Technology II.

Ing. Jan Tomek

CNC machines
Tool is moving in
coordinate system.
Tool position is then
defined by
coordinates.

When moving in
space we recognize
coordinates X,Y,Z or
X,Z
Shape generation
With CNC control we can program
complex toolpath
Simple tool complex path (compare with
mass production)

Video comparation of
tools
Turning
Turning
2 axes X,Z
3 axes X,Z,C + powered tools
4 axes X,Z,Y,C + powered tools
 QUICK TURN NEXUS 100-II

QUICK TURN NEXUS 400-II-MY

Controlled axes
Drilling
2D
Milling
2D; 2,5D
3D
4D rotary milling
5D multiaxis milling
Multiaxis machines
5 axis necessary
Aditional are for
Second turret
Sub-spindle
Pallete changer etc.
Programming of machines
Machining on CNC machines is controled by
a NC code.

NC code is a list of instructions for the

machine and also for the operator. Instruction
are executed in time order.

NC code must have a specific format so that

the control system of machine is able to read
it.
NC code example
NC code form
Structure and form of NC code is
standardized by international standard -
ISO 6983 Numeric control programs
formating

Differences between different control

system manufacturers and differences
between versions.
NC code structure
Lines (blocks)
Words
Word has a meaning and value part
S 1500
ISO nc code and the others
ISO is standardized code (G code)
Some manufacturers devoloped their own
standard for NC code native standard

Mazak Mazatrol
Heidenhein iTNC
Siemens - Sinumeric
NC code structure II.
Heading lines
Definition of relation between coordinate
system of CNC machine and program, type
of programing, work mode, working
conditions
Program body
Cutting and non-cuting moves, main program
and subprograms, tool changes
Ending lines
Tool return to home point, change to first tool,
coordinates reconstruction
Coordinate systems
Ways how to define a movement
a) Absolute programing position is in all
point expressed as a distance from
zero-point
b) Incremental programing position is
expressed as a change from last
postion
 2. 3.

1.

Absolut Incremental
G90 X0 Y0 Z50 G91
G0 X15 Y70 Z0
2. G0 X15 Y70 Z50
G1 X15 Y70 Z0 G1 X0 Y0 Z-50
G1 X25 Y0 Z0
3. G1 X25 Y70 Z0 G1 X0 Y0 Z50
G0 X25 Y70 Z50 G1 X-45 Y-70 Z0
1. G0 X0 Y0 Z50
Ways of programing
Manual programing
Shopfloor programming
Automated programing
Manual programing
Editors are used. Program is written
manually (by hand) line after line.
Used for simple parts (but complex too)
Toolpath is exactly
defined
Program can be adjusted
to save time
Can use canned cyles
Can be parametrized
Used in mass production
Manual programing
We need to know the functions: (many more function exist)

Movement functions:
G00 rapid movement
G01 linear interpolation/movement
G02/03 circular interpolation

G40 diameter compensation off

G41 diameter compensation on /right handed
G42 diameter compensation on /left handed

Support and help functions:

M06 tool change
M03/04 spindle start CW/CCW
M05 program stop
M30 program end
Manual programming

Specilzed editors
Predator G-code editor

G Wizard

Mikronex
show
 Shopfloor programing
Somewhere in between manual and automated
Uses cycles with parameters
We have to edit these
parameters manually
But the NC code
is generated
automatically
No postprocessing
Shopfloor programming
Control system use programming on
machine
- No costs (together with machine)
- Fast use (macros)
- Time waste (program x work)
- Comfort (on machine x in office with PC)
- Shape limitations

Heidenhein
show
Automated programming
Work with the sequential NC code
preparation
Uses CAM (Computer Aided
Manufacturing) software
For all parts including complex shapes
We dont need to compute the toolpath
We need correct postprocessor
 Sequential NC code preparation

Partprogram workpiece, Partprogram

material, cutting conditions,
tools
Procesor
Procesor according to
technology
CL data virtual toolpaths on CL-data
virtual machine
Postprocesor translator for
the specific CAM-control Postprocesor
systm-machine
combination
NC code toolpaths of a real NC-kd
tool on a real machine
CAM software
is Computer Aided Manufacturing (machining)

From simple 2-axis turning up to multiaxis

machining
Feature or technologically oriented
Special types of CAM for special purpose

Live presentation
xD software
2D just in two axis - turning
2,5D two axis, but in layers not
simultaneously
3D three axes simultaneously
multiaxis
4D four axis - one rotary axis (rotary
table)
5D five axis - maching (two rotary axes)
4Axis
xD software
2D just in two axis - turning
2,5D two axis, but in layers not
simultaneously
3D three axes simultaneously
multiaxis
4D four axis - one rotary axis (rotary
table)
5D five axis - maching (two rotary axes)
5D milling

http://youtu.be/Fjzhygzafr0
Tool movement programming
CAM software uses Strategies
Strategy is a general plan how to move
the tool durign machining

Continual development
Roughing offset, raster (Zig-Zag method)
plunging
Finishing strategies pencil milling,
streaming, rest material maching
Sequential NC code preparation

Partprogram workpiece, Partprogram

material, cutting conditions,
tools Procesor
Procesor according to
technology
CL data virtual toolpaths on CL-data
virtual machine
Postprocesor translator for
the specific CAM-control Postprocesor
systm-machine combination
NC code toolpaths of a real
tool on a real machine NC-code
Partprogram
Consist from:
- Geometrical part
- model(s) for machining, blank(s), jigs and
fixtures, tools and machines and other
geometrical parts
- Coordinate system and its position
- Start points, reference points, safety
clearance plane, transfer planes.

32
Partprogram
Consist from:
- Technological part
- Tool properties
- Operation steps
- Machining strategy
- Cutting and technological conditions
- Approach and retract moves, trasfer moves
of the tool
- Usage of special machine parts

33
CAM software developers
NX (Siemens PLM software) Catia
(Dassault systmes) both 10%
market share
PowerMill, FeatureCAM, ArtCAM
(Delcam company) ,InventorCAM
(Autodesk) Wildfire Pro/Ingineer
(PTC) 5%
EdgeCAM, SurfCAM, SolidCAM,
MasterCAM, OneCNC, ESPRIT,
GibbsCAM
Simulaton and verification
Simulation is used to
control generated
toolpaths for following
reasons:
- Colisions
- Undercuts (or rest
material)
- Postprocesing
check
Verification

NX show
Automated programing - review
We can do complex shapes, no need to
calculate control points
We can use simulation and verification
We can change the tool easily
But
We need postprocessor
Expensive
Program is always longer (again
expensive)