II Term CAM

Course on Computer Aided Manufacturing
By Abhishek Tevatia Assistant Professor, Maharaja Agrasen Institute of Technology, Rohini, Sec-22, Delhi 110086
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Computer Aided Manufacturing (ETME-401)
Second Term
Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
Topics to be covered
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Block diagrams of CNC operations. Nomenclature, types and features of CNC machine tools. Elements of CNC machines and systems. Machine control unit, Position control significance. Open loop and closed loop systems. and its
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Engineering analysis of NC positioning systems. Precision in NC positioning systems: resolution, accuracy and repeatability. control
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Actuators: DC servomotor, ac servomotor, stepper motor. Transducers and feedback elements: resolvers, inductosyns optical grating and encoders
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Modern CNC machines: CNC lathes. Turning centres. Machining centres. Automatic pallet changers. Automatic tool changers.
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Direct numerical control and applications.

CNC machine design features. Supporting structures. Guide ways. Ball screw-and-nut mechanisms. Machine spindles. Concept of rigidity and relation with accuracy.
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Computer aided programming: APT Part Programming. APT Part Programming cont
Lecture - 19
Block diagrams of CNC operations. Nomenclature, types and features of CNC machine tools.
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Computer Numerical Control (CNC): It is a self-contained NC system for a single machine tool uses a dedicated mini computer, controlled by the instructions stored in its memory, to perform all the basic numerical control function
Operational Features of CNC Machines
Function of CNC
Machine Tool Control: It is the primary function of the CNC system to control the machine tool. This involves conversion of the part program instructions into machine tool motion through the computer interface and servo-system. In Process Compensation: It is closely related function to machine tool control. This involves the dynamic correction of the machine tool motions for change or errors which
occur during processing. The main options are as follows:

Adjustment for errors sensed by in-process inspection probes and gauges. Re-computation of axis positions when an inspection probe is used to locate a datum reference on a work-part. Offset adjustments for tool radius and length. Adaptive control adjustments to speed and/or feed. Computation of predicted tool life and selection of alternative tooling when indicated. Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Improved programming and operating features: The soft wired control has permitted the introduction of many convenient programming and operating features. The main features are as follows: Editing of part programs at the machine. Graphic display of the tool path verify the tape. Provision of various types of interpolation; circular, parabolic and cubic. Support of old customary units and new metric units.
Use of specially written subroutines.

Manual data input (MDI) Local storage of more than single part program.
Diagnostics: Presently, CNC machines are equipped with a diagnostics capability to assist in maintaining and repairing the system. The main features of this provision are as follows: To minimization of downtime To give warning about imminent failurity of a certain component. To contain a certain amount of redudancy of components which are considered unreliable.
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Advantages of CNC
More Flexibility Reduce data reading error
On line editing of program

Diagnostic Conversion of unit Integration with DNC systems
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Disadvantages of CNC
High initial cost Higher maintenance cost Skilled CNC personnel Not suitable for long run application. Machines have to be installed in air-conditioned places.
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Lecture 20 & 21
Elements of CNC machines and systems. Machine control unit, Position control and its significance.
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A CNC System consists of the following six major Elements

1. Input Device 2. Machine Control Unit 3. Machine Tool 4. Driving System 5. Feedback Devices 6. Display Unit
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Constructional Details/Basic Components of NC Machines - MCU Cont
Machine Control Unit

Every CNC machine tool has a main unit, which is known as MCU,
consisting of some electronic circuitry (Hardware) that reads the CNC

program, interprets it and conversely translates it for mechanical action of the machine tool.
The MCU may be three types:

1. Housed MCU 2. Swing around MCU 3. Stand alone MCU Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Housed MCU: This MCU, itself, may be mounted on the machine tool or may be built in the casing of the machine.
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Swing around MCU: This MCU is directly mounted on the machine which can swing around it and can be adjusted as per requirement of the operartors positions
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Stand alone MCU: This MCU is enclosed in separate cabinet which is installed at some remote or same place near to the machine.
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Input Devices
Floppy Disk: A floppy disk is a disk storage medium composed of a disk of thin and flexible magnetic storage medium, sealed in a rectangular plastic carrier lined with fabric that removes dust particles. They are read
and written by a floppy disk drive (FDD).

USB Flash Drive: A USB flash drive is a removable and rewritable portable hard drive with compact size than a floppy disk.
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Data Buffer: A complete block of information, consisting of words, is read from tape and stored into temporary memory called buffer
Processor: Previously the processor or controller used vacuum tubes, now IC technology.
Output Channels and Actuators: The data stored in the buffer is converted into actuation signal and supplied through output channels in
the form of pulses.
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Control Panel: The control panel permits the operation to interface the machine operation manually.
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Machine Tool
It is the main component of an NC system, which executes the operations. It may
consist of a simple drilling machine to the most flexible machining centers.

It includes different parts/ sub-assemblies: Work Table Cutting Tool Jigs and Fixtures Motors for Driving Spindles and Tool Coolant and Lubricating System
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Lecture - 22
Open loop and closed loop systems.
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Computer Aided Manufacturing (ETME-401) Open Loop Control System: A control system, in which the final output value is not directly measured and checked against the desired value, is known as Open loop control system. In open loop control system, there is no feedback device to measure the actual position of tool slides or work table. Hence, it cannot be compared and verified
with the positional value given in command.
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Closed Loop Control System: A control system in which the displacement of

machine slide is balanced w.r.t. input signals mainly by the signal received from feedback devices, is known as close loop control system.
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Computer Aided Manufacturing (ETME-401) In this system, there are two input signals to drive a motor. As soon as the displacement takes place, another signal is generated by the position sensor known as Transducer, to know that weather the position has been achieved or not. This actual position signal is fed to the comparator device known as Differential Analyser which compares it with the command signal and produces
an electrical signal is fed to the servo motor through an amplifier to move the
machine slide in a direction to reduce the difference between the two signals (input and feedback) becomes zero and machine slide comes to rest in the correct position. This mechanism takes care of the inertia effects of machine slide. A feedback transducer is used to control the velocity of motor in the case of continuous path system. It is essential to ensure that the cutter follows the path as required by the profile. Such a control all have capabilities of upto
0.0001 mm resolution and speeds up to 10 m/ mm.
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Semi Close Loop Control System: In this system, a transducer is not for
measuring the exact position of the machine slide, but is derived from the rotary motion of the lead screw by a pinion and gear arrangement. Thus the linear displacement of the machine slide is directly proportional to the rotary displacement. This system is "closed" in the sense that it gives a feedback for displacement but "not closed" in the sense that it largely depends upon the accuracy of lead screw or the gear arrangement. These systems reduce the bulkiness by removing one part i.e. positional transducer.
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Lecture - 23
Engineering analysis of NC positioning systems.
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Open Loop Positioning System

An open loop positioning system typically uses a stepping to rotate the leadscrew. A steeping motor is driven by a series of electrical pulses, which are generated by
the MCU in NC system.

Each pulse causes the motor to rotate a fraction of one revolution, called the step angle. Step angle: = 360 / ns where is step angle and ns is the number of step angle for motor Angle through which motor shaft rotates: Am = np x where Am is angle of motor shaft rotation (degrees) and np is the number of pulses received by the motor Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Computer Aided Manufacturing (ETME-401) The angle of lead screw rotation: A = (np x ) / rg rg is the gear ratio rg = Am/A = Nm/N Nm rotational speed of motor in (rev/min) N is the rotational speed of the leadscrew (rev/min)
The linear movement of the worktable is given by the number of full and partial
rotations of the leadscrew multiplied by its pitch: x = pA / 360 x = x-axis position relative to the starting position (mm, inch) p = pitch of the lead screw (mm/ rev, in/rev) A/360 is the no. of leadscrew revolution Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Computer Aided Manufacturing (ETME-401) np = (360.x.rg)/p = (ns.x.rg)/p
Control pulse are transmitted from the pulse generated at a certain frequency,
which drives the worktable at a corresponding velocity or feed rate in the direction of the leadscrew axis. The rotation speed of the leadscrew depends on the frequency of the pulse train as follows: N = (60.fp)/ (ns.rg) where fp is the pulse frequency For a two axis table with continuous path control , the relative velocities of the axes are coordinated to achieve the desired travel direction. The table travel speed in the direction of leadscrew axis is determined by the
rotational speed as follows:

Vt = fr = N.p where Vt table travel speed and fr is the table feed rate (mm/min) Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Computer Aided Manufacturing (ETME-401) The required pulse train frequency to drive the table at a specified linear travel rate fp = (Vt. ns. rg)/ 60p
In Closed-Loop Positioning System all the formulas are same for details please see the book Automation Production System and Computer Integrated Manufacturing Chapter No. 6 pp no. 183
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Computer Aided Manufacturing (ETME-401) Numerical: The worktable of a positioning system is driven by a leadscrew whose pitch = 6.0 mm. The leadscrew is connected to the output shaft of a stepping motor through a gearbox whose ratio is 5:1 (5 turns of the motor to one turn of the leadscrew). The stepping motor has 48 step angles . The table must move a distance of 250 mm from its present position at a linear velocity = 500 mm/ min. Determine (a) how many pulses are required to move the table the specified distance and (b) the required motor speed and pulse rate to achive the desired table velocity. Given:
x = 250 mm
ns = 48 p=6 rg = 5 Vt = 500 mm/ min Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Computer Aided Manufacturing (ETME-401) The lead screw rotation angle A corresponding to a distance x A = 360x/ p = (360.250)/ 6 = 15000 degrees Step angle = 360 / ns = 360/ 48 = 7.5 degrees The number of pulses to move the table np = (360.x.rg)/p = Arg/p = (15000 x 5)/ 7.5 = 10, 000 pulses The rotational speed of the lead screw wrt to the table speed
N = Vt/ p = 500/ 6 = 83. 333 rev/ min

Motor speed Nm = rg. N = (5 x 83.333) = 416.667 rev/ min The applied pulse rate to drive the table fp = (Vt. ns. rg)/ 60p = (500x48x5)/ (60x6) = 333.333 Hz
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Lecture - 24
Precision in NC positioning systems: control resolution, accuracy and repeatability.
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For accurate machining or other processing performed by an NC, system, the

positioning system must possess a high degree of precision. Three measures of precision can be defined for an NC positioning system:
1. Control Resolution
2. Accuracy 3. Repeatability
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Computer Aided Manufacturing (ETME-401) Control Resolution refers to the control systems ability to divide the total range of the axis movement into closely spaced points that can be distinguished by the MCU. Control resolution is defined as the distance separating two adjacent addressable points in the axis movement.
Addressable points are locations along the axis to which the worktable can be
specifically directed to go.
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Computer Aided Manufacturing (ETME-401) Control Resolution of the electromechanical components
For Open Loop

CR1 = p/ ns.rg CR1 = Control Resolution of the electromechanical components (mm, in) p = pitch of the lead screw (mm/ rev, in/rev) ns = the number of step angle for motor rg = is the gear ratio For Open Loop
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For Close Loop

CR1 = p/ ns.rg. rge CR1 = Control Resolution of the electromechanical components (mm, in)
p = pitch of the lead screw (mm/ rev, in/rev)

ns = the number of step angle for motor rg = the gear ratio rge = gear reduction between the encoder and the leadscrew
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Computer Aided Manufacturing (ETME-401) Control Resolution of the computer control system CR2 = L/ (2^B 1) L is the axis range (mm, in) B is the number of bits in the storage register for the axis
CR = Max {CR1, CR2}
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Computer Aided Manufacturing (ETME-401) The Accuracy of any given axis of positioning system is the maximum
possible error that can occur between the desired target point and the actual
position taken by the system Accuracy = CR/ 2 + 3 is the standard deviation of the error distribution The Repeatability refers to the capability of the positioning system to return to a given addressable point that has been previously programmed. Repeatability = 3
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Lecture - 25
Actuators: DC servomotor, ac servomotor, stepper motor.
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Lecture - 26
Transducers and feedback elements: resolvers, inductosyns optical grating and encoders
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Feedback Devices:
Most of industrial control applications use electrical or
electronic hardware components for converting one physical qualities (speed, displacement etc. in case of CNC machine) into an signal uses for the feedback. The device that carries out this conversion is known as a transducer. The transducer may be analog or digital type depending upon the signal generated by them. An analog, generates a continuous signal such as voltage and current
usually in millivolts and the digital on the other hand, generates signal in the form
of a series of electrical pulses or combination of some parallel bits (binary digits). There are two types of feedback devices, required for close loop system, are as follows: Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Velocity Feedback: It is usually required in contorting applications. These can also be analog or digital type. A techo-generator is an 'analog' output voltage that is directly proportional to speed of the shaft. The magnitude of the voltage is directly represents the voltage is directly represents the magnitude of the speed. It is generally fitted on the servomotor shaft itself and is built in case of servomotor.
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Computer Aided Manufacturing (ETME-401) Another 'Digital' output feedback arrangement is usually made for measuring the velocity (rpm) of the shaft. A small magnet is fitted on the coupling periphery, which makes and breaks the contact of a small micro-switch (contact breaker). This will give a number of electrical pulses per minute directly proportional to shaft speed in rpm. This numerical value represent, is in the form of 'digital' feedback' to monitor to the monitor speed.
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Computer Aided Manufacturing (ETME-401) Positional Feedback It is very difficult to measure the position of the tool edge with reference to the machine slide due to the presence of burrs, jigs and fixtures, coolants
and sometimes due to complexity of the component shape. So, a

compromise is done by measuring the position of machine slid by taking into account the tool wear etc. In this case, one part of transducer is fixed to machine tool structure and the other part to moving machine slide. The measurement of the position of table may be obtained also in 'analog' or 'digital' form.
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Positional feedbacks are of two types which are as follows:

1.) Linear transducers Glass scales with line gritting Ferranti system Binary coded scale Inductosyn 2.) Encoders / Rotary Transducers Resolver Rotary encoder
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Computer Aided Manufacturing (ETME-401) Linear Transducer: A linear position measuring device indicates the position of slide directly. A simple analog linear transducer is best explained, where a sliding cont moves over a linear would potentiometer which allows to drop a small voltage 'V' depending upon the length of resistance selected by sliding contact. These systems have advantage of not having any gear train causing
error in transformation of displacement value act.
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Glass scales with line grating: It consists of two scales are transparent index
grating (sensing device) and glass scale. Both have a similar line graduation on them. These two scales make one unit consist of a light source, lenses and a
photocell. Because one of these scales have transparent lines and other scales
have opaque lines. The relative movement causes the light to pass through these regions, which is sensed by photocells The resistance of photocells changes with the intensity of light falling on it. The periodic signals in the form of pulses are converted proportionately into the displacement of work table by knowing the number of engraved lines per unit length on the linear scale. Usually, a width of 20 microns of the line is used.
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Ferranti system: It uses same type of gating scales except that the least count is improved by using moire effect. In this case the index grating is mounted slightly tilted w.r.t. line gratings on the glass scale. This interference produces a pattern known as Moire Fringes. The glass scale mounted on the slide of machine is moved towards the left or right. The fringe pattern travels upwards or downwards. Again, a photocell is used to measure this variation in light intensity.
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Computer Aided Manufacturing (ETME-401) Moir effect is a visual perception that occurs when viewing a set of lines or dots that is superimposed on another set of lines or dots, where the sets differ in relative size, angle, or spacing. The moir effect can be seen when looking through ordinary window screens at another screen or background. It can also
be generated by a photographic or electronic reproduction, either deliberately

or accidentally.
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Computer Aided Manufacturing (ETME-401) Binary coded scale: In this system a special sensor known as scanner is used for measuring the parallel strips with alternate bright and dark patches are
connected by an electrical contact representation contact represented by binary

1, which remain open i.e. 0 at bright patches. The outer-most strip has the smallest increment of 0.01 mm. the width of consequent rows are double the previous one. The total movement of the slide is calculated by adding up all the values of dark areas sensed. The scale reads the value 64 + 8 +2 + 1 = 75.
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Computer Aided Manufacturing (ETME-401) Inducto syn: It has also two parts the scale (equivalent to rotor) and the slider (equivalent to stator winding) having coils in the form of "hair pin turns" etched on to glass, steel or aluminum plates. The coils are bonded to the scale over an insulating layer. The counter coil is usually spaced, at an interval of 2 mm. when two different voltages are applied with these two slinging coils, a corresponding emf is induced. This emf directly corresponds to the position of slider w.r.t. the scale
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Encoder/Rotary Position Measuring Transducer: this feedback device

measures indirectly the position of the slide by measuring the angular rotation of the lead screw. A calculated gear train ratio relates the measured angle
proportionately to the displacement of the machine slide. Although it is not very

accurate. These are very popular because of being directly mounted on the machine and their compact size
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These are of two types:

Resolver: The resolver has two stator windings which are mounted at right angles to each other. The resolver belongs to a group of machines called synchronous. It is suitably geared so that a displacement of say 50 mm or 3600. A special electronic hardware which converts this cyclic signal into digital form is known as convertor. Encoders: This transducer consists of a glass disc fitted on the axis of lead screw. The disc has accurately etched lines calibrated on the similar to the glass scale in linear systems. Usually a disc of 60 mm can have 120 lines. These lines from alternate, tlting from light source. These types of transducers are also called as Quantizer used to get more accuracy. Another photocell may be used to sense
the same disc. Both photocells have a phase shifting of 90 i.e. the output
consists of two square shapes having a phase difference of 90.
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Lecture - 27
Modern CNC machines: CNC lathes. Turning centres. Machining centres. Automatic pallet changers. Automatic tool changers.
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AUTOMATIC TOOL CHANGER
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Computer Aided Manufacturing (ETME-401) The CNC machines are designed to perform a number of operations in a single setting of the job. A number of tools may be required for making a complex part. In a manual machine, the tools are changed manually whenever required. In a CNC machine, tools are changed through program instructions. The tools are fitted in a tool magazine or drum. When a tool needs to be changed, the drum rotates to an
empty position, approaches the old tool and pulls it. Then it again rotates to
position the new tool, fits it and then retracts. This is a typical tool changing sequence of an automatic tool changer (ATC).
The concept of the ATC is that the range of tools for a specific job shall be made
available for automatic selection and positioning. ATC cab be
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Drum Type
For holding small number of tools usually not more than 30, Stored on periphery of drum and tool search speed is faster.
Drum Type Automatic Tool Changer (ATC)

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Computer Aided Manufacturing (ETME-401) Chain Type For more number of tools (40 or more), tools search speed is less.
Chain Type Automatic Tool Changer (ATC)
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As soon as the tool selection command is received by the system, the selected
tool comes to a fixed place known as tool change position. The selected tool is transferred to the spindle from magazine after the previous tool is transferred to
the magazine from spindle. This is called tool change cycle. Automatic Tool Changer Advantages
1. Lines changed in seconds instead of hours. 2. Increase operator safety by changing tools automatically. 3. Change tools in seconds for maintenance and repair. 4. Increase flexibility. 5. Heavy and large multi-tools that are automatically exchanged. Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Lecture - 28
Direct numerical control and applications.
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Computer Aided Manufacturing (ETME-401) Direct Numerical Control can be defined as a type of manufacturing system in which several NC or CNC machines are controlled remotely
from a Host/Main frame computer or direct numerical control (DNC)

control of multiple machine tools by a single (mainframe) computer through direct connection.
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A DNC is specifically defined as A system connecting a set of
numerically controlled machines to a common memory for part

program or machine program storage with provision for on-demand distribution of data to machines by Electronic Industries Association (EIA). Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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In DNC, several NC machines are directly controlled by a computer, eliminating

substantial hardware from the individual controller of each machine tool. The part-program is downloaded to the machines directly (thus omitting the tape
reader) from the computer memory.

The basic DNC system requires following basic component: Main frame computer Memory Communication network NC machine tool.
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Computer Aided Manufacturing (ETME-401) The communication network can be done either through connecting the
remotely located computer, with lengthy cables to the individual machine control
directly or connecting the main frame computer with a small computer at individual operators station known as satellite computer. DNC system is expensive and is preferably used in large organizations. The
combination of DNC/CNC makes possible to eliminate the use of programme as

the input media for CNC machines. The DNC computer downloads the program directly to the CNC computer memory. This reduces the amount of communication required between the central computer and each machine tool.
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Computer Aided Manufacturing (ETME-401) Advantages of DNC (a) The computer can be remotely located, even a thousand miles away. (b) The computer can program simultaneously many NC machines.
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Adaptive Control (AC)

It is the technique of automatically adjusting of cutting parameters such as speed, feed and depth of cut etc. to an optimum satisfaction level during machining operation, and the maximum metal removal which will result in minimum machining cost.
Types of adaptive control Systems

1. Adaptive control with optimization (ACO) 2. Adaptive control with constrains (ACC) 3. Geometric Adaptive control (GAC)
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Adaptive Control with Optimization (ACO) The ACO systems attempts to maximize the ratio of work material removal rate to tool wear rate, known as index of performance. IP = MRR/ TWR IP = Index of Performance MRR = Material Removal Rate TWR = Tool Wear Rate
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Adaptive control with constrains (ACC)

In this system, the machining conditions such as feed rate or/and speed are
maximized within given limits of machine and tool constraints The Adaptive controllers are fed by signals of following three sensors: TCM Sensor: Tool Conditioning Monitor (TCM) sensors is a camera based image processing system, which checks the alignment, wear state of tool and chip formation. They are best for measuring cutting edge offset and indirectly the cutting force causing tool fracture
Tool Vibration Sensor: The vibration of the tool is measured by two meters, mounted on the machine spindle housing, known as accelerometer.
Spindle Torque Sensor: The torque of spindle is measured by strain gauges

mounted on the machine spindle or in the circumferential grooves of bearings. Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Geometric Adaptive Control (GAC)

GAC is the new concept in the area of adaptive control system. It is widely used in finish machining operations, where the main objective is to achieve a desired surface quality with accurate part dimension despite tool wear or tool deflection The main principal of GAC is high cutting speed for better surface finish
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Lecture - 29
CNC machine design features. Supporting structures. Guide ways. Ball screw-and-nut mechanisms. Machine spindles. Concept of rigidity and relation with accuracy.
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The general criteria for testing the performance of the CNC machine following factors are taken into account:
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Main Structure of the CNC Machine Tool

The main structure of the CNC machine tool comprises of a bed, a column or any
other member, such as head stock of lathe, which is rigidly connected to the bed.
The basic structure of the machine tool transmits cutting force from work-piece to the foundation. There are two type of forces which act upon: Static force due to the weight of the machine tool itself and pressure of the cutting tool on the workpiece Inertia force are exerted by rapid acceleration and deacceleration.
Both of the forces tends to bending or deforming the table and this may lead to
errors to the tune of 40mm.
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Computer Aided Manufacturing (ETME-401) The various steps which can be taken to counter cause are:
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Recirculating Ball Screw and

Nut Assembly
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Computer Aided Manufacturing (ETME-401) In CNC machines, conventional design of lead screw and its nut assembly is not used because: Lesser power transmission High inaccuracy due to backlash
action of higher rate of frictional forces due to sliding parts

To avoid all above difficulties Recirculating Ball Screw and Nut Assembly is used. It gives high efficiency during working Lesser wear and tear Longer working life
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Lecture - 30 & 31
Computer aided programming: APT Part Programming.
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Computer Aided Part Programming

CAPP offers the solution to the complex programming. It makes use of repeated patterns of events which occur oftenly on most of the engineering components. Advantages of CAPP Time saved in making long part programme Simplifying the part-programming procedures.
Lesser errors.
Automatic generation of codes No need to learn machine dependent part programming.
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Difference between Manual and CAPP System
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Difference between Manual and CAPP System Cont
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Difference between Manual and CAPP System Cont
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The APT language is the NC language. It is also used as the computer

program which performs the calculations to generate cutter position based on APT statements. These statements are given as under:
Geometrical statements: It defines the geometric elements of the workpiece.

Motion statements: Which defines the path taken by the cutting tool. Post processor statements: Which defines the feed and speeds and to acurate other features of the machine. Auxiliary statement/ Miscellaneous statements: Which defines the part, tool tolerances etc.
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Part Geometry Definitions in APT

Defining the point Point is the smallest and basic element required to define all other geometries. It is defined in one of the following ways:
Cartesian coordinate
PT1 = POINT/X, Y, Z PT1 = POINT/6, 5, 3
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By intersection of two lines PT1 = POINT/INTOF, LN1, LN2
By intersection of line and plane

PT1 = POINT/INTOF, PL1, LN1
By center of circle PT1 = POINT/CENTER, CR1
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Defining line
By joining two points
By a point and a perpendicular line LN2 = LINE/PT1, PERPTO, LN1
LN1 = LINE/PT1, PT2
By a point and parallel line LN2 = LINE/PT2, PARLEL, LN1
By a point and tangent to circle LN1 = LINE/PT2, LEFT, TANTO, CR1
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Defining a circle
By center point and radius CR1 = CIRCLE/CENTER, PT1, RADIUS, 205
Center point and a point on circumference CR1 = CIRCLE/ PT1, PT2
Centre point and tangent line
CR1 = CIRCLE/CENTER, PT2, LN1
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Defining a plane
By three points SIDE = PLANE/PT1, PT2, PT3
By a point and parallel plane TOP = PLANE/PT2, PARLEL, BOTTOM
By two points and perpendicular to other plane
PL1 = PLANE/PERPTO, PL2, PT1, PT2
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Motion Statement of Tool Initial position FROM/ X, Y, Z FROM/ PT1 FROM/SETPT
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Computer Aided Manufacturing (ETME-401) Point to point motion GO TO/ Symbol for geometry eg. GO TO/ PT1
This statement is used to position the cutter above required location e.g. locating
drill above a hole to be drilled. GODLTA/ X, Y, Z This is incremental instruction used to make movements of the tool in specified direction from its current position e.g. GODLTA/ 0, 0, -50 feeds drill 50 mm into work the GODLTA command is useful in drilling and related operations. The tool can be directed to a particular
hole location with the GOTO statement. Then the GODLTA command would be
used to drill the hole GOTO/PT1 GODLTA/0, 0, -50 Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Contouring motion statements

GO/symbol of geometric experession GO/TO, LN1, TO, CR2 e.g. GO/TO, LN1, TO, CR2 means tool movement touching the surface of LN1 onwards touching the contour of CR2
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Computer Aided Manufacturing (ETME-401) Intermediate movement commands In directing the tool to follow a contour six tool direction commands are used:
GOLFT
GORGT GOFWD GOBACK GOUP GODOWN
These six commands are used mostly with one of the three modifiers to define the check surface, drive surface or part surface Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
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Drive Surface: The drive surface is the surface along which the cut is made by next motion statements. The side of the tool is guided by DS for producing the desired shape of part. Part Surface: The part surface is the surface which guides the cutter point or tool bottom The check surface stops the tool thus indicating the end motion. This order of defining the surface is followed.
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The four modifiers are: TO
ON
PAST TANTO TANTO is used to check surface being tangent to the drive surface(s) mostly for circles. The general form of these statements is: GO/ [TO/ ON/ PAST], [Drive surface], [TO/ ON/ PAST], [Part Surface], [TO/ ON/
PAST], [Check Surface]

e.g. GO RGT/L1, PAST, L2 (It means that move on the right side along L1 until past L2)
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Post processor statements

MACHIN/UNIV for defining the name of the machine COOLNT/ON and COOLNT/OFF for switching coolant ON/OFF FINI advising the computer that program is terminated END Its shuts down the NC machine including MCU FEDRAT it stands for feed rate
134
Computer Aided Manufacturing (ETME-401) Miscellaneous/ Auxiliary Statements
Spindle speed
Clock wise SPINDL/2000, CLW Anticlockwise SPINDL/2000, CCLW Feed Rate FEDRAT/[feed rate value], IPM Or FEDRAT/[feed rate value], MMPM Tool change Where a preset tool is used LOADTL/1, LENGTH, 20 1 is the tool no. and 20 is tool length
Where preset tool is not used

LOADTL/2 Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi
135
Tool definition CUTTER/d
CUTTER/d, r
CUTTER/d, r, e, f, a, b, h
136
Computer Aided Manufacturing (ETME-401) Make the part program in APT
100
137
Computer Aided Manufacturing (ETME-401) Make the part program in APT

PT2 (40, 135)
100
PT3 (90, 110)
SetPT (0, 35)
PT1(40, 35)
PT 4 (115, 60)
PT5 (60, 35)
138
Computer Aided Manufacturing (ETME-401) Part no. WSHOP PRACTICE MACHIN/UNIV // Geometrical points are defined SET PT = POINT/0, 35, 0 PT1 = POINT/40, 35, -2
PT2 = POINT/40, 135, -2

PT3 = POINT/90, 110, -2 PT4 = POINT/115, 60, -2 PT5 = POINT/60, 35, -2
139
Computer Aided Manufacturing (ETME-401) // Now define the two surfaces TOPSRF = PLANE/PT1, PT2, PT5 BOTSRF = PLANE/PARLEL, TOPSRF, ZLARGE, 20 // Define the circles and lines
CR1 = CIRCLE/CENTER, PT3, RADIUS, 25

LN1 = LINE/PT1, PT2 LN2 = LINE/PT2, LEFT, TANTO, CR1 LN3 = LINE/PT4, RIGHT, TANTO, CR1 LN4 = LINE/PT4, PT5 LN5 = LINE/PT5, PT1
140
Computer Aided Manufacturing (ETME-401) // Define the tool, feed and speed LOADTL/1 CUTTER/20 FEDRAT/50, MMPM GO RGT/ LN2, TANTO, CR1
GO FWD/ CR1, TANTO, LN3

GO FWD/ LN3, PAST, LN4 GO RGT/ LN4, PAST, LN5
SPINDL/2000, CLW
// Define the motion statement FROM/SETPT GO/TO, LN1, TO, BOTSRF, TO, LN5 GO LFT/ LN1, PAST, LN2
GO RGT/ LN5, PAST, LN1

GOTO/SETPT FINI END
141

II Term CAM

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Course on Computer Aided Manufacturing

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Direct numerical control and applications.

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Operational Features of CNC Machines

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

occur during processing. The main options are as follows:

Computer Aided Manufacturing (ETME-401)

Use of specially written subroutines.

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

On line editing of program

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

A CNC System consists of the following six major Elements

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Machine Control Unit

consisting of some electronic circuitry (Hardware) that reads the CNC

The MCU may be three types:

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

and written by a floppy disk drive (FDD).

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

the form of pulses.

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

consist of a simple drilling machine to the most flexible machining centers.

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

with the positional value given in command.

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Abhishek Tevatia, Assistant Professor, MAE, MAIT, Delhi

Computer Aided Manufacturing (ETME-401)

Closed Loop Control System: A control system in which the displacement of