Project-Based Learning: Finite Element Analysis of CNC Tooling Surfaces

This study will focus on the analysis of various loading conditions to stress distributions and strain characteristics within the structural components of a pallet load station for a MAG3.EX 5-axis horizontal machining center, which is used to manufacture aerospace parts.Lean Six Sigma methodologies, metrology data, and the implementation of a failure modes and effects analysis in this research were utilized to examine the loading process of the machine for potential design failures and the consequences it may have on machining accuracy.The results point to design defects in the Pallet Work Set Station (WSS), which become physical phenomena when introduced to the highly accurate and robust MAG3.EX machine.The WSS succumbed to high stress concentrations and part deflections after being loaded onto a flat machining bed.The primary points of failure were identified as improper support of the machining bed and inadequate fixation to the support system.The findings of this study emphasize the need for improvement in system design specifications and wholistic maintenance practices in the aerospace manufacturing industry.These may take the form of regular metrology recordings, focused inspections on the tooling surface status, and increased mechanical support underneath the machining platform.This research recommends manufacturers to focus on additional system specifications and proactive maintenance that will help improve machine accuracy and reduce part defects.The researchers believe this study can serve as an important teaching tool for future engineers, showing them how to solve real-world problems by using a combination of theory and practical skills.The analytical processes used in this study and taught in engineering education institutions exposes the design shortcomings and incomplete standard in place at aerospace-grade manufacturing facilities pertaining to both equipment and processes.This research looks for higher standards, more demands, and additional regulations to improve the required safety and reliability of aerospace manufacturing equipment.Following the research presented in this paper will reduce defects, increase profitability, and streamline production in aerospace-grade manufacturing facilities.