computer aided manufacturing project

AMME5902

GROUP PROJECT This Assignment is worth 30% of your Assessment for AMME5902

The group project for AMME5902 is a combination of the effort of all of your group members. The Group Project is a group submission and must read as such. Careful editing and integrating of the various results from the various group members must be presented in a coherent manner with ample discussion.

The chief aim of the project is to arrive at comprehensive answers to the eight questions noted below. The report must include an introduction, contents page, all graphics, Excel spreadsheets, discussion, references and conclusions deemed necessary to convince management that you have a good understanding of the problem (or opportunity !) at hand.

1. Which of the three machines noted overleaf would you recommend using if your company needed 1000 gearboxes at the lowest possible price?

2. Which of the three machines noted overleaf would you recommend using if your company needed 1000 gearboxes in the shortest possible time frame?

3. If you combine the use of two machines (group’s choice of which two are used), how does this affect your group’s answer to the first two questions?

4. Production is scheduled to start on Monday the 6th of November 2017. What is the first week day

(Monday to Friday) that the 1000 gearboxes will be ready? (consider any public holidays) You may work Saturdays but at a 50% overtime penalty. You may not work on Sundays.

5. How many labour people (not admin.) do you need to produce the 1000 gearboxes by the cheapest

and by the quickest method? (Do not cross skills where labour costs are different).

6. If all your machinery is purchased new, what is your machinery worth at the end of the project?

7. Which method (i.e. cheapest or quickest) would you prefer to use in your factory and why? (Please discuss this point in great detail).

8. What would be the sale cost of one gearbox when you need to include a 125% profit?

Assumptions:

• Use the tool library from the standard Mori Seiki NV4000 setup to select your tools. • The stock pieces are made from Aluminium and are sized as per the blank sizes provided. • A “pallet” can hold 4 stock blanks at a time. • All machine cuts are done in one pass. • Plunge cuts are made at 2/3 of the feed rates that traversing cuts are made. • Rapid Traverse (G00) moves the tool at 6000mm/min for the Mori Seki, 2000mm/min for the

Cincinatti Milacron and 1200mm/min for the TMCMill. HINT: In CIMCO use the NC Functions Tab > Toolpath statistics

THIS ASSIGNMENT SHOULD TAKE THE AVERAGE GROUP APPROXIMATELY 20-25

HOURS TO COMPLETE The report is due no later than 11:00pm on Friday the 3rd of November 2017 (Week 13) the report must be submitted via Turnitin.

Parameter Value Comment Time Cost (ex GST) Machine A Cincinatti Milacron -$75,000.00 Min Motor Capacity 1.5 kW In X,Y & Z Max Spindle Speed 3,5000 RPM Max Feed Rate (Alum.) 390 mm/min In X,Y & Z Machine Charge Out -$120.00/hr Operator Charge Out -$130.00/hr Auto Pallet Changer 3.0 mins Machine B TMC Mill -$50,000.00 Min Motor Capacity 0.85 kW In X,Y & Z Max Spindle Speed 4,500 RPM Max Feed Rate (Alum.) 75 mm/min In X,Y & Z Machine Charge Out -$75.00/hr Operator Charge Out -$85.00/hr Manual Pallet Changer 40 mins Machine C Mori Seiki -$355,000.00 Min Motor Capacity 1.6 kW x 2 In X and Y Min Motor Capacity 3.0 kW x 1 In Z Max Spindle Speed 12,000 RPM Max Feed Rate (Alum.) 700 mm/min In X,Y & Z Machine Charge Out -$185.00/hr Operator Charge Out -$155.00/hr Auto Pallet Changer 1.95 min Hardware Aluminium (6061/64) -$42,000.00/m3 Silicon Sealer Require

20ml/gearbox Silicon Sealer 6 hours to set -$55.00/lt

Screws, Nuts, Washers Metric 5mm Dia. -$0.05/each Bearings with Seals Metric 16mm Dia. -$22.95/bearing and seal ADMINISTRATION Infrastructure costs 37.5 hrs / week Rent+Plant

Maint. etc. 37.5hrs / week -$7,500.00/week

Administration costs 37.5 hrs / week Labour 37.5hrs / week -$6,500.00/week Overtime Labour -50%/hr (up to 2hrs) Overtime Labour -75%/hr (2-4hrs) Depreciation All machines Simple -30%/year Federal Incentive Start up grant (once only) +$100,000.00 Utilities Elect, Water -$500.00 / week

AMME 5902

Project Feedback Sheet 2017

1. Which machine would you recommend to produce 1000 gearboxes at the lowest price? 0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 2. Which machines would you recommend to produce 1000 gearboxes in the shortest time frame?

0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 3. How does combining two machines affect the lowest price and time frame factors?

0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 4. When is the first week day that the 1000 gearboxes will be ready?

0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 5. How many labour people do you need to produce 1000 gearboxes by cheapest and quickest?

0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 6. If all machinery is purchased new, what is the machinery worth at the end of the project?

0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 7. Which method would you prefer to use in your factory and why?

0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 8. What would be the sale cost of one gearbox when you need to include a 125% profit?

0 no attempt, 2 for result with little or no analysis or discussion, 4 for result, analysis and discussion.

/4 9. Clear presentation on handwritten or printed A4 pages.

0 a messy submission which lacks content, 2 an average submission that is easily read, but lacks content, 4 a very good

submission that is very clear and provides comments which show insight into the various problems. /4 10. Conclusions / recommendations on costs to machine your component? Discuss how costs could be reduced in each of the sections plus references in APA6th or Harvard.

0 no attempt, 2 for weak attempt, 4 for good discussion with conclusions, recommendations and references.

/4

TOTAL /40 TOTAL /30

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