Professional Documents
Culture Documents
TECHNOLOGY
1
INTRODUCTION TO
CNC AND METAL
CUTTING
2
HISTORY
US Air Force commissioned MIT to develop the
first "numerically controlled" machine in 1949. It
was demonstrated in 1952.
At 1970-1972 first Computer Numeric Control
machines were developed.
Today, computer numerical control (CNC)
machines are found almost everywhere, from
small job shops in rural communities to
companies in large urban areas.
3
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.
4
CNC APPLICATIONS
Machining
2.5D / 3D
Turning ~ Lathes, Turning Centre
Milling ~ Machining Centres
Forming
2D
Plasma and Laser Cutting
Blanking, nibbling and punching
3D
Rapid Prototyping
5
SAMPLE
CNC MACHINES
6
CNC TURNING
7
CNC MILLING
8
CNC LASER CUTTING
9
CNC PLASMA CUTTING
10
CNC PRESS
11
CNC RAPID PROTOTYPING
12
INDUSTRIES MOST AFFECTED
by CNC
Aerospace
Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mold making
13
SAMPLE PRODUCTS
OF
CNC MANUFACTURING
14
AUTOMOTIVE INDUSTRY
Engine Block
15
AUTOMOTIVE INDUSTRY(Cont’d)
Different Products
16
AEROSPACE INDUSTRY
Aircraft Turbine Machined by
5-Axis CNC Milling Machine
17
CNC MOLD MAKING
18
ELECTRONIC INDUSTRY
19
RAPID PROTOTYPING
PRODUCTS
20
ADVANTAGES OF CNC
21
Utilization of computers in
manufacturing applications has
proved to be one of the most
significant advantages &
developments over the last couple
of decades in helping to improve
the productivity and efficiency of
manufacturing systems.
22
ADVANTAGES of CNC
Productivity
Machine utilisation is increased because
more time is spent cutting and less time is
taken by positioning.
Reduced setup time increases utilisation
too.
23
PROFIT increases as COST decreases
and as PRODUCTIVITY increases.
24
any means of helping
the workers to perform
their tasks more
efficiently
AUTOMATION
25
Transferred Results
skill
muscle power engine driven First industrial
machine tools revolution
manipulating mechanization hard automation
skill
vision skill use of position increase of
transducers, accuracy, part
cameras recognition
brain power cnc machines, industrial second industrial
robots, soft
automation, revolution
computer control of
manufacturing
systems 26
COST = COST OF
MANUFACTURING AND
COST OF MATERIAL
HANDLING
EFFICIENCY OF PRODUCTIVITY =
MANUFACTURING AVERAGE OUTPUT PER
MAN-HOUR
27
ADVANTAGES of CNC
Quality
Parts are more accurate.
Parts are more repeatable.
Less waste due to scrap.
28
ADVANTAGES of CNC
Reduced inventory
Reduced setup time permits smaller
economic batch quantities.
Lower lead time allows lower stock levels.
Lower stock levels reduce interest charges
and working capital requirements.
29
ADVANTAGES of CNC
Machining Complex shapes
Slide movements under computer control.
Computer controller can calculate steps.
First NC machine built 1951 at MIT for
aircraft skin milling.
30
ADVANTAGES of CNC
Management Control
CNC leads to CAD
Process planning
Production planning
31
DRAWBACKS of CNC
High capital cost
Machine tools cost $30,000 - $1,500,000
Retraining and recruitment of staff
New support facilities
High maintenance requirements
Not cost-effective for low-level production on simple
parts
As geometric complexity or volume increases CNC
becomes more economical
Maintenance personnel must have both mechanical
and electronics expertise
32
FUNDAMENTAL OF
METAL CUTTING
33
The metal cutting operations (also
called machining) is one of the
most important manufacturing
processes in industry today (as it
was yesterday).
34
MACHINING IS THE REMOVAL
OF MATERIALS IN FORMS OF
CHIPS FROM THE WORKPIECE
BY SHEARING WITH A SHARP
TOOL.
35
The main function of a machine tool
is to control the workpiece-cutting
tool positional relationship in such a
way as to achieve a desired
geometric shape of the workpiece
with sufficient dimensional
accuracy.
36
Machine tool provides:
work holding
tool holding
relative motion between tool
and workpiece
primary motion
secondary motion
37
Primary motion
Relative motion
between tool and Secondary motion
workpiece
39
CLASSIFICATION OF MACHINE TOOLS
40
BASIC COMPONENTS
OF CNC SYSTEMS
41
machine control unit
position transducers
42
ISO MACHINE TOOL AXIS DEFINITION
43
ISO MACHINE TOOL AXES DEFINITIONS
AXIS MACHINE TOOL WITH SPINDLE MACHINE TOOL WITH
NO SPINDLE
HORIZONT VERTICAL
AL AXIS AXIS
45
STANDARD LATHE
COORDINATE SYSTEM
46
STANDARD MILLING MACHINE
COORDINATE SYSTEM
47
NUMERICALLY CONTROLLED MACHINE
TOOLS:
An NC machine tool is functionally the same
as a conventional machine tool. The
technological capabilities NC machine tools
in terms of machining are no different from
those of conventional ones. The difference
is in the way in which the various machine
functions and slide movements are
controlled.
48
The functions and motions such as;
49
MACHINE TOOL
AUTOMATION
50
CNC SYSTEM ELEMENTS
A typical CNC system consists of the
following six elements
Part program
Program input device
Machine control unit
Drive system
Machine tool
Feedback system
51
NC SYSTEM ELEMENTS
52
OPERATIONAL FEATURES of
CNC MACHINES
53
PART PROGRAM
A part program is a series of coded instructions required
to produce a part. It controls the movement of the
machine tool and the on/off control of auxiliary functions
such as spindle rotation and coolant. The coded
instructions are composed of letters, numbers and
symbols and are arranged in a format of functional
blocks as in the following example
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number
54
PROGRAM INPUT DEVICE
The program input device is the
mechanism for part programs to be
entered into the CNC control. The most
commonly used program input devices are
keyboards, punched tape reader, diskette
drivers, throgh RS 232 serial ports and
networks.
55
MACHINE CONTROL UNIT
The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:
56
TYPES of CNC CONTROL
SYSTEMS
Open-loop control
Closed-loop control
57
OPEN-LOOP CONTROL
SYSTEM
In open-loop control system step motors are
used
Step motors are driven by electric pulses
Every pulse rotates the motor spindle through a
certain amount
By counting the pulses, the amount of motion
can be controlled
No feedback signal for error correction
Lower positioning accuracy
58
CLOSED-LOOP CONTROL
SYSTEMS
In closed-loop control systems DC or AC
motors are used
Position transducers are used to generate
position feedback signals for error
correction
Better accuracy can be achieved
More expensive
Suitable for large size machine tools
59
CONTROL
Desired path (p, v, a)
3-axis position control (encoder feedback)
Velocity control (tachometer feedback)
Torque control (current feedback)
Path generator
Linear interpolation
Circular interpolation
Complex path interpolation (contouring)
DRIVE SYSTEM
A drive system consists of amplifier
circuits, stepping motors or servomotors
and ball lead-screws. The MCU feeds
control signals (position and speed) of
each axis to the amplifier circuits. The
control signals are augmented to actuate
stepping motors which in turn rotate the
ball lead-screws to position the machine
table.
61
STEPPING MOTORS
A stepping motor provides open-loop, digital
control of the position of a workpiece in a
numerical control machine. The drive unit
receives a direction input (cw or ccw) and pulse
inputs. For each pulse it receives, the drive unit
manipulates the motor voltage and current,
causing the motor shaft to rotate bya fixed angle
(one step). The lead screw converts the rotary
motion of the motor shaft into linear motion of
the workpiece .
62
STEPPING MOTORS
63
RECIRCULATING BALL
SCREWS
Transform rotational motion of the motor
into translational motion of the nut attached to the
machine table.
64
RECIRCULATING BALL
SCREWS
Accuracy of CNC
machines depends on
their rigid
construction, care in
manufacturing, and
the use of ball screws
to almost eliminate
slop in the screws
used to move portions
of the machine.
65
COMPONENTS OF
RECIRCULATING BALL SCREWS
Ball screw
Ball nut (anti-backlash)
Ways
Linear bearings
67
POSITIONING
The positioning resolution of a ball screw drive
mechanism is directly proportional to the
smallest angle that the motor can turn.
The smallest angle is controlled by the motor
step size.
Microsteps can be used to decrease the motor
step size.
CNC machines typically have resolutions of
0.0025 mm or better.
68
MACHINE TOOL
CNC controls are used to control various
types of machine tools. Regardless of
which type of machine tool is controlled, it
always has a slide table and a spindle to
control of position and speed. The
machine table is controlled in the X and Y
axes, while the spindle runs along the Z
axis.
69
FEEDBACK SYSTEM
The feedback system is also referred to as
the measuring system. It uses position and
speed transducers to continuously monitor
the position at which the cutting tool is
located at any particular time. The MCU
uses the difference between reference
signals and feedback signals to generate
the control signals for correcting position
and speed errors.
70
CNC MACHINES FEEDBACK
DEVICES
71
ENCODERS
72
ENCODERS
73
INDUSTRIAL APPLICATIONS of
ENCODERS
74
RESOLVERS
A resolver is a rotary
transformer that produces
an output signal that is a
function of the rotor
position.
75
SERVOMOTOR with
RESOLVER
76
DRIVE MOTORS
DC servo motors
AC servo motors
Stepper motors
Hydraulic motors
POSITION FEEDBACK
Incremental encoder
Quadrature
Absolute encoder
Resolver
Tachometer
No feedback (open
loop)
POTENTIOMETERS
79
POTENTIOMETERS
80
CNC Programming
Manual
Write code directly
Computer-assisted
Draw cutter path
CAD/CAM
Draw the part
Cutter path is generated
VELOCITY FEEDBACK
Tachometers:
Electrical output is proportional to rate of
angular rotation.
Encoders, Resolvers, Potentiometers:
Number of pulses per time is proportional
to rate change of position.
82
CNC MACHINES
CUTTING TOOLS (CUTTERS)
83
CNC CUTTERS
84
TURNING CENTER CUTTERS
Types of cutters used on CNC turning
centers
Carbides (and other hard materials) insert
turning and boring tools
Ceramics
High Speed Steel (HSS) drills and taps
85
STANDART INSERT SHAPES
V – used for profiling, weakest
insert, 2 edges per side.
D – somewhat stronger, used for
profiling when the angle allows it,
2 edges per side.
T – commonly used for turning
because it has 3 edges per side.
C – popular insert because the
same holder can be used for
turning and facing. 2 edges per
side.
W – newest shape. Can turn and
face like the C, but 3 edges per
side.
S – Very strong, but mostly used
for chamfering because it won’t
cut a square shoulder. 4 edges
per side.
R – strongest insert but least
commonly used.
86
TYPICAL TURNING,
THREADING and PARTING
TOOLS
87
MACHINING CENTER CUTTING
TOOLS
Most machining centers
use some form of HSS or
carbide insert endmill as
the basic cutting tool.
Insert endmills cut many
times faster than HSS,
but the
HSS endmills leave a
better finish when side
cutting.
88
MACHINING CENTER CUTTING
TOOLS (cont’d)
Facemills flatten large
surfaces quickly and
with an excellent
finish. Notice the
engine block being
finished in one pass
with a large cutter.
89
MACHINING CENTER CUTTING
TOOLS (cont’d)
Ball endmills (both
HSS and insert) are
used for a variety of
profiling operations
such as the mold
shown in the picture.
Slitting and side
cutters are used when
deep, narrow slots
must be cut.
90
MACHINING CENTER CUTTING
TOOLS (cont’d)
Drills, Taps, and Reamers
Common HSS tools such as
drills, taps, and reamers are
commonly used on CNC
machining centers. Note that a
spot drill is used instead of a
centerdrill. Also, spiral point or
gun taps are used for through
holes and spiral flute for blind
holes. Rarely are hand taps
used on a machining center.
91
TOOL HOLDERS
All cutting tools must be held in a holder
that fits in the spindle. These include end
mill holders (shown), collet holders, face
mill adapters, etc. Most machines in the
USA use a CAT taper which is a modified
NST 30, 40, or 50 taper that uses a pull
stud and a groove in the flange. The
machine pulls on the pull stud to hold the
holder in the spindle, and the groove in
the flange gives the automatic tool
changer something to hold onto. HSK tool
holders were designed a number of years
ago as an improvement to CAT tapers,
but they are gaining acceptance slowly.
92
CNC PROGRAMMING
93
CNC PROGRAMMING
Offline programming linked to CAD programs.
Conversational programming by the operator.
MDI ~ Manual Data Input.
Manual Control using jog buttons or `electronic
handwheel'.
Word-Address Coding using standard G-codes
and M-codes.
94
Basics of NC Part Programming:
96
In defining the motion of the tool
from one point to another,
either
absolute positioning mode or
incremental positioning mode
can be used.
97
1. Absolute positioning. In this mode, the
desired target position of the tool for a
particular move is given relative to the origin
point of the program.
98
Structure of an NC Part Program:
Commands are input into the controller in
units called blocks or statements.
Block Format:
1. Fixed sequential format
2. Tab sequential format
3. Word address format
99
EXAMPLE:
Assume that a drilling operation is to be
programmed as:
100
1. Fixed sequential format
0050 00 +0025400 +0012500 +0000000 0000 00
0060 01 +0025400 +0012500 -0010000 0500 08
0070 00 +0025400 +0012500 +0000000 0000 09
101
Modal commands: Commands issued in the
NC program that will stay in effect until it is
changed by some other command, like, feed
rate selection, coolant selection, etc.
103
INFORMATION NEEDED by a
CNC
1. Preparatory Information: units, incremental or absolute
positioning
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.
104
BLOCK FORMAT
Sample Block
N135 G01 X1.0 Y1.0 Z0.125 F5
105
WORD-ADDRESS CODING
Example CNC Program
N5 G90 G20 Each instruction to the machine
N10 M06 T3 consists of a letter followed by a
N15 M03 S1250 number.
N20 G00 X1 Y1
N25 Z0.1
Each letter is associated with a
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 specific type of action or piece of
N40 G00 Z1 information needed by the machine.
N45 X0 Y0 Letters used in Codes
N50 M05
N55 M30 N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
106
G & M Codes
Example CNC Program
N5 G90 G20 • G-codes: Preparatory Functions
N10 M06 T3 involve actual tool moves.
N15 M03 S1250
N20 G00 X1 Y1 • M-codes: Miscellaneous
N25 Z0.1
Functions – involve actions
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 necessary for machining (i.e.
N40 G00 Z1 spindle on/off, coolant on/off).
N45 X0 Y0
N50 M05
N55 M30
107
G Codes
G00 Rapid traverse
G01 Linear interpolation
G40 Cutter compensation –
cancel
G02 Circular interpolation,
CW G41 Cutter compensation – left
G03 Circular interpolation, G42 Cutter compensation-
CCW right
G04 Dwell G70 Inch format
G08 Acceleration G71 Metric format
G09 Deceleration G74 Full-circle programming off
G17 X-Y Plane G75 Full-circle programming on
G18 Z-X Plane G80 Fixed-cycle cancel
G19 Y-Z Plane G81-G89 Fixed cycles
G20 Inch Units (G70) G90 Absolute dimensions
G21 Metric Units (G71) G91 Incremental dimensions
108
Modal G-Codes
109
Modal G-Code List
G00 Rapid Transverse G43 Tool length
G01 Linear Interpolation compensation (plus)
G02 Circular Interpolation, CW
G03 Circular Interpolation, G44 Tool length
CCW compensation (minus)
G17 XY Plane G49 Tool length
G18 XZ Plane
G19 YZ Plane
compensation cancel
G20/G70 Inch units G80 Cancel canned cycles
G21/G71 Metric Units G81 Drilling cycle
G40 Cutter compensation
cancel G82 Counter boring cycle
G41 Cutter compensation left G83 Deep hole drilling cycle
G42 Cutter compensation right
G43 Tool length compensation
G90 Absolute positioning
(plus) G91 Incremental positioning
110
M Codes
M00 Program stop
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps on
M11 Clamps off
M30 Program stop, reset to start
111
N Codes
Gives an identifying number for each block
of information.
112
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.
113
I,J, and K Codes
I, J, and K codes are used to
specify the
coordinate axis when defining the center
of a circle.
114
F,S, and T Codes
F-code: used to specify the feed rate
115
Application of Some Codes
G01 Linear Interpolation
Format: N_ G01 X_ Y_ Z_ F_
116
Application of Some Codes
G01 Linear Interpolation
. As an example, for the motion that occurs in x-
y plane with the same maximum speed for the x-
and y-axis, initial motion is at an angle of 45o to
the axes until motion in one of
117
Application of Some Codes
G01 Linear Interpolation
25
B C
20
15
5 10 15 20 25 30
118
Application of Some Codes
G01 Linear Interpolation
119
Application of Some Codes
G01 Linear Interpolation
15
10
A
5
5 10 15 20 25 30
120
G01 Linear Interpolation
N10 G00 X1 Z1
X
N15 Z0.1
N20 G01 Z-0.125 F5
N25 X2 Z2 F10
Z
121
G02 Circular Interpolation
G02 is also a preparatory function to specify that
the tool should be moved to a specified location
along a circular path in a clockwise direction. In
order to specify the path to the MCU, the end
point of the arc and the location of the center of
the arc should be specified. Within the block in
which the G02 code is programmed, the center
of the arc is given by specifying its location
relative to the start of the arc.
122
G02 Circular Interpolation (CW)
123
G02 Circular Interpolation (CW)
Circular interpolation from A to B
about a circle centered at C
N10 G02 X20000 Y10000
25 I5000 J15000 F2500
I=5 A C
20
15
J=15
10 B
C
5
5 10 15 20 25 30 124
Canned Cycles
The sequence of some machining operations is may be
the same for any part and for any machine. For example,
drilling a hole involves the following steps:
Position the tool above the point where the hole will be
drilled
125
Some Commonly Used Canned Cycle
Code Function Down feed At bottom Retracti
on
G81 Drilling Continuous No action Rapid
feed
G82 Spot face, Continuous Dwell Rapid
counterbore feed
G83 Deep hole drilling Peck No action Rapid
127
Three Main parts of a CNC
program
128
Three Main parts of a CNC
program
129
Three Main parts of a CNC
program
130
EXAMPLE OPERATION on CNC
MILLING MACHINE
131
G-CODE PROGRAM
First pass : conventional mill to
a depth of 0.125 around edge
profile. Tool 1 is a ½ 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
132
Second pass:
conventional mill to a
depth of 0.25 around
edge profile.
N35 Z-0.250
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
N60 Z0.125
133
Third pass:
conventional mill to a
depth of 0.125 around
pocket profile.
134
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
135
Advanced features:
136
Program Loading:
Through keyboard
Through punched tape reader
Through diskette drive
Through RS 232 serial port
Through network interface card
137
Direct Numerical Control (DNC):
A system in which a central computer
downloads the NC programs block by block
to many NC machine tools simultaneously is
called Direct Numerical Control (DNC)
system.
138
Direct Numerical Control (DNC):
139
Distributed Numerical Control (DNC):
140
Distributed Numerical Control (DNC):
141
Computer Aided Part Programming:
142
Advantages of applying computer-aided part
programming include the following:
143
The Aerospace Industries Association sponsored the work that
led to the first part programming language, developed in MIT in
1955.
This was called: Automatically Programmed Tools (APT).
APT is an English like simple programming language which
basically produce the Cutter Location (CL) data.
Using the cutter location data, the program can generate the
actual NC codes by using a postprocessor .
144
CAD/CAM Based Part Programming:
The output of any CAD package include the geometric data of the
part to be machined. Therefore, many CAD/CAM package can
produce cutter location (CL) data to be used for NC code generation.
There is still to be a process planning module for a workable NC
code generation.
Some of the CAD/CAM packages that have the NC code generation
capabilities are Computervision, CATIA, CADAM, ProEngineer,
MechanicalDesktop (Auto Desk).
145