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CHAPTER 1
INTRODUCTION
1.1 Overview of Computer Numerical Control (CNC) Machines
CNC means Computer Numerical Control. This means a computer converts the
design into numbers which the computer uses to control the cutting and shaping of the
material.
1. The design is loaded into the computer which is attached to the CNC machine.
The computer changes the design into a special code (numerical) that controls the
way the CNC cuts and shapes the material.
2. The material to be shaped is taped on to a block with double sided tape. This must
be done carefully so that it does not come off the block during machining.
3. The block is then placed in the vice, inside the CNC. It must be tightened up
carefully. If it is not secure when the machine starts to cut the material it can come
away from the vice. When the machine starts working, the vice moves up, down,
right and left according to the design.
4. The guard is placed in position. It protects the machine operator in case the
material is pulled out of the vice by the power of the cutter. For safety reasons, if
the guard is not in position the motor will not start.
5. The CNC is turned on and the shape is cut from the material. When the cutter has
stopped the shaped material can be removed from the vice.
CHAPTER 2
CNC WORK THEORY
Computer Numerical control (CNC) is used to automate the machine tools that are
operated by precisely programmed commands encoded on a storage medium, as opposed
to controlled manually via hand wheels or levers, or mechanically automated via cams
alone.
Computers play an integral part of the control. In modern CNC system computer-aided
design (CAD) and computer-aided manufacturing (CAM) programs are used for
development and machining of the final finished product.
The series of steps needed to produce any part is highly automated and produces a part
that closely matches the original CAD design. Modern CNC mills differ little in concept
from the original model built at MIT in 1952.
Mills typically consist of a table that moves in the X and Y axes, and a tool spindle that
moves in the Z (depth).
The position of the tool is driven by motors through a series of step-down gears in order
to provide highly accurate movements, or in modern designs, direct-drive stepper motor
or servo motors.
Open-loop control works as long as the forces are kept small enough and speeds are not
too great.
On commercial metalworking machines closed loop controls are standard and required in
order to provide the accuracy, speed, and repeatability demanded.
As the controller hardware evolved, the mills themselves also evolved. One change has
been to enclose the entire mechanism in a large box as a safety measure, often with
additional safety interlocks to ensure the operator is far enough from the working piece
for safe operation.
Dept. of Mechanical Engg. SCET Belagavi. Page 3
Study Analysis on VMC/CNC Machines
Most new CNC systems built today are completely electronically controlled. CNC-like
systems are now used for any process that can be described as a series of movements and
operations.
These include laser cutting, welding, friction stir welding, ultrasonic welding, flame and
plasma cutting, bending, spinning, hole-punching, pinning, gluing, fabric cutting, sewing,
tape and fiber placement, routing, picking and placing (PnP), and sawing.
For Fanuc generally the coding is done using G codes and M codes. G codes are used for
machining operations and movement of the tools whereas M codes are used for
controlling the spindle movement like on/off, rotation in clockwise or anti-clockwise
direction and also for tool change operation.
Turning Machine
+
NC System
NC Machine
+
Computer
CNC Machine
VMC HMC
(Vertical Machining Centre) (Horizontal Machining Centre)
Coordinate system is used for getting point to point movement of tool according to
coordinates of points.
+Y
Center of Origin
-X +X
0
-Y
Origin or Center Point: - It is the point at a plane where value of both axes zero.
Types of Coordinates: -
I. Absolute Coordinate: The value of any point will be taken with respect to center
point.
II. Incremental Coordinate: The value of any point will be taken with respect to
previous point.
CHAPTER 3
MACHINERY AND EQUIPMENTS
VMC machines were developed for higher precision and high speed over TMC
machines. It has moving table for easy access. The main difference between TMC and
VMC is tool holder (Headstock) is rotating and job which clamped on pallet (table)
moves in X-Y directions. Many operations like facing, turning, milling, profile cutting,
boring, drilling can be done easily with the help of VMC.
Mainly machine has three axis to move job and vertical column X-Y-Z. Usually pallet
can only move in X-Y direction and vertical column can move in Z- direction. In addition
to this 3 axis two more axis are available mainly for rotation and tilting action for easy
machining of even complex profiles.
VMC has ATC (Automatic Tool Changer) controlled by three servo motors to
automatically change the tool during machining process according to the requirement.
Vertical spindle can rotate up to 15000 rpm. Maximum torque that is available in any axis
is 700 Nm.
For fast work both two and six pallet VMC is also available which has APC
(automatic pallet changer) in which after completion of one operation in one job, pallet is
automatically rotated and another pallet is positioned for machining operation.
VMC can hold up to 120 tools in the tool post. All movements of pallet and vertical
column are through bolt screw. For less friction movement of saddle and pallet over
Linear Motion Guide ways (LM) either pneumatic or hydraulic system is used. The whole
VMC machine is operated by mainly Siemens and Fanuc controllers.
Job has to be cooled down while operation is being done on it due to friction between tool
and job. Cooling system of job is also installed along with vertical column. Generally,
1000 liters coolant tank is used.
Usually cooling fluid is mixture of water and cutting oil of job. Scrap cleaning system is
also installed in VMC so that accumulated scrap or chips can easily be drained by flow of
fluid.
The BMV51 series vertical machining center Vayu is fast, powerful, stable, and
accurate. Vayu superbly integrates in a line, but also serves excellently as a standalone
machine. The machine contours ensure smooth rear chip disposal. Vayu is ideal for
machining ferrous and non-ferrous components for a variety of applications.
Structure
The complete structure is made out of graded casting and heat treated for consistent
accuracy for long time. Broad rigid base with heavy cross ribs dampens the effect of
vibrations. The twin layer heavy column structure helps in balancing the whole machine
while taking high cutting load. Table of the machine is made of modular casting with the
addition of special alloys for consistent accuracy over a long time of period.
Advanced design with reinforced body structure through FEM analysis, the BMV 51
offers high cutting rigidity and low vibration to meet die and mold machining application.
3-Point Leveling
With the 3 Point support system, the machines can be quickly installed and relocated
easily. These machines can also be moved easily and do not require any kind of leveling
maintenance
Nurbs - Yes -
Spline interpolation - Yes (option) -
Ethernet facility Yes Yes Yes
Data server Optional - -
Remote diagnosis Standard Yes (option) -
Table 3.2: Machine Features
CHAPTER 4
INSTALLATION AND PREPARATION
4.1 Installation Precautions & Procedure
1. Only trained, qualified, qualified workers should operate forklift trucks, cranes or
similar equipment and apply slings.
2. Use only wires of dimensions specified in the manual. They must be strong enough to
support machine weights.
3. Before hoisting the machine, fixed each unit securely
4. Maintain a clean and orderly surrounding around the machine.
5. "POWER ON" on the control panel can be pressed only after the complete installation.
6. Be sure electrical cables and wires are not damaged during installation.
7. After installation, proper capacity should be checked before connection the wire to the
power source.
NOTE: Excessive oil and water in the air supply will cause the machine to malfunction.
The air filter regulator has an automatic drain function that should be empty in the bowl
before starting the machine. This must be checked daily for proper operation daily. Also,
excessive contaminants in the air line may clog the dump valve and cause air or water to
pass into the machine.
The air pressure-detecting switch installed in the system is factory-set to assure the proper
"signal". The drop of air supply to the solenoid control valves will cause improper
functioning of the pneumatic actuators. Do not tamper with this switch.
1. Avoid expose the machines to direct sunlight and/or near to a heat source, etc. Ambient
temperature during operation should be 0 through 40°C
2. Avoid installing machines in a location where the humidity fluctuates considerably and/or
highly humid.
3. Avoid installing machines in a dusty, misty location.
4. Install machines where no vibration source in surroundings is.
5. Install machines in a flat and smooth ground without or other particles. The minimum
bearing pressure of the floor is 5000 kg/m2.
6. The machine must be protected from electrical noise sources, such as electric welders and
an electric discharge machine.
7. Always ground machine independently. The ground resistance is should be 100 ohms or
less and the length of ground cable should be as short as possible.
8. The noise level at the operator's position should be under 85 dbA.
9. Foundation should be constructed of either reinforced or non-reinforced concrete with
thickness and consistency and should also be compatible to industry standard for its
machine weight.
CHAPTER 5
CNC PROGRAMMING
This milling machine has three (3) linear axes defined as X axis, Y axis, and Z axis. The
X and Y axis will move the machine table below and around the spindles centerline,
while the Z axis moves the tool spindle down toward or up and away from the machine
table. The machine zero position is where the spindle is pointing down at the upper right
corner, with the machine table all the way to the left in X axis and all the way toward you
in the Y axis and Z axis is up at the tool change position. Motion in the X axis will move
the machine table to the left with negative values and to the right with positive values.
Motion in the Z axis will move the tool toward the machine table with negative values
and away from the machine table with positive values.
Programs must begin and end with a % sign. The % signs are automatically entered in for
you, if you enter the program in on a HAAS control. A program may also contain a “ / “
symbol. The “ / “ symbol, sometimes called a slash, is used to define an optional block. If
a block contains this symbol, any information that follows the slash in a program block,
will be ignored when the BLOCK DELETE button is selected when running a program.
There is no positional requirement for the address codes. They may be placed in any order
within the block. The following page is a sample program as it would appear on the
control screen. The words following the “:” are not part of the actual program but are put
there as further explanation.
This program will drill four holes and mill a two-inch hole in a four-inch square plate
with X and Y zero at the center. The program with comment statements would appear like
this.
T1 M06 (½ IN. DIA. STUB Tool change to tool #1, (notes to operator)
DRILL)
G90 G54 G00 X-1.5 Y1.5 S1400 Abs posit, work offset#, rapid x y, spindle on cw
M03
G43 H01 Z1. M08 Tool length comp #1, z position, coolant on
G73 G99 Z-0.625 Q0.2R0.1 F5. High speed peck drilling, drill z-.625 deep, .2
peck
G80 G00 Z1. M09 Cancel canned cycle, rapid z1. Coolant Off
T2 M06 (5/8 DIA. 90 DEG. Tool change to tool #2, (notes to operator)
C'SINK)
G90 G54 G00 X-1.5 Y1.5 S900 Abs posit, work offset#, rapid to posit, spindle on cw
M03
G43 H02 Z1. M08 Tool length comp #2, z position, coolant on
G82 G99 Z-0.27 P0.5 R0.1 F12. Spot drill cycle to z-.27 deep, dwell .5 second
G80 G00 Z1. M09 Cancel canned cycle, rapid z1., coolant off
G90 G54 G00 X-2.3 Y2.3 S1100 Abs posit, work offset#, rapid to posit, spindle on cw
M03
G43 H03 Z0.1 M08 Tool length comp #3, z position, coolant on
X2.0 Cut a 2.0 in. Square cw with tool dia. Comp d03
Y-2.0
X-2.0
Y2.25
G40 X-2.3 Y2.3 G40 cancels comp while positioning away from part
To change tools, all that is needed is an M06 even without a G28 in the previous line. A
G28 can be specified to send all axes to machine home, or it can be defined to send a
specific axis home with G28 G91 Z0 and/or Y0 and/or X0 to send just these axis
specified to home position.
All M codes are activated or cause an action to occur at the end of a block, and only one
M code is allowed per block in a program.
1. G Codes come in groups. Each group will have a specific group number.
2. A G code from the same group can be replaced by another code in the same group. By
doing this the programmer establishes modes of operation. The universal rule here is,
codes from the same group cannot be used more than once on the same line.
3. There are modal G codes which, once established, remain effective until replaced with
another code from the same group.
4. There are non-modal G codes (Group 00) which, once called, are effective only in that
block they are in, and then, do not affect any other blocks.
The rules above govern the use of all codes for programming the Haas (and other)
controls. The concept of grouping codes and rules that apply will have to be remembered
if we are to effectively program the machine tool.
The following is a summary of the G codes. A “ * “ indicates the default within each
group, if there is one:
Each G code defined in this control is part of a group of G codes. The Group 0 codes are
non-modal; that is, they specify a function applicable to that block only and do not affect
other blocks. The other groups are modal and the specification of one code in the group
cancels the previous code applicable from that group. A modal G code applies to all
subsequent blocks so those blocks do not need to re-specify the same G code.
There is also one case where the Group 01 G codes will cancel the Group 9 (canned
cycles) codes. If a canned cycle is active (G73 through G89), the use of G00 or G01 will
cancel the canned cycle.
CHAPTER 6
OPERATOR CONTROL PANEL
6.1 Operating Panel Keys
3 CNC OFF Red P.B. Used for making CNC M/C OFF
10 Tail stock Rev/Forw. Foot switch Reverse & forward moment of tail
stock
16 Feed over ride switch S.S. Axis feed over ride from 0 TO
120%.
17 X1 S.P.B.
X1000 S.P.B.
20 M/c lock
22 Opt. stop
23 Block delete
CHAPTER 7
7.1 DELCAM
a. Delcam Feature CAM for milling machines, turning and turn/mill Centre’s, and wire
EDMs.
b. Delcam Power MILL for 2.5D to MultiAxis CAM.
Feature CAM deals a complete solution for milling, turning, turn/mill and wire
EDM. All of your machine tools can be programmed within a single user interface
designed to shorten programming times and reduce the learning curve for new users.
7.1.2 POWERMILL
PowerMILL will quickly create gouge free cutter paths on imported component
data. It supports Wireframe, Triangle, Surface and Solid models created by other Delcam
products or from neutral formats such as IGES.
7.2 MASTERCAM
Mastercam is the most widely used CAM software worldwide* and remains the
program of choice among CNC programmers. Mastercam Mill-Turn (MT) makes
machining on today's turning center and machining centers simpler and easier than ever.
Mastercam gives your shop the best possible foundation for fast and efficient multi-
tasking. It streamlines the programming process of complex machines with intelligent job
setups that are keyed to the exact machine in your shop. Mastercam ensures that you're
ready for any job. Mastercam delivers:
CIMdata, Inc. has reported for the 23rd year in a row that Mastercam is the most
widely used NC software package in the world! Mastercam has been delivering cutting-
edge CAD/CAM software for over 30 years, and is backed by the kind of worldwide
support and service that only the industry leader can provide.
CHAPTER 8
CONCLUSION
The advantage of a CNC system are that the operation of a conventional machine
is removed and the part production is made Automatic.
It reduces the labor work and hence highly efficient n the manufacturing process.
CNC machines have their wide scope because they are easy to handle, the work
becomes easier and jobs are done with perfection using the NC simulation
software.
REFERENCES