Rev.

1
 10/30/2011

NeedforUnconventionalProcesses
y New materials having high strength and hardness, such as
nimonic alloys and alloys with alloying elements such as

NTMM tungsten, molybdenum, and columbium are difficult to

machine by the traditional methods.
methods
y By conventional machining the MRR reduces with an
increase in the work material hardness.
y Need for development of nontraditional machining
processes which utilize other methods such as
BySKMondal electrochemical processes for the material removal.

NeedforUnconventionalProcesses InUnconventionalMachining
y Complex shapes. y Different forms of energy directly applied to the
workpiece to have shape transformation or material
y A very high accuracy is desired besides the complexity of removal from work surface.
the surface to be machined. y No chips, No lay pattern on work surface, no direct
physical contact between the tool and the workpiece .
y The tool material does not have to be harder than the
work material.
y Tool forces do not increase as the work material gets
harder.
y Economic metal removal rate does not decrease as the
work material gets harder.

ClassificationofNTMM 1.ThermalEnergyMethods
The Nontraditional Machining Methods are classified y Electricaldischargemachining(EDM)
according to the major energy sources employed in
machining. y LaserbeamMachining(LBM)
1.ThermalEnergyMethods y PlasmaArcMachining(PAM)
g
2.Electro ChemicalEnergyMethod y ElectronBeamMachining(EBM)
3.ChemicalEnergyMethods y IonBeamMachining(IBM)
4.MechanicalEnergyMethods

Page 2 of 45 1
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2.Electro ChemicalEnergyMethod 3. ChemicalEnergyMethods

These methods involve controlled etching of the
y ElectroChemicalMachining(ECM)
workpiece material in contact with a chemical solution.
y ElectroChemicalgrinding(ECG)
y Chemical Machining Method (CHM).
y ElectroChemicalHoning(ECH)
El t Ch i lH i (ECH)

y ElectroChemicalDeburring (ECD)

4. MechanicalEnergyMethods SomeObservations
y EDM has the lowest specific power requirement and can
y UltraSonicMachining(USM)
achieve sufficient accuracy.
y AbrasiveJetMachining(AJM) y ECM has the highest metal removal rate, MRR.
y USM and AJM have low MRR and combined with high
y WaterJetMachining(WJM)
g tool wear,, are used for nonmetal cutting.
g
y LBM and EBM have high penetration rates with low
MRR and, therefore, are commonly used for micro
drilling, sheet cutting, and welding.
y CHM is used for manufacturing PCB and other shallow
components.
y PAM can be used for clean, rapid cuts and profiles in
almost all plates upto 20 cm thick with 5o to 10o taper.

ShapesCuttingCapability LimitationsofNTMM
The various NTMM have some special shape cutting y Expensive set up, low MRR and skilled labour required.
capability as given below:
y The limitation of electrical machining methods is that
1. Micromachining and Drilling : LBM and EBM
the work material must be an electrical conductor. Also,
2 Cavity sinking and standard Hole Drilling: EDM and
2.
consumption of electrical energy is very large.
USM
y The NTMM which have not been proved commercially
3. Fine hole drilling and Contour Machining: ECM
economical are: USM, AJM, CHM, EBM and PAM.
4. Clean, rapid Cuts and Profiles: PAM

5. Shallow Pocketing: AJM

Page 3 of 45 2
 10/30/2011

ElectrochemicalMachining
y Electrochemical machining is the reverse of electro
plating
y The workpiece is made the anode, which is placed in

ECM close proximity to an electrode (cathode), and a high

amperage direct current is passed between them through
an electrolyte, such as salt water, flowing in the anode
cathode gap.
y Metal is removed by anodic dissolution and is carried
BySKMondal away in the form of a hydroxide in the electrolyte for
recycling or recovery.
y MRR in ECM depends on atomic weight of work material

ElectrochemicalMachining
y Variation in the current density will result in work
taking the electrodes shape.
y The electrode is fed with a constant velocity, and the
electrolyte is fed through the tool.

Fig- Electrochemical Machining process

ECMEquipment ECMEquipment
y Supply Voltage 2 to 35 V DC and Current 500 to 40,000 A
y The tooltowork gap needs to be maintained at a very
small value 0.1 to 0.25 mm. A servo drive is provided on
the tool axis for this purpose.
y The
Th electrolyte
l t l t needs d to
t be
b pumped
d through
th h this
thi gap att
high pressures ranging from 0.70 to 3.00 MPa. This
introduces a large amount of load on the machine,
because of the large working areas involved. Hence the
machine structure will have to be made rigid to a
withstand such forces.

Page 4 of 45 3
 10/30/2011

ECMEquipment Electrolyte
y The electrolyte consists of the metal debris removed The electrolyte is so chosen that the anode (workpiece)
from the anode, which will have to be filtered before it is is dissolved but no deposition takes place on the cathode
repumped into the system. (tool).
y Also a large amount of heat is generated during the
Properties electrolyte should be
electrolysis which heats up the electrolyte,
electrolysis, electrolyte and hence it 1. Highg electrical conductivityy
needs to be cooled. 2. Low viscosity
3. High specific heat
4. Chemical stability
5. Resistance to formation of passivating film on
workpiece surface
6. Noncorrosive and nontoxic
7. Inexpensive and readily available

Tool
The properties of tool materials should be:
1. High electrical and thermal comductivity
2. Easy machinability
3. Good shiffness

ForECMofsteelNaCl isusedastheelectrolyte. 4. High corrosion resistance

y Tool materials: Copper, brass, bronze, Al, Stainless

Steel, Cupro nickel, etc.
y Material wear / Tool wear: Infinite

Advantages Disadvantages
1. Complex threedimensional surfaces can be machined 1. Use of corrosive media as electrolytes makes it difficult to
handle.
accurately. Good for low machinability or complicated
2. Sharp interior edges and corners (< 0.2 mm radius) are
shapes. difficult to produce.
2. As ECM leads to atomic level dissolution, the surface 3. Very expensive machine.
fi i h is
finish i excellent
ll t (Ra 0.2 to
t 0.66 m)) with
ith almost
l t stress
t 4. Forces are large with this method because of fluid pumping
free machined surface and without any thermal forces.
damage. 5. Very high specific energy consumption (about 150 times
3. The tool wear is practically nil which results in a large that required for conventional processes),
number of components produced per tool. 6. Not applicable with electrically nonconducting materials
and jobs with very small dimensions
4. MRR is highest (1600 mm3/min) among NTMM and 7. Lower fatigue strength
comparable with conventional machining.

Page 5 of 45 4
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Applications PSU
y Any electrically conductive work material irrespective
of their hardness, strength or even thermal properties. ECMcannotbeundertakenfor
y The machining surface can be situated at any (a)steel
inaccessible.
(b)Nickelbasedsuperalloy
y Shape application blind complex cavities, curved
surfaces through cutting,
surfaces, cutting large through cavities.
cavities (c)Al2O3
y It is used for the machining of the gas turbine blades. (d)Titaniumalloy
y Die sinking
y Profiling and contouring
y Trepanning
y Grinding
y Drilling
y Micromachining

ECMCalculations
PSU Faradays laws state that,
Commercial ECM is carried out at a combination It E
of m=
(a) low voltage high current F
(b) low current low voltage Where m =weight(g)ofamaterial
(c) high current high voltage I =current(A)
(d) low current low voltage t =time(sec)
E =gramequivalentweightofthe
material
F =constantofproportionality
Faraday(96,500coulombs)

ECMCalculations ECMCalculations
EI AI
yMRR = F
g/s =
F. V
g/s
3

IfyouputE=equivalentweightinCGSi.e.g/mole
IfyouputE=equivalentweightinCGSi e g/mole
IinAmpere(A)
F=96500columb/molei.e.As/mole
TheMRRwillbeing/s

Page 6 of 45 5
 10/30/2011

ECMCalculations Example
y MRR for pure metal UsingECMremove5cm3/minfromanironworkpiece,
whatcurrentisrequired?
AI cm3 EI cm3
= Atomicweightofiron56,density7.8g/cm3 valency,2
vF sec F sec
y MRR for Alloy
Eeq I cm3

eq F sec

100 x 100 x v
= i and = i i
eq i i Eeq i Ai

Example Example(GATE2009)
Calculate the material removal rate and the Electrochemicalmachiningisperformedtoremove
electrode feed rate in the electrochemical materialfromanironsurfaceof20mmx20mmunder
machining of an iron surface that is 25 mm 25 mm thefollowingconditions:
in crosssection using NaCl in water as electrolyte. Interelectrodegap = 0.2mm
The gap between the tool and the workpiece is 0.25 SupplyVoltage(DC)
S l V lt (DC) = 12V
V
mm. The supply voltage is 12 V DC. The specific
Specificresistanceofelectrolyte
=2cm
resistance of the electrolyte is 3 c m
For iron, Valency, Z = 2 AtomicweightofIron = 55.85
Atomic weight, A = 55.85 Valency ofIron = 2
Density, = 7860 kg / m3 Faraday'sconstant = 96540Coulombs
Thematerialremovalrate(ing/s)is

Example Flowanalysis
Composition of a Nickel superalloy is as follows: y To calculate the fluid flow required, match the heat
Ni = 70.0%, Cr = 20.0%, Fe = 5.0% and rest Titanium generated to the heat absorbed by the electrolyte.
Calculate rate of dissolution if the area of the tool is 1500
mm2 and a current of 1000 A is being passed through the
cell Assume dissolution to take place at lowest valancy
cell.
of the elements.

y Neglecting all the heat losses

l2R = q e ce (B o )

Page 7 of 45 6
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Example
The electrochemical machining of an iron surface that is Overvoltage
25 mm 25 mm in crosssection using NaCl in water as y If the total over voltage at the anode and the cathode is
electrolyte. The gap between the tool and the workpiece V and the applied voltage is V, the current I is given
is 0.25 mm. The supply voltage is 12 V DC. The specific by,
V V
resistance of the electrolyte is 3 cm. I=
R
Estimate the electrolyte flow rate. Specific heat of the
electrolyte is given as 0.997 cal/gC. The ambient
temperature is 35C and the electrolyte boiling
temperature, is 95C.
Density, = 7860 kg/cm3

DynamicsofElectrochemicalMachining Example
In ECM operation of pure iron an equilibrium gap of 2
mm is to be kept. Determine supply voltage, if the total
overvoltage is 2.5 V. The resistivity of the electrolyte is 50
mm and the set feed rate is 0.25 mm/min.

y Schematic representation of the ECM process with no

feed to the tool

ElectrochemicalGrinding(ECG)
y In ECG, the tool electrode is a rotating, metal bonded,
diamond grit grinding wheel.
y As the electric current flows between the workpiece and the
wheel, through the electrolyte, the surface metal is changed
to a metal oxide, which is ground away by the abrasives. As
the oxide film is removed,
removed new surface metal is oxidized and
removed.
y ECG is a lowvoltage highcurrent electrical process.
y The purpose of the abrasive is to increase the efficiency of the
ECG process and permit the continuance of the process.
y The abrasive particles are always nonconductive material
such as aluminum oxide, diamond, or borazon (CBN). Thus
they act as an insulating spacer maintaining a separation of Equipmentsetupandelectricalcircuitforelectrochemicalgrinding.
from 0.012 to 0.050 mm between the electrodes.

Page 8 of 45 7
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ElectrochemicalGrinding(ECG)
y The process is used for shaping and sharpening OtherElectrochemicalprocesses
carbide cutting tools, which cause high wear rates on
expensive diamond wheels in normal grinding. y Electrochemicalpolishing
Electrochemical grinding greatly reduces this wheel
wear. y Electrochemicalholedrilling
g
y Fragile parts (honeycomb structures), surgical needles,
and tips of assembled turbine blades have been ECG y ElectrochemicalDeburring
processed successfully.
y The lack of heat damage, burrs, and residual stresses is
very beneficial, particularly when coupled with MRRs
that are competitive with conventional grinding but
with far less wheel wear.

PhysicalPrinciple
y Basic process

EDM

PhysicalPrinciple PhysicalPrinciple
y An arc jumps between two points along the path of least y The energy of the arc is so concentrated that it causes the
resistance. electrode, and the work to melt. But the electrode
material is chosen so that it melts less.

Page 9 of 45 8
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PhysicalPrinciple PhysicalPrinciple
y The metal and dielectric fluid is partly vaporized, y The blast from the expanding vapors knocks some
causing sudden expansion. molten particles loose, and the remaining molten metal
hardens.

CharacteristicsofEDM CharacteristicsofEDM
y Mechanics of material removal melting and y Uses Voltage of 60 to 300 V to give a transient arc lasting
evaporation aided by cavitation. from 0.1 s to 8 ms.
y The process is based on melting temperature, not y Typical cycle time is 20 ms or less, up to millions of
hardness, so some very hard materials can be machined cycles may be required for completion of the part.
this way.
way y Rotating
R t ti the
th wire
i ini an orbital
bit l direction
di ti will,
ill
y The arc that jumps heats the metal, and about 1 to 10% of Increase accuracy in form and surface finish
the molten metal goes into the fluid. The melted metal Decrease electrode wear
then recast layer is about 1 to 30 m thick, and is
generally hard and rough. y Surface finish obtained 0.25 m
y The electrode workpiece gap is in the range of 10 m to
100 m.

EDMTool EDMTool
Prime requirements EDM tool Material Theusualchoicesfortool(electrode)materialsare
1. It should be electrically conductive. y Copper,
2. It should have good machinability, thus allowing y brass,
easy manufacture of complex shapes. y alloysofzincandtin,
3. It should have low erosion rate or good work to tool y hardenedplaincarbonsteel,
wear ratio. y coppertungsten,
4. It should have low electrical resistance.
y silvertungsten,
5. It should have high melting point.
y tungstencarbide,
6. It should have high electron emission.
y coppergraphite,andgraphite.

Page 10 of 45 9
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WearRatio ServoMechanism
y One major drawback of EDM is the wear that occurs on y The gap between the tool and work has a critical
the electrode at each spark. Tool wear is given in terms of
wear ratio which is defined as, importance. As the workpiece is machined, this gap
tends to increase. For optimum machining efficiency,
Volume of metal removed work
W
Wear ratio
ti =
Volume of metal removed tool this gap should be maintained constant. This is done by
servo mechanism which controls the movement of the
y Wear ratio for brass electrode is 1: 1. For most other
metallic electrodes, it is about 3: 1 or 4: 1. electrode.
y With graphite (with the highest melting point, 3500C),
the wear ratio may range from 5: 1 up to 50: 1.

DielectricFluid IES2011Conventional
y Fluid is used to act as a dielectric, and to help carry away
Discuss the effects of insufficient dielectric and
debris.
y If the fluid is pumped through and out the end of the electrolyte circulation in the interelectrode gap on the
electrode, particles will push out, and mainly collect at
the edges. They will lower the dielectric resistance, Electric Discharge machining and Electro Chemical
resulting in more arcs. As a result the holes will be Machining process respectively. [5 Marks]
conical.
y If fluid is vacuum pumped into the electrode tip, straight
holes will result.
y Quite often kerosenebased oil.
y The dielectric fluid is circulated through the tool at a
pressure of 0.35 N/m2 or less. To free it from eroded
metal particles, it is circulated through a filter.

Relaxationcircuit Advantages
1. Hardness, toughness or brittleness of the material poses no
problems. Due to this EDM can be used for machining
materials that are too hard or brittle to be machined by
conventional methods.
2. The method does not leave any chips or burrs on the work
Fig-Relaxation circuit used for generating the pulses in EDM process piece.
piece
3. Cutting forces are virtually zero, so very delicate and fine
work can be done.
4. The process dimension repeatability and surface finish
obtained in finishing are extremely good.
5. The characteristic surface obtained, which is made up of
craters, helps in better oil retention. This improves die life.
6. Because the forces between the tool and the workpiece and
virtually zero, very delicate work can be done.

Page 11 of 45 10
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Disadvantages Applications
1. Only electrically conductive materials can be machined
y EDM can be used for machining any material that is
by EDM. Thus non metallic, such as plastics, ceramics
or glass, cannot be machined by EDM. electrically conductive, thus including metals, alloys and
2. Electrode wear and overcut are serious problems.
most carbides.
33. A rehardened,, highly
g y stressed zone is p
produced on the
work surface by the heat generated during machining. y EDM is widely used for machining burr free intricate
This brittle layer can cause serious problems when the
part is put into service. shapes, narrow slots and blind cavities etc., for example,
4. Perfectly square corners cannot be made by EDM. sinking of dies for moulding, die casting, plastic
5. High specific energy consumption (about 50 times that
in conventional machining) moulding, wire drawing, compacting, cold heading,
6. MRR is quite low forging, extrusion and press tools.

Applications Applications
y EDM is particularly useful when dealing with internal y The method is also employed for blanking parts from sheets,

cuts that are hard to get tools into. Machining tends to
work best with external cuts.
y In EDM method,
y Almost any geometry (negative of tool geometry) can be
generated on a workpiece if a suitable tool can be
fabricated (the use of punch as a tool to machine its own
mating die is commonly employed in EDM method).
cutting off rods of materials, flat or form grinding and
sharpening of tools, cutters and broaches.
method small holes,
holes about 0.13
0 13 mm,
mm in
diameter and as deep as 20mm diameters can be drilled
with virtually no bending or drifting of hole. Due to this,
EDM is particularly useful for machining of small holes,
orifices or slots in dieselfuel injection nozzles, or in aircraft
engines, air brake valves and so on.

WireEDM
IES2009Conventional y Wire EDM is a special form of EDM wherein the
i. What is the principle of metal removal in EDM electrode is a continuously moving conductive wire.
process?
ii. Describe the process with the help of sketch. y A thin wire of brass, tungsten, or copper is used as an
iii. List advantages and limitations of the system. electrode.
[15marks]
y The electrode wire is typically made with a 0.05 to 0.25
mm diameter, which is wire electrode wound between
the two spools.

y Deionized water is used as the dielectric.

Page 12 of 45 11

y Geometrically accurate but moderately finished straight
toothed metallic spur gears, both external and internal
type, can be produced by wire type Electro discharge
Machining (EDM).
Fig- Electric Discharge Grinding (EDG)
Page 13 of 45
10/30/2011
WireEDM
y This process is much faster than electrode EDM.
y This process is widely used for the manufacture of
punches, dies, and stripper plates, with modern
machines capable of cutting die relief, intricate
openings, tight radius contours, and corners routinely.
ElectricDischargeGrinding(EDG)
y EDG is similar to EDM except that the electrode is a
rotating wheel (usually graphite).
y Positively charged work pieces are immersed in or
flooded by a dielectric fluid and fed past the negatively
charged wheel by servocontrolled
servo controlled machine table.
table
y Metal is removed by intermittent high frequency
electrical discharges passing through the gap between
wheel and workpiece.
y Each spark discharge melts or vaporizes a small amount
of metal from the workpiece surface, producing a small
crate at the discharge sit, as in EDM.
ElectricDischargeGrinding(EDG)
y The spark gap is normally held at 0.013 to 0.076 mm
y The graphite wheel is rotated at 0.5 to 3 m/s
The method can be used for
1. External cylindrical grinding, internal grinding and
surface grinding.
2. Grinding carbide and steel at the same time without
wheel loading.
3. Grinding thin sections where abrasive wheel pressures
might cause distortion.
4. Grinding brittle materials or fragile parts where
abrasive materials might cause fracturing.
12
 10/30/2011

UltrasonicMachining
UltrasonicMachining

BySKMondal

UltrasonicMachining UltrasonicMachining
y In ultrasonic machining, a tool of desired shape vibrates at an y USM is mainly used for machining brittle materials
ultrasonic frequency (19 ~ 25 kHz) with an amplitude of {which are poor conductors of electricity and thus
around 15 50 m over the workpiece. cannot be processed by Electrochemical and Electro
y Generally the tool is pressed downward with a feed force, F. discharge machining (ECM and EDM)}.
p
Between the tool and workpiece, , the machining g zone is
flooded with hard abrasive particles generally in the form of
water based slurry.
y As the tool vibrates over the workpiece, the abrasive particles
act as the indenters and indent both the work material and
the tool. The abrasive particles, as they indent, the work
material, would remove the same, particularly if the work
material is brittle, due to crack initiation, propagation and
brittle fracture of the material.

UltrasonicMachining ProcessParameters
y At full indentation, the indentation depth in the work
material is characterized by w. Due to the indentation,
as the work material is brittle, brittle fracture takes place
leading to hemispherical fracture of diameter 2x under
the contact zone.
y If at any moment of time, there are an average n of grits
and the tool is vibrating at a frequency f then material
removal rate can be expressed as

2
y MRRw = ( w db )3/2 nf
3

Page 14 of 45 13
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EffectofmachiningparametersonMRR UltrasonicMachine

UltrasonicMachine UltrasonicMachine
y The basic mechanical structure of an USM is very similar y Feed mechanism to provide a downward feed force on
to a drill press. the tool during machining
y It has additional features to carry out USM of brittle y The transducer, which generates the ultrasonic vibration
work material. y The horn or concentrator, which mechanically amplifies
y The
Th workpiece
k i is
i mounted
t d on a vice,
i which
hi h can beb the
th vibration
ib ti to t the
th required
i d amplitude
lit d off 15 50 m and
d
located at the desired position under the tool using a 2 accommodates the tool at its tip.
axis table.
y The table can further be lowered or raised to
accommodate work of different thickness.
y Slurry delivery and return system

SubsystemsofUSM
Subsystemsof USM Transducer
y The ultrasonic vibrations are produced by the
transducer. The transducer is driven by suitable signal
generator followed by power amplifier. The transducer
B
for USM works on the following principle
Piezoelectric effect

A C Magnetostrictive effect

Electrostrictive effect

y Magnetostrictive transducers are most popular and

robust amongst all.
E D

Page 15 of 45 14
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ToolholderorHorn Tool
y Its function is to increase the tool vibration amplitude y Tools should be constructed from relatively ductile
and to match the vibrator to the acoustic load. materials.

y It must be constructed of a material with good acoustic y The harder the tool material, the faster its wear rate will
properties and be highly resistant to fatigue cracking. be.

y Monel and titanium have good acoustic properties and

are often used together with stainless steel, which is
cheaper.

Limitations Applications
y LowMRR y Used for machining hard and brittle metallic alloys,
y Ratherhightoolwear semiconductors, glass, ceramics, carbides etc.
y Lowdepthofhole y Used for machining round, square, irregular shaped
holes and surface impressions.
y Machining,
M hi i wire
i drawing,
d i punching
hi or small
ll blanking
bl ki
dies.

Note ChemicalMachining
y The following material is generally machined by USM y Chemicals are used to dissolve material
(i) Glass
(ii) Silicon y Masks are used to control attack
(iii) Germanium y Most common use is circuit boards and p
plates for
y Tool in USM is generally made of Steel
printing.

y Cutting speed of 0.00250.1 mm/minute very slow

Page 16 of 45 15
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ChemicalMachining PhotoChemicalMachining
y PCM is a material removal process using chemicals
(etchants) to produce high precision parts.
y This process is also known as Photo Etching, Chemical
Blanking and Photo Chemical Milling.
y Coat
C t both
b th sides
id off the
th plate
l t with
ith photoresist.
h t i t
(photoresist is a polymer that adheres to the metal when
exposed to UV light).
y Spray metal with etchant or dip it in hot acidic solution
to etch all material other than part covered with
photoresist (115 min.).
y Rinse the plate to ensure photoresist and etchant
removal.

PhotoChemicalMachining LaserBeamMachining

94

LaserBeamMachining LaserBeamMachining
y Direct laser beam against surface of workpiece, as in
y Produceslargeremelt zone
laser welding
y Canproduceholesassmallas0.0005mmdiameter
y Successive pulses from laser gun vaporize tiny bits of
y Canproducedeepholes
workpiece
k i
y Usedtoproducecoolingholesinblades/vanesforjet
y Location of laser beam controlled by computer
engines
y Workpiece need not be conductive

y Cuts are tapered

y Gotta trap overshoot from laser beam

95 96

Page 17 of 45 16
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ElectronBeamMachining ElectronBeamMachining
y Workpiece placed in vacuum chamber

y Highvoltage electron beam directed toward

workpiece

y Energy of electron beam melts/ vaporizes selected

region of workpiece

y Electron beam moved by deflection coils

y Similar process to EB welding

97 98

PlasmaArcCutting WaterJetMachining
y Plasma is a stream of ionized gas y Narrowjetofwaterdirected,athighpressureand
y Typical temperatures are very high velocity,againstsurfaceofworkpiece
y Same process as plasma welding, without filler metal y Jetofwatererodessurfaceofworkpiece,thereby
y Torch movement controlled by computer cuttingworkpiece
y Power requirements depend on material being cut, y Computercontroltoachieveshape
plus depth of cut
y Recast layer is deeper than with other processes

99 100

WaterJetMachining AbrasiveJetMachining(Dry)
y Similar to sand blasting, except that a very narrow jet
of air/abrasive particles achieves localized cutting

y Computer used to position jet

101 102

Page 18 of 45 17
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AbrasiveJetMachining AbrasiveWJCutting
y Used to cut much harder materials

y Water is not used directly to cut material as in Pure,

instead water is used to accelerate abrasive particles which
g
do the cutting
y 80mesh garnet (sandpaper) is typically used though 50
and 120mesh is also used
y Standoff distance between mixing tube and workpart is
typically 0.0100.200 important to keep to a minimum to
keep a good surface finish
103

AbrasiveWJCutting
y Evolution of mixing tube
technology
y Standard Tungsten Carbide
lasts 46
4 6 hours (not used much
anymore)
y Premium Composite Carbide
lasts 100150 hours
y Consumables include water,
abrasive, orifice and mixing
tube

Ch10:NonConventionalMachiningOperation
Q.No Option Q.No Option
1 D 8 D
2 B 9 A
3 B 10 B
4 D 11 D
5 D 12 A
6 B 13 A
7 A 14 B

Page 19 of 45 18

NC,CNC&Robotics
BySKMondal
WhatisthedifferencebetweenNCandCNC?
y The difference between NC and CNC is one of age and
capability.
y The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
cards
y As the technology evolved, the machines were equiped
with increasingly powerful microprocessors (computers)
with the addition of these computers, NC machines
become CNC machines.
y CNC machines have far more capability than their
predecessor. contd..
WheredidCNCgetstarted?
y 1940 Jhon Parson developed first machine able to drill
holes at specific coordinates programmed on punch
cards.
y 1951 MIT developed servomechanism
y 1952 MIT developed first NC machines for milling.
y 1970 First CNC machines came into picture
Nowadays modified 1970s machines are used.
Page 20 of 45
10/30/2011
WhatisNC/CNC?
y NC is an acronym for Numerical Control and CNC is an
acronym for Computer Numerical Control.
WhatisthedifferencebetweenNCandCNC?
y Some of the enhancements that came along with CNC
include: Canned Cycles, Sub Programming, Cutter
Compensation, Work coordinates, Coordinate system
rotation, automatic corner rounding, chamfering, and B
spline interpolation.
DoallmachinesspeakthesameCNC
language
y No, while there is fairly standard set of G and M codes,
there is some variation in their application. For example
a G0 or G00 command is universally regarded as the
command for rapid travel. Some older machines do not
have a G00 command. On these machines, rapid travel is
commanded by using the F (feed) word address.
1
 10/30/2011

WhatisaConversationalControl AreCNCmachinesfasterthan
y CNC machine tool builders offer an option what is conventionalmachines?
known as the conversational control. This control lets
y Yes, No, Sometimes. When it comes to making a single,
the operator/programmer use simple descriptive
simple part it is hard to beat a conventional mill or lathe.
lathe
language to program the part. The control then
CNC machines move faster in rapid travel than
displayed a graphical representation of the instructions
conventional machines.
so the operator/programmer can verify the tool path.

AreCNCmachinesmoreaccurate NC/CNCMachinesAdvantages
thanconventionalmachines? y High Repeatability and Precision e.g. Aircraft parts
y Volume of production is very high
y Yes, they can be. But like anything else it depends on y Complex contours/surfaces need to be machined. E.g.
Turbines
who
h is
i running
i the
th machine,
hi how
h well
ll the
th machines
hi has
h
y Flexibility in job change, automatic tool settings, less
been maintained, quality of setup and so on. scrap
y More safe, higher productivity, better quality
y Less paper work, faster prototype production, reduction
in lead times

NC/CNCMachinesDisadvantages NC/CNC/DNC
y Direct Numerical Control is a system that uses a
y Costlysetup,skilledoperators
central computer to control several machines at the same
y Computers,programmingknowledgerequired time
y Distributed Numerical Control (DNC): the central
y Maintenanceisdifficult computer
t downloads
d l d complete l t programs tot the
th CNC
machines, which can be workstations or PCs, and can get
the information for the machine operations.
y The speed of the system is increased, large files can be
handled and the number of machine tools used is
expanded.

12

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Directnumericalcontrol DNC

13 14

BasicCNCPrinciples
StepperMotor
y The stepper motor is special type of synchronous motor
which is designed to rotate through a specific angle
(Called step) for each electrical pulse received from the
control unit.

BasicLengthUnit(BLU)
y In NC machine, the displacement length per one pulse
output from machine is defined as a Basic Length Unit
(BLU).
y In the CNC computer each bit (binary digit) represents 1
BLU.
BLU
Bit = BLU
y Example: If one pulse makes a servo motor rotate by one
degree and the servo motor moves the table by 0.0001
mm, one BLU will be 0.0001 mm.
y The lead of a ball screw is related to the displacement
unit of the machine tool table.

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Example IES2011Conventional
y A DC servomotor is coupled directly to a leadscrew y The table of a CNC machine is driven by a Lead screw which
which drives the table of an NC machine tool. A is rotated by a DC servomotor. A digital encoder which emits
digital encoder, which emits 500 pulses per
1000 pulses per second is mounted on the lead screw as a
revolution, is mounted on the other end of the
leadscrew.
leadscrew If the leadscrew pitch is 5 mm and the feedback device. If the lead screw p
pitch is 6 mm and motor
motor rotates at 600 rpm, calculate rotates at 500 rpm, find
(a) The linear velocity of the table 1. Basic length Units of the system
(b) The BLU of the NC system
2. Linear velocity of the table.
(c) The frequency of pulses transmitted by the encoder.
3. Frequency of pulses generated by the feedback device.
[5 Marks]

StatementforLinkedAnswersquestions:S1 GATE 2008Q1 (StatementinS1)

In the feed drive of a PointtoPoint open loop CNC The Basic Length Unit (BLU), i.e., the table
drive, a stepper motor rotating at 200 steps/rev drives a movement corresponding to 1 pulse of the pulse
table through a gear box and lead screwnut mechanism generator, is
(pitch = 4 mm, number of starts = 1). (a) 0.5 microns (b) 5 microns
Output rotational speed
The gear ratio = Input rotational speed is given by U = 14 ( ) 50 microns
(c) i (d) 500 microns
i
The stepper motor (driven by voltage pulses from a pulse
generator) executes 1 step/pulse of the pulse generator.
The frequency of the pulse train from the pulse
generator is f = 10,000 pulses per minute.

GATE 2008Q2 (StatementinS1) ControlSystemspossibleinCNCMachine

A customer insists on a modification to change the BLU y Point to point mode:
of the CNC drive to 10 microns without changing the
table speed. The modification can be accomplished by

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Pointtopointstraightlinemode

Coordinatesystem
y All the machine tool use Cartesian Coordinate system.
y The first axis to be identified is the Z axis, This is
followed by X and Y axes respectively.

Righthandcoordinatesystems

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Absolute and Incremental Coordinate System

5axesCNCverticalaxismachiningcentreconfiguration Absolute Coordinate System Incremental Coordinate System

Thefollowingarethestepstobefollowed
whiledevelopingtheCNCpartprograms.
y Processplanning
y Axesselection
y Toolselection
y Cuttingprocessparametersplanning
y Jobandtoolsetupplanning
y Machiningpathplanning y For a CNC machine control unit (MCU) decides cutting
y Partprogramwriting speed, feed, depth of cut, tool selection , coolant on off
y Partprogramproving and tool paths. The MCU issues commands in form of
numeric data to motors that position slides and tool
accordingly.

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PartProgramming CNCprogramming
Importantthingstoknow:
y FANUCCONTROLL
CoordinateSystem
y SIEMENSCONTROLL
Units,incrementalorabsolutepositioning
Coordinates:X,Y,Z,RX,RY,RZ
Feedrateandspindlespeed
CoolantControl:On/Off,Flood,Mist
ToolControl:Toolandtoolparameters

TableofImportantGcodes
ProgrammingKeyLetters Code Meaning Format
y O Programnumber(Usedforprogramidentification)
G00 RapidTransverse N__G00X___Y___Z___
y N Sequencenumber(Usedforlineidentification) G01 LinearInterpolation N__G01X___Y___Z___F___
y G Preparatoryfunction G02 CircularInterpolation, N__G02X__Y__Z___R___F___
y X Xaxisdesignation CW N__G02X___Y__Z__I___J__K__F__
y Y Yaxisdesignation
g
G
G03 CircularInterpolation,
C l l N G X___Y___Z__R__F___
N__G03 X Y Z R F
y Z Zaxisdesignation
y R Radiusdesignation CCW N__G03 X__Y__Z__I__J__K__F__
y F Feedratedesignation G04 Dwell N__G04P___
y S Spindlespeeddesignation
G17 XY Plane
y H Toollengthoffsetdesignation
y D Toolradiusoffsetdesignation G18 XZPlane
y T ToolDesignation G19 YZPlane
y M Miscellaneousfunction

TableofImportantGcodes TableofImportantGcodes
Code Meaning Format Code Meaning Format
G20/G70 InchUnit G44 Toollengthcompensation N__G44H__
G21/G71 MetricUnit (minus)
G28 AutomaticReturntoReference G49 Toollengthcompensation
Point cancel
G40 Cuttercompensationcancel G
G80 C y
Cancelcannedcycles
G81 Drillingcycle N__G81Z__R__F__
G41 Cuttercompensationleft N__G41D__
G42 Cuttercompensationright N__G42D__ G90 Absolutepositioning
G91 Incrementalpositioning
G43 Toollengthcompensation N__G43H__ G92 Absolutepreset,changethe N__G92X__Y__Z__
(plus) datumposition

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Rapidtraverse:G00 Linearinterpolation:G01
y G01:
y G00:
y linearinterpolationatfeedspeed.
y tomakethemachinemoveatmaximumspeed.
G91G0lX200.0Y100.0F200.0
y Itisusedforpositioningmotion.
G90G00X20.0Y10.0
G90G00X20 0Y10 0 Y
G91:
End
End incremental 100.0
G90: coordinates
(20,10)
absolute
coordinates (10,10)

Start (0,0)
Start 200.0 X

Circularinterpolation:G02,G03 Circularinterpolation:G02,G03
y G02,G03:
y Forcircularinterpolation,thetooldestinationandthecircle Y
centerareprogrammedinoneblock
y G02isclockwiseinterpolation,G03iscounterclockwise X R=-50mm
interpolation End SpecifyRwith
G 02 R signbeforeit:
G17 X __ Y __ F __;
G 03 I __ J __ 180 +R
G 02 R R=50mm >180 R
G18 X __ Z __ F __; Start
G 03 I __ K __
G 02 R
G19 Y __ Z __ F __;
G 03 J __ K __ G91G02X60.0Y20.0R50.0 F300.0
End Circlecenter,radius G91G02X60.0Y20.0R50.0 F300.0
point

Circularinterpolation:G02,G03 Circularinterpolation:G02,G03
N0010G92X200.0Y40.0Z0;
Y y SpecifyCenterwithI,J,K N0020G90G03X140.0Y100.0I60.0F300
End
N0030G02X120.0Y60.0I 50.0 G92:
y I,J,Karetheincremental
Or Todefineworking
distancefromthestartof
N0010G92X200.0Y40.0Z0
N0010G92X200 0Y40 0Z0 coordinate
X thearc;
h
N0020G90G03X140.0Y100.0R60.0F300
y Viewingthestartofarcas N0030G02X120.0Y60.0R50.0
Start theorigin,I,J,Khave
Y
j positiveornegativesigns. G90:
Center absolute 100 R50
i coordinates 60 R60
40
X
O 90 120 140 200

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Circularinterpolation:G02,G03 ToolCompensation
AnnotationforCircularInterpolation y ToolRadiusCompensation
y I0.0,J0.0,andK0.0canbeomitted. y LefthandG41
y IfX,Y,Zareallomittedintheprogram,thatmeans y RighthandG42
startandendofarcaresamepoints.
startandendofarcaresamepoints y CanceltoolradiuscompensationG40
C l l di i G
N0020G02I20.0(afullcircle)
y ToolHeightCompensation
y IfI,J,K,andRallappearsincircularinterpolation
y PositiveG43
instruction,RisvalidandI,J,andKareinvalid
y NegativeG44
y CanceltoolheightcompensationG49

ToolRadiusCompensation CancelToolCompensation:G40
y Toolradiuscompensationsmakeitpossibleto
programdirectlyfromthedrawing,andthuseliminate y Notethedifferencebetweentwoways
thetooloffsetcalculation
N0060G01 X2.000Y1.700
G41(G42)D N0060G40G01 X2.000Y1.700M02
N0070G40
7 4 M02
y D:theradiusoftooltocompensateissavedinamemoryunitthat
D th di ft lt t i di itth t
isnamedD
y G41/G42isdirectlyrelatedwithdirectionoftoolmovementand
whichsideofpartiscut.

rampoffblock effectivetotheendpoint

ToolHeightCompensation ToolHeightCompensation
G43(G44)H y Example:
y N0010G91G00X12.0Y80.0 G91:
y H:specifiedmemoryunitusedtosaveheight
y N0020G44Z32.0H02 incremental
compensationoftool. coordinates
y Positivecompensation(G43):
y Ifweput0.5mmintoH02,
realposition=specifiedposition+valuesavedinH
y realposition=32.0 0.5=32.5
y Negativecompensation(G44):
realposition=specifiedposition valuesavedinH y Canceltoolheightcompensation:G49

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TableofImportantMcodes Rulesforprogramming
y M00Programstop
Block Format
y M01Optionalprogramstop
y M03Spindleonclockwise N135 G01 X1.0 Y1.0 Z0.125 F5

y M04Spindleoncounterclockwise Sample Block

Restrictions on CNC blocks
y M05Spindlestop Each may contain only one tool move
y M06Toolchange Each may contain any number of non-tool move G-codes
Each may contain only one feed rate
y M08Coolanton Each may contain only one specified tool or spindle speed
y M09Coolantoff The block numbers should be sequential
Both the program start flag and the program number must be
y M10Clampson independent of all other commands (on separate lines)
The data within a block should follow the sequence shown
y M11Clampsoff in the above sample block
y M02orM30Programstop,resettostart

ToolHome

ExampleofCNCProgramming Top
View
y WhatMustBeDoneToDrillAHoleOnACNC
VerticalMillingMachine
g

1.)X&YRapidToHolePosition
Front
View

Top
View 2.)ZAxisRapidMove
JustAboveHole Top
View
3.)TurnOnCoolant
5
5.)ZAxisFeedMoveto
4.)TurnOnSpindle
) O i dl DrillHole

.100
Front Front
View View

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Top Top
View View 7.)TurnOffSpindle
6.)RapidZAxisMove
OutOfHole 8.)TurnOffCoolant

9.)X&YAxisRapid
MoveHome
Front Front
View View

HeresTheCNCProgram! ToolAtHome ToolAtHome

Top O0001 Top O0001

View N005G54G90S600M03 View O0001
NumberAssignedtothisprogram
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N025G00Z.1M09
Front N030G91G28X0Y0Z0 Front
View N035M30 View

ToolAtHome

Top O0001 Top O0001

View N005G54G90S600M03 View N005G54G90S600M03
N005 SequenceNumber N010G00X1.0Y1.0
G54 FixtureOffset
G90 AbsoluteProgrammingMode G00
G R idM i
RapidMotion
S600 SpindleSpeedsetto600RPM X1.0 XCoordinate1.0in.fromZero
M03 SpindleoninaClockwiseDirection Y1.0 YCoordinate1.0in.fromZero

Front Front
View View

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Top O0001 Top O0001

View N005G54G90S600M03 View N005G54G90S600M03
N010G00X1.0Y1.0 N010G00X1.0Y1.0
N015G43H01Z.1M08 N015G43H01Z.1M08
G43 ToolLengthCompensation N020G01Z.75F3.5
H01 SpecifiesToollengthcompensation
G01 StraightLineCuttingMotion
Z.1 ZCoordinate.1in.fromZero
Z.75 ZCoordinate.75 in.fromZero
Front M08 FloodCoolantOn Front F3.5 FeedRatesetto3.5in/min.
View View

O0001
O0001 N005G54G90S600M03
Top Top
View N005G54G90S600M03 View N010G00X1.0Y1.0
N010G00X1.0Y1.0 N015G43H01Z.1M08
N015G43H01Z.1M08 N020G01Z.75F3.5
75 3 5
N020G01Z.75F3.5 N025G00Z.1M09
N025G00Z.1M09 N030G91G28X0Y0Z0
G91 IncrementalProgrammingMode
Front G00 RapidMotion Front G28 ZeroReturnCommand
Z.1 ZCoordinate.1in.fromZero
View M09 CoolantOff
View X0,Y0,Z0
X,Y,&ZCoordinatesatZero

APTLanguage
Top O0001
y APT (Automatically Programmed Tools)
View N005G54G90S600M03
y The APT language consists of many different types of
N010G00X1.0Y1.0 statements made up of the following valid letters, numerals
N015G43H01Z.1M08 and punctuation marks.
N020G01Z .75F3.5
N020G01Z.75F3.5 y Letters: ABCDEFGHIJKLMNOPQRSTUVWXYZ
N025G00Z.1M09 y Numerals: 0123456789
Front N030G91G28X0Y0Z0 / Aslashdividesastatementintotwosections.eg.,
N035M30 GO/PAST,
View
M30 EndofProgram , Acommaisusedasaseparatorbetweentheelementsin
astatementgenerallytotherightoftheslash.
= Anequalsisusedforassigninganentitytoasymbolic
name,e.g.,P1=POINT/25,50,30.

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Words ThecompleteAPTpartprogramconsistsof
thefollowingfourtypesofstatements
y The words to be used in the statements are built up from
one to six letters or numerals with the first one being a y Geometry

letter. No special character is allowed in the words. y Motion

y Postprocessor

y Compilationcontrol

OtherPartProgrammingLanguages
y ADAPT (ADaptation APT) was the first attempt to adapt APT APTLanguage
programming system for smaller computers
Additionalstatements:
y AUTOSPOT (AUTOmatic Sytem for POsitioning Tools) was
developed by IBM and first introduced in 1962 MACHIN/DRILL, 2
COOLNT/
y EXAPT (EXtended subset of APT) was developed jointly in
German in about 1964 by several universities to adapt APT for Forexample:
p COOLNT/MIST COOLNT/FLOOD COOLNT/OF
European use. It is compatible with APT and thus can use the FEDRAT/
same processor as APT SPINDL/
y COMPACT was developed by Manufacturing Data Systems, Inc. Forexample: SPINDL/ON SPINDL/1250, CCLW
(MDSI) TOOLNO/
y SPLIT (Sundstrand Processing Language Internally Translated) TURRET/
was developed by Sundstrand Corporation, intended for its own END
machine tools
y MAPT (MicroAPT) is a subset of APT, to be run on the
microcomputers 75 76

Point (POINT)
APTLanguage
OthercapabilitiesofAPT,themacrofacility,withusevariableargumentasina
FORTRANsubroutine,forexample: PTA = POINT/ 3,4,5
P0 = POINT/0.0, 0.3, 0.1
FROM/P0
CALL/DRILL, X=1.0, Y=1.0, Z=0.1, DEPTH=0.7
y
CALL/DRILL, X=2.0, Y=1.0, Z=0.1, DEPTH=0.7
GOTO/P0 (3, 4, 5)

whenthedefinitionofthemacroDRILLis: PTA
DRILL = MACRO/X, Y, Z, DEPTH
GOTO/X,Y,Z z
GODLTA/0,0, -DEPTH
GODLTA/0,0, DEPTH
TARMAC
x

77

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Point (POINT) Point (POINT)

PTB = POINT/ INTOF, LIN1, LIN2 PTD = POINT/ YSMALL, INTOF, LIN3, C1 y
PTD = POINT/ XSMALL, INTOF, LIN3, C1
PTC = POINT/ YLARGE, INTOF, LIN3, C1
PTC = POINT/ XLARGE, INTOF, LIN3, C1 PTC

LIN2

LIN3
PTB C1
LIN1

PTD

Point (POINT) Point (POINT)

PTE = POINT/ YLARGE, INTOF, C1, C2 PT7 = POINT/ CENTER, C6

PTE = POINT/ XLARGE, INTOF, C1, C2 y
PTF = POINT/ YSMALL, INTOF, C1, C2
PTF = POINT/ XSMALL, INTOF, C1, C2 C1 y

C6
PTE

PT7

PTF C2

x
x

Line (LINE) Line (LINE)

LIN4 = LINE/ PT6, 15, -30, 3

LIN1 = LINE/ P1, P2
y
y
PT6
P2

P1
L4 (15,30,3)

LIN1

x x

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Line (LINE) Line (LINE)

L12 = LINE/ PT4, ATANGL, 20, XAXIS
LIN = LINE/ POINT, ATANGL, ANGLE (in degrees), LINE
L14 = LINE/ PT1, ATANGL, 40
L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS
L16 = LINE/ PT3, ATANGL, 40, YAXIS y
LINE2
y
PT3 L14
L
P1

40
PT1 L12
L16 30 LINE1
PT4

LINE2=LINE/P1,ATANGL,30,LINE1
40 20

x
15 x
L15
(32,3,2)

Line (LINE) Line (LINE)

LIN = LINE/ SLOPE, SLOPE VALUE, INTERC, MODIFIER, d LIN = LINE/ ATANGL, DEGREES, INTERC, MODIFIER, d
where the slope value is y/x. The modifier options are [XAXIS, The modifier options are [XAXIS, YAXIS], and d is the
YAXIS], and d is the corresponding intercept value on the selected corresponding intercept value on the selected axis (i.e., modifier).
axis (i.e., modifier).

y y

LINE1 LINE1

LINE1=LINE/SLOPE,1,INTERC,XAXIS,6 LINE1=LINE/ATANGL,30,INTERC,d
=30
x x
(6,0)PointofXIntercept d

Line (LINE) Line (LINE)

L2 = LINE/ PT51, RIGHT, TANTO, C11
The LEFT & RIGHT modifier indicates whether the line
L3 = LINE/ PT40, RIGHT, TANTO, C11
is at the left or right tangent point, depending on how
L4 = LINE/ PT40, LEFT, TANTO, C11
one looks at the circle from the point.
L3 Right

L1 = LINE/ PT51, LEFT, TANTO, C11 PT40

L1

L1 Left

C11 Left L4

PT51 PT51

Right L2

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Line (LINE) Line (LINE)

L6 = LINE/ LEFT, TANTO, C3, LEFT, TANTO, C4
L6
L6 = LINE/ RIGHT, TANTO, C4, RIGHT, TANTO, C3
C4
Left
C3
Right L6
Right
C4
L8 L9
C3
L7

Left
The descriptive words LEFT and RIGHT are used by L8 L9
looking from the first circle written towards the L7
second circle.

Line (LINE) Line

LN3 = LINE/ PNT6, PARLEL, LN15 LN5 = LINE/ INTOF, PLAN1, PLAN2
LN4 = LINE/ PNT5, PERPTO, LN13
LN5

y
PNT6 PNT5
LN3

LN4

LN15 PLAN1
LN13

PLAN2

Plane (PLANE) Plane (PLANE)

PLAN10 = PLANE/ PT6, PT12, PT15 PLAN14 = PLANE/ PT4, PARLEL, PLAN10
PLAN14 = PLANE/ PARLEL, PLAN10, YSMALL, 3.0
PLAN10
PLAN10
PT15
PT15
PT6 PT12
y PT6 PT12
y 3.0
3.0

PT4 PT4
z
z
PLAN14
PLAN14

x x

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Circle (CIRCLE) Circle (CIRCLE)

C1 = CIRCLE/ 3, 6, 5, 4.3 C3 = CIRCLE/ CENTER, PT6, TANTO, LN4

C1 = CIRCLE/ CENTER, PT3, RADIUS, 4.3 C7 = CIRCLE/ CENTER, PT8, PT5
y y y
C1 LN4
PT5
4.3

PT3 PT6 PT8

(3,6,5) C3 C7

x x x

The Machining Plan The Machining Plan

Contouring: z
Checksurface
y Part surface: the surface on which the end of the Drivesurface

y
tool is riding.
Directionof
y Drive surface: the surface against which the edge of cutter cuttermotion

the tool rides. x

y Check surface: a surface at which the current tool

motion is to stop. Partsurface

The Machining Plan The Machining Plan

Motion commands:
CS CS CS GOLFT/ : Move left along the drive surface
GORGT/ : Move right along the drive surface
GOUP/ : Move up along the drive surface
DS DS DS GODOWN/ : Move down along the drive surface
GOFWD/ : Move forward from a tangent position
TO ON PAST
GOBACK/ : Move backward from a tangent position

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GOUP
FROM/PTARG
GO/TO,L1,TO,PL2,TOL3
GOLFT GORGT/L3,PAST,L4
GOFWD PL4
PL3
Present tool
GOBACK position

GORGT
PL2
GODOWN PL1

Previous PTARG
tool position (starting location of cutter)

Machining Specifications Machining Specifications

Postprocessor commands for a particular machine tool are: FEDRAT/ : specifies the feed rate for moving the tool along the
MACHIN/ : used to specify the machine tool and call the part surface in inches per minute:
postprocessor for that tool: FEDRAT/ 4.5
MACHIN/ DRILL,, 3 SPINDL/ : gives the spindle rotation speed in revolutions per
COOLNT/ : allows the coolant fluid to be turned on or off: minute:
COOLNT/ MIST SPINDL/ 850
COOLNT/ FLOOD TURRET/ : can be used to call a specific tool from an automatic
COOLNT/ OFF tool changer:
TURRET/ 11

Machining Specifications Machining Specifications

TOLERANCE SETTING: Nonlinear motion is accomplished in
straight-line segments, and INTOL/ and OUTTOL/ statements
dictate the number of straight-line segments to be generated.
INTOL/ 0.0015
OUTTOL/ 0.001
PARTNO: identifies the part program and is inserted at the start of
the program.
CLPRNT: indicates that a cutter location printout is desired.
CUTTER: specifies
p a cutter diameter for offset ((rough
g versus finish
cutting). If a milling cutter is 0.5 in. in diameter and we have
CUTTER/ 0.6
then the tool will be offset from the finish cut by 0.05 in.

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Machining Specifications
FINI: specifies the end of the program.
APTLanguage
OtherMotionstatements:
GO/{TO}, Drive surface, {TO} Part surface, {TO},
Check surface
Or
GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
Check surface
AndthesamewithPASTorONinsteadofTO
GOLFT/
GORGT/
GOUP/
GODOWN/
GOFWD/
GOBACK/
Forexample:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST, L1, TO, PS, TANTO, C1

110

IES2008
Name the four types of statements in a complete APT
IES2007
Prepare part using APT language for milling the contour
part program. Prepare part program for geometry shown in Fig. in a single pass. D [20Marks]
C 110
description of the contour shown in the figure below: R30
Y B
[15Marks] Q
30 40

20

L2 C1 110
L3 20
R 120
135

E
+

+
R40
L4 40
80 L1
A F
C2
100 + 40 P
+

L5
20 Material : M S.
R P1
P2 20
X 8 mm

IES2006
Prepare part program to machine the contour shown in
IES2011Conventional
the figure using APT on CNC milling machine. State the method of defining line segment of
R30
[15Marks]
cutter motion using APT program format.
R20
[5 Marks]

100 mm
80

60 50
200 mm

Material: MS Thickness: 8.0 mm

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Whatisanindustrialrobot?
Robotics A robot is a reprogrammable, multifunctional
manipulator designed to handle material, parts, tools or
specialized devices through variable programmed
motions for the performance of a variety of tasks.

AdvantagesofRobots DisadvantagesofRobots
y Robotics and automation can, in many situation, increase y Robots lack capability to respond in emergencies, this can cause:
productivity, safety, efficiency, quality, and consistency of Inappropriate and wrong responses
products A lack of decisionmaking power
y Robots can work in hazardous environments A loss of power
y Robots need no environmental comfort Damage to the robot and other devices
Human injuries
y Robots work continuously without any humanity needs and
y Robots may have limited capabilities in
illnesses
Degrees
D off Freedom
F d
y Robots have repetable precision at all times Dexterity
y Robots can be much more accurate than humans, they may have Sensors
mili or micro inch accuracy. Vision systems
y Robots and their sensors can have capabilities beyond that of Realtime Response
humans y Robots are costly, due to
y Robots can process multiple stimuli or tasks simultaneously, Initial cost of equipment
humans can only one. Installation Costs
y Robots replace human workers who can create economic Need for peripherals
problems Need for training
Need for Programming

WhatCanRobotsDo?
Asimov'sthreelawsofrobotics
IndustrialRobots First law (Human safety):
y A robot may not injure a human being, or, through
Material handling
inaction, allow a human being to come to harm.
Material transfer
Machine loading and/or unloading Second law (Robots are slaves):
Spot welding
Continuous arc welding MaterialHandling y A robot must obey orders given it by human beings,
Spray coating
Manipulator except where such orders would conflict with the First
Assembly Law.
Inspection
Third law (Robot survival):
y A robot must protect its own existence as long as such
Assembly protection does not conflict with the First or Second
Manipulator
SpotWelding
Law.
Manipulator

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Allrobotshavethefollowingbasiccomponents:
1. Manipulators: the mechanical unit, often called the
WristConfigurations
"arm," that does the actual work of the robot. It is
composed of mechanical linkages and joints with actuators y Wristassemblyisattachedtoendofarm
to drive the mechanism directly or indirectly through gears, y Endeffector isattachedtowristassembly
chains, or ball screws.
2. Feedback devices: transducers that sense the p positions of y Functionofwristassemblyistoorientendeffector
various linkages and joints and transmit this information to y Bodyandarmdeterminesglobalpositionofend
the controllers in either digital or analog Form. effector
3. End effectors: the "hand" or "gripper" portion of the y Twoorthreedegreesoffreedom:
robot, which attaches the end of the arm and perform the y Roll
operations of the robot. y Pitch
4. Controller: the brains of the system that direct the y Yaw
movements of the manipulator.
5. Power supply:

EndEffectors
y Thespecialtoolingforarobotthatenablesitto GrippersandTools
performaspecifictask
y Twotypes:
y Grippers tograspandmanipulateobjects(e.g.,
parts)duringworkcycle
y Tools toperformaprocess,e.g.,spotwelding,spray
painting

DegreesofFreedom DegreesofFreedom(contd.)
y A total of six degrees of freedom is needed to locate a
y The degree of freedom or grip of a robotic system can be
robots hand at any point in its work space.
compared to the way in which the human body moves. y Although six degrees of freedom are needed for
y For each degree of freedom a joint is required. maximum flexibility, most robot employee only three to
five degrees of freedom.
y The degrees of freedom located in the arm define the y The more the degrees of freedom,
freedom the greater is the
configuration. complexity of motions encountered.
y The three degrees of freedom located in the arm of
y Each of the five basic motion configurations utilizes three
a robotic system are:
degrees of freedom in the arm. The rotational reverse: is the movement of the arm
y Three degrees of freedom located in the wrist give the end assembly about a rotary axis, such as leftandright
swivel of the robots arm about a base.
effector all the flexibility.

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DegreesofFreedom(contd.)
The radial traverse: is the extension and retraction
of the arm or the inandout motion relative to the
base.
The vertical traverse: provides the upanddown
motion of the arm of the robotic system.
y The three degrees of freedom located in the wrist,
which bear the names of aeronautical terms, are
Pitch or bend: is the upanddown movement of the
wrist.
Yaw: is the rightandleft movement of the wrist.
Roll or swivel: is the rotation of the hand.

RobotControlSystems
JointDriveSystems y Limitedsequencecontrol pickandplace
operationsusingmechanicalstopstosetpositions
y Electric
y Useselectricmotorstoactuateindividualjoints
y Playbackwithpointtopointcontrol records
workcycleasasequenceofpoints,thenplaysback
y Preferreddrivesystemintoday'srobots
thesequenceduringprogramexecution
y Hydraulic
y Playbackwithcontinuouspathcontrol
y Useshydraulicpistonsandrotaryvaneactuators
greatermemorycapacityand/orinterpolation
y Notedfortheirhighpowerandliftcapacity
capabilitytoexecutepaths(inadditiontopoints)
y Pneumatic
y Intelligentcontrol exhibitsbehaviorthatmakes
y Typicallylimitedtosmallerrobotsandsimplematerial
itseemintelligent,e.g.,respondstosensorinputs,
transferapplications
makesdecisions,communicateswithhumans

WorkingEnvelope
RobotControlSystem
Cell Level2
Supervisor

Controller Level1
&Program

Joint1 Joint2 Joint3 Joint4 Joint5 Joint6 Sensors Level0

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RoboticArcWeldingCell RobotProgramming
y Leadthrough programming
y Robotperforms y Work cycle is taught to robot by moving the
fluxcoredarc manipulator through the required motion cycle and
welding(FCAW) simultaneously entering the program into controller
operationatone memory for later playback
workstation
k i
y Robot programming languages
whilefitter
changespartsat y Textual programming language to enter commands
theother into robot controller
workstation y Simulation and offline programming
y Program is prepared at a remote computer terminal
and downloaded to robot controller for execution
without need for leadthrough methods

Leadthrough Programming Leadthrough ProgrammingAdvantages

y Advantages:
1. Poweredleadthrough y Easilylearnedbyshoppersonnel
y Commonforpointto
y Logicalwaytoteacharobot
pointrobots
y Nocomputerprogramming
y Usesteachpendant
y Disadvantages:
2. Manualleadthrough
y Downtimeduringprogramming
y Convenientfor
continuouspath y Limitedprogramminglogiccapability
controlrobots y Notcompatiblewithsupervisorycontrol
y Humanprogrammer
physicalmoves
manipulator

CAD CAM
ComputerAidedManufacturing(CAM):
Computer Aided Design (CAD): Used for creating the
y ComputerAidedProcessPlanning(CAPP)
product database y ComputerizedmaterialResourcePlanning(MRP)
y NCpartprogramming
y Geometric Modeling
g
y RobotProgramming
R b P i
y Engineering Analysis y ComputerizedScheduling
y Computerizedprocesscontrol
y Design Review and Evaluation
y ComputerizedManufacturingControlbyFMS
y Automated Drafting y Shopfloorcontrol
y ComputerAidedQualityControl(CAQC)
y ComputerAidedInspection

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WhatisanFMS?
y A flexible manufacturing system (FMS) is a
manufacturing system in which there is some
amount of flexibility that allows the system to
react in the case of changes.
y Two categories of flexibility
y Machine flexibility, covers the system's ability to be
changed to produce new product types, and ability to
change the order of operations executed on a part.
y Routing flexibility, which consists of the ability to
use multiple machines to perform the same operation
on a part, as well as the system's ability to absorb
largescale changes, such as in volume, capacity, or
capability.
FMSComponents
y Most FMS systems comprise of three main
systems
y Work machines (typically automated CNC
machines) that perform a series of operations;
y An integrated material transport system and a
computer that controls the flow of materials,
tools, and information (e.g. machining data
and machine malfunctions) throughout the
system;
y Auxiliary work stations for loading and
unloading, cleaning, inspection, etc.

FMSGoals AdvantagesofFMS
y Reduction in manufacturing cost by lowering direct y Faster, lower cost changes from one part to another
labor cost and minimizing scrap, rework, and material which will improve capital utilization
wastage. y Lower direct labor cost, due to the reduction in number
y Less skilled labor required. of workers
y Reduction in work in process inventory by eliminating
workinprocess y Reduced inventory,
y, due to the p planning
g and
the need for batch processing. programming precision
y Reduction in production lead time permitting y Consistent and better quality, due to the automated
control
manufacturers to respond more quickly to the variability
of market demand. y Lower cost/unit of output, due to the greater
productivity using the same number of workers
y Better process control resulting in consistent quality.
y Savings from the indirect labor, from reduced errors,
rework, repairs and rejects

DisadvantagesofFMS
y Limited ability to adapt to changes in product or product
mix (e.g., machines are of limited capacity and the
tooling necessary for products, even of the same family,
is not always feasible in a given FMS)
y Substantial preplanning
pre planning activity
y Expensive, costing millions of dollars
y Technological problems of exact component positioning
and precise timing necessary to process a component
y Sophisticated manufacturing systems

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APT Program
MACHIN/ MILL
CLPRNT
UNITS/MM
P0 = POINT/ 0, 0, 3
P1 = POINT/ 1, 0
L1 = LINE/ P1, SLOPE, 0
L2 = LINE/ P1, SLOPE, 90
L3 = LINE/ PARLEL, L1, YLARGE, 2
L4 = LINE/ (POINT/ 4, 2), SLOPE, 1, L3
P3
L5 = LINE/ (POINT/ 6,
6 4),
4) ATANGL,
ATANGL 270,
270 L4
L4 L5
L6 = LINE/ (POINT/ 10, 0), PEPTO, L3
P2 = POINT/ INTOF, L3, L4 P2 P4
L3 L3
P3 = POINT/ INTOF, L4, L5
P4 = POINT/ INTOF, L5, L3 L2 L6
PL = PLANE/ P1, P2, P3 P1 L1
CUTTER/ 60
TOLER/ 0.1
SPINDL/ 200
COOLNT/ ON P0
FEDRAT/ 20

APT Program
APTLanguage
FROM/ P0
GO/TO, L1, TO, PL, TO, L2 Example:
GOFWD/ P1, PAST, L3
GORGT/ L3, TO, P2
GOLFT/ P2, ON, P3
P3
GORGT/ P3, TO, P4
L4 L5
GOLFT/ P4, PAST, L6
GORGT / L6, PAST, L1 L3 P2 P4 L3
GORGT / L1, TO, P1 L2 L6
COOLNT/ OFF
P1 L1
SPINDL/OFF
END
FINI
P0

148

APTLanguage APTLanguage
Answer: Example1:
FROM/SP
GO/TO, L1, TO, PS, ON, L6
GORGT/L1, PAST, L2
GORGT/L2, TANTO, C1
GOFWD/C1, TANTO, L3
GOFWD/L3, PAST, L4
GOLFT/L4, PAST, L5
GOLFT/L5, PAST, L6
GOLFT/L6, PAST, L1
GOTO/SP

149 150

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APTLanguage APTLanguage
Answer: Example2:
P0 = POINT/0.0, 3.0, 0.1
P1 = POINT/1.0, 1.0, 0.1
P2 = POINT/2.0, 1.0, 0.1
FROM/P0
GOTO/P1
GODLTA/0, 0, -0.7
GODLTA/0, 0, 0.7
GOTO/P2
GODLTA/0, 0, -0.7
GODLTA/0, 0, 0.7
GOTO/P0

151 152

APTLanguage
ReferenceBook
Answer: y CAD/CAM:ComputerAidedDesignand
FROM/SP ManufacturingByGroover
GO/TO, L1, TO, PS, ON, L4 y CNCMachines ByB.S.Pabla,M.Adithan
GORGT/L1, PAST, L2 y Machinetooldesignandnumericalcontrol By
GOLFT/L2,
GOLFT/L2 PAST,
PAST L3 Mehta
GOLFT/L3, PAST, C1 y ComputerControlOfManu.Systems ByKoren
GOLFT/C1, PAST, L3
GOLFT/L3, PAST, L4
GOLFT/L4, PAST, L1
GOTO/SP

153

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