Subtractive Manufacturing

About the Course

This course focuses on building advanced CAD and CAM skills with a strong emphasis on designing for manufacturability, transitioning from additive processes (like 3D printing) to precision subtractive methods.

Course Outline:

Phase 1: Fundamentals of 2D Cutting

• Tools & Technologies: Laser and plasma cutters.

• CAD Focus: Introduction to sheet-metal design—flat pattern cutting followed by bending into shape.

Phase 2: Introduction to CNC Routing (Woodworking)

• Hands-On Experience: Operate a 1000mm x 1000mm CNC router to machine wood, introducing lower-force machining concepts.

• Core Concepts: Work offsets, material probing, simple tooling (end mills, chamfer bits).

• CAM Skills: First exposure to 2.5D adaptive clearing, feeds and speeds optimization, depth of cut, and step-over strategies.

Phase 3: High-Speed CNC Machining (Metals)

• Machinery: Benchtop mills with rapid speeds (9000 mm/min), a 3-hp spindle, and an automatic tool changer.

• Theory: Detailed exploration of metal machinability, cutting tool geometries and materials, chip formation, tool deflection and wear, feeds and speeds calculations, and interpolation of off-axis shapes.

• CAD/CAM Proficiency: Develop custom tool libraries, simulate toolpaths including advanced 3D toolpaths (e.g., scallops), error detection, and create parts requiring custom soft-jaws.

Phase 4: CNC Lathe Operations

• Hands-On Learning: Operate Tormach's 8L CNC Lathe (single-point turning, no live tooling or sub-spindle).

• Project Highlight: Design and machine a functional 3D printer extruder—linking this project back to knowledge gained in the Rapid Prototyping prerequisite course.

Stay tuned—more details will be shared as the semester approaches. Get ready to elevate your skills from prototyping to precision machining!

After meeting the DF-2100 prerequisite, please enroll through YES.

Questions?

Reach out to Professor David Florian at [email protected]