5.2 METHODS OF PART PROGRAMMING There are two methods of part programming, namely 1, Manual part programming 2. Computer Aided Part Programming eee MANUAL PART PROGRAMMING The process of generating part programs manually by a part programmer is known as Manual Part Programming. This technique is widely used for work pieces of simple geometry. To prepare a part programme using manual method, the programmer writes machining instructions on a special form called Manuscript. The manuscript is a listing of the relative tool and workpiece locations. It also includes other data, such as, preparatory commands, miscellaneous functions, and speed ‘feed specifications. These will be written by him ina coded form called Program Manuscript. This would be punched on a paper tape and the tape will be fed into the tape reader of the machine controller. Steps involved in manual part programming are shown in Fig 5.3 Programmer Fig $.3 ; Manual Part Programming T + The organisation of words within a block is called Program but collection of words. There are three types of program Scanned with CamScannerScanned with CamScannerunit to execute the instructions that are represented by two digits preceded by G ie, Goo. used to prepare the controller for linear § functions (G-Codes) are given in the follo Code G00 Go Go Go Goa Gos G7 Gis to follow. The preparatory function is G99. For example GOI is Interpolation, some of the preparatory wing table. _ Table 8.1: Preparatory Functions (G Codes) _____Punetion i lit iis ke a lockwise) 4 2 ee Circular interpolation (Anti clockwise) Dwell £57 i= ¥en eee, 4 Tal XY plane designation + __ Thread cutting _ Cutter compensation-control Cutter compensation-left Cutter compensation-right Thread cutting eycle Dimensioning in inch units Dimensioning in nietric units Canned cycle-cancel Canned cycles Scanned with CamScannerScanned with CamScannercutting tools available for use on CNC machining centers, it is unlikely that any two tools used in a program will be exactly the same length. And you will not know precisely how long each tool will be when you write the program. The figure below shows three different types of cutting tools to illustrate this point. Tool length » compensation will allow you to write programs even though you don't know how long the cutting tools will be at production time. When a tool is fixed in the spindle, its coordinate values are programmed according to its length. If the tool is replaced by another tool, say 20 mm shorter in length, and then the tool movement would be 20 mm less along the Z-axis if same programmed values are used. So, the alternative is to modify the program every time the tool is changed. In NC practice, all tools being used are measured and the difference in length with respect to previous tool is stored with the associated tool number, whenever these tools are called into action by programmed instruction, the respective compensation values are activated and automatically taken into account in tool motion. This phenomenon is called Tool Length Compensation. Fig, 5.5 illustrates the tool length compensation. [ Scanned with CamScanner1. If the actual tool length is more than the assumed tool (during programming), the difference should be mentioned as follows G43 TO1 Where G43 - specifies code for tool length compensation TO1- Specifies code for tool selection in which 01 specifies the address where the difference of tool length will be mentioned iS . If the actual length is less than the assumed tool, the difference should be mentioned as follows G44 TOL Where G44 - Specifies code for tool length compensation TO1 - Specifies code for tool selection in which 01 specifies the address where the difference of tool length will be mentioned The following program example explains how tool length compensation taken care of for the tools shown in Fig.3.11. Tool number 2 is assumed tool during programming. Tool numbers 1 and 3 are actual tools that are to be used after tool number 2 during machining. Tool numbers 1 and 3 are shorter than assumed tool, so, in the program G44 code is used. ae E Scanned with CamScannerTOOL NOSE RADIUS COMPENSATION When programming a CNC machine with a turning tool that has a rounded tip, errors in cutting can occur on tapered edges and circular contours. This is corrected automatically by using a Tool Nose Radius (TNR) compensation command in a CNC control. Too! nose radius compensation is required for generating accurate profiles. The code G41 is used for tool nose radius compensation to the left of programmed path. The code G42 is used for TNR to the right of the programmed path. G40 is used for tool nose radius compensation cancel. Fig. 5.6 illustrates tool nose radius compensation. G41 (the workpicee is on the left side) Workpiece G41 (the workpiece is on the left side) Fig 5.6 : Illustration of Tool Nose Radius Compensation 5.3 WRITING A PART PROGRAMME first instruction in any part programme is to inform the control system about set-up conditions for doing machining. The first block of instructions the following : Scanned with CamScannerThe first block of instruction will be as follows "NOOO1 G90 G70 G94 M03 S800 EOB Each block is terminated by typing end of block (EOB) character. PART PROGRAM FOR CNC LATHE OPERATIONS In case of CNC lathe operations, only two axes (x-axis and Z-axis) are involved The Z-axis is the axis of the spindle and x-axis is the direction of transverse motion of the tool post. To write CNC part programme for lathe operations the following procedure is adopted. (i) Move the cutting tool to a point near the job in a rapid mode (G00) (ii) Set linear interpolation (G01) and move to the required depth of cut in X-direction. (ili) Move along Z-axis to the required length of the job as per drawing. (iv) Set rapid mode (G00) and retract the tool along X-axis. (v) Move to start point in GOO mode. PART PROGRAM EXAMPLES: EXAMPLE 5.1 Write the part program to make the component as shown in Fig. 5.7. The bar stock available is 40 mm dia. rod. omg S7: no Th to matin o aCy (i) Facing operatior (i) To reduce the dia of the bar from 40 mm to 36 tO mm. The part programme for the component shown in Fi 5.7 in Fig, NOO10 N0020 N0030 N0040 0050 ‘N0060 ‘NO0070, ‘NO0080 NO090 NO100 GTi G90 TO! F200 GOO X22.00 GOO x0 Gol ZO X40.00 Z~ 80.00 G00 X42.00 G94 EOB M03 S800 Z1.00 EOB EOB EOB EOB EOB EOB EOB EOB Got0Z=20) EOB (Tool No.1, feed rate 200 m/min speed 800 rpm) (In rapid mode, move to X = 22, Z = 1) (Move to X = 0, Z remaining constant) (Go to Z = 0 in G01 mode) (Move to X = 40 in G01 mode. This is facing operation) (Move to Z =~ 80 in GO1 mode. This is a dummy cut parallel to the axis of the job) (With draw the tool to X = 42. So that when the tool is taken back to Z = 0, it does not leave a scratch mark on the job) (Move in rapid to Z = 0) (Move to X=36 in GOI mode. It givesa depth of ut of 2mm) (Move to Z =~ 80 to do turning operation) (Withdraw the tool to x = 42 in rapid movement) Scanned with CamScannerScanned with CamScannerIn CNC machines depth of cut is limited like conventional machines. So the material is removed in number of cuts. Each time the tool is fed against work piece 2 to 3 mm for rough cut and 0.75 mm to 1 mm for finished cut and turning is done upto the desired length. The tool is taken back to the starting position and the cycle is repeated. Consider the job shown in Fig. 5.9 where the diameter is to be reduced to 30 mm from 40 mm, the maximum depth of cut being limited to 3 mm. ANSWER : The part of programme for the component shown in Fig. 5.9 is given below NOL G9 G71 G94 FS00 $1000 TO! EOB G00 X41.00 21.00 M03 EOB GOI Z-30.00 EOB Noz NB GO! X37.00 EOB NOt G00 X41.00 21.00 BOBScanned with CamScannerCNC ANSWER: 'N0060 ‘NoO80 G71. G90G94 EOB ‘TO1 M03 S800 EOB G00 X100.00Z1.0EOB GO1 X80.00 Z0.00 EOB G02.X100Z-30 150.00 J0.00 EOB (I: Distance from are start point to arc centre point in X-axis (J: Distance from are start point to arc centre point in Z-axis) G01Z-120E0B M02 EOB CNC program example for Circular Interpolation (CW & CCW). — Scanned with CamScannerANSWER : N0O10 G71 G90 G94 EOB N0020 TOI M03 S800 EOB N0030 G00 X35.00 21.00 EOB N0040 G01 Z-20.00 EOB N00S0 G02 X67.00 Z-36.00 116.00 J0.00 EOB NO0060 G01 X68.00 EOB N0070 G03 X100.00 Z-52,00 10.00 J0.00 EOB NO0080 GOI Z-82,00 EOB N0090 GOO X150.00 250.00 EOB No100 M02 EOB mms .4 SUBROUTINES The subroutines which are also called as Sub Programmes, provide the capability of programming certain fixed or frequently repeated operations. Subroutines are stored in the memory under separate programme numbers. Whenever a particular feature is required within the programme, the associated subroutine is called for execution. The subroutines may be called anytime and repeated any number of times. After execution of subroutine the control return to the main programme Subroutine is represented in the form of codes and symbols. Ex: L ~ 221 (Start of subroutine no. 221) bi M — 17(End of subroutine) ‘subroutine can be called anywhere in the main Programme by just subroutine eceded by letter L.which change are specified by symbols like * or num ibers like #1, #2... program, in the instruction to calll the required subroutine, the value of the parametres are specified in the order in which they appear in the subroutine. The followin example shows the use of macros. s Examples : - In the main Main program Macro. : 1010 NO10 G01 X60.00 F1000 N020 G91 X#1 N030 Y#2 N040 X# -3 N0S0 Y#-4 M98 P1010 L2; 40.00; 50.00 40.00; 50.00 In the main program M98 P1010 L2, M98 specifies miscellaneous function 98 call for subroutine, the number after P refer macro (subroutine) being called L2 specifies number of times called. Here, the subroutine (Macro) 1010 is called twice and the values of the parametres 9m #1 to #4 would be 40.00, 50.00, 40.00, 50.00 mm respectively. re of NC system is the facility of canned cycles. These are also called cycle is defined as a set of instructions, in built or stored in the m fixed sequence of operations. The canned cycles can be si ‘command and as such reduce the programming time for repetitive and commonly used machining ored under G-code address. G81 to G89 are d to cancel the canned cycle. a my Scanned with CamScanner| Computer Aided Manufacturing Siang, (i) Canned cycle for turning. (ii) ‘Canned cycle for threading (iii) Canned cycle for rough turning (iv) Canned cycle for finish turning. Canned Cycle for Turning : In order to machine the component on CNC machine the depth of cut is limitation, a number of cuts to be given one way of writing the part program for achieving the required diametre on CNC lathe machine is by repeating the same steps. Since the same steps are being repeated every time, the part programme becomes unnecessary lengthy, occupies large computer memory and the part programmer has to spend more time in writing the part program. In order to save part programming time and computer memory, canned cycles for turning are available in the control system, The programmer has to first write an instruction block to position the cutting tool at the starting point and then call the fixed cycle for turning as follows : N5 G81 X-2.00 Z-30.00 F200 EOB Where, G81 is the code for the canned turning cycle. X-2.00 denotes that the depth of cut is 2 mm. 2-30.00 denotes that the length to be machined is 30 mm. _ 2, Canned Cycle for Thread Cutting : In order to call and use a fixed cycle for - cutting ‘on a CNC lathe machine, the information is given as follows :Scanned with CamScannerCamp ite Aidee Mean aetna Tata, 5.5 COMPUTER AIDED PART PROGRAMMING In computer aided part programming the computer generates the part programme required to machine the component. The process of generating part program partly by the part programmer and partly by the computer is known as Computer Aided Part Programming. This is also called as Computer Assisteq Part Programming. It is normally referred as CAPP. The part programmer's job in the CAPP is to first define the geometry of the component from the component drawing. The geometry or shape of the component is split into simple elements like points, lines, arcs, full circles etc. The geometry of elements of the component is defined using simple abbreviated English like terms which are understood by the computer and control system. From the geometry of the component, the system generates the data required to machine the component. This data is called Cutter Location Data (CL). The data does not contain G or M codes. The cutter location data is then post processed in the computer to translate it into a form which a particular machine control system can understand. The post-processing involves addition of G codes, M codes and other machine dependant information in the required format. The part programme at this stage is machine dependent and can be used for a specific machine only Fig. 5.14 shows the computer aided part programming system. Scanned with CamScannerGMGEED CNC Programming ap STEPS INVOLVED IN COMPUTER AIDED PART PROGRAMMING The above mentioned computer aided part programming procedure can be resolved into following steps : 1. Part Programmer's Responsibility : (a) Defining the work part geometry. (b) Stating the sequence of operations to be carried out along the tool path. 2. Computer's Job : (a) Input Translation : The part programmer enters the program using the APT or other language. The input translation component converts the coded instructions contained in the program into computer usable form, preparatory to further processing. (b; Arithmetic Calculations : The arithmetic calculations unit of the system consists of a comprehensive set of subroutines for solving the mathematics required to generate the part surface. The arithmetic unit is really the fundamental element in the part programming package. This unit frees the programmer from the time-consuming geometry and trigonometry calculations to concentrate on the workpart processing. (c) Cutter/tool Offset Computation : The purpose of the cutter offest computation jis to offese the tool path from the desired part surface by the radius of the cutter. This means that the part programmer can define the exact part outline in his geometry statements. ssor : The final task of the computer inc omputer assisted part g is to take the general instructions and make them specific to a fate computer program that has been written § machien tool. The output of the rrect format for the machien on Scanned with CamScannerADVANTAGES OF COMPUTER AIDED PART PROGRAMMING The following are the advantages of using computer aided part programming 1. Part programming is considerably simplified. 2. The part programmes generated are accurate and efficient. 3. All arithmetic calculations are done by computer, resulting in saving time and elimination of errors. 4. The part programming for different machines can be done by a single person, which can then be post processed for specific machines. 5. If new machines are used, only a post processor may be needed to integrate the new machines with the existing system. COMPUTER AIDED PART PROGRAMMING LANGUAGE In computer aided part programming the geometry of elements of the component is defined using simple abbreviated english like terms. This is knows as Computer Aided Part Programming Language. There are a large number of part programming languages. The most widely used part programming languages are APT and COMPACT Il. TYPES OF PART PROGRAMMING LANGUAGES APT (Automatically Programmed Tools) : APT stands for Automatically Programmed Tools. This is most widely used programming language. In n assumed that the work piece remains stationary and Scanned with CamScanner& Sompeckt + This ts a package available from Manufacturing Data Systems, Inc (MDSD. The NC language is similar to SPLIT in many of its features. MDSI leases the Compact-Il system to its users on a time-sharing basis, The part programmer uses a remote terminal to feed the program into. one ‘of the MDSI computers, which in tum produces the NC tape, |. ADAPT (Adaptation of APT) ; Several part programming languages are based directly on the APT program One of these is ADAPT, which was developed by IBM under Air Force contract. It was intended to provide many of the features of APT but to utilize a significantly smaller computer, ADAPT is not as powerful as APT, but can be used to program for both positioning and contouring jobs. |. Exapt (Extended Subset of APT) : This was developed in Germany starting around 1964 and is based on the APT language. There are three versions: EXAPT | designed for positioning (drilling and also straight-cut milling), EXAPT Il designed for turning, and EXAPT Ill designed for limited contouring operations, One of the important features of EXAPT is that it attempts to compute optimum feeds and speeds automatically. TYPES OF APT PROGRAMME STATEMENTS. APT : APT stands for Automatically Programmed Tools. This is most widely used programming language. In programming using APT, it is assumed that the work Piece remains stationary and the cutting tool does all the moving. The APT Programme Consists of Four Types of Statements : (a) Geometric Statements : These are also called definition statements. These are used to define the geometric elements like point, circle, arc, plane ete. "Motion Statements: The motion statements are used to define the cutterScanned with CamScannerINTOL (Inside tolerance) OUTTOL (Outside tolerance) CLPRNT (Print cutter location data) 85.6 APT PROGRAM FOR A SIMPLE DRILLING JOB Write the APT program for drilling 3 holes for the aluminium component given below. k—— ns —_ | | Fig 5.15: The drill will be operated at a feed of 0.05 mm/rev and a spindle speed of 1000 rev/min (corresponding to a surface speed of about 0.37 m/sec, which is slow for the aluminium work material). At the beginning of the job, the drill point will be positioned at a target point located at x = 9, 9 = ~ 50, and z = + 10 (axis units are millimeters). The program begins with ol positioned at this target point. | SAMPLE PART DRILLING OPERATIONScanned with CamScannerEXAMPLE PART PROGRAMME FOR MILLING Consider th i ah eee shown in Fig. 5.17 (a). It is assumed that the component pote e ra cut to rough shape and it is required to write a part programme fi ly is cut. The APT programme for this component is given below. The cutter path is shown in Fig. 5.17 (b) -— 109 —__ -— 0 a) Fig 5.17: PART NO/SAMPLE JOB 1 MACHINE/MILLING 1 CLPRNT PO = POINT / 0, - 20.0, 0 P1=POINT/0, 0,0 P2 = POINT / 150.0, 0, 0 Scanned with CamScannerU3 = UNE / P3, P4 L4= UNE / Pa, PS LS = LINE / PS, PG. LS = UNE / P6, P7 U7 = LINE /P7, PB U8 = LINE / P8, Ps PL1 = PLANE / 0, 0, ~20.0, 150.0, 0, -20.0, 0, 100.0, -20.0 CUTTER / 10.0 SPINDLE / 580 FEDRAT/ 80 COOLNT/ON FROM / PO GO/TO, L4 TO, PL, TO, LB GO RGT/L1, PAST, L2 GOUP / L2, PAST, L3 GOLFT/L3, TO, La GODOWN / L6, TO, L7 GOLFT/L7, PAST, L8 GODOWN / L8, PAST, Lt ‘will be positioned so that its center tip 0, y = ~ 50, and z = + 10. The program ‘em ta aie :Fig 5.1 PARTNO SAMPLE PART MILLING OPERATION MACHIN/MILLING,OS CLPRNT UNITSIMM CUTTER/20.0 REMARK Part geometry, Points and Lines are defined 25 mm below part top surface PTARG = POINT/O, -50.0, 10.0 P14 = POINT/O, 0, - 25.0 P2 = POINT/160.0, 0 - 25.0 _ P3 = POINT/160.0, 60.0, ~ 25.0 Scanned with CamScanner_.____ a ammeparaeraer a, PL1 = PLANEIP1, P2, pq REMARK Milling cutter motion statements FROMIPTARG, ‘SPINDL/1000, CLw FEEDRAT/50, IPM GOTO, L1, TO PL1, ON, La GORGTI/L1, PAST, L2 GOLFT/L2, TANTO, C1 GOFWDIC1, PAST, L3 GOFWD/L3, PAST, L4 GOLFTIL4, PAST. L1 RAPID GOTOPTARG ‘SPINDUOFF FINI 5.7 ADVANTAGES OF COMPUTER AIDED PART PROGRAMMING OVER MANUAL PART PROGRAMMING Scanned with CamScanneram DIFFERENCES BETWEEN MANUAL PART PROGRAMMING AND COMPUTER ‘AIDED PART PROGRAMMING ‘The following are the differences between manual part programming and computer aided part programming. |'S.No. Manual Part Programming Computer Aided Part Programming 1, | Part programs are generated manually _| Part programs are generated partly by the by a part programmer, part programmer and partly by the computer, | 2._| Itis time consuming process. It is less time consuming process. 3, | Itneeds an expert programmer, It does not need an expert programmer as | some activities are done by the computer system. | 4, | Ifa person is expert in programming ‘The part programming for different machines | in one machine, he will not be able to can be done by a single person, which can develop part programme for another then be post processed for specific machines. machines, a | 5, | Arithmetic calculations are done by the | Arithmetic calculations are done by the part programmer. So errors may be arised. | computer. So errors may be eliminated. | 6. | Part programming is written using Part programming is written using CAPP Gendinctea ete languages like APT, COMPACT II. 7. | Part program is difficult to understand. | Part programming is simplified. patents Part programs generated are accurate and 8. | The part programmes g* - : efficient. neither accurate nor efficient. Difficult program for the components Programming easier for the components having complicated features. Scanned with CamScanner