Manufacturing Department Mechanical Engineering University Technology Malaysia

Manufacturing Process SKMM2713

Monday -2013/05/20 AIE/NR

CAD: Computer Aided Design

CAM: Computer Aided Manufacturing

CNC: Computer Numerical Control

CAD/CAM ( Computer Aided Design and Computer Aided Manufacturing)

:It is the technology concerned with the use of computers to perform design and manufacturing functions.

CAD
:it can be defined as the use of computer systems to perform certain functions in the design process.

Computer aided Manufacturing(CAM)

CAM: is the use of computer systems to plan, manage and control the operations of manufacturing plant through either direct or indirect computer interface with the plants production resources

From CAM definition, the application of CAM falls into two broad categories: 1. Computer monitoring and control . Computer Process data Process data
Control signals

Process

Computer

Process

2. Manufacturing support application .

Computer

Process data Control signals

Mfg operations

Benefits of CAM:
1) Improve productivity.

2) Lead time reduction.

3) Reduce engineering personal requirements.

4) Improve accuracy of product.

CONT

5) Reduce training time for routine drafting.

6) Fewer errors in NC part programming. 7) Provide the potential of using more existing parts and tooling.

8) Waste can be kept to a minimum.

Some typical applications of CAD/CAM

1) Process planning and scheduling. 2) Programming for numerical control and Industrial robots. 3) Design of dies and molds for casting. 4) Die for metal working operations. 5) Design of tooling and fixtures and EDM electrodes. 6) Quality control and inspection. 7) Plant layout.

Computer Numerical control (CNC)

History of CNC
1949 US Air Force asks MIT to develop a "numerically controlled" machine. 1952 Prototype NC machine demonstrated (punched tape input) 1980CNC machines (computer used to link directly to controller) 1990DNC: external computer drip feeds control programmer to machine tool controller

DEFINITION
In CNC (Computer Numerical Control), the instructions are stored as a program in a micro-computer attached to the machine. The computer will also handle much of the control logic of the machine, making it more adaptable than earlier hard-wired controllers.

Conventional vs. CNC machine

Conventional vs. CNC machine

Difference between Conventional M/C & CNC M/C

Item 1. Movement 2. Feed Conventional machine Acme screw manual CNC machine Ball screw motor Linear scale

3.measurement manual

CNC APPLICATIONS
- Machining 2.5D / 3D Turning ~ Lathes, Turning Centre Milling ~ Machining Centres 2-Forming 2D Plasma and Laser Cutting Blanking, nibbling and punching 3D Rapid Prototyping

SAMPLE CNC MACHINES

CNC TURNING

CNC MILLING

SAMPLE CNC MACHINES

CNC LASER CUTTING

CNC PLASMA CUTTING

SAMPLE CNC MACHINES

CNC PRESS

CNC RAPID PROTOTYPING

Advantages of CNC
1) Easier to program. 2) Easy storage of existing programs.

3) Easy to change a program.

4) Avoids human errors. 5) NC machines are safer to operate. 6)Complex geometry is produced as cheaply as simple ones.

7) Usually generates closer tolerances than manual

machines .

DRAWBACKS of CNC
1) High capital cost )Machine tools cost $30,000 $1,500,000 ).

2) Retraining and recruitment of staff .

3) New support facilities .

4) High maintenance requirements.

5) Not cost-effective for low-level production on simple parts. 6)Maintennce personnel must have both mechanical and electronics expertise .

CNC SYSTEM ELEMENTS

A typical CNC system consists of the following six elements 1) Part program

2) Program input device

3) Machine control unit

4) Drive system
5) Machine tool 6) Feedback system

STANDARD MILLING MACHINE COORDINATE SYSTEM

STANDARD LATHE COORDINATE SYSTEM

RIGHT HAND RULE

Vertical Machine

Horizontal

Machine

Zero and reference points on CNC

Zero Point of machine on a CNC lathe

Machine Zero Point and Work part zero point on CNC milling machine

Additional Axis of Movement (A) FOURTH AXIS ROTARY MOTION : Rotate about axis X. (B) FIFTH AXIS ROTARY MOTION: Rotate about axis Y. (C )AUXILIARY EXTERNAL ROTARY AXIS :Rotate about axis Z.

Programming Systems
Two types of programming modes, the incremental system and the absolute system, are used for CNC.

What is the value in X and Y for each hole in absolute and incremental positing .

CNC Positioning systems

Point-to-Point Positioning

Point-to-point positioning is used when it is

necessary to accurately locate the spindle,

or the workpiece, perform such operations

as drilling, reaming, boring, tapping.

Point-to-Point Positioning

Continuous Path (Contouring)

Contouring, or continuous path machining, involves work such as that produced on a lathe or milling machine, where the cutting tool is in contact with the workpiece as it travels from one programmed point to the next.

Continuous Path (Contouring)

G-codes (preparatory functions):

Most G-codes set the machine in a mode which stays in effect until it is changed or cancelled by another G-code. These commands are called modal.

Modal G-Code List

G00 G01 G02 CW G03 Rapid Transverse Linear Interpolation Circular Interpolation, Circular Interpolation, CCW G17 XY Plane G18 XZ Plane G19 YZ Plane G20/G70 Inch units G21/G71 Metric Units G40 Cutter compensation cancel G41 Cutter compensation left G42 Cutter compensation right

G43 Tool length compensation (plus) G44 Tool length compensation (minus) G49 Tool length compensation cancel G80 Cancel canned cycles G81 Drilling cycle G82 Counter boring cycle G83 Deep hole drilling cycle G90 Absolute positioning G91 Incremental positioning

CIRCULAR PLANE SELECTION

G17 XY CIRCULAR PLANE SELECTION

G18 XZ CIRCULAR PLANE SELECTION

G19 YZ CIRCULAR PLANE SELECTION

CUTTER COMPENSATION

G41 Cutter Compensation Left That is the tool is moved to the left of the programmed path to compensate for the radius of the tool

G42 Cutter Compensation Right

That is the tool is moved to the right of the programmed path to compensate for the size of the tool.

NOTE :G40 Cancel Cutter Comp G41 and G42

TOOL LENGTH COMPENSATION

G43 Tool Length Compensation + (plus) This code selects tool length compensation in a positive direction. That is; the tool length offsets are added to the commanded axis positions.

M or miscellaneous codes :

:are used to either turn ON or OFF different

functions which control certain machine tool

operations

M Codes
M00 M01 M02 M03 M04 M05 M06 M08 M09 M10 M11 M30 Program stop Optional program stop Program end Spindle on clockwise Spindle on counterclockwise Spindle stop Tool change Coolant on Coolant off Clamps on Clamps off Program stop, reset to start

X,Y, and Z Codes

X, Y, and Z codes are used to specify the coordinate axis. Number following the code defines the coordinate at the end of the move relative to an incremental or absolute reference point.

I,J, and K Codes

I, J, and K codes are used to specify the coordinate axis when defining the center of a circle. Number following the code defines the respective coordinate for the center of the circle.

F,S, and T Codes

F-code: used to specify the feed rate S-code: used to specify the spindle speed T-code: used to specify the tool identification number associated with the tool to be used in subsequent operations.

CNC Programming:

The first step in producing a CNC program is to take the information from the print and produce a program manuscript

1) Manual Write code directly 2)Computer-assisted Draw cutter path 3) CAD/CAM Draw the part Cutter path is generated

INFORMATION NEEDED by a CNC

positioning

1) Preparatory Information: units, incremental or absolute

2) Coordinates: X,Y,Z, RX,RY,RZ 3) Machining Parameters: Feed rate and spindle speed 4) Coolant Control: On/Off, Flood, Mist 5) Tool Control: Tool and tool parameters

6) Cycle Functions: Type of action required

7) Miscellaneous Control: Spindle on/off, direction of rotation, stops for part movement

This information is conveyed to the machine through a set of instructions arranged in a desired sequence Program.

BLOCK FORMAT
Sample Block :N135 G01 X1.0 Y1.0 Z0.125 F5
Restrictions on CNC blocks. Each may contain only one tool move. Each may contain any number of non-tool move G-codes. Each may contain only one feedrate. Each may contain only one specified tool or spindle speed. The block numbers should be sequential. Both the program start flag and the program number must be independent of all other commands (on separate lines). The data within a block should follow the sequence shown in the above sample block.

Block of Information
CNC information is generally programmed in blocks of five words

Three Main parts of a CNC program

Part 1- Program Petup
N5 G90 G21
N10 M06 T2 N15 M03 S1200

(Absolute units, metric)

(Stop for tool change, use tool # 2) (Turn the spindle on CW to 1200 rpm)

General formula for calculating the cutting parameters

To move tool at point B write block as : G90 G01 X110 Y75.0 F20;

To move tool at point B write block as : G91 G01 X80.0 Y45.0 F20;

RAPID POSITION COMMAND

G00 RAPID POSITIONING MOTION *X Positioning X axis motion *Y Positioning Y axis motion *Z Positioning Z axis motion *A Positioning A axis motion

LINEAR INTERPOLATION COMMAND

G01 LINEAR INTERPOLATION MOTION *X Linear X-axis motion *Y Linear Y-axis motion *Z Linear Z-axis motion *A Linear A-axis motion *F Feed rate in inches (mm) per minute

CIRCULAR INTERPOLATION COMMANDS

G02 CW CIRCULAR INTERPOLATION MOTION & G03 CCW CIRCULAR INTERPOLATION MOTION *X Circular end point X-axis motion *Y Circular end point Y-axis motion *Z Circular end point Z-axis motion *A Circular end point A-axis motion *I X-axis Distance from start point to arc center (If R is not used) *J Y-axis Distance from start point to arc center (If R is not used) *K Z-axis Distance from start point to arc center (If R is not used) *R Radius of the arc to be machined (If I, J, K are not used) *F Feed rate in inches (or mm) per minute

G02 CCW CIRCULAR INTERPOLATION

EXAMPLE

G02 CW CIRCULAR INTERPOLATION USING "I", &"J" FOR THE X & Y AXIS

G02 CW CIRCULAR MOTION USING "R"

G03 CCW CIRCULAR INTERPOLATION

EXAMPLE

G03 CCW CIRCULAR INTERPOLATION USING "I", &"J" FOR THE X & Y AXIS

EXAMPLE : Cutter Compensation (G41/G42/G40)

Three Main parts of a CNC program

Part 1- Program Petup
N5 G90 G21
N10 M06 T2 N15 M03 S1200

(Absolute units, metric)

(Stop for tool change, use tool # 2) (Turn the spindle on CW to 1200 rpm)

Three Main parts of a CNC program

Part 2- Chip Removal
N20 G00 X1 Y1 (Rapid to X1,Y1 from origin point) N25 Z0.125 (Rapid down to Z0.125) N30 G01 Z-0.125 F100 (Feed down to Z-0.125 at 100 mm/min) N35 G01 X2 Y2 (Feed diagonally to X2,Y2) N40 G00 Z1 (Rapid up to Z1) N45 X0 Y0 (Rapid to X0,Y0)

Three Main parts of a CNC program

Part 3- System Shutdown
N50 M05
N55 M00

(Turn the spindle off)

(Program stop)

EXAMPLE OPERATION on CNC MILLING MACHINE

First pass : conventional mill to a depth of 0.125 around edge profile. Tool 1 is a inch dia. end mill.
% :1002 N5 G90 G20 N10 M06 T1 N15 M03 S1200 N20 G00 X0.125 Y0.125 N30 Z0.125 N35 G01 Z-0.125 F5 N40 X3.875 N45 Y4.125 N50 X0.125 N55 Y0.125

Second pass: conventional mill to a depth of 0.25 around edge profile.

N35 N40 N45 N50 N55 N60

Z-0.250 X3.875 Y4.125 X0.125 Y0.125 Z0.125

Third pass: conventional mill to a depth of 0.125 around pocket profile.

N65 N70 N75 N80 N85 N90 N95 G00 X1.25 Y1.0 G01 Z-0.125 F5 X1.75 Y2.5 X1.25 Y1.0 Z0.125

Fourth pass: climb mill to a depth of 0.125 across remaining material.

N100 Y2.125 N105 X2.625 N110 Z0.125 N115 G00 X-5 Y-5 Z5 N120 M05 N125 M30

Exercises 1-Write CNC blocks for paths as shown below.

2)Write CNC program for machining w/p as dawning