Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
1. Machine tools
2. Introduction to CNC and CAM
3. NC axes on machine tools
4. Machine and CNC coorporation
5. The structure of NC programs
6. Example of NC program for thread milling
7. Cutting conditions
8. Milling strategies – entrance strategies
9. Milling strategies – examples of technological strategies
10. Milling strategies – examples of geometrical strategies
11. Some thoughts on 5-axis milling strategies
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of the copyright owner.
Tailstock
Spindle
Motor
Milling cutter
Control system
Coolant supply
Machine table
Chip conveyor
Manual control
Frame
Conventional machine
The movements of the tool are controlled by
an operator. Complex workpieces are
difficult to produce.
CNC machine
The movements of the tool are controlled by
computer, programmed by an operator.
Complex workpieces are easy to produce.
Elements of NC system
Part program
Machine control unit (MCU)
The machine tool
Tail stock
Chip conveyor
Lathe bed
Chip conveyor
Tool slides
Tool slides
Table slides
Cover
Tool storage and
automatic changer
Machine
table
NC command
CAM
Links CAD to CNC
PS. CAM terminology is
very supplier dependant.
coordinate system.
Tool
reference
point
Z length
Point-to-point programming
Line programming
Curve programming
Workpiece
A point-to-point system moves the tool from one position to another and
disregards the path along the way. Each axis of motion is controlled
independently so that the path steps from the start position to the next
position as shown in the picture. The path is not unique as some point-to-
point systems first satisfy the X command and then the Y, while others
reverse the order. Because the traverse path is not controlled, point to
point systems are primarily used in applications for positioning, e.g. drilling.
NURBS interpolation
Linear interpolation uses straight line
segments to approximate the path of a
curve. NURBS interpolation uses curved
line segments instead. In this way, NURBS
interpolation reduces the number of
program blocks needed for precision
milling of a complex form.
Finsihing
Semi finishing
500 Roughing
400
300
200
100
Correct RPM
Chip thickness? Table feed
Machine accuracy
Deviations in perpendicularity of the machine spindle.
Deviations in straightness.
Thermal influences.
Deviations due to weight and cutting forces.
Peaks due to collision/friction of protective covers.
Elastic deformation.
Incorrect parameter settings.
X
Profile of workpiece Milling path
50 12000
49.999
10000
49.998
49.997
8000
49.996
49.995 6000
49.994
4000
49.993
49.992
2000
49.991
49.99 0
100 1000 2500 5000 10000 0.5 0.2 0.1 0.05 0.02 0.01 0.005 0.001 0.0005 0.0001
Accurate movements?
Stability
1. Normal stable vibration. There is no
variation in the chip thickness, the vibration
does not automatically strengthen and will
not increase.
RPM
Line number
Preparatory function
End point coordinates
Technological information
Machine function
What is G-Code?
• G-Code programming is a very robust and simple language. G-codes are what
CNC machines run on. A CNC control program process the G-code line by line
and send this information to the machine. The machine then takes this
information and makes precise movements.
Where does G-Code come from?
• It comes from the CAM program. When the design is processed in the CAM
program, various machining parameters and inputs are matched with the CNC
machine the workpiece will be run on and then post-processed. The CAM
program then spits out very precise G-codes for the machine and the workpiece.
Post Processors
• A post processor is a specific way the CAM program will process the design.
There are standard ones and custom ones. If a standard one doesn’t work for,
most good CAM software gives the option to customize the post processor to fit
specific needs.
G0 or G00 – Rapid traverse. The most rapid movement the CNC machine
can make to the next position. If moving in multiple axes, each axis will
move as fast as they can independently of one another.
G1 or G01 – Linear interpolation. A straight move with a speed defined by
an “F” (F=Feed) If moving in multiple axis, the machine will move in each
axis until it reaches its defined position.
G2 or G02 – Circular interpolation Clockwise. A circular movement in 2-axis
in a clockwise motion. Will create an arc to a specified radius defined by an
R or I/J/K combination.
G2 or G03 - Circular interpolation Counter Clockwise. A circular movement
in 2-axis in a counter-clockwise motion. Will create an arc to a specified
radius defined by an R or I/J/K combination.
G4 or G04 – Dwell. Machine will dwell once reached position to a user
defined time, noted by a “P”.
G5 or G05 – Spline definition/interpolation.
G0 or G00 – Rapid traverse. The most rapid movement the CNC machine
can make to the next position. If moving in multiple axes, each axis will
move as fast as they can independently of one another.
Be careful with how the machine reacts to this.
10 20 30 40 50 60 70 80 90
G0 or G00 – Rapid traverse. The most rapid movement the CNC machine
can make to the next position. If moving in multiple axis, each axis will
move as fast as they can independently of one another.
G1 or G01 – Linear interpolation. A straight move with a speed defined by
an “F” (F=Feed) If moving in multiple axis, the machine will move in each
axis until it reaches its defined position.
Copyright © Seco Tools AB 54
G2/G3 – circular interpolation
P0
R N60
N50 G5 G41 P1
rf + rp
FK = Fp
rp FK
rf Fp
rp
rK
P0
R N60
N50 G41 P1
Intermediate movements
Y
90
N30
With function G60 is active, only when
80 3 4 exact position of the sentence is
70 N40 achieved, the following sentence
60 N20 5 movement starts.
50 N50 6
40 With function G64 is active, the machine
30 2 does not stop at the end of the sentence
20 1 N10 movement, but is continuously moving
10 X to the next position.
10 20 30 40 50 60 70 80 90
The G70 and G71 commands set the measuring system for
inch or metric conditions.
G70 and G71 commands remain stored.
Absolute coordinates
Y
90 G90
80 3 4 1 X = 20 Y = 20
70
2 X = 30 Y = 30
60 5
3 X = 30 Y = 80
50 6
40 4 X = 60 Y = 80
30 2 5 X = 60 Y = 60
20 1 6 X = 70 Y = 50
10 X
10 20 30 40 50 60 70 80 90
Incremental coordinates
Y
90 G91
80 3 4 1 X = 20 Y = 20
70
2 X = 10 Y = 10
60 5
3 X = 0 Y = 50
50 6
40 4 X = 30 Y = 0
30 2 5 X = 0 Y = –20
20 1 6 X = 10 Y = –10
10 X
10 20 30 40 50 60 70 80 90
X Z
5
Y
X Z
N370 G0 Z-17.5
X Z
G1 = linear movement
G5 = Enables tangential entry strategy
G11 = Correction of the feed for circular movement
G64 = Enables continuous movement
X-66.05 = Linear movement in X
Y0 =Keeps the Y axis at the current position
F55 = Set feed to 55 mm/min
66.05
X Z
19
Y
66.05
X Z
G1 = linear interpolation
G5 = Enables tangential entry strategy
G11 = Active correction of the feed circular motion
X-64 X = linear movement to the center of the hole
Y0 = Y Maintain the current position
F165 = Adjust the feed to 165 mm/min
X Z
N410 G0 G60 Z5
N410 G0 G60 Z5
5
Y
X Z
D = Diameter (mm)
n = rpm
n ×π × D
vc = = [m / min]
1000
f = feed (mm/rev)
Copyright © Seco Tools AB 85
Introduction
v f = n × Zc × f z = [mm / min]
Zc = Effective number of teeth
Vc = Cutting speed (m/min)
f = Zc × f z = [mm / rev]
N = rpm
Ap = Axial depth of cut (mm)
Ae = Radial depth of cut (mm)
Fz = Feed per tooth (mm/tooth) n = rpm:
v × 1000
n= c = [rpm]
F = Feed per revolution (mm/rev)
Vf = Feed speed (mm/min) π × Dc
n × π × Dc
vc = = [m / min]
1000
Feed
Feed
ae
ae ae
D1
D D D1
D0 D0
Entrance strategy
Geometrical strategy:
linear and non-linear
complex (circular, helical,
trochoidal, …)
radial and axial
…
Technological strategy:
hard cutting
high speed cutting
high feed cutting
high RPM cutting
high performance cutting
…
Feed
Depth of cut
ALU HSM
STEEL HSM
TiAl6V HSM
Temperature
Critical temperature
Temperature
Contact time
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
46 – 55 HRc 0.05D
56 – 62 HRc 0.01D
63 – 70 HRc 0.005D
Peel milling
Small radial cutting depth.
Large axial cutting depth.
High cutting speed.
Geometry of cutter important.
Eliminates semi finishing.
Trochoidal milling
Combination technology and
geometry.
Based on “small arc of
engagement”.
Small radial cutting depth.
The axial cutting depth and
cutting speed can be increased.
Trochoidal milling
The roughing cycle with the classic
methods.
Trochoidal milling only when there
is risk of cutter jamming (big radial
depth of cut).
Avoid milling with the full cutter,
so that higher feed can be used.
Raceline milling
The tool path is smoothed to
minimise sudden changes in feed
direction, this allows higher feeds
and gives longer tool life (less
breakage).
Plunge milling
Method for larger overhang and weaker machines.
Medium cutting speed.
Good method for difficult materials such as Inconel.
Roughing method which increases productivity.
Thin walls
External roughing Helical milling Internal roughing
Thin walls
Thin buttoms
Steep walls
Correct RPM
Ø cutter
Ø effective
• 13
Copyright © Seco Tools AB
1
Ball nose cutter
Shank inclination
n : 12000 t/min
Vf : 2500 mm/min
ae = ap : 0.3 mm Coated micrograin
• 13
Copyright © Seco Tools AB
2
Ball nose cutter
Shank inclination
n : 12000 t/min
Vf : 2500 mm/min
ae = ap : 0.3 mm
PCBN insert
Tool life : 50
• 13
Copyright © Seco Tools AB
3
Ball nose cutter
Shank inclination
n : 12000 t/min
Vf : 2500 mm/min
ae = ap : 0.3 mm
CBN insert
• 13
Copyright © Seco Tools AB
4
Cutter with round inserts
• 13
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5
Cutter with round inserts
Price of Price of
tool inserts Performance Programming
Ball nose
Round
insert
• 13
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6
Cutter with round inserts
• 13
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7
Cutter with round inserts
Plunge milling
• 13
Copyright © Seco Tools AB
8
Cutter with round inserts
Drive a primary curve only or primary and secondary curve where cuts
are trimmed at the intersection of the secondary curve.
Walk the cutter into or away from the flow curve.
High speed machining possible for transition smoothing and precision
finishing.
One-way or zig-zag machining.
Copyright © Seco Tools AB 150
Radial machining
A
X
Z Z
C
A B
x y x
y
3-axis machining 5-axis machining
Applications
Structural elements
• Engines
• Turbine blades
Mould and die industry
Automotive industry
Marine industry
Medical industry
Z
A
C
X
Y
A
Y
X Z
B
Z
X Y
Automatic indexing
Automated 3+2 milling offers an alternative if the machine does not
fulfil the dynamic requirements for 5-axis simultaneous milling. Large
areas that require various tool angles are programmed and milled in a
single operation. Automatic indexing scans for fixed tool inclinations
for the corresponding tool paths. If there are possible holder
collisions, the respective path segment can be subdivided into smaller
segments with the corresponding tool positions.
Simultaneous 5-Axis
Both rotary and linear axes move
during cutting
Rotary axes must support continuous
movement
Tool axis can vary during a movement
Generally, HSM is not possible because
rotary axes are slow
Simultaneous 5-Axis
Simultaneous 5-Axis
Simultaneous 5-Axis
Simultaneous 5-Axis
Positional 5-Axis
Positional 5-Axis
Positional 5-Axis
5-axis machining
→ Short tool life
Small 2) Tool center cutting
pitch Ball end
mill
3-axis
machining
5-axis
machining
Multi-surface machining
3-axis with single chucking
machining
5-axis machining
Contour
machining
Simultaneous 5-axis
machining
5-axis technology
5-axis strategies:
• Through a line
• Through a point
• Profiling
• Trimming
• Swarf
Automatic calculation of optimum lead
and lag
Collision checking on tool paths
Visualization
Support for full range of cutting tools
Through a point
The tool is aligned so that the axis passes through a specified point
with the cutting end pointing away from the point
Through a point
Keep tool short
Better surface finish
Longer tool life
Shorter cycle time
Through a line
The tool is aligned so
that the axis passes
through a specified line
with the cutting end
pointing towards the line.
Swarf machining
Tool path generation from surfaces
From wireframe and using all tool
types including tapered tools
Swarf machining
Improved results over surface swarf
Where surfaces are not truly
developable
Where internal surface structure is poor
Where edge matching is not perfect
Through a curve
Tool is controlled by a single curve
Ensures full control over tool path
movement
Eliminate potential machine tool
collisions
Improve surface finish by having
more control over machine tool
kinematics
Collision avoidance
Simulation
Tool paths in different colors gives
clearer understanding of machining
process
Color changes for axis reversal and
possible dwell marks
Virtual visualization
Takes into account cutter geometry and feeds and speeds to allow
approximate visualization of the part before machining has taken place.
Roughing
Work in 3 axis. Release an axis when a problem of accessibility occurs.
Advantages: good dynamics and good machine stability.
Rest roughing
Same strategy as the 3 axis with possibility of tool tilting.
Finishing
Work in 4 axis with the 5th axis clamped according to an angle. Release the
5th axis to avoid collisions.
Advantages: the tool is always in contact with the workpiece. Continuous
machining resulting in an excellent surface finish.