Computer Aided Seam Manufacturing | CM Integrable Machines TOPICS Systems of NC/CNC Machine Tools 3.1 _ Introduction to Computer Aided Manufacturing (CAM) NC Machine Tools Classification of NC (Numerical Control) Machine Tool Systems ‘Advantages of NC Machine Tools Limitations of NC Machine Tools ‘Applications of NC Machine Tools CNC Machine Tools Classification of CNC (Computer Numerical Control) Machine Tool SYSTEMS Advantages (Features) of CNC Machine Too! Limitations of CNC Machine Tools ‘Applications of CNC Machine Tools Introduction to Computer Aided Manufacturing (CAM), Coordinate system, Working principal of CNC Lathe, Turing Centers, Milling Machine, Machining Centers. Steps in developing CNC part program, Tool and geometric compensations, CNC Lathe and Mill part programming, Canned cycles, subroutine and Do loop, DNC Machine Tools Adaptive Control (AC) System Introduction to Part Programming Coordinate Systems used in Manual Part Programming Format of Manual Part Programming Tool and Geometric Compensations Manual Part Programming for CNC Lathe (Turing Center) Manual Part Programming for Mi (Machining Center) IM Integrable Machines3.1. INTRODUCTION TO CAD/CAM 1 led to the emergence of wo wfacturing, the fields of design and n © CAD/CAM : The entry of computers new areas known as 4. Computer-Aided Design (CAD) : Computer-Aided Design (CAD) cam be defined as the Ws of computer systems to assist in the creation, modification, synthesis, analysis, and/or optimization of design. (CAM) : Computer-Aided Manufacturing (CAM) can be defined as the use gh the direct or 2. Computer-Aided Manufacturing of computer systems to plan, manage, the manufacturing machine. rraditionally, the des the CAD/CAM has led to the great and control the manufacturing operations throug ve been treated as indirect computer interface Integration of Design and Manufacturiny two distinct and separate activities. However, gn and manufacturing ‘er integration of design and manufacturing. 2 NC MACHINE TOOLS he machine tools, of which the various funetions are NC (Numerically Controlled) machine tools are t ‘The NC program consists of a set of Instructions or controlled by program fed to it, without human operator. ments for controlling the motion of the drives of the mac ol stater Jnine tool as well as the motion of the cutting, tool, Functions controlled by program in NC machine to (Starting and stopping of the machine tool spindle; (ii) Controlling the spindle speed Positioning the tool at desired locations and gutding it along the desired path; Gai (iv) Controlling the feed rate; and (©) Changing the tools. 3.2.1 Elements of NC Machine Tool System : Part Drawing | ==>) Machine Too! | Machine Control Unit (MCU Fig. 3.2.1(2) : Elements of NC Machine Tool System Serer1 Computer Aided Manufacturing feedback (1 pat screw Mecnansm TET ‘Servo Motor No fF Ck == Magnetic Box i cH Machine ena The basic elements of NC machine tool system are as follows [Fig, 3.2.1(a)] Basie Elements of NC ‘Machine Too! System 1. Par drawing and part program 2. Program tape '3, Machine control unit (MCU) “4. Machine tool Part drawing and part program : Using the part drawing and the cutting process parameters, the part program is written. The part program is a set of step by step instructions to the machine tool for carrying out the operations. The set of instructions include : (Instructions for position of machine tool spindle with respect to work table; (i) Instructions for cutting operations; and (ii) Instructions for selection of spindle speeds, cutting tools, etc. Methods used for part programming of NC machine tools : (Manual part programming, (i) Computer-aided part programming. ] A number of languages are available for part programming. The most popular language used is APT. Program tape : ‘The part program is entered on the program tape. The tape is a long wound roll of one inch width. The program is entered on the tape in the form of punched holes. The holes are punched with the help of punching machine. The tape medium is now absolute and now-a-days the program is input through the magnetic cassettes, floppy discs or compact discs. Machine Control Unit (MCU) : Parts of machine control unit (MCU) : () Tapereader (il) Controller ‘The program tape is read by the tape reader. The controller takes input from the tape reader and actuates the drives and the tools of the machine tool.W_ computer niegaed Manuacurng 3 Camputer ie Maacrg 4. Machine tool : * The machine tool is operated by the controller of the machine control unit. In NC machine tools, one or more of the following functions may be automatic: (i) Starting and stopping of the machine tool spindle ; (i) Controlling the spindle speed ; (iii) Positioning the tool tip at the desired locations and guiding it along the desired path by automatic control of the slide motions ; (iv) Controlling the feed rate; and (¥)_ Changing the tools + Main components of NC machine tool [Fig. 3.2.1(b)]: (Work table (Gi) Machine tool spindle (iii) Drive units (iv) Machine control unit (vi) Magnetic box (v) Feedback mechanisms (vil) Manual control 3.3 CLASSIFICATION OF NC (NUMERICAL CONTROL) MACHINE TOOL SYSTEMS NC machine tool systems can be classified on different basis. Fig. 3.2.1 shows the classification of NC machine tool systems Open-Loop Type ‘according to NC Machines Control Loop Foodback Systems Closed-Loop Type ‘NC Machines PontioPort Finite Positioning Systems Contr! NC Machines. Sregt Cut Systems ‘Recording to Sana Nic Machines Type of PE ceouare oo! Motion Control "Two and Hat Continuous Axes Contourng E>} Path Control Nc Machines a Contouring Malas ontouring ‘Absolute Programming } Path Control ‘CNC Machines Two Axes Contouring i Jaxes Contouring Two Three Aves ‘Contouring Program Methods ‘Absolute Programming CNC Machine Systems Therementar b>) Programming [CNC Machine Systems ‘According to Type ‘of Controller Hybrid Controller P| cnc systems | i > Straight Controtlor CNC Systems. ‘CNC Horizontal ‘According to ‘Axis and Type of =>) Operations il enc ming E "centre Fig, 3.8.1 : Classification of CNC Machine Tool Systems 3.8.1 According to Control Loop Feedback Systems : According to control loop feedback systems, the NC machine tool systems are classified as : 1. Open-Loop Type GNC Machines 2. Closed-Loop Type CNC MachinesBF computertn + Open-Loop Type CNC Machines exvated Manat Alded Manutaty : Wig The open-toop control systems do not have & feedback mechanism. ‘The opentoop machine tool controls, (Fig, 3.8.2) have only yy sestey motion control but do not have any pine Tos tas Goa Box k4| slacamen ke provision for a feedback, which need to be Leone compared with the input for better control and correction of erocomputor Ori Metr ive system, Fig. 18.2 : Open-Loop Type CNC Machine + Example of open-loop type CN CNC drilling machine, 2. Closed-Loop Type CNC Machines: " CHC Cone + The closedtoop contro! systems have a feedback mechanism. The closed-loop machine tool controls (Fig. 383) have the motion control with a provision of feedback, Which can be used for accurately controlling Ue acne Too Ss the drive system by comparing it with the | 5ypicomer input information until the required or ae desired position is achieved. Bove Note Fig. 3.8.3: Closed-Loop Type CNC Machine + Example of closes-loop type CNC machine + CNC lathe machine. 3.8.2 According to Type of Too! Motion Control : ‘According to the type of tool motion control modes, the CNC machine systems are clasifedas (Fig 3.8.4) ious Path, sR Comms Gwe uecns | stv ag yin¥ Computer Integrated Manufacturing, 343 Computer Aided Manufacturing Finite Positioning Control CNC Machines : The finite positioning contrat machine systems are further subdivided into two types ()Point-to-point (PTP) CNC Machine (ii) Straight-cut CNC Machines ()_Point-to-point (PTP) CNC machines : In point-to-point [PTP] CNC machines, the ‘movement of cutting tool from one predefined position to another predefined position is important, while the path along which this tool moves is irrelevant. Example of point-to-point (PTP) CNC machines : CNC drilling, punching and spot welding machines. This type of control mode is least expensive of the all modes. (ii) Straight-cut CNC machines : 2 ‘The straight-cut or straight line control mode is an extension of the point-to-point control mode with the provision of straight line cut or machining. This straight line cut is obtained by controlling the movement of tool with controlled feed rate in one of the axis direction at a time. Examples of straight-cut CNC. machines : face milling, pocket milling and stepped turning operations. Continuous Path Control CNC machines : The control system is used for continuous, continuous/contouring path multaneous motions of cutting tool and workpiece along different contoured profiles and curved surfaces. In this control mode, most of the slide motions are controlled simultaneously so that their relative positions pass through the desired contouréd path of the final shape of the required product. ‘Types of continuous/contouring path control systems: CMe la. Explain, with neat sketch 2 axes, 2% axes an 3. axes of] CNC machines, SEALS i) () Two axes contouring (i) Two and half axes contouring (ii) Three axes contouring xes contouring ‘Two axes contouring : In this control mode, tool is, controlled simultaneously in only two axes : X and Y, as shown in Fig. 3.8.5. y Two Axes Contour naling x Fig. 3.8.5 : Two Axes Contouring Position Control Two and half axes contouring : In two and half axes contourit machining is inclined to the plane of motion of tool (ie. X-Y plane), as shown in Fig. 3.8.6. ig control mode, the plane of ‘Contr Ptane or Machining Plane Note : Too! axis is parallel o Z-axis Fig, 3.8.6 : Two and Half Axes Contouring Position Control Settee2 SE _ Computer tntograted Manufacturing if) Three axes contouring : three axes as shown in Fig. 3.8.7. ‘Tee Axes Contour ing Fig. 3.8.7 : Three Axes Contouring Position Control Gv) Multi-axes contouring: z Fig. 3.8.8 : Multi-Axes Contouring Position Control In three axes contouring control mode, tool is controlled simultancously in Computer Aided Manufactur ng + In multiaxes contouring, control nae (Fig. 3.88), unlike other modes, the orientation can be changed with the tog motion. + Forexample, a six-axes machine tool is capable of moving the tool simultaneously along each, primary axis and also can rotate about each primary axis at the same time. 3.8.3 According to Programmi 1g Methods : ‘+ According to the methods of programming of tool movement path, the CNC machines systems are classified Into two types : ‘Absolute ‘Systems Programming CNC Machine Incremental ‘Systems Programming CNC Machine 1. Absolute Programming CNC Machine Systems : In cartesian coordinate geometry system using absolute measurement, each point is always specified using same zero established for a given coordinate system, as shown in Fig. 3.8.9. v Incremental] incremental point |x 7 Coordinate | Coordinate ei pt 10 10 | P2 3 po Ge euloe ae x Lo | j-—25_,} Po 50. 3 c 0 Fig. 3.8.9 : Absolute Programming System Incremental Programming CNC Machine Systems : In cartesian coordinate geometry system using incremental measurement, each point is specified using the reference of the preceding point position, as shown in Fig. 3.8.10.1 ® puter Integrated Manufactur 16 omputer Aided Mantactag 3.8.5 According to Axis and Type of 2 Multipte program storage = The lane compere Operations Acconding to axis and the type of operations, C machines are classified as: NC Horizontal Machining Centre ENC Vertical Machining Centre NCTuring Centre CNC Milling Centre 3-9 ADVANTAGES (FEATURES) OF NC MACHINE TOOLS TS |O- Explain four important features of CNC machine over| NC machines. |O. What are the features of CNC machines compared to| NC machines ? ERE Most of the advantages of NC machine tools are also applicable to the CNC machine tools, Following are some of the additional advantages of CNC machines ‘Advantages (Features) Of CNC Machine Tools 9 1- Ease of program input 2. Multiple program storage 3. Online part programming and editing 4. Use of short programs 5. Greater loxibilty of system _—eEeEeEeEeEeEaEyxRR 66. Use of advanced interpolations 7. Automatic tool compensation ‘8. Auto-generation of part program for ‘existing components 8. Change in system of units Ease of program input : Part program can be easily entered into computer memory using alphanumeric Keyboards or through storage devices like : CD or floppy disc. Now-a-days even the modeling data can be directly converted into the part program with the help of translators. 5 avemory allows the storage of melite proprant These programs ca be recalled for the produce as per the requirement. This is highly convening against the program tapes of NC machine Online part programming and editing : 19 yo machines, the part program is stored on the tape which is difficut to edit or modify. tn CNC machines, as the part program is stored in computer memory, it can be easily edited or modified. Even the onling editing of part program is possible. Use of short programs : Writing of additional repetitive programs can be minimized because of the use of subroutines or micros, The subroutines can be called into the existing program listing whenever required, which saves lot of time and also makes the program short and compact. Greater flexibility of system : One of the major advantage of CNC over conventional NC is its Aexibility. The new systems and controls can be added and at low cost. Use of advanced interpolations : The NC system uses only straight and circular interpolations. The CNC system software allows the use of advanced interpolations for helical, eubie and parabolic relative Automatic tool compensation : In NC system. the actual tool dimensions have to be adjusted in setting. There is no provision for automatic toot ‘wear compensation. In CNC system, the tool wear is measured by the built-in sensor, The controller computes and automatically applies the tool compensation. Thus, the dimensional accuracy of the component is maintained — automaticaly irrespective of the tool wear. Auto-generation of part program for existing components : In CNC system, the shape of the existing part can be traced by using the probe which can be contact type or non-contact type. The traced shape is stored in the computer memory and is used to auto-generatea part program. This feature can be used for reverse engineering, wherein existing part can be used for auto-generation of part program. Change in system of units : The CNC system can easily convert the programs written in one system of units (for example : MKS) to another system of units (for example : SI). weetcommuter Ine ufacturing 3.10 LIMITATIONS OF CNC MACHINE TOOLS a7 Computer Alded Manufacturing, 3. Requirement of spectalised operators + As CNC am for manufacturing cessity of highly skilled machines 1 of different parts, there Is 1 quire part prog Limitations Of CNG Machine Tools 11 APPLICATIONS OF CNC MACHINE TOOLS ‘The CNC machine tools cover following application CNC Turning Centre CNC Machining Centre CNC Welding and Cutting Machine 1. Higher investment cost 2. Higher maintenance cost a 3, Requitement of specialised oper alors 1, Higher investment cost In CNC machines specialised technology is used which incre. initial cost. a more ases the CNC Laser Cutting Machine CNC Wire-Cut EDM [Electrical Discharge Machining] Centre CNC Die-Casting Machine CNC Disc Grinder 8. CNC Gear Shaper 12 SYSTEMS OF NC/CNC MACHINE TOOLS 2, Higher maintenance cost : The maintenance cost of CNC machines is high, The NC/CNC machine tools consist of number of systems, The major syst below: , shown in Fig. 3.12.1, are discussed Eca [Actuator Suppor] [_ Foedback ‘Automate Boarings Systoms ‘Tool Changors = bes + Resrcusatng | [+Rotay, + Magazine Type Bal-Screw Encoders + Sadie + Tarot eae (Sido ways) | ]«Ac Sone Systems + Linear Learn Motors + Linear Motion Encoders Guidoways a = stepper Motors = Fuss motors Material Pallet changer] [Lubrication =] [Coolant Tooting | |rtanaling Systems|. Systems System System |= Toots = Toot Hoisers Fig. 312.1 : General Constituents of NC/CNC Machine Tools WE hatesSE _Computer Integrated Mam 3.12.1 Structure : ‘The NC/CNC machine tool structure consists of following parts : 1. Bed 3 2. Saddle or slide-ways 4, Table Column 1. Bed: The NC/CNC machine tool bed is usually made of high-quality cast iron with heavy ribbing to Provide high stiffness and low weight. The cast iron bed provides the necessary damping to reduce the vibrations generated because of: igh speed, heavy- uty machining and large material removal rates. 2, Saddle (slide-ways) : The saddle or slide-way, normally mounted on the hardened and ground bed. ways, provides the machine tool with the X-axis linear movement. 3. Column : The column is mounted on the saddle. Its designed with high torsfonal strength to prevent distortion and deflection during machining. The column provides the machining centre with the Y- axis linear movement. 4, Table: The table is mounted on the bed. It provides the machining centre with the Zaxis linear movement. 3.12.2 Spindle and Feed Drives : * In most of the machine tools, the drives are used to drive spindle and feed motion devices; both of which are either holding workpiece or cutting tool. ‘+ Types of drives : spindle drive and feed drive, ‘© Most commonly used drive Steppermotors 2, DC servo motors Fluid motors AC servo motors 1. Stepper motors. ‘+The stepper motors are usually used in open loop control systems where feedback is not Tequired. The common application of stepper ‘motors is in machine tool slides or feed drives. * Usually, stepper motor works in incremental steps. The common step size (angular rotation) is 1.8". Thus, one step of stepper motor rotates, the lead screw of slide by 1/200 of a revolution. 318 = Computer Aided Manus 2, DC servo motors : + DC drives are widely used in yg ‘machines with closed loop control system, © Advantage of DC motor speed of rotation, ‘© Limitations of DC motors dimensions and large weight. # ea8 of cont OSH, tay 3. AC servo motors : + Inclosed loop control systems, the alternaty to DC servo motors are AC servo motors. ‘+ Advantages of AC servo motors : high powe, to weight ratio, low rotor inertia, constag, continuous torque, constant overload capacity over the full speed range, and no requiremen, of additional cooling of motor. 4. Fluid motors : ‘The fluid motors are also used for driving the spindle, Usually high pressure oil or air is used for running the motor. 9.12.3 Actuator Support Bearings : ‘The actuator support bearings are required for rotary and linear motions. They are of two types : 1. - Re-circulating ball screw systems 2. _Linear motion guideways 4. Re-circulating ball screw systems : Fig. 3.12.2: Re-ci * The re-circulating types of ball screw [Fig 3.122] are widely used in Nc/Cit es where rotary motion of motor converted to linear motion using lead sce ‘These are specifically required in slide ways ‘+ In such systems, the balls are in continues circulation between nut and screw dunt complete motion of slide. eetCom tio hence, have a low coefficient of friction, and 8 rated is magnifies output. «In addition, these re-circulating ball. screw ‘+ Arotary encoder with 360 lines can give 360 systems can be preloaded. This helps. in pulses per revolution. reducing backlash in two-directional motions Lp Soren of slides attached to the lead serews, to give a square wave Linear motion guideways : + tn NC/CNC machines, there are support structures which moves on either bed ways or slide ways. To minimise friction and wear in such sliding elements, — ines Dee rolling elements are used. The systems used for such purpose are called as linear motion systems. Fig. 3.12.4 : Rotary Incremental Encoder 2. Linear encoder : Ligh Source sig hoon Fig. 3.12.3 : Linear Motion System 3.12.4 Feedback Systems : Sang dence ‘roost Cass) + In closed loop control system, there is requirement Fig. 3.12: of feedback devices. Encoder is one such position Linear Encoder + The linear encoder consists of glass scale with line grating, connected to the slides which moves over stationary guide ways, as shown in Fig. 3.125. + Types of incremental Encoders as Feedback + Therelative movement between the glass scale Devices fixed to slides and photoelectric sensing device fixed to guide results in alternate light pulses ‘which generates an electric pulse. The periodic Rotary encoders signals are processed and converted into * The rotary encoder consists of a glass disc with equlvalen$ Hiner movement: accurately etched lines at equal regular intervals, as shown in Fig. 3.12.4, on the outer periphery of the disc. Tool changer : ‘The disc is connected to the lead screw either feedback device, used for measuring the position of the tool edge with reference to the NC/CNC machine slide, 3.12.5 Automatic Tool Changers : In NC/CNC machines, the various tools are to be directly or through timer belt. used for different machining operations; but at a +The disc rotates between a light source and a time only one tool can be used for one type of photodiode. The eatched lines make or break machining. The automatic tool changer is a device the photoelectric beam and a pulse signal which is capable of storing a number of preset tools which can be automatically called for use by the part program. SireeB SE_Computer integrated Manufacturing 3-20 Computer Aided Many, “Types of Tool Changers Used in NC/CNC Machine | 3.12.6 Tooling > Tools 1. Magazine type 2. Turret head 1. Magazine type > * The magazine is a storage and retrieval device for cutting tools. In drum type tool magazine, shown in Fig. 3.126, tools are mounted on a drum Periphery for loading and unloading operation. On a typical drum type magazine, 60 tools can be mounted, Fig. 3.12.6 : Drum Type Tool Magazine 2 Turret head : Fig. 3.12.7 : 12-Tool Disc Turret In turning centers, tools are mounted in turret head. It is a small tool storage and indexing system [Fig. 3.12.7). ‘The turret system is cheap as compared to magazine system, The tooling in NC/CNC machine tools include, Tools 2. Tool holders Tools : In all NC/CNC machines, machining tools are as that normally used in lathe, milling, shaping drilling machines with one difference of comma, Too! holders : features of shanks. 0 18 A | on Fig. 3.12.8 : Standard Tool Holders ‘The various types of tool holders, normally used in NC/CNC machines, are shown in Fig. 3.12.8. These may vary depending upon the country specific standards, Inasingle NC/CNC machine, all the tool shanks and tool holders should follow common tool adapter designs for smooth loading and unloading of tools. 3.12.7 Material Handling Systems : Some of the material handling mechanisms used in NC/CNC machines are explained below : Bar feeder Robot loaders 2. Parts catcher Chip conveyor |. Bar feeder : Normally when continuous supply of materi is required, for example in manufacturing & screws, bar feeders are used. ‘The bar feeder is a device capable of handlit 2-4m long raw material bars. It eliminates loading of individual part as a raw materi erentBF Commuter Integrated M: Parts catcher : lamufacturing The ps catcher catches ® the filly or parti ned workpi yeah machined workpiece and deposits a next machining fatty, + The parts catcher complements the bar feeder, and parts catcher are used to reduce the loading and unloading time, Robot loaders : ‘The bar feeder The robot loaders communicat te with the main controller unit and are capable of doing a variety of aed Computer Aided Manufacturing into containers for storage and recycling, 3.12.8 Pallet Changer Systems : * The workpieces are mounted on the pallet and pallets are moved around the machining facility ina logical manner. The workpiece pallet changer systems are of two types changer system| pallet cl gperations, such as loading and unloading of parts, | ‘inest pallet changer system toring and retrieving parts trom’ poles + Atypical tinear pallet changer system fs shown transporting Parts to gauging stations and changing in Fig. 3.12.9. In first case (Fig. 3.12.9(a)], the chuck jaws. pallets are moved in inverted-U path in front of : machine spindle, 4. Chip conveyor * In second case [Fig. 3.12.9(b)], the pallets are A chip conveyor picks up all the chips from the bed moved linearly with pallet rotation facility for of the machine and transport out of the machine bed proper machining. Position 1 Postion 2 Positions abies Table2 Seiting Staton h ce) @ Fig. 3.12.9 : Linear Pallet Changer Systems& Computer Integrated Mamufact 3 a Computer Aided Man Rotary pallet changer system : In rotary pallet changer system, shown in Fig. 3.12.10, pallets are indexed one by one for machining operation to be performed on workpieces mounted on each pallet in clockwise or counterclockwise rotation in front of machine spindle, Fig. 3.12.10 : Rotary Pallet Changer System 3.12.9 Lubrication System : + NC/CNC machines should have proper lubrication system for smoother operation of slides and other devices where relative motion takes place for precise machining with minimum wear and minimum heat generation. + These lubrication systems are operated by different lubricant pumps controlled by using various sensors. 3.12.10 Coolant System : + In NC/CNC machines, the machining operations generate heat during metal removal. This heat may ‘damage the tool or the workpiece. +n order to avoid this, there shoul 4p coolant system operated continuously wih of coolant pumps. #INNG/CNC machines, there are two types ofc :imistand Mod, As the name Suggests, mist gi is Just lke sprinkling type and Mood ezolag! overflowing type. 3.13. DNC MACHINE TOOLS CN [a. Explain DNC machine, with block aiagram. [Q. Explain direct numerical control. TURIN la. Write a short note on : Direct Numerical Control (ON6| system, EEA ‘+ Direct Numerical Control (DNC) Machine Tools: Direct numerical control (DNC) machine tools is a ‘manufacturing system in which a number of ‘machines are controlled through a central computer by direct connection hy hy ‘The central computer provides the programming {instructions to each machine tool as well as receive the data from the machine tools. Thus it is a two way information exchange. As per the requirements of individual machine tool control, DNC computer is, providing or communicating instructions and commands instantly to the individual machine tools. Cenital DNC Computer ‘wih Buk Cental Memory Machine Tools Fig, 3.13.1: DNC Machine Tool Systemcomputer I ted Manufacturing 3:23 ier Aided Manufacturing DNC Machine Tools with Satellite Computers aan compare If the network of machine tools is large, then use is made of ntermediate computers known as satellite computers, as shown in Fig, 3.13.2. Each satellite computer Is @ aicomputer and controls 7 rminicomputer ols smaller groups of machine tools by receiving the instructions from the central computer. The satellite ‘Omputer take off some of the burden of the central computer. (Central DNC Compute win Buk Cental emery Sate Computer Sate ‘Satelite Jcompuser Machine Tools| lacing Tos Machine Toole Fig. 3.13.2 : DNC Machine Tool System with Satellite Computers 3.13.1 Basic Elements of DNC Machine Tool System ‘A DNC system consists of following elements [Fig 3.13.1]: 3.13.2 Main computer Memory for storing part program listing Communication network and Interfaces Machine tools Functions of DNC Machine Tool ‘System: ‘The main functions of DNC machine tool system are asfollows : 1 To control the machine tools placed at different locations from a single computer. To facilitate the storage and editing of part programs of all machine tools by single central computer. To maintain the data base of all machine tools centrally by receiving the data from the machine tools, 4, To integrate CAM with CAD. 3.13.3. Advantages of DNC Machine Tools : la. State advantages of DNC over CNC. TZSUEINETAE) 1. Iteliminates punched tapes and tape readers, which are the weakest components in the NC system. 2. Large memory of DNC allows it to store a large amount of part programs. 3, Same part program can be run on the different ‘machines at the same time without duplicating it at individual machi Central DNC computer can keep close control over 4 the complete machine shop. 5, Individual machine performance report can be obtained on demand. 6. DNC uses a central computer, which can be easily isolated from the machine shop and kept in suitable environment. 7, The data related to manufacturing can be centrally maintained and updated, thereby effectively ‘managing the inventory and scheduling. ene[2._ State limitations of DNC over CNC. UAE 1. Im the event of failure of central DNC computer, the complete activities of the machine shop will come to standstill, 2. DNC Is expensive and its use is justified where high automation is required 3.14 ADAPTIVE SYSTEM [University Questions | JO. Explain, with suitable example CONTROL (Ac) ‘adaptive control system, 12. Explain the functions of adaptive control system, SB Computer Aided Manu 1 Increased tool life, -ased productivity 4 Increased accuracy by making tolerance 4, , constraint, 5. Maximum component safety, 6. Minimum human intervention, and 7. Easy part programming. 3.14.2 Types of Adaptive Control (AC) Systems : ‘of adaptive controls in Nel machines ? Explain adaptive control by optimization (aco). |. What are the different types of adaptive control system: ln NC machines ? Explain any one adaptive contra system in det [sreu may 3] ‘+ Adaptive Control (AC) System : Adaptive Control System is a control system which measures output process variables and uses these output process variables to control the speed and/or feed. Some of the output process variables used in adaptive control are : spindle deflection, force, torque, cutting temperature, ‘vibration amplitude and power requirements. By using adaptive control, in-process lime can be reduced by proper selection of speed and feed during machining, ‘+ Examples of adaptive control (AC) system : Adaptive control Is suitable for following types of (Variable geometry of cut in the form of changing depth or width of cut: (1) Variable workpiece hardness and variable machinability; (il) Variable workpiece rigidity. 3.14.1 Advantages of Adaptive Control (AC) ‘Systems = IQ. State advantages of adaptive control’systems in NC| ‘machines over NC system. 1. Increased production rates, ‘The adaptive control systems are of two types : “Types of Adaptive Contra (BC) Systems 1 Adaptive Gontral with Opimization (ACO) 3 Acapive Cont wih Conse (AGO) (© Adaptive Controt with Optimization (ACO) : + In adaptive control with optimization (ACO), the performance is optimized according to prescribed performance index Pl. ‘The performance index s given by, Tool wear rate PI * Adaptive control with optimization is a close Joop control system. In this system, the sensors measure the various output procest Parameters such as: Cutting torque, tool wear, tool temperature and machine vibrations. ‘+ These measurements are used by the adaptive controller to compute the real tine performance index. + This computed performance index (PD & compared with the set value of maximus performance Index in a system. The softwart then computes the feed and spindle speed © as to maximize the performance index. eatoptimum value ot qertarmenes Pie SAA shows the Weck a Types of part propramming Offeeding the part programming to the machine, the part programming ean be of two types 2.15.1 Steps In Part Programming Fig. 3.24.1: ACO System Gi) Adaptive Control with Constraints (ACC) + In adaptive control with constratne (ACC), the process parameters such am using Sone fool wear, tool temperature and machine Wiorationa ‘are stored in pacar sown te sasure the output process parameters. The measured values of process parameters are compared with the limiting values stored In system soRware If the measured values exceed the limiting values, the system computes the required feed and/or spindle speed so as to maintain the process parameters within the limit. Fig. 3.14.2 shows the block diagram of ACC system. Fig. 3.14.2: ACC system 3.15 INTRODUCTION TO PART PROGRAMMING Part programming : The part programming ts the Set of machining Instructions, written In standard format for the NC/CNC machine. These Instructions Gin be elther punched on the tape using the &pe Dunching machine or directly fed to the computer. “The NG/ENC machine tols receive the directions for operation through a punched tapes or through a part programs stored im computer memory. The art programming can ether be done manually or [emer rea Fig. 3.15.4: Steps In Part Program Preparation wrSE _Computer Integrated Manufacturing, The various teps followed in the preparatic Part programming are shown in Fig. 3.15.1. * The above information ts entered in a program sheet in a particular format acceptable by the ‘machine tool. The information given on the program sheet is either punched on a tape using tape punching machine or directly fed to the computer, 3.16 COORDINATE SYSTEMS USED IN MANUAL PART PROGRAMMING The coordinate systems used in part program listings are explained below: 1. Absolute System 2,_Incremental System, 1, Absolute System : In absolute system, the coordinates are mentioned in the program with respect to one reference point (datum). 2, Incremental System : In incremental system, the coordinates of a point are mentioned in the program with respect to the previous point. 3.17 FORMAT OF MANUAL PART PROGRAMMIG = Block: Block is a group of words or group of coded instructions for the NC/CNC system to execute a particular movement. Word: Each coded instruction in part program is called as, word. Different Words in Block: ‘The words in the block are in the following order: (Program number (0) (i Sequence number (N) (iit) Preparatory functions (@) (iv) Coordinate functions (X, ¥,, U,V, Wand IJ, K) (v) Feed functions (F) (vi) Spindle speed functions (8) (vit) Too! functions (7) > 3:26 Computer Aided Manu, ctr functions (M) (vii) Miscetlaneo (Program number (0) :A four-digit number the letter 0 in program numbering, The progr numbers can be configured in'a manner tht alge “General Programs” (00000-07999), “Cusg Macro Programs” (08000-08999) and “Macha, ‘Tool Macro Programs” 09000-09999. Sequence number (N code) : The sequence number, also known as N code is used to indeniy the,block within the NC / CNC program. The block can be searched in a program by the controler through the sequence number. The sequence number is designated by a letter ‘N’ followed by three digit number; for example, N100. Some controllers require sequence numbers to be input in ascending order, while other controllers allow any three digit numbers after letter ‘N’. (il) Preparatory functions (G-codes)_: The preparatory functions, also known as G-codes, are used to prepare the controller for instructions that are to follow. The letter ‘G’ is followed by the two digit number. The two digit number prefixed by letter ‘G’ indicate a predefined function. For example, word G02 Is used to prepare NC controller unit for circular interpolation along an arc in elockwise direction. (iv) Coordinate functions (X, ¥,Z, U, V, W, and I,J, K) The coordinate function designate the position of the tool. In a two-axes system, only two ofthe words would be used. For example, the tooltip coordinates (100, 25) are represented as X100 Y25. Feed function (f) : This function is used to specify the feed rate. The letter ‘Fis followed by the feed rate in mm/min. For example, F90 indicates feed rate is 90 mm/min. once feed rate is programmed in block, it remains in all subsequent blocks ill iti replaced by another value (vi) Spindle speed function () : This function specifies the spindle speed. The letter ‘S' is followed by the spindle speed in r.p.m. (vil) Too! functions (T) : This word is needed only fo ‘machines with a tool turret or automatic t0% changer. It indicates which tool is. to be used ‘operation. For example TOS indicates a tool intr Gi) w) position 5. Sic abla intel nartadeatliina cer nt 2gF computer Integrated Manufacturing 327 Computer Aided Manufacturing (sii) Miscellanceous functions (M-code) : The miscellaneous functions, also known as M-code, are used for indicating the miscellaneous functions like : coolant on or of, spindle on or off, spindle CW or CCW, program stop.ete Format of Block in Manual Part Programming : + Any Part Program contains number of blocks, Each block contains number of words. The format is the method of writing the ‘Words’ in each ‘Block’. + The different formats are used in NC/CNC programming depending upon the requirements of the NC/CNC controller Irrespective ofthe format, each ‘Block’ must contain the ‘Words in following order [Fig, 3.17.1] N S xvzascuK s T 0B sO Mt M1 ue 4 =| Fea Spina V1 Toot End of Funcion | | Fun Speed VY unc 0 Functen |] 5 Function, __ Bock Fig. 3.17.1 : Format of Manual Part Programming + Typical example of block in manual part programming : N100 G02 X70 Y20 F100 Sisoo ToS Mo7 * Only the functions which are charged, have to be specified in the subsequent blocks. For example, once a feed rate Is programmed in a 3.17.1. Types of Formats of Block in Manual Ee eras a eee aeeeeuey Part Programming : blocks till itis replaced by another ‘F’ value. ‘These are four basic formats of blocks used in part | 3+ Tab Sequential Format: programming. - ‘In a tab sequential format, two words are Types of Formats of Block in separated by a ‘tab’ character. Manual Part Programming * Two or more tabs immediately following one another indicate that the word, which would 7. Fixed Sequential Format have normally occupied the location of tab is redundant and has been omitted. * The examples of tab sequential format are as 3. Tab Sequential Format aoe 001 tab 90 tab 50.0 tab120 —tab07 eob tab 40.0 tab 30.0 tab 1400 2. Block Address Format 4, Word Address Format 1. Fixed Sequential Format: 002 tab 02 tab50.0 tab120 — tab07 eob * In fixed sequential format, each NC Block is of tab 40.0 tab tab the same length and contains same number of words, 4. Word Address Format: * For example, even if the feed and speed are the + Inword address format, each word is preceded same for ten blocks of NC program, same feed by a letter which indicates the type of data that function and spindle speed function must be follows. The redundant words are admitted. coded in each block. ‘* The example of the word address formats, 2 Block Address Format: NOO1 G90 G01 X40.2 YS0.3 F100 1000 MO7 * In block address format, there is no need to specify the same as well as redundant information in subsequent NC blocks.B . Computer Alded Manat, og ted Manufacturing 3 3.18 TOOL AND GEOMETRIC COMPENSATIONS IW GNC machines, the tools and cutters used are of different slzes, shapes and geometries. Therefore these my be a method to compensate for the varied lengths of tools and varied radil of the cutters. The methods used j, ‘compensation of tool length and cutter geometry specifically radius are discussed below : 1. Tool Length Compensation 2,__Cutter Radius Compensation Tool Length Compensation : ‘* Most of the CNC machines use multiple tools and length of each tool in different. Therefore, the * programmer has to account for the individual tool lengths while programming the Z-dimension. * IN CNC machines, all the tools are measured in assembled state by using a tool measuring device, known as tool pre-setter. This tool pre-setter can be mechanical, electronic or optical. These tools are input in 2 Programmable tool resistor of the CNC machine. Thus all the tool lengths are stored in a tool register which isa memory location in the computer. Hoe Hoo. Fig. 3.18.1 : Tool Length Compensation or Offset for Different Types of Tools © The distance of a given tool tip from the surface of the workpiece is known as tool length offset Hl’. The tool length offsets HO1, HO2, H03, ete. for different tools are estimated from the tool length and stored in the tool register (Fig. 3.18.1). © The tool length offset function G43 is used to set tool length offset ‘ON’. Cutter Radius Compensation : Compensation -Lets_( ‘ppicatie torino Pat Fig. 3.18.2 : Cutter Radius Compensationions, it become: by offsetting the contour by an amount ener ny amount eq + Fig. 3.16.2 shows the workpiece contour alculate the tool cutter path for preparing the program ius of the ct ter. caleutation, one shou reales ena athe tool path fora typleal workplece,Hesldes the problem of ifaconpattion cqualsitieny whenever the cutter size changes, the program would need editing, But memory, the program could he the eter fs entered and stored in the tot register of the computer er ieee written for the workplece profile, and hence, no change in programme Is ” we can say that the programme is written with a zero cutter radius. + The codes G40, G41 and G42 ‘ are used for radius a hese codes once programmed in an} programme remain active till cancelled by. ime eae usher el ace () Cutter radius compensation left (641) : Itis used when the cutter is es rer is on the left of the programmed tool path when looking in the direction of the tool mover the radius compensation is considered to the left of the programmed contour. (i) Cutter radius compensation right (642) : It is used when the cutter is on the right of the programmed tool path when looking in the direction of the tool movement, and hence, radius compensation is to the right of the programmed contour. The tool radius is always positive. If the programmed path is determined for a specific size of the cutter, the compensation value would be positive or negative depending on whether the cutter used for machining is oversized or undersized. (iil) Compensation OFF (G40) : ‘This function cancels any cutter radius compensation applied previously. Table 3.18.1 : Cutter Radius Compensations nfe {x |ylz{efs[elelmls|s Description. No | Gao CANCEL Cutter radius compensation nt | Ga2 | x15 ~ 11 | Cutter radius compensation -right, with offset for tool is D11 ne | Gas | x15 11 | Cutter radius compensation — loft, with offset for tool is O11 3.19 MANUAL PART PROGRAMMING FOR CNC LATHE (TURNING CENTER) + Inlathe or turning center, the workpiece is rotating and turrets, tools are stationary, which are mounted on the sliding from Fanuc, Allen tour of the programmed tool path. The controllers may be © The cutting tool follows the cor ‘depending upon the manufacturer. Bradley, Bendix, Toshiba, Hinumerik, etc, * Twoaxes of a CNC lathe : (Horizontal Z-axis: line joining chuck cer (i) Horizontal X-axis line perpendicular fo Z-axis but in horizontal plane. 3.191. Coordinate System (Axes Designation Conventions) Used in Turing Center |O. Explain, with neat sketch, coordinate, ntre and tall stock centre. system for lathe and dling CNC machines.¥¥_computerntegrated Manufacturing ‘The different categories of axes used in NC / CNC machines are as follows : Main Axes (X,Y, Z) Rotational Axes (A, B, C) Secondary Linear Axes (U,V, W) Incremental Dimensions in Circular Interpolation (I,J, K) 1. Main axes (X, Y, Z): ‘The nomenclature of three main axes (X, Y, and Z) is based on the right hand rule, involving the middle finger, index finger, and the thumb of the right hand, as shown in Fig. 3.19.1. The thumb indicates the orientation of X-axis, the index finger indicates Y-axis and the middle finger points in the direction of Z-axis. + $8 & en (2) Main Axes (b) Rotational Axes Fig, 3.19.1 : Machine Axis Designation 2. Rotational Axes (A, B, C): ‘© Designation of each'rotational axis is based on the linear axis about which the rotation occurs. ‘* When looking along a main axis in positive direction, clockwise rotation is positive. * Alsrotation about X-axis, + Bisrotation about Y-axis. ‘© Cisrotation about Z-axis, ‘Secondary Linear Axes (U, V, W): The other useful secondary linear axes designations are: Uis parallel to the X-axis, Vis parallel to the Y-axis Wis parallel to the Z-axis, 3:20. » Computer Aided Manu, ty i 4. Incromental Dimensions In Circular inter, (hk): «Tis used as Incremental dimension in during circular interpolation, + is used as incremental dimension in Yay, during circular interpolation, used as incremental dimension in Za during circular interpolation. og Xan 3.19.2 Zero Points and Reference Point: u la. Explain fixed zero and floating zero for CNC machine. ]Q. Explain with neat sketch : Machine Origin, Work Piece Origin and Program Origin. State importance of each! (Origin may be treated as Reference) KEZTUBIENET EI rm ‘The various zero points and reference points used in coordinate system are discussed below : Fig. 3.19.2: Zero Points and Reference Points for Lathe Various Zero Points and Reference Points Used in Turning Conter 1, Machine Zero or Fixed Zero Point (My 2. Blocking Point - Workplace Zero or Floating Zoro Point (A) 8, Program Zero Point (W) 4, Start Point (B) 5. Reference Point (R) 1. Machine Zero or Fixed Zero Point (M) : * The machine zero point (M) is the mactin® reference position or the origin of machi? Coordinate system. On all NC/CNC machines the machine zero point is located at Positive end of each axis travel range. watt$F _computer Integrated Manufacturing 331 Computer Aided Manufacturing 2, Workplace Zero or Flosting Zero Point (A) *+ From above equation the spindle speed can be i : ete ing recommended values of locking point (A) is the workpiece zero point cetermined Blocking point (A) ‘piece zero point. cutting speed given in Table 3.19.1. 4, Program Zero Point (W) : 2, Feed (t,): © Program zero point (W) is a starting point of workpiece-blank, It fs called as program zero point, as all the tool travels are specified with respect to this point, ‘+ Itis advisable to place the program zero point in such a manner that, the dimension in the workpiece drawing can be conveniently converted into coordinate values. 4, Start Point (B) : ©The start point (B) is to be determined in the program. This is the point from where the first. tool starts the machining process. 5. Reference Point (R) : + The reference point (R) of the machine is determined by measuring systems. It is essential to know the distance between ‘R’ and ‘Min order to relate the position of the axis to that of the reference point. © Normally reference point is not fixed, it fs a floating point. 3.19.3. Cutting Process Parameter Selection for Turning Applications : ‘The various cutting process parameters used in turning applications are : 1. Cutting Speed (V) 2 Feed (fm) 3._Depth of Cut (t) 1. Cutting Speed (v) : ‘+The cutting speed (V) of a tool is the speed at which the metal is removed by the tool from the workpiece. In a lathe, it is the peripheral speed of the workpiece and is given by, ‘DN = ooo /min Where,D = diameter of workpiece, mm N_ = spindle speed, rpm. ©The feed of a cutting tool in a lathe is the distance the cutting tool advances for each revolution of the spindle and workpiece. ‘© The feed in mm/revolution (fey) and the feed in mm/min (fy) are related by the equation, fm = NX fev where, N =the spindle and workpiece speed, F. p.m. frey = feed in mm/rev fy = feed in mm/min ‘+ Refer Table 3.19.1 for recommended values of cutting feeds for lathe work. + Increased feed reduces the cutting time. However increased speed greatly reduces the cutting tool life. Coarser feeds are used for roughing and fine feeds for finishing cuts. 3. Depth of Cut (t): + The depth of cut (t) is the perpendicular distance measured from the machined surface to the uncut surface of the workpiece. + Ina lathe, the depth of cut is expressed by using equation, Dy- Dz ' 2 where, Dy = diameter of the workpiece surface before machining, mm D2 = diameter of the workpiece surface after machining, mm, © The depth of cut varies inversely as the cutting speed. Table 3.19.1 gives the recommended values of cutting process parameters for lathe work.q Computer Aided Mana, BF computer Lathe work Cutting Speed, m/min Depth ofcut,mm | Heavy Cut Medium Cut Light Cut Fine Cut 5-10 25 05-2 0.1-0.5 Feed, mm/rev 0.25-0.5 0.2-0.3 0.05-0.2 Tool Material Hss_| carbide | Hss_| carbide | uss_| Carbide | HsS__| Carbide Workpiece Material Free-machining steel | 20-40 | 90-150 | 40-70 | 120-180 | 40-110 | 150-250 | 50-120 | 200-500 Mild steel 25-35 | 60-120 | 30-50 | 80-150 | 30-60 | 120-200 | 40-80 | 150-450 60-120 | 25-50 | 90-150 | 30-70 Medium carbon steel | 15-25 | 50-110 | 25-45 120-300 Alloy steel 10-15 | 30-65 | 15-25 | 40-80 50-110 | 20-25 | 60-120 | 20-30 | 90-150 15-35 | 60-100 | 20-45 | 80-180 30-60 _| 120-300 Tool steel 15-20 Stainless steel 15-20 | 40-60 | 15-25 | 40-70 | 15-30 | so-80 | 20-50 | 50-90 Cast iron - | 20-25 | 60-90 | 25-30 | 70-100 | 35-45 | 80-110 | 40-60 | 80-120 100-200 | 150-600 60-150 | 70-100 | 80-180 | 90-120 | 90-450, Aluminium, Alloys _ | 40-70 60-150 | 90-120 | 90-180 | 100-200 | 120-310 40-60 | 50-110 | 60-100 Copper, Alloys 3.19.4 G-Codes (Preparatory Functions) Used in Turning Center : la. Explain codes G00, G01 and G02 in part programming. la. Explain G28, G03, and G13 with suitable examples. l@. Explain the linear, circular CW and circular CCW interpolation with G code word address format. 1. Explain G28, G04, G40 and G41 code in part programming. ‘Some of the G-codes, used in turning center, are discussed below : ‘Common G-Codes (Prefatory function) Used in Tunning Center 1. Rapid Tool movement (G 00) 2. Linear Interpolation (G 01) 3. Clockwise Circular Interpolation (G 02) ‘4, Counterclockwise Circular interpolation (G 03) Rapid Tool Movement (G00) : G00 is the positioning function and used for rapid movement of a tool to the specified position. Usi ‘G00’ the cutting tool can be positioned near the cutting surface in shortest possible time. 1 weetcomputer Integrated ‘N100) G00 + Aided Manufacturing, x25 35 ‘Specified Postion Whore Culling Too! to Roach (25.35) Rapid Movement of Cutting Too! Soquonce Numbor 2, Linear Interpolation (G01) : + GOL is the function for the motion of a cutting tool along a straight line from a current po: final position ata given feed rate. Itis a function for near interpolation. + Example of function G01": ui) ot xo vas F120 ue “Gren Food Rate "20 mi Final Positon ot sting Toot (20,48) | near Interpolation ‘oration ‘Soquence Number 3, Clockwise Circular Interpolation (G02) : PPU - May 13, Dec.16 © G02 is a function for circular interpolation in clockwise direction. It is the function which direct the tool along the circular path in clockwise direction at a given feed rate (Fig. 3.19.3). It is important to note that, the cutter must be at the start of the arc i.e: point A when function G02 is executed. |hod, the are can the centre of are. A typical example of are vector method is, N20 coz x70_¥25 M525 F150 ed by knowing the coordinates of end po int Food Rate +50 mminin ‘Genie ofare 6 (45,25), End Powntor Ae 8 (70.25) [circutar interpoiation “Clockwise ‘Sequence Number Ia Gi) Are radius method : In this method, the arc can be generated by knowing the coordinates of end point and the radius of arc. A typical example of arc radius method is, Ni20 02 xrs__¥25 Res F150 10 mein Redus rare ‘261mm Ena Pott are B78). Hl [Creuse interptaton “Clooewce ‘Sequence Number i 4. Counter Clockwise Circular Interpolation (03) * 603 is the function for circular interpolation in counterclockwise direction Its the function which dire the tool along the circular path in counter clockwise direction at a given feed rate (Fig. 3.19.4), Iti important to note that, the cutter must be at the start of the arc ie. point A when function G03 is executed, p25 8 as.25) | Fig. 3.19.4 : Circular Interpolation-Counterclockwise |“SF computor Integrated Manufacturing 35 ymputer Aided Manufacturing ‘Two methods of circular interpolation in counterclockwise direction ‘Two methods of circular i of circular interpolation In counterclockwise direction (0 Are vector method ) Arc radius method @ _Arevector method : In this method, the arc can be generated by knowing the coordinates of end point and the centre of arc. A typical example of are vector method is, N130 Gos x45 Ys Ms ws F150 Feed Rate 460 main (Gente or are (45,25), End Pont of Are 8 (85,50) [Circular interpotaton “Counterlockwise ‘Sequence Number (ae Gi) Arc radius method : In this method, the arc can be generated by knowing the coordinates of end point and the radius of arc. A typical example of arc radius method is, N30 coo x45 Y50 estat. Jair) R25. F150 Food Rate 460 mmnin Radius of Are 25 mm i End Pointot Are Circular Interpolation] “Counterciocewiso | ‘Sequence Number wie>: Computer Aided Man wae ‘Table 3.19.2 : G-Codes (C-type) and Their Functions G-Code _| Required Axis /Other Inputs Functions coo [x [¥ [2 [sm [rs] Rapa Travel orvoot _—~ cos |x fy Jz] Linear interpolation-straight line motion ata given feed ra coo Le fem S| clockwise Circular Interpolation oF Clockwise Hay hohe toe interpolations or R for Radlus cos v fz [wT | | Gounerdioskwiee Gieaar Tarpon oF Couper Cece Sere Netca tterpolatons or R for Radius coe SG ‘well (Stppage of Motion fora Programmed Length of Pima) Delay in Seconds Goo Exact Stop ] 10 Programmable Data Taput 10.6 Tool Retract and Recover cat Programmable Data Input Mode Gancel x |e M_| FS] Polar Coordinates Interpolation oer rh (% ¥) = Pote Contre Coordinates, casa Polar Coordinates Interpolation Gancel a7 1X0 Fane Selection, Z= Tool Axis aa 2X Plane Selection, ¥= Tool Axis [exo '¥2 Plane Selection, X= Tool Axis [zo Outer Diameter / Internal Diameter Cutting Cycle [fcza Threading Cycle zz Stored Stroke Gheck Function ON es] ‘Stored Stroke Gheck Function OFF cae End Face Turning Cycle | cas Spindle Speed Fluctuation Detection OFF | 26 Spindle Speed Fluctuation Detection ON i [caro |v _|w Reference Position Return Check few [ev | ‘Automatic Retr oF Home Fost oF 7agh [azo [wv _[w Movement From Reference Position [eso [vu ]v_|w Return to Second, Third and Fourth Reference Position [esx ‘Skip Function xa 2 ais SPs [orcad cova [= FE ar$F computer Integrated Mamuiaet ‘G-Code Required Axis /Other Inputs. Functions - 7 M |r |s Vara Lead Thread Cutting =Pheh G35. Clockwise Circular Thread Cutting G36 Counter-Clockwise Circular Thread Cutting oa? ‘Automatie Foo! Offset (axis) 637.1 Automatic Tool Offset (X-axis) G38, ‘Tool Radius / Tool Nose Radius Compensation : With Vector Held = "Tool Radius / Tool Nose Radius Compensation : Corner Rounding Interpolation 0 ‘Tool Radius / Tool Nose Radius Compensation; Cancel (Cutter Compensation OFF) m “Tool Radius / Tool Nose Radius Compensation or Offset: Left a2 ‘Tool Radius / Tool Nose Radius Compensation or Offset: Right #8 ‘Too! Length Compensation (Positive) ON cH “Too! Length Compensation (Negative) ON 6437 ‘Tool Offset 49 Tool Length Compensation: Cancel / OFF soa Programmable Mirror Image Cancel ost Programmable Mirror Image 502 Polygon Turning Cancel 51.2 Polygon Turning 52 Local Coordinate System Setting 053 Machine Coordinate System Setting os Workpiece Coordinate System 1 Selection 55 Workpiece Coordinate System 2 Selection 086 ‘Workplece Coordinate System 3 Selection 637 ‘Workiece Coordinate System 4 Selection ese Workpiece Coordinate System 5 Selection 59 Workplece Coordinate System 6 Selection Got Exact Stop Mode Gea “Automatic Corner Override Mode G63 “Tapping Mode Gea cutting Mode 6s Macro Call G66 Macro Modal CallF_computer integrated Mam Functions COMPU Ase Mant Required Axis /Other Inputs s [sz Macro Modal all A7 Cancel [ess Mirror Image ON Por Double Turret or Balance Cutting Mage Goa Coordinate System Rotation Start or 3-Dimenstonal Coordings System Conversion Mode ON Goo Mirror Image OFF For Double Turret or Balance Cutting Woh ance! Goo Goordinate System Rotation Cancel oF S-Dimensional Coordinay System Conversion Mode OFF G70. Inch Mode Programming 71 Metric Mode Programming G72 Finishing Gyete ie Stock Removal in Turning 74 ‘Stock Removal in Facing i= Pattern Repeating Cycle 76 End Face Peck Drilling Cycle [ez77 Outer Diameter / Internal Diameter Drilling Gyele [eve] Multiple-Thread Cutting Cycle [cso | Canned Cycle Cancel for Drilling [oer [xfvfz|[™ S_| Spot Driting x] ¥] 2] ™] | s | counter Boring e82, 1 | T= Delay In Seconds x] ¥] 2] ™ || S_| caterer ace prining 683; ial K Delay In Seconds, K = Peck Depth, [xT [2 fie [os] Peck-prining cycte acer le fe 1= Delay In Seconds, K = Peck Depth, Gea Cycle for Face Tapping [cas x{y [zm] | s | cydetorFace Boring [ca7 x fy [2 [om [| s | cyete torside brining [cae x{v [2 [m [er] s | cycetorside Tapping [css xfy [iz [om [F ['s | cycteforsiae Boring [coo | Absolute Programming [oor | Incremental Programming [coz | Coordinate System Setting or Max Spindle Speed Clamp [csza Workpiece Coordinate System Preset [c94 Feed Per Minutecomputer Integrated Manufacturing 339 Computer Aided Manufacturing, code | Required Axis /Other Inputs Functions 7 Feed Per Revolution a Constant Surface Speed Control or Constant Surface Speed Control Cancel 6962 Spindle Indexing Execution (Waiting for Completion) wee <__| Spindte indexing Execution (Not Waiting for Completion) i Spindle Indexing Completion Check SV Speed Control Mode ON 698 | Canned Cycle: Return to Initial Level 699 Canned Cycle: Return to R Point Level 3.19.5 M-Codes (Miscellaneous Functions) Used in Turning Center : ‘Explain code MOS in part programming. EE «The miscellaneous functions or M codes are used for indicating the miscellaneous functions of NC/CNC machines like : coolant ON or OFF, spindle ON or OFF, spindle CW or CCW, program stop, ete. «The common miscellaneous functions (M-codes), used in part-program, are given In Table 3.19.3. ‘Table 3.19.3 : M-Codes M-code ee Z Functions M100 | Programme STOP — terminate the auto operation fi mo1 | Optional or Planned Stop woz _| Programme END M03 ‘Spindle Rotation ON - forward/clockwise rotation [Spr - May 13 | Moa Spindle Rotation ON- reverse/counter-clockwise rotation MoS __| Spindle Rotation STOP ‘M06 __| Automatic Too! Change MO7 Coolant. ON [mist] Mos Coolant ON {flood} Mos__| Coolant OFF m0 | chuckOpen [max | chuck close 00 « uo | m12__| Tallstock Quill IN M13 Tailstock Quill OUT : M17 | Turret Indexing Forward 3 wie | Turret Indexing ReverseComputer Aled Nana, 0 Computer Integrated Manufactur Functions i M-Code re ORE x ae M19__| Programmable Spindle Orientation M21 Tailstock forward / IN M22 __| Tailstock backward / OUT M23 | Thread Gradual Pull-OuwON ede M24 __| Thread Gradual Pull-Out OFF it to M30 END of Tape - tape will rewind automatically Or End of program, with return to program top Mai Gear select - gear 1 Maz Gear select - gear 2 M43___| Gearselect- gear 3 M44 | Gearselect- gear 4 M48___| Feedrate Override Cancel - OFF (Deactivated) Mao Feedrate Override Cancel - ON (Activated) MS2__| Unload Last tool from spindle M98___| CALL sub-Program M99 | RETURN Program Sub-Routine 3.19.6 Programming Types used in Turing Applications : In NC/CNC lathes, the programming can be done using elther diameter or radius modes which are explained below: Programming Types used in Turing Applications 1. Diameter based programming 2, Radius based programming | 4. Diameter based programming : In diameter based programming mode, normally the value of diameter is specified in the column for X- axis. Therefore in this mode, for 1mm of Programmed movemerit of tool, there is actual 0.5 ‘mm movement of tool in radial direction. 2. Radius based programming : In radius based programming mode, normally the value of radius is specified in the column for X-axis, Therefore in this mode, for 1mm of programmed ‘movement of tool, there is actual 1mm movement of tool in radial direction. 3.19.7 Subprogram (Subroutines) : + Subprograms are also called as mini programs or subroutines. Subprograms are used wherever repetition of part program is required, for example, boring cycle. * The subprograms are stored at the end of main program and can be called at any time and for any number of times during the execution of main program. Use of subprograms or subroutines help in shortening the program length and also preven the repetition of statements where same machining features are required more than once. 3.19.8 Macros : * Macros are also called as parametric subroutines. 2 machining, it is necessary to use same type f operations with same steps but with variation dimensions. * Such similar steps with dimensional variations # be converted into parametric subroutines, calle! macros. ——nur Integrated Manufacturing ¥ 3 ter Aided Manufacturing. 9.9 Canned Cycles Motions of drill bit in drilling cycle The canned cele consists of a series of motions | | (Rapid approach to workplece repeated number of times like : driling, boring and | | (i). Drill at feed rate Eeping et The canned cycles in NC/CNC programs ne iso called as multiple-repetitive cycles, (iii) Rapid return to initial position. © Commonly Used Canned Cycles: «Some of the frequently used canned cycles are given below in the regular programming format: Commonly Used Canned Gycies (@ G81 Daling Cyclo | (0) G74 - Stock Removal Cyc (09 GTI -ttple Stock Removal Gaia (01 G78- Mutiple Threading (Tapping) Gye (0) G85 Bonng Gyete ) 681- riting Cyto: Fig. 3.19.5 : Canned Cycle for Drilling Operation lo. Explain the canned eyele for Dring. la. Explain canned cycle for driling in proper word address format i 3 Typical example of a canned cycle for drilling operation : Nios | GB, ,X100 200 57-200, | R20, 1 F100 , | S000 c=] (Coordinates of Port ‘where Orting Breaktvough Distance * Format of canned cycle for drilling operation (Fig. 3.19.5) : N G81 XYZRE rateEF _Computer integrated Manufacturing 342 ¥ Driling Cycle with : Drill from zag 2-30, and feed rate of 100mm/min, Computer Aided Many (ii) G74 - Stock Removal In Facing : [io Jon [0 [2 ‘Stock Removal Cycle _ with [xo [ove x30 | 2.60 F50 Incremental depth of cut of 1mm, fea rate of 50 mm/min and diametsy Di _| reduced from X40 to X30. (il) G73 ~ Stock Removal in Turning : [2. Explain multiple roughing cycle (G 73), with sketch. —«o ax Le Nao | coo | x40 | za N20 | 73 | x30 | z-60 F50 D, Stock removal cycle with depth of cut of 1 mm, feed rate of 50 mm/ min and diameter reduced from X40 to X30 (v)_G72- Finishing Cyete : ]Q. Explain finishing cycle (G 72), with sketch. (¥)_G78- Multiple Threading Cutting (Tapping) Cyck la. Explain the canned cycte for Tapping. JQ. Explain canned cycle for tapping n proper word address format. |@. Explain canned cycles for Threading on hortzontal machining center. N30 G72 F50__ Finishing cycle with feed rate of SO mm/min SS SSS Sa N10 | G7 | x19.09256 | z-30 | 10 | k2.4572 | Fs | p1 Thread height, h=2.4572mm ‘Thread angle, A= 60° Depth of cut, D=1mm Feed rate, __F=50 mm/min AGO ‘Threading Cycle with : Minor diameter, d,= 19.09256 mm cet ¥aa P10 gio | vo | wo finishing cycle whenever required with feed rate of 1Smm/min. ‘The steps in canned boring cycle are shown in Fig, 3.19.7. 4 Food Rate 3.19.10 General Structure of Turning Part Program : { Rapia Traverse © Parameters to be included in part program at the beginning: o (i) dimension mode programming mode (ii) speed range selection, (iv) tool selection, (v) feed rate selection, (vi) tool in the home position, and (vii) spindle and coolant on condition. * Parameters to be included in part program at «The general structure for the part program of lathe isgiven in Table 3.19.4. the end: @ rapid tool positioning to staring reference point, (i). tool return to home position, (iW) spindle and coolant off, (iv) program end, and (W) tape rewind. ‘Table 3.19.4 : Part Program Format 7 Cemponent Drawing” woe, x[z[[kje[m [is | 1 Description oun Program Number no | c90 Absolute Program Mode ni |o71 Metric Mode ; Max Spindle Speed Clamp, Medium Gear Select, melee Maa.) 51500, Spindle speed 1500 rpm n3_| coe Feed Rate in mm/min n4 | G28 | uo | wo Go to Home Position B Ns Mo6 "70101 | Tool Change, Tool No. 01 with Offset No. 01 Ne Mo3 | $1500 * “| spindle ON with Spindle Speed 1500 r-p.m. n7 | coo | xs0 | za Mos Rapid Tool Positioning to (50, 1), Coolant ON Ll t=‘e Computer Aided Maney, c ‘Component Drawing” x i[e[x[zfifkle[u] os T. Description NO nio| . na | . naz |. Various Machining Operations N13 Nis Nis N16 naz |. naa | coo} x0 | za Rapid Tool Positioning to (0, 1) Ni9 | G28 | vo | wo Go to Home Position N20 Mos Spindle OFF N21 ‘Moo Coolant OFF N22 Moz Program END M30 END of Tape and REWIND N23 Example 3.19.1 : Write a manual part program for facing operation of the component, shown in Fig. P. 819.1. Assume spindle sample as 1500 r.p.m. and feed rate as 0.2 mmirev. : | a emia Fig. P. 3.19.1computer Integrated Manufacturing ee Computer Aided Manufacturing, ‘olution = 6 {x{zlil[x [ene BaleMs li Sh] om Description 74 oe Program Number xo | 690 [Xo Absolute Program Mode mi | G7 Metric Mode nz | 692 Maz | sto Max Spindle Speed Clamp, Medium Gear Select, Spindle Speed 1500 rpm. N3_| 695 Feed Rate In mm/rev. | we pees 628 NDS a Goto Home Position ' NS MOG 70101 | Tool Change, Tool No. 01 with Offset No. 01 N6 Mos | 1500 Spindle ON with Spindle Speed 1500 rpm. N7_| Goo | x50 | Z1 Mos Rapid Tool Positioning to [50, 1], Coolant ON na | cos | xs0 | 2-1 Fo2 1500 Linear Interpolation Cutting with Depth of Cut of 1mm, Feed Rate of 0.2 no | cor {x0 | za ine 1800 Linear Interpolation Cutting with Depth of Cut of 1mm, FromXS0 to X0. n1o| Goo | xo | za Rapld Tool Positioning to [0,1] nat | Goo | x50 | Zi 5 Rapid Tool Positioning to [50,1] a2 Linear Interpolation Cutting with Depth of N12 | ot | x50 | 2-2 FO2 $1500 reat ot aur’, Feed Rate Baal Linear Interpolation Cutting with Depth of nis | cor | xo. | 2-2 ro Si504 Cut of 2mm, From X50 to X0. ni4 | coo | xo_| 21 Rapid Tool Positioning to [0,1], mas coo esa za Rapid Tool Positioning to [50,1] Linear Interpolation Cutting with Depth of vio | Gor | xs0 | 2-3 Foz ae Cut of 3mm, Feed Rate of 0.2 Linear Interpolation Cutting with Depth of n17| Go1| xo | 2-3 F02 Se Cut of 3mm, From X50 to XO. id Tool Positioning to [0, 1] nis | Goo'| xo | 21 Rapid Tool Fostioning | Go to Home Position nig | G28 | uo_| wo N20 MOS Spindle OFF Coolant OFF Naa ‘M09 D = M02 Program EN & REWIND = M30 END of Tape |speed as 600 r, Example 3.19.2 : Write a manu: fal part program for finishing tho component, as shown in .m., and feed rato as 0.2 mmrev. Ss Computer Aided Many cd Monty 9. P8102. Asam et * a ~§ s 2 [ 1% | Fig. P. 3.19.2 Solution : Nee ei eke en ee ise ae Description 04172 Program Number Nno_[690 Absolute Program Mode mi_|o7 Metric Mode Max Spindle Speed Clamp, Low Gear ma ee Mis" | 5600 Select, Spindle speed 600 p.m, n3_| cos Feed Rate in mm/rev. na _|c2e] uo | wo Go to Home Position Tool Change, Tool No. 01 with Offset ie Mis Topor | Tet hangs Too No.2 wi Ofer indle ON with Spindle Spee ie wee fee Spindle ON with Spindle Speed 600 rpm. Rapid Toot Positioning to [42, 1], Mo nz |oo] x42} za 8 Goolabt on ne [coo] xao | 2 Rapid Too! Positioning to [20, 1] Stock Removal Cycle Incremental Depth of Cut of 1mm with Feed Rate N9 [G73 x30 | Z:60 abet PY | 6f02, and Diameter Reduced From X40 to X30 N10 | Goo} x3z_[ za Rapid Tool Positioning to [32, 1] nat | coo | x30 [21 “ Rapid Tool Positioning to [32,1] ‘Stock Removal Cycle incremental Depth of Cut of 1mm with Feed Rate nz | 673} x20 | 2-30 Fo2 D1 of 0.2, and Diameter Reduced From X30 to X20 naz Goo} x22 [zi Rapid Too! Positioning to [22,1] __| nis | G28] vo | wo Go to Home Position Nas, Mos Spindle OFF NIG Mos Coolant OFF NI7 Moz Program END N18 M30 END of Tape & REWINDgy commuter tntegratd Manmfacturing Frampte 8.18.8 ¢ Woite a manual pait program for finishing the component, as shown in Fig. P. 9.19.3. Assumo spindlo ‘ps 600 THM. aNd food rate as 0.2 mnvrev. sent : 7. Computer Aided Manufacturing an 2 Fig. P. 3.19.3 solution : nio{[x{zlitKi rj js |r Description 01173 Program Number xo [690 Absolute Program Mode wi [ova Metric Mode a eee Max Spindle Speed Clamp, Low Gear Select, Spindle speed 600 r.p.m. n3 [G95 Feed Rate in mm/rev na |c28| vo | wo Go to Home Position . Ns M06 70101 | Tool Change, Tool No. 01 With Offset No. 01 No. M03 | s600 Spindle ON with Spindle Speed 600 r-p.m, n7 |coo|xs2| 21 Mos Rapid Tool Positioning to [52, 1], Coolant ON xa |coo|x2s| 21 Rapid Tool Positioning to [25, 1] | | oe ae ein Le Toterpolaton Cutng with Feed Rate of 0.2, N10 Go1 | xso | 2-20 FO2 $600 Linear Interpolation Cutting from [25, 0] to [50,-20] N11 | coo |xs2| 21 Rapid Too! Positioning to [52, 1] N12 | ¢28| vo | wo Go to Home Position N13 MOS ‘Spindle OFF Nig Mog Coolant OFF Nis Moz Program END i w30] END,of Tape & REWINDBs SE _computer integrated z 40 Computer Aided, anu, z Example 3. Write a manual part program for fin ing the componont, as shown in Fig. P. 3404, Assam ‘speed as 800 r.p.m. and feed rato as 0.2 mmvrov, ng g Fig. P3194 Solution : N G x Zz I K| F M Ss. 7 Description: il 04174 Program Number xo | cso Absolute Program Mode na | 7a Metric Mode nz | G92 maa | s600 Sia ae aoe Low Geat Seer, n3_| c9s Feed Rate in mm/rev na | c2| vo | wo Go to Home Position NS Mo6 "70101 [Tool Change, Tool No. 01 with Offset No. 01 Ne Mo3 | sooo Spindle ON with Spindle Speed 600 rpm. = (ealaae ee sb Ton rong 6,20, Cn Linear Interpolation Cutting With Feed Rate] ne | cox | x40 |2-20 Fo2 600 Lean Gat Cloclowise Circular Interpotation Cutting Ng | Goz| xo | zo | 1-20 | KO | Fo2 ree From X40 to XO with Radius 20 wio | coo | xo | zz Rapid Tool Positioning to [0,2] wit | 28] vo | wo Go to Home Position wiz Mos Spindle OFF N13 ‘M09 Coolant OFF a Moz Program END Nis M30 END of Tape & REWIND = os$¥_computer Integrated Manufacturing Granple 9.495 = Wilo a manual pan pega eey a Computer Aided Manufacturing speed as 8001. and food rato as 0.12 mney, Nn’? COMPONENT, as shown in Fig. P. 3.19.5. Assume spina Fig. P.3.9.5 Solution = nico [x {iz 1] Ki] Fi Mm Ss iT Description 04175 Program Number No _| G90 Absolute Program Mode Ni | G71 Metric Mode n2 | 692 mad lisse Max Spindle Speed Clamp, Low Gear Select, Spindle speed 800 r.p.m, N3 | G95 Feed Rate in mm/rev_ N4 | G28 uo wo. NS Mos T0101 ‘Tool Change, Tool No. 01 with Offset No. 1 Né Mos | se00 Spindle ON with Spindle Speed 800 r.pm. Rapid Tool Positioning to N7 | Goo | x52 | 2-20 ch) {52, -20], Coolant ON Linear Interpolation Cutting with Feed NB | Go1 | xsO | Z-20 Fo2 5000) Rate of 0.2, from X52 to XSO Counter-Clockwise Circular Interpolation 0 9 | cos | x10 | zo | 10 | K20 | Fo2 S80 Cutting from X50 to X10 with Radius 20 wio| coo | x10 | ze Rapid Tool Positioning to [10, 2] maul peal ance eee Go to Home Position nt Mos Spindle OFF a MO9 Coolant OFF aa Mo2 Program END M30 END of Tape and REWINDBS wnputer Aled Manta, Fig. P. 3.19.6 Solution : + Assumptions (Material of workpiece: mild steet (i) Material of drill high speed steel Git) Cutting speed (V):30 m/min and (iv) Feed (9 : 0.1 mm/rev. + Spindle speed 1000V _1000%30 v2 [on wr som | [are ain ar : | Tool Change, Tool No. 08 N7 | Goo | xo 21 Mos Rapid Tool Positioning to'[0, 1], Coolant ON we [co | w [ 2 poate eoree omc no | cat | x0 | 230 roa] —_{s2oa0] [Petting ets wits romz10 10730 io | Goo | xo Rapid Too! Positioning to [0, 1] eeExample 3.19.7 : Write a manual part program for finishing a for Computer Aided Manufacturing, FiMios T Description MOS Spindle OFF ‘Mo9 Coolant OFF Moz Program END M30 END of Tape and REWIND. ged component, as shown in the Fig. P. 3.19.7. Assumo the and feed on the tuming centre as 400 r, p.m. and 0.35 mmvrev res sumo 1 mm is fo be removed a aaraaanae rev respectively, Assumo 1 mm material is to bo remov as | ol Js. Fig. P.3.19.7 Solution : ni[ej xz kK] F [fos Description 0417 Program Number No_| G90 “Absolute Program Mode. ni _| G71 Metric Mode N2 | Gop fea (eae er Spindle Speed Gan, Low Gear Select, n3_| Gas Feed Rate in mm/rev na | c2e |_vo_| wo Go to Home Position NS. Mos "70101 | TOO1 change, Tool No 01 with Offset no 01 No M03 | s400 Spindle ON with Spindle Speed 400 r-p.m. w7 | coo | x32 | z1 M08 Rapid Tool Positioning to [12,1]. Coolant on we | Gor | x22 [ 2-18 0.35 $400 Linear Interpolation Cutting with Feed Rate of 0.35 mm/ rev Speed 400 r-p.m. no | Gor | x20 | 2-23 F035 $400 Interpolation cutting form [12, -16] to [20,-23] n10 | Goa [x20 | 2-40 F035 $400 Interpolation cutting form [20,~23] to [20,-40] nar | Goi [ x50 | 2-50 F035 $400, Interpolation cutting form [20,~40]to (50, -50] wiz | coo | xsi | za Rapid Too! Positioning 413 | cze | uo_[ wo Go to Home Poisiton Nig ‘MOS Spindle OFF ry M09 Coolant OFF. MiG ‘Moz Program END M7 M30 END of Tape and Rewind‘'B hy ‘manual part program for fishing a forged compbnent, as shown in Fig. P. 9.19.8. Assume SE computer integrated wufacturing 52 Computer Aided Maris Write % Soeed and fed on the ting cant ar 409 rp, and 0:25 mmfrveuon raepectWey. ASSUME Tran mae emoved radial trom extemal diameter Fig.P.2398 Note : Raw material: MS @100 x 80 mm, spindle speed, S = 400 r. p.m. and feed, t= 0.38 mmvrev 4 Solution: njelx[z[r[x[er [mls [+ Description 00178 Program Number no | c90 Absolute Program Mode mi_|o7 Metric Mode Max Spindle Speed Clamp, Low Gear Select, : 00 v2 | 2 ves |e Spe sped 00 pam 7a os Fontaine na [a2e[ uo |wo Goto Home Position | NS Mos To101 | Tool Change, Tool No.1 with offset No.01 | N6 mos | sao0 Spindle ON with Spindle Speed 400 rpm, n7_[aoo|xs0 | za Mos Rapid Tool Positioning to (50, 1], Coolant ON Linear Interpolation Cutting with Feed Rated ns | co1| x50 | 2-25 Fos! 400 | 935, from 71 to2-25 with Constant X50 | lockwise Circular Interpolation Cutting fr) ng |co2| x60 | 23015 | x0 | road * Circular Interpolation Cutting fo X50 toX60 with Radius § : near Interpo 4 nia | oa eae “|e see a Linear Interpolation Cutting with Feed Rate 0.35 from 230 197-60 with Constant X60_, a e0i| ape lee aa cae Linear Interpolation Cutting from {60, -6]°| [200,-80}SE _ computer Integrated Manufacturing — 353 computer Aided Manufacturing N 6 x z piRet Fiul|s Description { sx2 | ooo | x12 | 21 s Rapid Too! Positioning tol102, 1) wis 62s | v0 [wo mone —— oto Home Postion Nit | ib |__| Mos Spindle OFF S Lis Moo Coolant OFF Nis Moz Program END Ni? | M30 END of Tapeand REWIND Example 8.18.8 : Write a pa Ft program to tum a raw bar of carbon ste 1 of 104 mm diameter as per the component drawing shown in Fig. P, 3.19.9, using stock removal cycle G74. All dimensions are in mm. 104 Y a3) - [owe az Fig. P.3.19.9 Note : Raw material: MS 6 104 x 80 mm, spindle speed, S= 400 r. p.m. and food, f = 0.25mm/rev ‘Solution : : nfo] x | z x| Fr [ms Description 04179 Program Number xo | G90 Absolute Program Mode ni_|o71 Metric Mode [Max Spindle Speed Clamp, Low Gear Select, TE ea oe | cae Spindle speed 400 rpm. n3_| G9s Feed Rate in mm/rev na [ze] vo | wo [Go to Home Position NS. M06 70101 | Tool Change, Too! No. 01 with Offset No. 01 nde ON with Spindle Speed 400 r-p.m. N6 Mos | s400 Spindle ON with Spindle Speed 400 rp. atermF_computer integr ited Manufacturing 354 com) M Description n7 | Goo] xi04 | aa maa ala Too Postoning to 104 1 cas stock Removal Cyele with theremena| NB | G73 | x100 | z-100 Depth of Cut of Imm with Feed Rateatoag| es PL |Material Removed from Z1 to Z-100 ‘a Diameter Reduced from X104 to X100 N9_| Goo | x100 |_ 21 Rapid Tool Positioning to [100, 1] stock Removal Cycle with Increment] n1o | c73| x70 | 280 Poze pz__[Pepth of cut of 1mm with Feed Rate of0.25| Material Removed from Z1 to 2-80 and Diameter Reduced From X100 to X70 Ni1_| Goo | x70 | 21 [Rapid Tool Positioning to [70, 1] [stock Removal Cycle (Along With Taper iz | G73 | xs0 | 2-20 oneal py |Twning] with Incremental Depth of Cut of ‘Imm with Feed Rate of 0.25, and Diameter Reduced from X70 to X50 N13 | Goo} xs2 | z1 Rapid Tool Positioning to (52, 1] N14 | G28] UO wo |Go to Home Position Nas Mos Spindle OFF N16 ‘Moo Coolant OFF N17 M02 Program END Nig M30 END of Tape and REWIND Example 3.19.10 : Write a CNC part program to turn a mild steel bar of size and shape, as shown in Fig. P. 3.19.10. Use canned cycle for both rough turning and finish cut. Take feed rate of 0.5 mm/rev and spindle speed of 200 r.p.m. EEUELENELAPIN _. Fig. P. 3.19.10 Note : Raw Material : MS 080 x 140mmSE _computer Integrated Manufacturing 3.55 Computer Aided Manufacturing ‘Solution : N x ifKieim|s |r Jossso : Program Number no | G90 Absolute Program Mode Na | 671 Metric Mode nz | 692 Raaeileann Max Spindle Speed Clamp, Low Gear Select, [Spindle speed 200 r.p.m. N3_| G95 Feed rate in mm/rev : na | G28 | Uo | wo Go to Home position NS Mo6 70101 | Tool Change, Tool No. 01 with offset No. 01 N6 Mo3 | $200 [Spindle ON with Spindle speed 1500rpm n7_| Goo | xeo | z1 Mos Rapid Tool positioning to [80, 1], Coolant ON [Stock Removal Cycle with incremental depth of| ne | SSS aoe leas vis 200 pos {ut oF OSmm with Feed rate of 0.5 mm/rev, material removed from Z1 to 2-30 and diameter} reduced from X80 to X76 ng |coo| x77] Zz Rapid Tool positioning to [77, 1] [stock Removal Cycle with incremental depth of| ora | x7s | 2135 a 5200| po.as [Ct 9f 025mm with Feed rate of 0.5 mm/rev, nro 78 | 2 : material removed from Z1 to Z-135 and diameter| reduced from X77 to X75 N11 | Goo | x76 |_Z1 Rapid Tool positioning to [76, 1] Stock Removal Cycle with incremental depth of = 5200 pos | &f 25mm with Feed rate of 0 mm/rev, t2| (G7a) eee) Ze : ' | material removed from Z1 to Z-75 and diameter| reduced from X76 to XS2 N13 | coo | x53 | 21 Rapid Tool positioning to [53, 1] [Stock Removal Cycle with incremental depth of cut of 0.25mm with Feed rate of 0.5 mm/rev, Z 125 pias) G72) MeO) (ezeze ms, $200} D0.25 |; terial removed from Z1 to 7-75 and diameter reduced from X51 to X50 Nis | Goo | xs1 | 21 Rapid Tool positioning to [51, 1] Goo | xso | 2-75 Rapid Too! positioning to [50, -75] ii Linear Interpolation with cutting tool (Taper Go| 278) Zu a Turning)cutting from [50, -75]to [75, -90] oo | x76 | z1 Rapid Tool positioning to [76, 1] TeehineslednéB a) Compster Nise Mant, N XG M N16 | Goo} xo | zo Rapid Tool Positioning to [0, 0} waz | cos | x25 | 2-28 | tad wal ros Counter-clockwise Circular Interpolation Gun, i from XO to X25 with Radius of 25mm nis | coo | x26 | 2 Rapid Tool Positioning to [26, 1] | x19 | Goo} xo | za Rapid Tool positioning to [0, 1] | n20 | cze | vo | wo Go to Home position Nat ‘MOS Spindle OFF N22 Mo9 Coolant OFF N23 Moz Program END Not M30 JEND of Tape & REWIND | Example 9.19.11 : Write a CNC part program for rough tuming and finishing of the component, shown in Fig. P.3.19.11, by using canned cycle. Assume suitable speed, feed and depth of cut for a mild steel workpiece of size « 50 mm x 50 mm and HSS cutting tool. ET Ra t0_[ 10 | Al emonsions awn mm Fig. P.3.9.1 Solution : Assumptions : (@ Cutting speed (V) : 30m/min GU) Feed (fev) + .0Smm/rev, ‘* Spindle speed and feed (mm/min) : Spindle Speed, Feed, f= Nxt, ‘Shaft Diameter, D, mm 1000V _ 1000 x 30 =NxX0.05, mm/min NoomD xD 1 TPM. 50 190,986=191 9.55=10 40 238.732 = 239 11.9512 20 477465 =478 23.87 =24 erent Bied M: nx [G s 04181 Program Number no | G90 Absolute Program Mode Na_| 70 Metric Mode nz | G92 prailisicca Max Spindle Speed Clamp, Medium Gear Select, Spindle speed 1500rpm n3_| G94 Feed rate in mm/min Na_| G28 | vo | wo Goto Home position NS aoe roxor | 729! Change, Tool No 01 with offset No. N6 Mos | sis00 Spindle ON with Spindle speed 1500rpm nz | coo} xs2} zi fae Rapid Too positioning to [52, 1], Coolant Stock Removal Cycle with incremental depth of cut of 2mm with Feed rate of 12, ns | G73 | x42 | 2-38 Fi2 5 # ; % S159) D2 | material removed from Z1 to 2-38 and diameter reduced from X52 to X42 no | coo| xe2| 21 Rapid Tool positioning to [42, 1], Coolant Stock Removal Cycle with incremental depth of cut of 0.25mm with Feed rate of wn | G73) 540.2 saat S191 | D025 | 1) material removed from Z1 to 2-38 and diameter reduced from X42 to X40 Clock-wise Circular Interpolation Cutting Na | Goz | x44 | 2-40 | 12 | Koo | FS from X40 to X44 with radius of 2mm niz | coo | x46 | 21 Rapid Tool positioning to [46, 1] N13 | Goo | x40 | Z1 Rapid Tool positioning to (40, 1] ‘Stock Removal Cycle with incremental depth of cut of 2mm with Feed rate of 12, Nut | G73 x22 | 7-10 Fe. $239 | D2 | material removed from Zi to 2-10 and diameter reduced from X40 to X22 nas | coo | x22 | 21 Rapid Tool positioning to [22, 1] Stock Removal Cycle with incremental depth of cut of 0.25mm with Feed rate of N16 _| G73 | X20 | 2-10 Eze $478 | D025 | 24. material removed from Z1 to 2-10 and diameter reduced from X22 to X20 Linear Interpolation with cutting tool N17 | Gor | x40 | 2-20 FOS (Taper Turning)cutting from (20, -10}to [40,-20), nis | Goo | xaz | za. Rapid Tool positioning to [42,1] 19 | Goo | x16 | 20 Rapid Tool positioning to [16, 0] TeatareleayeEe SF _Computer integrated Manufacturing 3:58 Computer Aided Manta Ney x} 2 [alee lw [es fer Counter Clock-wise Circular Interpoatzg| N20 | co3 | x20] 22 | 100] K-2 | ro2s Cutting from X16 to X20 with radius 2mm nai | Goo | x22 | 21 Rapid Too! positioning to [22, 1] nz | coo | xo | 21 Rapid Tool positioning to [0,1] N23 | c28 | uo | wo Go to Home position N24 Mos Spindle OFF N2s Moo Coolant OFF N26 Moz Program END N27 M30 END of Tape & REWIND Example 3.19.12 : Write complete part program for the component shown in Fig. P. 9.19.12, RS * 228 235, ig. P. 3.19.12 Note : Raw material: MS 960 x 50 mm, Spindle speed, S = 400 r.p.m. and feed, {= 0.25 mmvrev Solution : ne [x [oz [a [xp fw [os] or Description 4182 Program Number No | c90 Absolute Program Mode na | G71 Metric Mode alae mailers Max Spindle Speed Clamp, Low Gear Select, Spindle speed 400 r.p.m. n3 | cos F025 Feed Rate in mm/rev na | G28 | vo |. wo Goto Home Position