectangular sketch on top of the brick-like object. Then we are able to get
the snap of the corners of the rectangle sketch. Then we use the Hole function to create
counterbore types and simply click the four corners of the rectangle sketch and four holes
wouldve appeared. We chose a counterbore diameter of 20mm and 10mm diameter for the head.
This would basically mean that the hole has a diameter of 20mm for a depth of 20mm and then a
diameter of 10mm for the remaining of the depth of the block.
After the four holes are done, then we proceed to the middle part of the block. We draw a
sketch of 100mm50mm in the middle of the block and remove the materials by extruding the
rectangle box downwards by 20mm which is half of the depth of the block. Then we create a
cylinder in the middle of the block with a height of 20mm, which gives the protruding island.
Once again remove the materials in the middle of the cylinder by using extrude. Now we are
done with this simple product.
2.2 Fillet and Chamfer
Then we are going to add some fillet and chamfer to this product to ensure that the
product has no sharp edges or abrupt change in the direction during milling to improve millings
quality and prolong the lifetime of milling tools. This is also done to ensure stress levels of the
object are kept within a minimum level. We use a 1mm chamfer for the outer rectangle and
radius of 5mm for the fillet in the inner rectangular part of the object to make it easier for the
milling operations to be done. We are trying to prevent sharp edges design in the inner rectangle
to have a smoother and better surface finish.
2.3 Material of workpiece
We choose the material of this product to be Cast Iron since cast iron can easily be found
at a cheaper price too. But it all depends on the application of the product. We assume this
machine part is used under low stress conditions, therefore we choose the cast iron. For higher
stress applications we can change the material of the product anytime to stronger materials such
as steel or titanium for more extreme applications. This can be done by simply right-clicking the
product and choosing the appearance and choose any material that you want ranging from steel
to titanium to bronze alloys.

3.0 Computer Aided Manufacturing

In computer aided manufacturing, we simply choose the cam function in the Autodesk Fusion
360. In this part, we are basically trying to tell the machine how to cut the stock into our
finishing product form.

3.1 Work Coordinate System

First thing we have to do is changing the mode into CAM mode after designing. Then, we
click the Setup to setup our Work Coordinate System. The Work Coordinate System is where
we provide input to tell the machine how we define the work coordinate system with respect to
the product. Now, we define the origin of the X-Y-Z axis to be at the top corner of the product.
This is done to input to the computer so that the computer can know the position of the product.
3.2 Cast Iron Stock
After that, we choose the size of the stock that we would want to cut into our final product.
The stock is the raw material, Cast Iron in this case that comes in the form of a block. The stock
must not be too big as to waste too much materials which would result in higher cost for the final
product. However, it should not be too small either for the product to meet the requirements of
the product dimension. Therefore, an easy method is to choose the Relative Size box mode.
Then we choose the offset of the stock to be 1mm for this case. We are of course free to choose
whatever offset that we want depending on the delicacy of the product design. Therefore, we
should take that into account when choosing the size of our stock. Since we chose the offset of
the stock to be 1mm relative to the product, the stock size that we are going to put into the CNC
machine and cut will be 201mm101mm41mm.
Now we can put the stock into the CNC machine by clamping it tightly inside the CNC
machine. The stock is clamped on its 200mm side with a depth of 12mm to allow the clamp to
have some grip on the stock.
3.3 Face milling
First, we have to shave off the additional materials of 1mm thickness from the top of the
stock. To do this, we choose Face to shave off the top face of the stock. We choose a face mill
#1-50mm Face Mill with a cutting diameter of 50mm and 130mm overall length. Then we
choose the coolant that we want to use in this case. Coolants are extremely vital in any CNC
operations as they blast or carry away the chips that are cut from the material. Very often these
chips has high temperature from the friction of metal being cut, therefore it is important that
these chips are carried away to prevent excessive damage to the tool cutter and to allow the
product to have a really smooth surface finish. There are a variety of coolants to choose from
such as flood, through tool and air. Flood is done by aiming several nozzles at the surface the
material is being cut and coolants are flooding the entire material as it is being cut. Through tool
is where some expensive CNC machines they offer coolants that flow through the tools directly
into the spot materials is being cut. For our case, we choose the Flood coolant for simplicity. For
the feed and speed of the tool, default feed and speed is used, which is the value recommended
by the software where surface speed is about 15m/min, feed per revolution is 0.00175mm and
spindle speed is 95.5rpm among a few of the important info.
3.4 Toolpath
After doing this, the toolpath will appear where they are basically lines indicating the path
that the tool cutter will take to machine the product. Blue indicates contact of the tool with the

surface of the product. We can simulate the process of the tool cutting the stock by choosing
Simulate in the tool bar. Doing so, we are able to identify any mistakes or things that we have
missed when designing.
3.5 2D Contour milling
After the top face is shaved, next we want to cut the the outer perimeter of the stock. We
chose the 2D Contour for the tool cutter to go around the workpiece. We chose a #3 - 16mm flat
end mill. An important note is that since the product is clamped inside the CNC machine, we are
not able to cut all the way down to the bottom of the work piece as we would destroy the clamp.
The clamp makes it harder for CNC machine to perform 2D contour cuts. Therefore, we break it
down into two steps by cutting it two times. First time we cut, we leave a 12mm which is the
dimension of the materials being clamped. Then we would flip the product and then mill the
other side. This is where the Heights tab comes in handy. We choose the Bottom Height and
then choose the offset to be 12mm. This ensures that the mill leaves the 12mm at the bottom of
the workpiece alone. Simulation can be done again to show that the machine only cuts half of the
contour. After that we can flip the workpiece to allow the machine to cut the remaining contour.
3.6 Open Pocket Milling
Now we are trying to cut the middle part of the workpiece with the island by doing open
pocket milling. The middle part being a hollow cylinder with a thickness. In order to minimize
the wear and tear and prevent the damaging and breaking of tools we are going to use the
2D Adaptive Clearing where roughing operation is done that uses an computer optimized
toolpath when cutting the workpiece that avoids abrupt direction changes. As a result, less stress
is being exert on the cutting tool and the machine which we are able to prolong the lifetime of
both of them.
One important note is that we need to take into consideration of the island in the middle
of the workpiece. Therefore, we must not choose a cutting tool larger than the dimension
between the island and the outer edge of the middle rectangle which is 15mm in this case. So we
must choose a cutter that is smaller than 12mm to allow for some space for the cutter to move.
After consideration, we chose a #7-10mm flat end mill to mill the open pocket with the island in
the middle. Refering to appendix, from the tool path, we can see the entry point is a corkscrew,
helix spiral shape which is the optimized toolpath instead of plunging straight down into the
workpiece. The cutting are also done in spiral motions instead of straight cuts to reduce the stress
on the cutting tools. Due to the roughing cut nature, the #7-10mm flat end mill leaves some stock
for more detailed cut to take place later. At the Passes Tab we choose 0.5mm radial and axial
stock to leave which means all walls would have 0.5mm stock left not cut. We then use a new
and sharper #7-10mm flat end mill to cut the remaining stock as it would produce a much
smoother and shinier surface finish than with the rough cut flat end mill which wouldve become
blunt by the time it reaches the outer surface.

3.7 Drilling ( Spot drill and standard drill )

To do the drilling operations, we open the Drilling tab and then choose a Spot Drill. The
reason why we chose the spot drill instead of the drill is to drill a spot to allow the standard drill
to fix its drilling point better. Without the spot drill, the standard drill would have a hard time
gripping onto the surface to drill and would wander off course and making the holes less
accurate. We choose a #70-10mm spot drill and choose Model Top and put in value of -1mm to
drill a spot of 1mm deep to allow for the standard drill later. After that is done, we choose the
#30-10mm drill to drill the four holes by drilling through the bottom where we drill all the way
through the bottom of workpiece. Then we choose the #8- 20mm drill to drill the four holes to
only 20mm depth. Therefore we now have a hole with 2 different diameter.
3.8 Tapping
Now we want to perform tapping for the middle hole of the workpiece. Therefore, we
chose M10x1 mm tap right hand which has a diameter of 10mm to tap the center of the
workpiece. Now we have finished this face, we are going to finish up the rest of the workpiece
by flipping it around and repeat all the steps from creating local coordinate again. Then we
remove the face, cut the stock by using 2D Contour to obtain our final product with the specified
dimensions.
Finally, we would want to check the simulations of the cutting process to identify any
problems or inconsistency easily. This can be done by clicking Simulation. By ticking the Stock,
we are able to see how the whole milling process is done right from the Stock until the finished
product. We can also see all the toolpath which indicates the paths that the cutter will take to cut
the stock.

4.0 Precautions
In order to get that perfect and smooth surface finish, make sure to replace any blunt or
damaged cutter. By doing so we are able to obtain a better quality final product. In addition,
before any milling process, make sure to wipe the surface of the workpiece clean to make sure
there are no chips on the surface as they will affect the product quality.

5.0 Appendix

Figure 1. Toolpath on the workpiece

Figure 2. In the process of milling

Figure 3. Finished product with toolpath

Figure 4. Behind view of the machine component