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Benefits of DNC
1. NC. Without punched tapes.
2. Greater computation & Flexibility.
3. Convenient storage of NC Part Programme in
computer file. (General format of Programme as
C.L. file.)
CNC MachinesAdvantages/Disadvantages
Advantages:
High Repeatability and Precision e.g. Aircraft parts
Volume of production is very high
Complex contours/surfaces need to be machined.
E.g. Turbines
Flexibility in job change, automatic tool settings,
less scrap
More safe, higher productivity, better quality
Less paper work, faster prototype production,
reduction in lead times
Disadvantages:
Costly setup, skilled operators
Computers, programming knowledge required
Maintenance is difficult
Repetation of batches-------------------------Often.
Complexity of the operation Carried out-High.
Number of operation per Component-----Many.
Time lag between operation ------------------ Low.
Ratio of cutting time to non cutting time --Low.
Variety of Components to be produced ---More.
Design changes-----------------------------------Frequent.
Non uniform cutting conditions -------------Required.
Cost of special tooling involved--------------High.
Skill required by the operator ---------------High.
MACHINE TYPES
1. Group 1: -M/C Tools with rotating tool i.e. Milling
M/C, Drilling M/C, Boring M/C , Tapping M/C
2. Group 2: -M/C Tool with Rotating work piece i.e.
Lathe.
3. Group 3: -Non Rotating work Piece and non
rotating tool i.e. Shaper, Planer, EDM, Wire cut.
4. Group: -Other than above Z Categories i.e. NC
Drafting.
Classification of Controllers
1. Point to Point type (P-Type)
A. )Only Positioning.
B.) No Control over Feed speed.
C.) Semi Automatic Drilling M/C Spot Welding M/C etc.
2. Position Control (2PL)
3. 2L/3L Controllers.
4. Continuous Control (C-Type Controllers)
A.) 2CLa.) 2 Axis Controllers.
b.) Simultaneous Control of two Axis + Feed control of
one Axis.
c.) Can make 2-D Fig. Like Circle, Arc Ellipse.
B.) 3C
a.) 3 Axis Simultaneous
b.) Can do interpolation in 3 Dimensions
C.) Can Produce Sphere
Rotator Axis
A,B,C
Principal:
Second:
Tertiary:
X,Y,Z
U,V,W
P,Q,R
Axes convention
Axes convention
The tool can be moved to any position in a 3 dimensional cartesian
co-ordinate system.
The Z axis is along the spindle axis. The X and Y axes are
perpendicular to Z.
VMC (Vertical Machining Center)
Open-loop Control
Stepper motor is used, having a predefined amount of revolution.
Current pulses are send from MCU to individual motors.
Movement/rotation depends on number of pulses send.
Advantages:
Position is maintained just by keeping track of number of revolutions.
Can produce a movement of 1/1000th of an inch, for a single pulse.
Cheap and less complex.
Easy to maintain.
Drawback:
Assumption: Motor movement is precise, i.e. motor is moving the exact
amount depending on the number of pulses.
No way to correct errors, because no feedback.
This control is not suitable for large machines requiring greater power
because of limitation of stepper motor to generate high torque.
Closed-loop Control
Direct current (DC) motors are used.
Can generate high levels of torque.
Can be reversed.
Unlike stepper motors, it cannot achieve very precise
movement.
Separate positions sensors are required.
Position information is fed back as a signal to the controller.
Major advantage: because of feed back and servo motors
Types of NC control systems reversible feature, errors can
be corrected, by comparing with target position.
Thus formed a closed loop.
Higher accuracy than open loop systems because of feed
back.
Applications:
Larger NC machines because of higher loads.
For greater accuracy, any kind of load.
Expensive and complex.
ComponentProducing
production
Type Machining
Form
Planning
of
in Machining
which
Process
stock
Work
Speeds
type
Required
Operation
material
(Machine
CNC
holding
and
Program
Machining
feeds
isand
schedule
Setting)
supplied
location
Proving
program
and time estimation
Coordinates System
Incremental Coordinate System
A X2.000 Y2.000
B X1.000 Y-2.000
What is the value in X and Y for each hole in absolute G90 positioning when each move
is defined from a single fixed part zero point of an X0 Y0 origin point.
PT1 = X______ Y______
PT2 = X______ Y______
PT3 = X______ Y______
PT4 = X______ Y______
From PT8 to PT9 = X______
PT5 = X______ Y______
From PT9 to PT10 = X______
PT6 = X______ Y______
PT7 = X______ Y______
From PT10 to PT11 = X______
PT8 = X______ Y______
From PT11 to PT12 = X______
Y______
Y______
Y______
Y______
From PT12 to PT13 = X______ Y______
From PT13 to PT14 = X______ Y______
What is the value for each hole in INCREMENTAL G91 positioning when each move
is defined from the previous position and the zero point shifts with the new position.
Part Programme
The coded instructions or commands listed in a logical sequence to have a
machine tool perform a specific tasks or a series of tasks in order to produce a
finished product in the minimum amount of time.
Programming Format
% Programme Number.
N Sequence Number (Block Identification Number).
G Preparatory functions (G00 to G99). This prepares the M/C for next
operation.
X,Y,Z Primary motion Dimension in the X,Y,Z direction respectively.
U,V,W Secondary motion Dimension in the X,Y,Z direction respectively.
P,Q,R Tertiary motion Dimension in the X,Y,Z direction respectively.
I,J,K
Distance to the are center or thread leads parallel to X,Y,Z respectively.
A,B,C Angular Dimension around in the X,Y,Z direction respectively.
R Parameters.
F Feedrate.
S Spindle Speed/Cutting Speed.
T/D Tool number.
M Miscellaneous function (Machine Codes)
EOB End of Block.
6. MODAL COMMANDS : Codes that are active for more than the line in which they
are issued are called MODAL commands. Rapid traverse, feedrate moves, and
canned cycles are all examples of modal commands. A NON-MODAL command which
once called, are effective only in the calling block, and are then immediately forgotten
by the control.
7. PREPARATORY FUNCTIONS : "G" codes use the information contained on the line
to make the machine tool do specific operations, such as :
1.) Move the tool at rapid traverse.
2.) Move the tool at a feedrate along a straight line.
3.) Move the tool along an arc at a feedrate in a clockwise direction.
4.) Move the tool along an arc at a feedrate in a counterclockwise direction.
5.) Move the tool through a series of repetitive operations controlled by "fixed cycles"
such as, spot drilling, drilling, boring, and tapping.
8. MISCELLANEOUS FUNCTIONS : "M" codes are effective or cause an action to
occur at the end of the block, and only one M code is allowed in each block of a
program.
9. SEQUENCE NUMBERS : N1 thru N99999 in a program are only used to locate and
identify a line or block and its relative position within a CNC program. A program can
be with or without SEQUENCE NUMBERS. The only function of SEQUENCE
NUMBERS is to locate a certain block or line within a CNC program.
List of G-codes
G-code
Function
G00
Positioning rapid traverse
G01
Linear interpolation (feed)
G02
Circular interpolation CW
G03
Circular interpolation CCW
G04
Dwell
G20
Inch unit
G21
Metric unit
G28
Automatic zero return
G40
Tool nose radius compensation cancel
G41
Tool nose radius compensation left
G42
Tool nose radius compensation right
G43
Tool length compensation
G54
Work co-ordinate system 1 selection
G55
Work co-ordinate system 2 selection
G56
Work co-ordinate system 3 selection
G57
Work co-ordinate system 4 selection
G58
Work co-ordinate system 5 selection
G59
Work co-ordinate system 6 selection
G80
G81
G82
G83
G84
G85
G86
G87
G90
G91
G94
G95
G98
G99
List of M codes
M codes vary from machine to machine depending on the functions
available on it. They are decided by the manufacturer of the
machine. The M codes listed below are the common ones.
M-codes Function
M00
Optional program stop automatic
M01
Optional program stop request
M02
Program end
M03
Spindle ON clock wise (CW)
M04
Spindle ON counter clock wise (CCW)
M05
Spindle stop
M06
Tool change
M07
Mist coolant ON (coolant 1 ON)
M08
Flood coolant ON (coolant 2 ON)
M09
Coolant OFF
M30
End of program, Reset to start
M98
Sub program call
M99
Sub program end
History of CNC
The word address format
Each line of program == 1 block
Each block is composed of several instructions, or (words)
Sequence and format of words:
N3 G2
F3.2
S4
X+1.4 Y+1.4
T4 M2
Z+1.4
I1.4
J1.4
K1.4
tool
Format
N__ G02/03 X__ Y__Z__ I__ J__K__ F__ using the arc center
OR
N__ G02/03 X__ Y__Z__ R__ F__ using the arc radius
G02 moves along a CW arc
G03 moves along a CCW arc
Arc center
The arc center is specified by addresses I, J and K. I, J and K
are the X, Y and Z co-ordinates of the arc center with
reference to the arc start point.
Arc radius
The radius is specified with address R.
Block format
N__ G02 X__Y__ Z__ R__ F__
N__ G03 X__Y__ Z__ R__ F__
DWELL COMMAND
G04 Dwell
Format G04X_; or G04F_; or G04P_;
X: Specified time(decimal point is permitted)
F: Specified time(decimal point is permitted)
P: Specified time(decimal point is unpermitted)
Explanation G04 command dwell. The execution of the
next block is delayed by the specified time, specify dwell for
each rotation in feed per rotation mode. Dwell is use to stop
feed for specified period of time.
G04 X15 ,G04 F15, G04 P15000
Here M/C will Dwell for 15 second. The function Not modal. It
can be used in Boring, Making CAM Profile, at these point
dwell is required.
SUBROUTINE
A subprogram is a separate program called up by another
program. The use of subprograms can significantly reduce the
amount of programming on some parts. Subroutines allow the
CNC programmer to define a series of commands which might
be repeated several times in a program and, instead of repeating
them many times, they can be called up when needed. A
subroutine call is done with M98 and a Pnnnn. The P code
command identifies the O program number being used when
executed with M98
M99: -An M99 ends a sub-program and returns back to the next
line in the main program after the M98 sub-program call.
Canned cycles
Canned or fixed cycles are programming aids that simplify
programming. Canned cycles combine many programming
operations and are designed to shorten the program length,
minimize mathematical calculations, and use minimal tool motions.
Examples : drilling, peck drilling, tapping, boring, back spot facing.
G81 Drilling cycle
G82 Drilling cycle with dwell (Counter bore cycle)
G83 Peck drilling cycle / deep drill
G84 Right hand tapping cycle
G85 Boring / Reaming cycle
G86 Boring cycle
G87 Back boring cycle
G74 Left hand tapping cycle
G76 Fine boring cycle
G98/G99 plane of return point
When the tool gets to the bottom of the hole, it can return back to
the plane of R point and the initialized plane initialized by G98/G99.
Generally speaking, G99 is used in the first drilling plane while G98
is used in the last drilling, even though we use G99 to drill, the
plane of the initialized position would keep the same.
G81 X_Y_Z_R_F_K_
X_ Y_: Data of hole site
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute
coordinate
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G82 X_Y_Z_R_P_F_K_
X_ Y_: Data of hole site
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time (absolute coordinate
P_: Pause time (unit ms)
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G83 X_Y_Z_R_Q_F_K_
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time (absolute coordinate
Q_: Offset of hole bottom
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G85 X_Y_Z_R_F_K_
X_ Y_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute coordinate
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G86 X_Y_Z_R_F_K_
X_ Y_: Data of hole site
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute coordinate
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G87 X_Y_Z_R_Q_P_F_K_
X_ Y: Data of hole site
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute coordinate
Q_: Offset of hole bottom
P_: Pause time (unit ms)
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G88
Fixed point dring cycle (G88)
Format G88 X_Y_Z_R_P_F_K_;
X_ Y_: Data of hole site
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute coordinate
P_: Pause time (unit ms)
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G89
Boring cycle(G89)
Format
G89 X_Y_Z_R_P_F_K_
X_ Y_: Data of hole site
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute coordinate
P_: Pause time (unit ms)
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G73
Rapid depth drill circle(G73)
Format G73 X__Y__Z__R__Q__ F__K__
X_ Y_: Data of hole site
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute coordinate
Q_: Depth of cutting per time no symbol, increment
F_: Feeding rate of cutting
K_: Number of replication (if necessary)
G76 X__Y__Z__R__Q__P__F__K__
Z_: Depth of the bottom of hole(absolute coordinate
R_: Starting point or raising point per time absolute coordinate
Q_: Offset of hole bottom
P_: Pause time (unit ms)
F_: Feeding rate of cutting
K_: Number of replication (if necessary)