ISSN 1068-798X, Russian Engineering Research, 2009, Vol. 29, No. 8, pp. 841–847. © Allerton Press, Inc., 2009.

Original Russian Text © E.V. Kurnasov, 2009, published in STIN, 2009, No. 5, pp. 23–29.

Design of Housing Components in NCCAD System

E. V. Kurnasov
Moscow State University of Instrument Engineering and Information Sciences
DOI: 10.3103/S1068798X09080218

The great popularity of CAD/CAM/CNC systems in The development of a three-dimensional model of

designing numerically controlled systems has not arisen
by chance. In fact, the rapid development of integrated
CAD systems and systems for production control has
greatly influenced the design principles of numerically
controlled systems. The basic approach currently is the
integrated design and manufacture of parts.
In addition, in the design of machine parts, the
designer and technologist consider the part differently
and use different geometric modeling systems. For
example, the designer is interested in the operation of
the part in relation to the other parts in the product. The
technologist, by contrast, is interested in the possibility
of manufacturing the part with the available equipment.
Thus, the integration of CAD/CAM/CNC technolo-
gies in numerically controlled systems not only permits
fundamental change in the production technology from
the development stage to the manufacture of the final
product but also rules out problems due to different
software formats.
The MAX Computer GmbH (Germany) NCCAD
system is a CNC/CAN/CAM system, including a com-
puter-assisted design (CAD) module, a module for
specification and graphical simulation of the machining
parameters (CAM module), and a module for numeri-
cal control of the machine tool (CNC module).
the housing component in Figs. 1 and 2 relies on the
panel of 3D graphics and cross sections (Fig. 3), which
permits 3D-construction of plastic zones of this part
and analysis of their cross sections. There are always
two plastic zones in the NCCAD system: the Circle
zone and the Rectangle zone. For the blank in Fig. 2, we
need to create three plastic zones: 1) plastic rectangle
ABCD: 2) plastic rectangle KMDP; 3) a plastic circle
(a hole of diameter D = 35 mm with a bevel edge,
obtained after making a hole of radius R = 15.5 mm in
the blank).
The optimal sequence of operations to obtain the
model of the housing component is as follows.
1. Operation 005: drilling a hole with a diameter D =
6 mm; producing a hole with a radius R = 17.5 mm by
3D machining.
2. Operation 010: milling the lower part of the hous-
ing component by 3D machining.
3. Operation 015: milling the upper part of the hous-
ing component; drilling seven holes with a diameter
A–A
105
49 ∅6 R15,50 54.4
R17,50
R10 R28

Within the framework of a single program set, the

47.7

NCCAD system is responsible for the entire develop-

25

ment and manufacturing process: development of

1

12

11
5

drawings, formulation of the control program for the 15 20

machine tool in CNC code; and charging of the control 41 45 6 4 5
6 holes 4 holes 4 holes
program directly into the machine tool.
∅6 A B
14.96

17.68 10.2 10.2

We now consider the design procedure for a housing B B–B

5

component in the NCCAD system (Fig. 1).

54.4

In the NCCAD system, this part may be obtained on

13.6

∅ 35 8
the basis of 3D-analysis of three-dimensional figures
34

16
(such as a rectangular parallelepiped and a right cylin-
der) and the 2D capabilities of the system.
10.2

A B
Analysis of the housing-component blank (Fig. 2)
shows that it may be represented by two rectangles:
ABCD and KMDP. (The dash-dot line shows the divi-
sion between these rectangles.) Fig. 1. A drawing of the housing component.

841
842 KURNASOV

105 Y
97
60
R 15.5 B3 35 C3

10.2
H3
55 V3
Q3 D3
A3 M3
J3
N3 8

54.4

10.2 17.68
16
B C

39.44
40.8
F3

D L3 E3 W3
A M
14.96

I3

10
54.4
O 10 K3 T3 P3 X

6.12
105
K P
4.32 20.68 18.3 44.7

5.5
O
Fig. 2. A drawing of the blank for the housing component. O 0 X

9.7
R 17.50

19.8
S3_2 F3_2
D3_1

28
F3_1

41
R 10

53
1 6 S3_1 O β O3_2 O3_3
3_1

19 R3_2 N3_2
2 5
K3_2
3 Z 01 Z 02

Fig. 4. A drawing of the component for operation 015.

4

Then the coordinates of the vertices of the plastic

Fig. 3. NCCAD system’s panel for 3D graphics and cross
sections: 1) plastic zone (rectangle); 2) plastic zone (circle);
3) 3D view; 4) spare buttons; 5) analysis of cross section;
6) new cross section.
D = 6 mm, four holes with a diameter D = 4 mm, and
four holes with a diameter D = 5 mm.
Each operation is assigned to a separate file of the
NCCAD system as an individual drawing with techno-
logical data.
We now consider operation 015 in more detail. The
drawing of the part produced by operation 015 is shown
in Fig. 4. First, 3D machining of the external contour is
required.
To this end, two plastic zones are created: plastic
rectangle K3M3D3P3 (with cross section M3D3) and
plastic rectangle A3B3C3D3 (with cross section B3C3).
To construct these zones, we determine the coordi-
nates of the vertices on the same diagonal; note that, in
the NCCAD system, it is assumed that, for the extreme
left point of the component in the XOY plane, the coordi-
nates along the OX and OY axes are no less than +10 mm.
rectangles are as follows:
K 3 : x = 10 + ( 35 – 16 ) = 29 mm, y = 10 mm;
D 3 : x = 10 + 97 + 8 = 115 mm,
y = 10 + 39.44 = 49.44 mm;
A 3 : x = 10 mm, y = 10 + 39.44 = 49.44 mm;
C 3 : x = 10 + 97 + 8 = 115 mm,
y = 10 + 54.4 = 64.4 mm.
We consider the plastic rectangles and their cross
sections through the point K3 (for K3M3D3P3) and point
A3 (for A3B3C3D3). In isolating rectangle K3M3D3P3, we
need to position the crosshairs of the cursor at point K3
or P3 but not at point D3 or M3, since the latter points
belong to both rectangles and therefore error is possi-
ble. Specifically, instead of the cross section for plastic
zone K3M3D3P3, we might construct the cross section
for rectangle A3B3C3D3 at side A3D3. This error cannot
be corrected; plastic zone A3B3C3D3 must simply be
reconstructed.
It is relatively simple to create rectangles in the
NCCAD system: pushing the corresponding button on
the instrument panel (Rectangle; or Rectangle Plastic
Zone), we activate a state row by double-clicking the
mouse; we introduce the coordinates of the first point
on the diagonal of the rectangle (in the present case,

RUSSIAN ENGINEERING RESEARCH Vol. 29 No. 8 2009

 DESIGN OF HOUSING COMPONENTS IN NCCAD SYSTEM 843

point K3); pressing the Enter Key, we again activate a O 3_3 : x = 0 + 4.32 + 20.68 + 18.3 + 44.7 = 88 mm,
row; we introduce the coordinates of the second point
(D3); and we press the Enter key. z = 0 – 28 = – 28 mm;
Note that, on entering the coordinate in the row, the R 3_2 : x = 0 + 4.32 + 20.68 + 18.3 + 44.7 = 88 mm,
fractional part of the coordinate is separated from the z = 0 – 41 = – 41 mm;
integer part by a point, while one coordinate is sepa-
rated from the next by a comma (for example, the coor- N 3_2 : x = 0 + 105 = 105 mm,
dinates of point D3 will be: 115, 49.44).
z = 0 – 41 = – 41 mm;
Note that, if the machining of some contour is not K 3_2 : x = 0 + 105 = 105 mm,
planned in the given operation, it must be placed in the
ninth layer, which is tacitly set aside for those graphical z = 0 – 53 = – 53 mm.
constructions that are not to be cut on the machine tool.
The corresponding sequence is as follows: on the con- For the contour in the cross section of the smaller
trol panel, press the Layer button; press button 9 (for rectangle, we obtain the following coordinates (Fig. 4).
the ninth layer); draw the contour with the calculated D 3_1 : x = 19 – 19 = 0 mm, z = – 9.7 mm;
coordinates; switch back to the first layer (button 1).
S 3_2 : x = 25 – 19 = 6 mm, z = – 5.5 mm;
The model of the component for operation 015 after
constructing the plastic rectangles is shown in Fig. 5. F 3_2 : x = 43.3 – 19 = 24.3 mm, z = – 5.5 mm;
The contours in the cross section must now be speci- O 3_3 : x = 88 – 19 = 69 mm, z = – 28 mm;
fied. As is evident from Fig. 4, the contour in the cross sec- R 3_2 : x = 88 – 19 = 69 mm, z = – 41 mm;
tion of the large rectangle D3A3B3C3 will be a discontinu-
ous line S3_1F3_1D3_1S3_2F3_2O3_3R3_2N3_2K3_2, i.e., the N 3_2 : x = 105 – 19 = 86 mm, z = – 41 mm;
whole upper contour of the part. The contour in the cross
section of the smaller rectangle K3M3D3P3 will be the dis- K 3_2 : x = 105 – 19 = 86 mm, z = – 53 mm.
continuous line D3_1S3_2F3_2O3_3R3_2N3_2K3_2. We may now construct the contours in the cross sec-
Since the coordinate origin for the contours in cross tions using the Arc and Discontinuous Line buttons on the
sections of the plastic rectangles passes through differ- instrument panel in the View Cross Section XZ window.
ent points (S3_1 for D3A3B3C3; and D3_1 for K3M3D3P3), To construct a discontinuous line, we activate a row;
we must first find the coordinates for the larger contour introduce the coordinates of the first point of the dis-
in the cross section (the discontinuous line continuous line; press the Enter button; again activate a
S3_1F3_1D3_1S3_2F3_2O3_3R3_2N3_2K3_2). Then, to determine line; introduce the coordinates of the next point; press
the coordinates of the points of the smaller contour (the dis- Enter; and, finally, after constructing the whole discon-
continuous line D3_1S3_2F3_2O3_3R3_2N3_2K3_2), we must tinuous line, press the Esc key.
subtract the distance between points S3_1 and β (the dis- To construct an arc (Fig. 6), we activate a row; enter
tance between the OZo1 and OZo2 axes) from the coor- the coordinates of the first point of the arc; press the
dinates along the OX axis for all the points of the con- Enter key; again activate a row; enter the coordinates of
tour. The values of the coordinates along the Z axis the second point; and press the Enter key. Lastly, we
remain the same here. enter the coordinates of the center of the arc in a row.
Thus, for the contour in the cross section of the
larger rectangle, we obtain the following coordinates
NCCAD screen
(Fig. 4). File Edit View Parameters Correct

S 3_1 : x = 0, z = 0 – 28 = – 28 mm;
F 3_1 : x = 0 + 4.32 = 4.32 mm,
z = 0 – 19.8 = – 19.8 mm;
D 3_1 : x = 0 + 19 = 19 mm,
z = 0 – 9.7 = – 9.7 mm;

S 3_2 : x = 0 + 4.32 + 20.68 = 25 mm,

AD 0.01 118.48 OD 0.01 118.48 AP 90.00 118.48 OP 90.00
z = 0 – 5.5 = – 5.5 mm; Rectangle plastic zone Show first point

F 3_2 : x = 0 + 4.32 + 20.68 + 18.3 = 43.3 mm,

Fig. 5. Model of the component for operation 015 after con-
z = 0 – 5.5 = – 5.5 mm; structing the plastic rectangles.

RUSSIAN ENGINEERING RESEARCH Vol. 29 No. 8 2009

844 KURNASOV

B K Operation 015 includes not only 3D machining but

Q also 2D machining, i.e., the boring of holes in the part
C
(Fig. 4); this entails constructing circles in the model of
A P
the component.
Circles are created as follows in the NCCAD sys-
Fig. 6. Arcs. tem: press the Circle or Circle Plastic Zone button; acti-
vate a row; introduce the coordinates of the center of
the circle (for example, point W3 or point I3); press the
To construct the arc ACB in Fig. 6, we must enter the Enter key; activate a row; introduce the coordinates of
coordinates first of point A, then of point B, and then of a point belonging to the circle (for example, point F3 or
the center C. To construct arc KQP, we enter the coor- point T3); press the Enter key.
dinates first of point K, then of point P, and finally of the
center Q. The contours of these holes are constructed in the
XOY coordinate plane.
As is evident from Figs. 4 and 6, the arc S3_1O3_1F3_1 To this end, we first find the coordinates of the cen-
is analogous to arc ACB, while arc O3_3O3_2F3_2 is anal- ters of these circles:
ogous to arc PQK.
The contour in the cross section may be constructed point I 3 : x = 10 + 35 = 45 mm,
by two methods: y = 10 + 6.12 = 16.12 mm;
1) successive construction of all the parts of the pri- point L 3 : x = 10 + 35 = 45 mm,
mary contour (arc S3_1F3_1, discontinuous line
F3_1D3_1S3_2F3_2, arc F3_2O3_3, discontinuous line y = 10 + 6.12 + 10.2 = 26.32 mm;
O3_3R3_2N3_2K3_2), followed by construction of all the parts point J 3 : x = 10 + 35 = 45 mm,
of the second contour (discontinuous line D3_1S3_2F3_2, arc
F3_2O3_3, discontinuous line O3_3R3_2N3_2K3_2); y = 10 + 6.12 + 10.2 + 17.68 = 44 mm;
2) construction of all the arcs and then of all the seg- point V 3 : x = 10 + 35 = 45 mm,
ments and discontinuous lines between them.
y = 10 + 6.12 + 10.2
The second method is preferable, since the construc-
tion may then be simplified by selecting the option Object + 17.68 + 10.2 = 54.2 mm;
Link in the Line–Grid–Step–Link window. The cursor point Q 3 : x = 10 + 60 = 70 mm,
may then be linked to the already existing points of the arc
(for example, F3_1, F3_2, and O3_3 for the first contour). As y = 10 + 40.8 = 50.8 mm;
a result, the coordinates of these points need not be entered point H 3 : x = 10 + 97 = 107 mm,
again in the row when constructing segments.
The contours (3D views) of the parts obtained in the y = 10 + 6.12 + 10.2
cross sections are shown in Figs. 7 and 8. + 17.68 + 10.2 = 54.2 mm;

View in cross section View in cross section

3D view 3D view

AD 22.01 12 X['] 20 Y['] 0 Z['] 15 Scale [%] 150 AD 43.12 X['] 20 Y['] 0 Z['] 15 Scale [%] 150
Straight line Indicate initial point Discontinuous line Indicate initial point

Fig. 7. Contour (3D view) in cross section of larger plastic Fig. 8. Contour (3D view) in cross section of smaller plastic
rectangle D3A3B3C3 (Fig. 4). rectangle D3P3K3M3 (Fig. 5).

RUSSIAN ENGINEERING RESEARCH Vol. 29 No. 8 2009

 DESIGN OF HOUSING COMPONENTS IN NCCAD SYSTEM 845

point N 3 : x = 10 + 97 = 107 mm, (a) (b)

Technology Technology
y = 10 + 6.12 + 10.2 + 17.68 = 44 mm; Page 1
Number 3 Layer 1 Element 3
Page 1
Number 15 Layer 1 Element 15

Machining Parallel to cross section Machining Parallel to cross section

point W 3 : x = 10 + 97 = 107 mm, Trajectory Positive form Trajectory Positive form
correction correction
Relay before Spi- Relay before Spi-
y = 10 + 6.12 + 10.2 = 26.32 mm; Relay after
ndle
Spi- Relay after
ndle
Spi-
ndle ndle
Safe position 5.00 Safe position 5.00
point U 3 : x = 10 + 97 = 107 mm, Stop for manual repair Stop for manual repair
Machining Machining
y = 10 + 6.12 = 16.12 mm. database User database User

Supply 0.12 Supply 0.12

To construct a circle, we need not only its center but Tool diameter 6.40
0.80
Tool diameter 6.40
0.80
Depth per pass Depth per pass
one other point on its circumference. However, there is
no need to find such a point for each of the 15 circles. It Coverage factor (%) 0.00 Coverage factor (%) 0.00

is sufficient to use a single circle of each radius (there Zero-point

displacement of Z axis 21.00
Zero-point
displacement of Z axis 0.00
are three such circles, with radii of 3, 2.5, and 2 mm, Spindle data Spindle data
respectively; Fig. 1, views A–A and B–B). The other Notes
Material Type Bearing
Notes
Material Type Bearing

points are obtained by copying, thereby shortening the

coordinate calculations. OK Page 2 Switch ? OK Page 2 Switch ?

Therefore, we find the points of three circles with

different radii:
1) for the circle with its center at point W3 and radius
r = 2 mm, we determine the coordinates of point F3
F 3 : x = 10 + 97 + r = 10 + 97 + 2 = 109 mm,
y = 10 + 6.12 + 10.2 = 26.32 mm;
2) for the circle with its center at point I3 and radius
r = 2.5 mm, we determine the coordinates of point T3
T 3 : x = 10 + 35 + r = 10 + 35 + 2.5 = 47.5 mm,
y = 10 + 6.12 = 16.12 mm;
3) for the circle with its center at point I3 and radius
r = 3 mm, we determine the coordinates of point E3
E 3 : x = 10 + 35 + r = 10 + 35 + 3 = 48 mm,
y = 10 + 6.12 = 16.12 mm.
We now construct the circles. The optimal method
of construction (copying) is as follows:
1) construct a circle (center at W3; r = 2 mm) passing
through point F3 and copy it at points N3, L3, J3 (by the
method considered later);
2) construct a circle (center at I3; r = 3 mm) passing
through point E3 and copy it at point Q3;
3) construct a circle (center at I3; r = 2.5 mm) pass-
ing through point T3;
4) construct circles (center at I3, r = 3 mm; center at
I3, r = 2.5 mm) and copy them at points V3, H3, U3.
In the CAD module, copying a graphical element
(without changing its angular position) is accomplished
as follows:
1) press the Copy button;
2) select the zone to be copied (indicate the graphi-
cal element to be copied or its first point in the working
field, by means of the cursor);
Fig. 9. Window for specifying the machining parameters for the
contours of the milled part; a) first contour; b) second contour.
3) indicate the baseline point from which copying is
to proceed by means of the cursor or by entering
numerals in the state row;
4) indicate the point to which copying is to proceed
by means of the cursor or by entering numerals in the
state row.
In the present case, it is more expedient to indicate
the circle by means of the cursor in the working field.
The baseline point at which copying begins is the center
of the circle to be copied (points I3, W3). The point to
which copying proceeds is the center of the generated
circle (points L3, J3, V3, Q3, H3, N3, U3).
When the circles have been constructed, the model of
the housing component is ready for manufacture on the
machine tool. We need only specify the required techno-
logical data.
To specify the machining parameters, we proceed as
follows:
1) press the Technology button;
2) by means of the cursor, indicate one point of the
graphical element whose manufacturing technology is to
be formulated, and left-click the mouse; for a plastic cir-
cle, we must position the cursor as in the case of pressing
the Analysis of Cross Section button; for a plastic rectan-
gle, the center of the crosshairs must be at any vertex,
while the cursor lines align with the sides of the rectangle;
3) open the Technology dialog window, by moving
the cursor from the selected point (an auxiliary line
extends from the point behind the cursor) and left-
clicking the mouse when the cursor is at a convenient
point of the working field;
4) in the Technology window (Fig. 9), specify the
corresponding parameters (supply, tool diameter, depth

RUSSIAN ENGINEERING RESEARCH Vol. 29 No. 8 2009

846 KURNASOV

(a) (b) NCCAD screen

Technology Technology File Edit View Parameters Correct
Page 1 Page 1
Number 3 Layer 1 Element 3 Number 15 Layer 1 Element 15
9 8
Machining Individual element Machining Individual element 12
14 13
Trajectory No Trajectory No
correction correction 5 4
Relay before Spi- Relay before Spi- 15
ndle ndle
Relay after Spi- Relay after Spi-
ndle ndle 6
Safe position 5.00 Safe position 5.00 3
16
Stop for manual repair Stop for manual repair 10 7
Machining User Machining User
17 11
database database
Supply 0.12 Supply 0.14
Tool diameter 6.00 Tool diameter 6.00 AD 0.01 118.48 OD 0.01 118.48 AP 90.00 118.48 OP 90.00
Total depth 53.00 Total depth 42.00 Tehnology Rectangle plastic zone Show first point
Depth per pass 0.80 Depth per pass 0.80

Zero-point Zero-point
displacement of Z axis 0.00 displacement of Z axis 0.00
Spindle data Spindle data
Material Type Bearing Material Type Bearing Fig. 11. Machining objects in operation 015: 1, 2—sur-
Notes Notes
faces; 3–17—holes.
OK Page 2 Switch ? OK Page 2 Switch ?

Fig. 10. Window for specifying the machining parameters

in drilling holes; a) hole 3; b) hole 5.

(a) (b)
3D View 3D View
View View

X['] 20 Y['] 0 Z['] 15 Scale [%] 160 X['] 20 Y['] 0 Z['] 15 Scale [%] 160

Fig. 12. Simulation of the machining of a housing component (Fig. 1) for operation 015 at different machining angles (a, b).

per pass, coverage factor for the developed technol- In operation 015 (Fig. 11), we should note the fol-
ogy), and press OK. lowing points.
The machining technology may also be selected by 1. We need to specify a zero-point displacement of
the operator from the database built into the NCCAD the Z axis: 21 mm (Fig. 9a).
system or from a data formulated by the operator. 2. Since holes with different diameters are bored, it
is best to specify the machining sequence so that all
Note the item Zero-Point Displacement of Z Axis: holes of a single diameter are bored first, followed by
this displacement must be entered if the height of the holes of another diameter, and so on. This reduces the
machined part is more than 32 mm. If several objects number of tool changes.
whose height is greater than 32 mm appear in a single
CAD module of the NCCAD system, it is sufficient to 3. Holes 9, 14, 5, 15, 6, and 16 and holes 8, 12, 4, 3,
specify the zero-point displacement for one object. In 7, and 11 are of different depths, but the technological
fact, the value entered for the Zero-Point Displacement specifications for holes 3–10 require a depth of 53 mm
of Z Axis informs the numerical control system regard- (Fig. 10a); those for holes 11 and 12 require 46 mm; and
ing the displacement of the program’s zero point rela- those for holes 15 and 16 require 42 mm (Fig. 10b).
tive to the machine tool’s zero point. This permits sim- Thus, the hole depth is calculated from the following
ulation of machining on the machine tool. formula: the highest point of the part (the zero point) is
the distance from the lower part of the hole to the lower
Examples of the window for specifying the machin- point of the part. This permits the use of constant drill
ing parameters of contours are shown in Fig. 9, while length and avoids resetting the tool’s path sensors dur-
examples of the window for specifying the machining ing machining. A single setting is sufficient, for the
parameters of drilled holes are shown in Fig. 10. longest tool.

RUSSIAN ENGINEERING RESEARCH Vol. 29 No. 8 2009

 DESIGN OF HOUSING COMPONENTS IN NCCAD SYSTEM
Note that adjustment of the tool path and the zero
point of the blank is manual in the present case, since
this a relatively laborious procedure and requires par-
ticular care. The smallest error in adjustment may result
in an accident during machining.
After the part has been designed and the manufac-
turing technology has been specified, we may begin the
simulation of machining in the CAM module of the
NCCAD system. If the simulation does not proceed as
planned, the design may be corrected. In other words,
RUSSIAN ENGINEERING RESEARCH Vol. 29 No. 8
847
the errors in the technology, in the cross-section con-
tour, or in the contour of the part are identified, and
appropriate corrections are introduced.
To begin the simulation, the following selections are
made in the corresponding menus: Execution
Table + 3D View. Then the simulation begins. At the
end, a 3D view of the part produced by this technology
is seen. The simulation of machining is shown at differ-
ent angles of view in Fig. 12.
2009