CAM Systems & CNC Machine Overview - Lecture 3

CAM Systems & CNC Machine
Overview - Lecture 3
Overview to Computer Aided

Manufacturing - ENGR-2963 - Fall 2005
Class Manager - Sam Chiappone
History
1955 - John Parsons and US Air Force define a
need to develop a machine tool capable of
machining complex and close tolerance aircraft
parts with the same quality time after time
(repeatability). MIT is the subcontractor and
builds the machine for the project.
Intro to CAM
Rensselaer Polytechnic Chiappone
Institute
History: Continued
1959 - MIT announces Automatic Programmed
Tools (APT) programming language
1960 - Direct Numerical Control (DNC). This
eliminates paper tape punch programs and allows
programmers to send files directly to machine
tools
Intro to CAM
Institute
History: Continued
1968 - Kearney & Trecker machine tool builders
market first machining center
1970s - CNC machine tools & Distributed
Numerical Control
1980s - Graphics based CAM systems introduced.
Unix and PC based systems available
Intro to CAM
Institute
History: Continued
1990s - Price drop in CNC technology

1997 - PC- Windows/NT based Open Modular
Architecture Control (OMAC) systems
introduced to replace firmware controllers.
Intro to CAM
Institute
Control Systems
Open-Loop Control
Stepper motor system
Current pulses sent from control unit to motor
Each pulse results in a finite amount of revolution of
the motor001 is possible
Intro to CAM
Institute
Control Systems
Open-Loop Limitations
Control unit assumes desired position is achieved
No positioning compensation
Typically, a lower torque motor
Open-Loop Advantages
Less complex, Less costly, and lower maintenance
costs
Intro to CAM
Institute
Control Systems
Closed-Loop Control
Variable DC motors - Servos
Positioning sensors -Resolvers
Feedback to control unit
Position information compared to target location
Location errors corrected
Intro to CAM
Institute
Control Systems
Closed-Loop Advantages
DC motors have the ability to reverse instantly to adjust
for position error
Error compensation allows for greater positional
accuracy (.0001)
DC motors have higher torque ranges vs.. stepper
motors
Closed-loop limitations
Cost
Intro to CAM
Institute
Three Basic Categories of
Motion Systems
Point to Point - No contouring capability
Straight cut control - one axis motion at a time is
controlled for machining
Contouring - multiple axiss controlled
simultaneously
Intro to CAM
Institute
Three Basic Categories of
Motion Systems
Intro to CAM
Institute
CNC vs. NC Machine Tools
Computer Numerical Control (CNC) - A
numerical control system in which the data
handling, control sequences, and response to input
is determined by an on-board computer system at
the machine tool.
Intro to CAM
Institute
CNC
Advantages
Increased Program storage capability at the machine tool
Program editing at the machine tool
Control systems upgrades possible
Option -resident CAM system at machine tool
Tool path verification
Intro to CAM
Institute
NC
Numerical Control (NC) - A control system which
primarily processes numeric input. Limited
programming capability at the machine tool. Limited
logic beyond direct input. These types of systems are
referred to as hardwire controls and were popular
from the 1950s to 1970s.
Intro to CAM
Institute
Machining Centers
A machining center can be defined as a machine tool

capable of:
Multiple operation and processes in a single set-up
utilizing multiple axis
Typically has an automatic mechanism to change tools
Intro to CAM
Institute
Machining Centers
Machine motion is programmable
Servo motors drive feed mechanisms for tool axiss
Positioning feedback is provided by resolvers to the
control system
Intro to CAM
Institute
Machining Centers
Example - A turning center capable of OD
turning, external treading, cross-hole drilling,
engraving, and milling. All in machining is
accomplished in one set-up. Machine may have
multiple spindles.
Intro to CAM
Institute
Machining Centers
Intro to CAM
Institute
Programming Methods
Automatically Programmed Tools (APT)
A text based system in which a programmer defines a
series of lines, arcs, and points which define the
overall part geometry locations. These features are
then used to generate a cutter location (CL) file.
Intro to CAM
Institute
Programming Methods-APT
Developed as a joint effort between the aerospace
industry, MIT, and the US Airforce
Still used today and accounts for about 5 -10% of all

programming in the defense and aerospace industries
Intro to CAM
Institute
Requires excellent 3D visualization skills
Capable of generating machine code for complicated

part programs
5 axis machine tools
Intro to CAM
Institute
Part definition
P1=Point/12,20,0
C1=Circle/Center,P1,Radius,3
LN1=Line/C1. ATANGL,90
Cutter Commands
TLRT,GORT/LN1.TANTO,C1
GOFWD/C1,TANTO,L5
Intro to CAM
Institute
Programming Methods-CAM
Computer Aided Machining (CAM) Systems
Graphic representation of the part
PC based
Integrated CAD/CAM functionality
Some built-in expertise
Speed & feed data based on material and tool specifications
Intro to CAM
Institute
Tool & material libraries

Tool path simulation
Tool path editing
Tool path optimization
Cut time calculations for cost estimating
Intro to CAM
Institute
Import / export capabilities to other systems
Examples:
Drawing Exchange Format (DXF)
Initial Graphics Exchange Standard (IGES)
Intro to CAM
Institute
The Process CAD to NC File
Start with graphic representation of part
Direct input
Import from external system
Example DXF / IGES
2D or 3D scan
Model or Blueprint
(At this point you have a graphics file of your geometry)
Intro to CAM
Institute
Define cutter path by selecting geometry

Contours
Pockets
Hole patterns
Surfaces
Volume to be removed
(At this point the system knows what you want to cut)
Intro to CAM
Institute
Define cut parameters
Tool information
Type, Rpm, Feed
Cut method
Example - Pocket mill zig-zag, spiral, inside-out
Rough and finish parameters
(At this point the system knows how you want to cut the part)
Intro to CAM
Institute
Execute cutter simulation
Visual representation of cutter motion
Modify / delete cutter sequences
(At this point the system has a generic cutter location (CL)
file of the cut paths)
Intro to CAM
Institute
Post Processing
CL file to machine specific NC code
Filters CL information and formats it into NC code
based on machine specific parameters
Work envelope
Limits - feed rates, tool changer, rpms, etc.
G & M function capabilities
Intro to CAM
Institute
Output: NC Code
Numerical Control (NC) Language

A series of commands which direct the cutter motion
and support systems of the machine tool.
Intro to CAM
Institute
Output: NC Code
G-Codes (G00, G1, G02, G81)
Coordinate data (X,Y,Z)
Feed Function (F)
Miscellaneous functions (M13)
N - Program sequence number
T - Tool call
S - Spindle command
Intro to CAM
Institute
Output: NC Code
NC Program Example
N01G90 G80
N03 GOO T12 M06
N05 GOO X0 Y0 Z.1 F10 S2500 M13
N07 G1Z-.5
N09 G02 X-10. I0J0F20
N13 X0Y10
N17 X10Y0
N19 X0Y-10
N21 X-10Y0
N23 M2
Intro to CAM
Institute
Example of CNC
Programming
What What Must Be Done To Drill A Hole On A
CNC Vertical Milling Machine
Intro to CAM
Institute
Tool Home
Top
View
1.) X & Y Rapid To Hole Position

Front
View
Intro to CAM
Institute
Top
View 2.) Z Axis Rapid Move
Just Above Hole
3.) Turn On Coolant
4.) Turn On Spindle
.100
Front
View
Intro to CAM
Institute
Top
View
5.) Z Axis Feed Move to
Drill Hole
Front
View
Intro to CAM
Institute
Top
View 6.) Rapid Z Axis Move
Out Of Hole
Front
View
Intro to CAM
Institute
Top
View 7.) Turn Off Spindle
8.) Turn Off Coolant
9.) X&Y Axis Rapid

Move Home
Front
View
Intro to CAM
Institute
Heres The CNC Program! Tool At Home
Top O0001
View N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N025 G00 Z.1 M09
Front N030 G91 G28 X0 Y0 Z0
View N035 M30
Intro to CAM
Institute
Tool At Home
Top O0001
O0001
View Number Assigned to this program
Front
View
Intro to CAM
Institute
Tool At Home
Top O0001
View N005 G54 G90 S600 M03
N005 Sequence Number
G54 Fixture Offset
G90 Absolute Programming Mode
S600 Spindle Speed set to 600 RPM
M03 Spindle on in a Clockwise Direction
Front
View
Intro to CAM
Institute
Top O0001
View N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
G00 Rapid Motion
X1.0 X Coordinate 1.0 in. from Zero
Y1.0 Y Coordinate 1.0 in. from Zero
Front
View
Intro to CAM
Institute
Top O0001
View N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
G43 Tool Length Compensation
H01 Specifies Tool length compensation
Z.1 Z Coordinate .1 in. from Zero
Front M08 Flood Coolant On
View
Intro to CAM
Institute
Top O0001
View N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
G01 Straight Line Cutting Motion
Z-.75 Z Coordinate -.75 in. from Zero
Front F3.5 Feed Rate set to 3.5 in./min.
View
Intro to CAM
Institute
Top O0001
View N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N025 G00 Z.1 M09
Front G00 Rapid Motion
Z.1 Z Coordinate .1 in. from Zero
View M09 Coolant Off
Intro to CAM
Institute
O0001
N005 G54 G90 S600 M03
Top
View N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N025 G00 Z.1 M09
N030 G91 G28 X0 Y0 Z0
G91 Incremental Programming Mode
Front G28 Zero Return Command
View X0, Y0, Z0

X,Y,& Z Coordinates at Zero
Intro to CAM
Institute
Top O0001
View N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N025 G00 Z.1 M09
Front N030 G91 G28 X0 Y0 Z0
View N035 M30
M30 End of Program
Intro to CAM
Institute
Output: NC Code - Canned
Cycles
Intro to CAM
Institute
CAD to NC Code
Import DXF Geometry
File IGES Direct input
Tool Path Generation

What you want to cut
How you want to cut
Tool Type
CL Rpms Feeds
Post Process
File Method
Canned cycles
Cut direction
NC Code OEM
N1 G80 G90 Custom
N3 G0 T01 M06 Language
N5 G0 X0 Y0
Intro to CAM
Institute
Advantages of CNC Machine
Tools
Ease of part duplication

Flexibility
Repeatability
Quality control through process control
Intro to CAM
Institute
Tools
Accommodates simple to complex parts geometry

Improved part aesthetics
Increased productivity
Technology costs are decreasing
Intro to CAM
Institute
Tools
Reduced set-up time

Reduced lead times
Reduced inventory
Better machine utilization
Job advancement opportunities
Intro to CAM
Institute
Tools
CNC machine tools are more rigid than

conventional machine tools
$$$- Climb milling requires about 10 - 15 % less horsepower vs.
conventional cutting, but requires a ridged machine tool with no
backlash
Increased Rpms and feeds
Intro to CAM
Institute

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CAM Systems & CNC Machine

Overview to Computer Aided

1990s - Price drop in CNC technology

A machining center can be defined as a machine tool

Still used today and accounts for about 5 -10% of all

Capable of generating machine code for complicated

Tool & material libraries

Initial Graphics Exchange Standard (IGES)

Define cutter path by selecting geometry

Numerical Control (NC) Language

1.) X & Y Rapid To Hole Position

4.) Turn On Spindle

8.) Turn Off Coolant

9.) X&Y Axis Rapid

View X0, Y0, Z0

Tool Path Generation

Ease of part duplication

Accommodates simple to complex parts geometry

Reduced set-up time

CNC machine tools are more rigid than

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