Computer Aided Manufacturing

Introduction

Raw materials

Manufacturing Process

Finished part

Manufacturing Processes

Turning

Drilling

Milling

Shaping

EDM

Laser machining

Ultrasonic machining

Machine tools

Lathe

Milling machine

How does the table move along X- Y- and Z- axes ?

Precise components

Controlling tool movements using numerical data

Numerical control
NC has been defined by the Electronic Industries Association (EIA) as a system in which actions are controlled by the direct insertion of numerical data at some points. The system must automatically interpret at least some portion of this data

Machine tool Control unit Program of instruction

Components of a CNC machine

In general there are three basic components of an operational NC
1. 2. 3. Programme of instruction. A machine control unit. Machine tool.

Numerical control (NC) - machine can be controlled electronically

Computer Numerically Controlled (CNC) - machine actually has its own microprocessor and memory
Direct Numerical Control (DNC) - wired to a central computer

Need for CNC

Computer Numerical Control (CNC) - A numerical control system in which the data handling, control sequences, and response to input is determined by an on-board computer system at the machine tool.

To manufacture complex curved geometries in 2D or 3D using controlled cutter motions Machining components with repeatable accuracy Unmanned machining operations

Machining center
A machining center can be defined as a machine tool capable of: Multiple operation and processes in a single set-up utilizing multiple axis Typically has an automatic mechanism to change tools

Components Of CNC Machine Tool

Position transducer Machine table Gear box Tachometer

Controller

Motor
Leadscrew Servo drive

control cabinet

Converting the rotational motion of the motors to a linear motion.

Lead screws
Nut

Leadscrew

Pitch

Pitch (p): the distance between adjacent screw threads

Number of teeth per inch (n):

n=1/p
BLU = p / n

BLU: Basic Length Unit (machine resolution)

Position measurement

Control Loops
Open loop - No position feedback.
table pulses motor

Use stepping motor.

Closed Loop

_
Up-down counter DAC Amp

Differential amplifier

Shaft

DC Mot or

Tachomet er

Encoder

+
Reference pulses

Closed-loop control mechanism

Coordinate systems
y y z x

Right hand rule Z axis align with the spindle - +Z moves away from the workpiece or the spindle. X axis - Lathe: perpendicular to the spindle. Horizontal machine: parallel to the table. Vertical machine: +X points to the right.

Motion control

Motion control

Basic Elements of NC Program

a. Preparatory functions: which unit, which interpolator, absolute or incremental programming, which circular interpolation plane, cutter compensation, etc. b. Coordinates: three translational, and three rotational axes. c. Machining parameters: feed, and speed. d. Tool control: tool diameter, next tool number, tool change. e. Cycle functions: drill cycle, ream cycle, bore cycle, mill cycle, clearance plane. f. Coolant control: coolant on/off, flood, mist. g. Miscellaneous control: spindle on/off, tape rewind, spindle rotation direction, pallet change, clamps control, etc. h. Interpolators: linear, circular interpolation

Part Program

Part program: A computer program to specify

- Which tool should be loaded on the machine spindle; - What are the cutting conditions (speed, feed, coolant ON/OFF etc) - The start point and end point of a motion segment - how to move the tool with respect to the machine.

NC WORDS G codes
Table 9.1 G codes g00 g01 g02 g03 g04 g08 g09 g17 g18 g19 g33 g34 Rapid traverse Line ar interpolation Circular inte rpolation, CW Circular inte rpolation, CCW Dwe ll Acceleration Deceleration X-Y Plane Z-X Plane Y-Z Plane Thread cutting, cons tant lead Thread cutting, increasing lead g40 g41 g42 g70 g71 g74 g75 g80 g81 -9 g90 g91 Incremental de imension programming Cutter compensation - cancel Cutter compensation - left Cutter compensation -right Inch format Metric format Full circle programming Off Full circle programming On Fixed cycle cancel Fixed cycles Absolute dimension programming

NC WORDS- F and S Codes

F Code. feed speed. inch/min (ipm), or ipr. F code must be given before either G01, G02, or G03 can be used. Example: N0100 G02 X7.000 Y2.000 I5.000 J2.000 F6.00 S Code. cutting speed code. Programmed in rpm. S code does not turn on the spindle, spindle is turned on by a M code.

N0010 S1000

NC WORDS- T and R Codes

T Code. tool number. Actual tool change does not occur until a tool change M code is specified. R Code. cycle parameter.
The cycle may be programmed in one block, such as (cycle programming is vendor specific.): N0010 G81 X1.000 Y2.000 Z0.000 R 1.300
1 0.7" 0.3" 1" 3

(1,2,2) Initial height 2 R plane

5 Z point 4

NC WORDS M Codes
M Code. miscellaneous word.

Table 9.2. M codes m00 Program stop m01 Optional stop m02 End of program m03 Spindle CW m04 Spindle CCW m05 Spindle off m06 m07 m08 m09 m30 Tool change Flood coolant on Mist coolant on Coolant off End of tape

Offsets
Fixture
G10, G54, G54.1 Diameter Tool Length compensation Part-Edge compensation Cutter Compensation Next Slides

Tool Radius Compensation

Cutter Compensation Shifting tool path so that the actual finished cut is either moved to the left or right of the programmed path. Normally, shifted exactly by tool radius Tool Entry and Exit Issues

Tool Radius Compensation

Start of Compensation.
(a) G41 (b) G42

G41 (or G42) and G01 in the same block ramp takes place at block N0010. N0010 G01 G42 X0.500 Y1.700 N0020 G01 X1.500
G41 G42

(0.5, 1.7) (1.5, 1.7)

G41 (or G42) and G01 in separate blocks the compensation is effective from the start.

N0010 G41
N0020 G01 X0.500 Y1.700 N0030 G01 X1.500

G41

G42

Tool Radius Compensation

Inside Corner.

Cutter path is inside a corner, stops at the inside cutting point

N0010 G41 N0020 G01 X1.500 Y2.000 N0030 G01 X0.000 Y1.600
(0, 1.6)
G42

(1.5, 2.0)

Use of M96 and M97. Cutting tool that is larger than the height of the step, M97 must be used N0010 G41 N0020 G01 X1.000 Y1.000 N0030 G01 Y0.800 M97 N0040 G01 X2.000
G41 M97

G41

M96

Advantages
Increased Program storage capability at the machine tool Program editing at the machine tool Control systems upgrades possible Option -resident CAM system at machine tool Tool path verification