Manufacturing Level 3 - Advanced Machining & Fixtures

Learning Objective

Execute complex machining operations requiring tight tolerances and surface finish specifications, program and operate CNC machines using CAM software to generate toolpaths from CAD models, fabricate sheet metal parts (an occasional rather than everyday process for this team, so it lives here rather than in Level 2), design and fabricate custom fixturing for repeatable part production, develop comprehensive process planning documentation, and coordinate manufacturing with design requirements. This level typically takes a full season and centers on a capstone project reviewed and signed off by a mentor -- this is where students move from following instructions to operating independently and making informed manufacturing tradeoffs.

Prerequisites

• Manufacturing Level 2 - Power Tools, Machining & Digital Fabrication
• CAD Level 2 - Part Design & Assembly
• Mechanical Level 2 - Mechanism Design & Analysis

Primary Resources

• Chief Delphi -- FRC/CNC Class
• Chief Delphi -- CNC Routers for FRC Robotics
• FRC Zero -- Machining & Fabrication
• NASA RAP Robotics Design Guide

Tasks

1. Advanced Machining

   • Perform complex milling operations
   • Machine precision turned components
   • Achieve specified surface finishes
   • Machine to tight tolerances (+/-0.001")

2. CNC Machining & CAM

   • Understand G-code fundamentals and how toolpaths are generated from a CAD model
   • Generate a toolpath for a part using CAM software
   • Set up and safely operate a CNC router or mill
   • Machine a part on a CNC machine from a CAD model through to a finished part

3. Sheet Metal Fabrication

   • Lay out a sheet metal part from a drawing, including bend allowances
   • Bend a sheet metal part using a brake
   • Punch or nibble a sheet metal part

4. Fixture Design

   • Design a custom fixturing system
   • Create modular fixture components
   • Implement quick-change features
   • Validate fixture repeatability

5. Process Planning

   • Create detailed operation sequences
   • Specify tooling requirements
   • Document setup procedures
   • Develop inspection protocols

6. Design Integration

   • Review designs for manufacturability
   • Suggest design improvements
   • Coordinate with the design team
   • Capstone project: independently plan, fixture, and manufacture a complex part or small assembly, reviewed and signed off by a mentor

Level 3 Completion Requirements

• Mentor-reviewed capstone project, independently planned, fixtured, and manufactured
• Successfully program and machine a part on a CNC machine from a CAD model
• Successfully fabricate a sheet metal part from a drawing
• Design and validate a custom fixture for repeatable production
• Create comprehensive process planning and inspection documentation

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