002-CNC Machine Tools+Programming

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM ME 445 INTEGRATED MANUFACTURING SYSTEMS
CNC TECHNOLOGY and CNC PROGRAMMING

2004 1
JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM
AUTOMATION IN MANUFACTURING SYSTEMS TRENDS IN INDUSTRY

THE OBJECTIVE:
TO BE COMPETITIV THROUGH INCREASING PRODUCTIVITY AND TOTAL QUALITY ASSURANCE
2004 2
COST = COST OF MANUFACTURING AND COST OF MATERIAL HANDLING
EFFICIENCY OF MANUFACTURING
PRODUCTIVITY = AVERAGE OUTPUT PER MAN-HOUR PROFIT = INCOME - COST
2004
PROFIT increases as COST decreases and as PRODUCTIVITY increases.
PRODUCTIVITY through AUTOMATION AUTOMATION
2004
any means of helping the workers to perform their tasks more efficiently
AUTOMATION
transfer of the skill of the operator to the machine
2004 5
JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM Transferred skill muscle power manipulating skill vision skill Results
engine driven machine tools mechanization
First industrial revolution hard automation increase of accuracy, part recognition second industrial revolution
use of position transducers, cameras

cnc machines, industrial robots, soft automation, computer control of manufacturing systems
brain power
2004
Utilization of computers in manufacturing applications has proved to be one of the most significant developments over the last couple of decades in helping to improve the productivity and efficiency of manufacturing systems.
2004 7
The metal cutting operations (also called machining) is one of the most important manufacturing processes in industry today (as it was yesterday). yesterday).
2004
MACHINING Is The Removal Of Materials In Forms Of Chips From The Workpiece By Shearing With A Sharp Tool.
2004
The main function of a machine tool is to control the workpiece-cutting tool workpiecepositional relationship in such a way as to achieve a desired geometric shape of the workpiece with sufficient dimensional accuracy.
2004
10
Machine tool provides : work holding tool holding relative motion between tool and workpiece primary motion secondary motion
2004 11
JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM Primary motion
Relative motion between tool and workpiece
Secondary motion
Cutting motion Feed motion Cutting speed Feed rate

2004 12

machine control unit position transducers
work holding device tool holding device
2004
13
CLASSIFICATION OF THE CHIP REMOVING METHODS ACCORDING TO THE RELATIVE MOTION
2004
14
CLASSIFICATION OF MACHINE TOOLS

THOSE USING SINGLE POINT TOOLS lathes shapers planers boring m/cs etc. THOSE USING MULTIPOINT TOOLS drilling m/cs milling m/cs broaching m/cs hobbing m/cs etc. THOSE USING ABRASIVE TOOLS grinding m/cs honing m/cs etc.
2004
15
ISO MACHINE TOOL AXIS DEFINITION
2004
16

AXIS MACHINE TOOL WITH SPINDLE axis of spindle, (+Z) as tool goes away from the work piece MACHINE TOOL WITH NO SPINDLE perpendicular to work holding surface, (+Z) as tool goes away from the workpiece
ISO MACHINE TOOL AXES DEFINITIONS
MACHINE TOOL WITH ROTATING WORKPIECE
MACHINE TOOL WITH ROTATING TOOL HORIZONTAL AXIS VERTICAL AXIS horizontal and parallel to the work holding surface, (+X) to the right when viewed from spindle towards column parallel to and positive in the principal direction of cutting (primary motion)
radial and parallel to cross slide, (+X) when tool goes away from the axis of spindle
horizontal and parallel to work holding surface, (+X) to the right when viewed from spindle towards work piece
apply right hand rules
2004
17
RIGHT HAND RULE

Vertical Machine Horizontal Machine
2004
18
STANDARD LATHE COORDINATE SYSTEM
2004
19
STANDARD MILLING MACHINE COORDINATE SYSTEM
2004
20
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.
2004 21
The functions and motions such as ;
turning the spindle on and off setting cutting speeds setting feed rate turning coolant on and off moving tool with respect to workpiece
are performed by Machine Control Unit (MCU) in NC machine tools.
2004 22
INTRODUCTION TO CNC
2004
23
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 1970were developed. Today, computer numerical control (CNC) machines are found almost everywhere, from small job shops in rural communities to companies in large urban areas.
24
2004
DEFINITION

In CNC (Computer Numerical Control), the Control), instructions are stored as a program in a micromicrocomputer attached to the machine. The computer will also handle much of the control logic of the machine, making it more adaptable than earlier hardhard-wired controllers.
25
2004
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
26
2004
SAMPLE CNC MACHINES
2004
27
CNC TURNING
CNC MILLING
CNC LASER CUTTING
2004
30
CNC PLASMA CUTTING
2004
31
CNC PRESS
2004
32
CNC RAPID PROTOTYPING
2004
33
INDUSTRIES MOST AFFECTED by CNC

2004
Aerospace Machinery Electrical Fabrication Automotive Instrumentation Mold making

34
SAMPLE PRODUCTS OF CNC MANUFACTURING
2004
35
AUTOMOTIVE INDUSTRY Engine Block
2004
36
AUTOMOTIVE INDUSTRY(Cont d)
Different Products
2004
37
AEROSPACE INDUSTRY Aircraft Turbine Machined by 5-Axis CNC Milling Machine
2004
38
CNC MOLD MAKING
2004
39
ELECTRONIC INDUSTRY
2004
40
RAPID PROTOTYPING PRODUCTS
2004
41
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.
2004
42
ADVANTAGES of CNC

Quality
Parts are more accurate. Parts are more repeatable. Less waste due to scrap.
2004
43
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.
2004
44
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.
2004
45
ADVANTAGES of CNC

Management Control
CNC leads to CAD Process planning Production planning
2004
46
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 costlowAs geometric complexity or volume increases CNC becomes more economical Maintenance personnel must have both mechanical and electronics expertise
47
2004
CNC SYSTEM ELEMENTS
2004
48
CNC SYSTEM ELEMENTS

A typical CNC system consists of the the following six elements

2004
Part program Program input device Machine control unit Drive system Machine tool Feedback system
49
NC SYSTEM ELEMENTS
2004
50
OPERATIONAL FEATURES of CNC MACHINES
2004
51
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
2004
52
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 The input devices are keyboards, punched tape keyboards, reader, diskette drivers, throgh RS 232 serial ports and networks. networks.
2004
53
MACHINE CONTROL UNIT

The machine control unit (MCU) is the heart of a CNC system. It is used to perform the following functions:

Read coded instructions Decode coded instructions Implement interpolations (linear, circular, and helical) to generate axis motion commands Feed axis motion commands to the amplifier circuits for driving the axis mechanisms Receive the feedback signals of position and speed for each drive axis Implement auxiliary control functions such as coolant or spindle on/off, and tool change
54
2004
TYPES of CNC CONTROL SYSTEMS

OpenOpen-loop control Closed-loop control Closed-
2004
55
OPENOPEN-LOOP CONTROL SYSTEM

In open-loop control system step motors are used openStep 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
56

2004
CLOSEDCLOSED-LOOP CONTROL SYSTEMS

In closed-loop control systems DC or AC motors closedare 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
57

2004
DRIVE SYSTEM

A drive system consists of amplifier circuits, stepping motors or servomotors and ball leadleadscrews. 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 leadlead-screws to position the machine table.
58
2004
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 .
59
2004
STEPPING MOTORS
2004
60
RECIRCULATING BALL SCREWS

Transform rotational motion of the motor into translational motion of the nut attached to the machine table.
2004
61
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.
62
2004
2004
63
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.
64

2004
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.
2004
65
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.
66
2004
CNC MACHINES FEEDBACK DEVICES
2004
67
POTENTIOMETERS
2004
68
POTENTIOMETERS
2004
69
ENCODERS

A device used to convert linear or rotational position information into an electrical output signal.
2004
70
ENCODERS
2004
71
INDUSTRIAL APPLICATIONS of ENCODERS
2004
72
RESOLVERS

A resolver is a rotary transformer that produces an output signal that is a function of the rotor position.
2004
73
SERVOMOTOR with RESOLVER
2004
74
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.
2004
75
CNC CUTTERS

Turning center cutters Machining center cutters
2004
76
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

2004
77
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.
78
2004
TYPICAL TURNING, THREADING and PARTING TOOLS
2004
79
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.
2004
80
JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM MACHINING CENTER CUTTING TOOLS (cont s)
Facemills flatten large surfaces quickly and with an excellent finish. Notice the engine block being finished in one pass with a large cutter.
2004
81
MACHINING CENTER CUTTING TOOLS (cont s)

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.
2004
82
MACHINING CENTER CUTTING TOOLS (cont s)

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.
2004 83
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.
2004 84
CNC PROGRAMMING
2004
85
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'. WordWord-Address Coding using standard G-codes and MGMcodes.
86
2004
Basics of NC Part Programming :

During secondary motion, either the tool moves relative to the workpiece or the workpiece moves relative to the tool In NC programming, it is always assumed that the tool moves relative to the workpiece no matter what the real situation is.
2004 87
The position of the tool is described by using a Cartesian coordinate system. If (0,0,0) position can be described by the operator, then it is called floating zero. zero.
In defining the motion of the tool from one
point to another, either absolute positioning mode or incremental positioning mode can be used.
2004 88
1. Absolute positioning. In this mode, the desired positioning.
target position of the tool for a particular move is given relative to the origin point of the program.
2. Incremental positioning. In this mode, the next positioning.
target position for the tool is given relative to the current tool position.
2004 89
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
2004
90
EXAMPLE :
Assume that a drilling operation is to be programmed as :

The tool is positioned at (25.4,12.5,0) by a rapid movement. The tool is then advanced -10 mm in the z direction at a feed rate of 500 mm/min., with the flood coolant on. The is then retracted back 10 mm at the rapid feed rate, and the coolant is turned off.
91
2004

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 2. Tab sequential format 0050 TAB 00 TAB +0025400 TAB +0012500 TAB +0000000 TAB TAB 0060 TAB 01 TAB TAB TAB -0010000 TAB 0500 TAB 08 0070 TAB 00 TAB TAB TAB -0000000 TAB 0000 TAB 09 3. Word address format N50 G00 X25400 Y125 Z0 F0 N60 G01 Z-10000 F500 M08 N70 G00 Z0 M09
2004 92
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 Nonmodal commands : Commands that are effective only when issued and whose effects are lost for subsequent commands, like, a dwell command which instructs the tool to remain in a given configuration for a given amount of time.
2004 93
CNC PROGRAMMING
2004
94
INFORMATION NEEDED by a CNC

1. 2. 3. 4. 5. 6. 7. Preparatory Information : units, incremental or absolute positioning Coordinates: X,Y,Z, RX,RY,RZ Machining Parameters: Feed rate and spindle speed Coolant Control: On/Off, Flood, Mist Tool Control: Tool and tool parameters Cycle Functions: Type of action required 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 Program.
2004 95
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 feed-rate 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
2004
96
WORDWORD-ADDRESS CODING
Example CNC Program

N5 G90 G20 N10 M06 T3 N15 M03 S1250 N20 G00 X1 Y1 N25 Z0.1 N30 G01 Z-0.125 F5 ZN35 X3 Y2 F10 N40 G00 Z1 N45 X0 Y0 N50 M05 N55 M30
Each instruction to the machine consists of a letter followed by a number. Each letter is associated with a specific type of action or piece of information needed by the machine.
Letters used in Codes N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
2004
97
G & M Codes
Example CNC Program

N5 G90 G20 N10 M06 T3 N15 M03 S1250 N20 G00 X1 Y1 N25 Z0.1 N30 G01 Z-0.125 F5 ZN35 X3 Y2 F10 N40 G00 Z1 N45 X0 Y0 N50 M05 N55 M30
G-codes : Preparatory Functions involve actual tool moves. M-codes : Miscellaneous Functions involve actions necessary for machining (i.e. spindle on/off, coolant on/off).
2004
98
G Codes

G00 Rapid traverse G01 Linear interpolation G02 Circular interpolation, CW G03 Circular interpolation, CCW G04 Dwell G08 Acceleration G09 Deceleration G17 X-Y Plane XG18 Z-X Plane ZG19 Y-Z Plane YG20 Inch Units (G70) G21 Metric Units (G71)

G40 Cutter compensation - cancel G41 Cutter compensation - left G42 Cutter compensation - right G70 Inch format G71 Metric format G74 Full-circle programming off FullG75 Full-circle programming on FullG80 Fixed-cycle cancel FixedG81G81-G89 Fixed cycles G90 Absolute dimensions G91 Incremental dimensions
99
2004
Modal G-Codes G
Most G-codes set the machine in a mode Gwhich stays in effect until it is changed or cancelled by another G-code. These commands Gare called modal .
2004
100
Modal G-Code List G
G00 G01 G02 G03
Rapid Transverse Linear Interpolation Circular Interpolation, CW 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)
2004

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
101
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
102
2004
N Codes

Gives an identifying number for each block of information. It is generally good practice to increment each block number by 5 or 10 to allow additional blocks to be inserted if future changes are required.
2004
103
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.
2004
104
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.
2004
105
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.
2004
106
Application of Some Codes G01 Linear Interpolation

Format : N_ G01 X_ Y_ Z_ F_

Linear Interpolation results in a straight line feed move. Unless tool compensation is used, the coordinates are associated with the centerline of the tool.
107
2004

As an example, for the motion that occurs in x-y example, plane with the same maximum speed for the xxand y-axis, initial motion is at an angle of 45o to ythe axes until motion in one of the axes is completed and then the balance of the motion occurs in the other axis. This is called point-topoint-topoint motion. motion.
2004
108

25 B 20 15 10 A 5 Positioning motion from A to C N10 G00 X30000 Y20000 F0 C
5
2004
10
15
20 25
30
109

G01 is another preparatory function to specify that the tool should be moved to a specified location along a straight line path. It is referred to as linear interpolation. This function is typically used to specify machining of straight features such as turning a cylindrical surface in turning, cutting a slot in milling, etc.
2004
110

25 20 15 10 A 5 Linear interpolation from A to C N10 G01 X30000 Y20000 F2500 C
2004
10
15
20 25
30
111
G01 Linear Interpolation

X
N10 G00 X1 Z1 N15 Z0.1 N20 G01 Z-0.125 F5 ZN25 X2 Z2 F10
2004
112
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.
113
2004
G02 Circular Interpolation (CW)

The G02 command requires an endpoint and a radius in order to cut the arc. I,J, and K are relative to the start point. N_ G02 X2 Y1 I0 J-1 F10 Jor N_ G02 X2 Y1 R1
2004
114
G02 Circular Interpolation (CW)

Circular interpolation from A to B about a circle centered at C N10 G02 X20000 Y10000 I5000 J15000 F2500
25 20 15
I=5 A
J=15 10 C 5 B
2004
10 15 20 25
30
115
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 Set the correct spindle speed Feed the tool into the workpiece at a controlled feed rate to a predetermined depth Retract the tool at a rapid rate to just above the point where the hole started
2004 116
Some Commonly Used Canned Cycle Code G81 G82 G83 G84 G85 G86 Function
Drilling Spot face, counterbore Deep hole drilling Tapping Through boring(in & out) Through boring(in only)
Down feed
Continuous feed Continuous feed Peck Continuous feed Continuous feed Continuous feed
At bottom
No action Dwell No action Reverse spindle No action Stop spindle
Retraction
Rapid Rapid Rapid Feed rate Feed rate Rapid
2004
117
G81 ILLUSTRATION
2004
118
Three Main parts of a CNC program

Part 1- Program Petup 1
N5 G90 G21 G21 N10 M06 T2
(Absolute units, metric) metric)
(Stop for tool change, use tool # 2) N15 M03 S1200 (Turn the spindle on CW to 1200 rpm)
2004
119
Three Main parts of a CNC program

Part 2- Chip Removal 2
N20 G00 X1 Y1 N25 Z0.125 N30 G01 Z-0.125 F100 ZF100 N35 G01 X2 Y2 N40 G00 Z1 N45 X0 Y0
(Rapid to X1,Y1 from origin point) (Rapid down to Z0.125) (Feed down to Z-0.125 at 100 mm/min) Zmm/min) (Feed diagonally to X2,Y2) (Rapid up to Z1) (Rapid to X0,Y0)
2004
120
Three Main parts of a CNC program Part 3- System Shutdown 3
N50 M05 N55 M00 M0
( Turn the spindle off ) ( Program stop )
2004
121
EXAMPLE OPERATION on CNC MILLING MACHINE
2004
122
G-CODE PROGRAM

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
2004
123
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
2004
124
Third pass : conventional mill to a depth of 0.125 around pocket profile. N65 G00 X1.25 Y1.0 N70 G01 Z-0.125 F5 N75 X1.75 N80 Y2.5 N85 X1.25 N90 Y1.0 N95 Z0.125
2004
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
2004
126
Advanced features :

Execution of the part of the program in a rotated or mirrored position. Ability to scale the program and produce larger or smaller programs. Three dimensional circular interpolation which produces a helical shape. Parabolic and cubic interpolation.
127
2004
Program Loading :

Through keyboard Through punched tape reader Through diskette drive Through RS 232 serial port Through network interface card
2004
128
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.
2004
129
Direct Numerical Control (DNC) :

( conts )
This system used to work with the early NC machine tools which can not read more than a block of information at a time. The central computer feed the program information one block at a time. When the machine execute the information, the next block of information would be fed.
2004
130
Distributed Numerical Control (DNC) :

Distributed NC is known by the same acronym as Direct Numerical Control (DNC). After the introduction of CNC, the machine tools have had the capability of storing large amount of information. Therefore, there have been no need to have drip feed information system, like, Direct Numerical Control. Instead, Distributed Numerical Control is introduced. In such a system, a host computer communicate with many CNC machine tools via networks and download or upload programs.
131
2004
Distributed Numerical Control (DNC) : ( conts )

With Distributed Numerical Control systems, it is possible to monitor the activities in individual CNC machine tools on host computer. Therefore, better shop floor control can be achieved.
2004
132
Computer Aided Part Programming :

NC program preparation may be tedious and difficult if the part to be machined has a complex geometry. The main difficulty is to find out the cutter locations during the machining. Computers may be used to assist the programmers in preparing the NC codes.
2004
133
Advantages of applying computer-aided computerpart programming include the following :

It reduces the manual calculations involves in determining the geometric characteristics of the part. It provides the cutter path simulation. It provides tool collision checking. It shortens the program preparation time. It makes the program preparation easier.
134

2004
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 .

2004
135
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).
136
2004

002-CNC Machine Tools+Programming

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

002-CNC Machine Tools+Programming

Uploaded by

Copyright:

Available Formats

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM ME 445 INTEGRATED MANUFACTURING SYSTEMS

CNC TECHNOLOGY and CNC PROGRAMMING

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

AUTOMATION IN MANUFACTURING SYSTEMS TRENDS IN INDUSTRY

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

COST = COST OF MANUFACTURING AND COST OF MATERIAL HANDLING

PRODUCTIVITY = AVERAGE OUTPUT PER MAN-HOUR PROFIT = INCOME - COST

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

PROFIT increases as COST decreases and as PRODUCTIVITY increases.

PRODUCTIVITY through AUTOMATION AUTOMATION

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

use of position transducers, cameras

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM Primary motion

Relative motion between tool and workpiece

Cutting motion Feed motion Cutting speed Feed rate

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

work holding device tool holding device

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

CLASSIFICATION OF THE CHIP REMOVING METHODS ACCORDING TO THE RELATIVE MOTION

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

CLASSIFICATION OF MACHINE TOOLS

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

ISO MACHINE TOOL AXIS DEFINITION

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

ISO MACHINE TOOL AXES DEFINITIONS

MACHINE TOOL WITH ROTATING WORKPIECE

apply right hand rules

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

RIGHT HAND RULE

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

STANDARD LATHE COORDINATE SYSTEM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

STANDARD MILLING MACHINE COORDINATE SYSTEM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

NUMERICALLY CONTROLLED MACHINE TOOLS :

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

The functions and motions such as ;

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

Machining - 2.5D / 3D - Turning ~ Lathes, Turning Centre - Milling ~ Machining Centres

SAMPLE CNC MACHINES

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

CNC LASER CUTTING

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

CNC PLASMA CUTTING

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

CNC RAPID PROTOTYPING

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

INDUSTRIES MOST AFFECTED by CNC

Aerospace Machinery Electrical Fabrication Automotive Instrumentation Mold making

SAMPLE PRODUCTS OF CNC MANUFACTURING

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM

AUTOMOTIVE INDUSTRY Engine Block

JURUSAN TEKNIK MESIN dan INDUSTRI FT - UGM