Production Systems: Machine Tools, Flexible Computer Integrated Production (B-KUL-H01Z4A)

6 ECTSEnglish56 First termCannot be taken as part of an examination contract
POC Werktuigkunde

The student learns and knows the structure of machine tools and flexible manufacturing systems. He can analyze an existing production system and explain the functions of the various components and systems (construction of the machine, machine tool control from CAD, ...,..). Given a CAD-model of a mechanical product, the student can select the most optimal operations (process planning) and can generate the different programs required to control the flexible production system. More specific objectives can be found under the description of the various related learning zctivities (OLA's).

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1. The student knows and learns how modern production machines and/or systems constructed. The student can explain the role and function of the different components (frames, guides, actuators, control,..) of an existing machine or system (based on real machine or a drawing/model). 
2. Based on a given product specification (dimensions, precision, lot sizes, ..), the student can conceptually design a machine / system conception (component selection).
3. The student knows the different ways to automate a production machine/system (computer control). He learns how the control of a production system is performed.
4. The student knows the problems related to the thermal and dynamic behavior of production machines and systems. He also learns the methods / procedures for the improvement of the thermal and dynamic behavior of the machine tool/system. 
5. The student knows the procedures (and methods) for the purchase of a production machine and system. This will include methods to measure the accuracy, dynamic and thermal behavior of the machine tool.  

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Based on the knowledge gained in the lectures, this learning activity has the following goals: 
1. The student can indicate the different components of an existing machine tool and explain the functions of these components. 
2. Based on a given production order a production machine and / or system, the student has to conceive a production machine, including the necessary calculations
3. The student can automate an existing machine (switching of components (eg. actuators) and programming of it  using a PLC.
4. The student performs the quality control and evaluation of a machine tool (dynamic, thermal)

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The student can independently generate the input (data files) for the computer controlled machining of a workpiece. Given a CAD model of a workpiece, the student has to make, using a commercially available CAPP/CAM system, a process plan and for each operation the required machine tool programs 

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1. The student learns and knows the various methods (hand-programming, programming languages​​, CAM,...) to program computer controlled machine tools and measuring machines 
2. The student knows the various software blocks and databases (e.g. CAM postprocessor, CL-data,...) and know how they are linked to each other.
3. The student learns and knows the different algorithms to calculate toolpaths for various machining methods: point to point machining, contour machining and operations for complex shaped surface machining. He should also know the different CAD representation models and know what can be achieved with each model. He learns the capabilities of feature-based programming systems.
4. The student learns and knows the various methods of computer aided process planning (CAPP). He knows the principles, algorithms, advantages and disadvantages. The student can make, for given work piece, a complete process plan using the algorithms he has learned. 

Basic knowledge of machine construction (machine elements), production techniques and materials.
Basic knowledge CAD

Activities

2.4 ects. Production Machines and Systems: Lecture (B-KUL-H04W0a)

2.4 ECTSEnglishFormat: Lecture18 First term
POC Werktuigkunde

The course comprises the following chapters:


 

  • Concepts for production machines and systems
  • Construction of machine tools (building forms, materials, construction, ..)
  • Tool spindles (construction, drives, tool holder systems) 
  • Clamping, slides, .. (guides, drives, positioning systems, ..)
  • Controllers (PLC, NC programming, "feature-based" controls, communications, adaptive control)
  • Flexible production systems (integration of machines, palletizing, communication between machines, ..)
  • Thermal stability of machine tools
  • Dynamic behavior of machine toolsQuality control of machine tools 

Study cost: 1-10 euros (The information about the study costs as stated here gives an indication and only represents the costs for purchasing new materials. There might be some electronic or second-hand copies available as well. You can use LIMO to check whether the textbook is available in the library. Any potential printing costs and optional course material are not included in this price.)

The course text is a set of detailed slides (text provides enough to completely understand the content). This slides are available at Toledo 

Classical lectures! The teacher covers the material using PowerPoint presentations, supplemented by notes on the blackboard

2.4 ects. Computer Integrated Production: Lecture (B-KUL-H04W8a)

2.4 ECTSEnglishFormat: Lecture18 First term
POC Werktuigkunde

The course contains the following chapters:

1. Introduction - overview Computer aided manufacturing (link from CAD to the production machine)
2. Recapitulation of CAD systems (CAD modeling systems, ..) - serves as the basis for the further detailed discussion of CAM systems
3. Principles of tool path generation (CAM) for various purposes (point to point operations, contour machining, machining of complex shapes)
4. Feature-based toolpath generation
5. NC post-processors (link CAM to NC machine)
6. Principles, methods and algorithms for computer aided process planning
7. Computer controlled clamping of workpieces
8. Computer aided quality control

The course text is a set of detailed slides (text provides enough to completely understand the content). This slides are available at Toledo 

Online lectures! The teacher covers the material using PowerPoint presentations, supplemented by notes on the blackboard

0.6 ects. Computer Integrated Production: Excercises (B-KUL-H04W9a)

0.6 ECTSEnglishFormat: Practical10 First term
POC Werktuigkunde

There are four sessions offered (using an available CAPP/CAM system)

Session 1: Introduction (learning to use the system) + toolpath generation for easy turning and milling operations.

Session 2: tool path generation for machining of complex geometries

Session 3 & 4: Calculation of a complete process plan and for each operation the right machine program for a give complex shaped part. After having made all the programs, the workpiece will be machined on an available computer controlled multi-tasking machinel.

 

When you register for a new academic year and retake the course you are not exempted from lab sessions and exercises

For the various practical sessions, course material is available on Toledo

The student works out the sessions in an independent way. The CAD/CAM system ESPRIT is available.

0.6 ects. Production Machines and Systems: Laboratory Sessions (B-KUL-H04X1a)

0.6 ECTSEnglishFormat: Practical10 First term
POC Werktuigkunde

The four objectives are translated into four practical sessions:
 
Session 1 & 2 (2x2, 5 hours): Study of the construction of a production machine / system. Firstly, a number of production machines / systems (available in the workshop of the department of mechanical engineering) are explained. The student must also independently analyze an existing machine. Furthermore, during this practicum a production machine / system is designed based on a given product specification.
Session 3: Actuation of machine tools (PLC, positioning) 
Session 4: Evaluation of machine tools (accuracy of the machine, dynamic behavior, ..)

When you register for a new academic year and retake the course you are not exempted from lab sessions and exercises

For the various practical sessions, course material is available on Toledo

The students work in a lab session in groups of 4 students. If a guiding text (explaining the lab session) is available, it should be read in advance. The students are supervised by an assistant, but the practical session should be done by the student as independent as possible.

Evaluation

Evaluation: Production Systems: Machine Tools, Flexible Computer Integrated Production (B-KUL-H21Z4a)

Type : Exam during the examination period
Description of evaluation : Oral, Written
Type of questions : Open questions
Learning material : None


Part "Production Machines and Systems" : Oral exam
Part "Computer Integrated Production" : Written exam
Both parts are closed book

Lab session attendance is compulsory.
Unjustified absence for a lab session or exercise session results in a score of 0/20 for the whole course.
When you register for a new academic year and retake the course you are not exempted from lab sessions and exercises

 

It is not possible to retake lab sessions, so a retake of the exam is not possible in case of an unjustified absence for a lab session.