My name is Bob Arcipowski, instructor of the Precision Machining Major at South Technical High School and I believe Mastercam software has allowed me to grow and expand a notable high school machining program. I inspire and guide my students through a two-year program by helping them first to develop sound fundamental machining skills and then demonstrate how to apply those skills to real world design and manufacturing projects using Mastercam software.
Students initially study safety along with set up and operation of conventional machines such as the drill press, saw, grinder, milling machine and lathe. Once they have mastered these machines, they transition to applying their skills using Mastercam software along with CNC programming, which include set-up and operation of both a 3-axis vertical mill and a 2-axis lathe. Upon completion of the major, they have a sound foundation in manufacturing and engineering careers to build upon as they begin post-secondary education or entry-level employment.
Including state-of-the-art technology and innovative projects, it is by far, the best way to motivate my students. During their second year of training, they are led through a senior project which requires them to develop, design, and manufacture a multi-part mechanical device that showcases the skills they have acquired throughout their major. Past students have manufactured everything from off road scooters, bicycles, and chess sets to weed pulling tools and 1/10 scale machine tool models. They are required to create all of their blueprints and toolpaths using Mastercam software.
This year, two of my students, Eric Glaser and Carl "Cal" Lommel, wanted to design and manufacture a mini-bike chopper that would be powered by a lawnmower style engine. Initially, I was reluctant. A project of this magnitude would require a high level of skill and perseverance to see it all the way through to completion. I did eventually give them the green light because both Eric and Cal were very advanced students and demonstrated an outstanding work ethic.
After an overall design concept was chosen, which was based on a full size Harley Chopper, they went to Mastercam and began drawing a chopper of their own design. Cal stated that Mastercam was really helpful in the beginning design stage because it allowed us to draw, modify and redraw a scale drawing of our chopper before ever cutting a piece of metal. Eric said Mastercam was really easy to learn which helped us get a quick start on our project. A full scale blueprint based on their Mastercam work was created (with the help of our Graphics Design Major) to use as a template when mocking up their frame. Once their frame tubing was bent and coped, students in the Welding and Fabrication major tack welded the chopper frame together. A custom chopper needs a design theme to give it a unique personality and, after a lengthy brain storming session, a "machinist" theme was chosen.
The photos demonstrate how Mastercam was used extensively to design and toolpath many components of the chopper from handlebar mounts (micrometers) to the triple fork plates and front axle supports (dial calipers). Cal mentioned that he not only used Mastercam to draw and toolpath the triple fork plates, but he also was able to use the same drawing to quickly manufacture a fixture to hold the plates for a secondary setup. Cal also said he really liked how easy it was to engrave lettering on the plates in addition to importing our Precision Machining logo into Mastercam by using the Rast2Vect option. The custom rear sprocket, along with rear frame gussets, were also designed and machined using Mastercam software and CNC machines. When Cal started working on the sprocket design, he wasn't sure where to start until I showed him the Sprocket option in Mastercam which made quick work of drawing the outside tooth profile before he designed the bolt-hole pattern and pockets to match the rear rim design.
When Eric and Cal left the classroom after learning a new topic for the day, they were able to immediately apply it to a chopper part they were working on in the shop. It became very clear to me that Mastercam was an integral part of their project because most components for their chopper began as a drawing in the design stage and ended with a toolpath at the final stage. The project took most of their second year to complete and became the focal point for learning Mastercam along with the CNC portion of their curriculum.
The chopper turned out to be a work-of-art and the "Machinist" theme was fantastic because the guys were able to infuse their interest in manufacturing and machining into their designs ideas. This is one the most impressive senior projects my students have ever built, and my students could not have produced such a professional piece of mechanical design without Mastercam. When I began teaching Mastercam, I noticed student excitement about machining increased. That interest easily translated into higher level learning and student self-motivation which is the ultimate goal for all teachers. |