AIM: To study the basic components and details of CNC machine. BASIC COMPONENTS: An operational CNC machine consist of i) Program of instruction ii) Machine control unit iii) Machine tool. PROGRAM OF INSTRUCTION: It is the detailed step by step instruction which tell the machine tool what to do. The program can input to the system either by manual data input or by a punched tape. MACHINE CONTROL UNIT: It is also called as the controller unit. It is considered as the brain of the machine. It reads the part program and controls the machine tool operation. It consists of two units. (1) Data processing unit (2) Control loop unit. CONTROL LOOP UNIT: The control loop unit receives the data from data processing unit and converts it into control signals. The data usually provides the control 2
information such as the new required position of each axis, its direction of motion and velocity and auxillary control signals to relays. MACHINE TOOL: The machine which performs the machining operation is called machine tool. The machine tool consists of workable and spindle as well as the motor. It also includes the cutting tool work fixture and other auxiliary equipment needed in the operation.
RESULT: Thus the basic components of CNC machine have been studied
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PART PROGRAMMING FUNDAMENTALS (CNC TURNING)
EXPT. NO: 2 DATE :
AIM: To know about part programming fundamentals for CNC turning.
1. CO-ORDINATE SYSTEM FOR A CNC LATHE: Machining of the work piece by an NC programming requires a co- ordinate system to be applied to the machine tool. As all machine tool have more than one slide, it is important that each slide is identified individually. There are three planes in which movements can take place: (1.) Longitudinal (2.) Transverse (3.) Vertical. Each plane is assigned a letter and is referred to an axis (i.e.) (1.) Axis-x (2.) Axis-y (3.) Axis-z 4
The three axis are identified by the upper case x, y and z and the direction of movement along each axis specified as either (+) or (-). The three axes are always at right angles and parallel to work holding surface. The z-axis is at right angles to both x and y axis. 2. MACHINE ZERO POINT: The manufacturers of the machine specify machine zero point. This is zero point for the co-ordinate system and reference point in the machine on turning the lathe. The machine zero point is generally at the center of the spindle nose face. The main spindle axis represents the z-axis, and the face determines x-axis. 3. WORK PIECE ZERO POINT: The point determines the work piece co-ordinate system in relation to the machine zero point. The work piece zero point is chosen by the programmer and the input to the system. 4. NC PROGRAM BUILT UP: In an NC program, the machining system operations for producing a part on the machine tool are laid down in a form that the control system can understand. A program is composed of several blocks. A block is a collection of NC works. An NC word is collection of address, letter and sequence of number.
BASIC COMPONENTS: An operational CNC machine consist of iv) Program of instruction v) Machine control unit 5
vi) Machine tool.
PROGRAM OF INSTRUCTION: It is the detailed step by step instruction which tell the machine tool what to do. The program can input to the system either by manual data input or by a punched tape.
MACHINE CONTROL UNIT: It is also called as the controller unit. It is considered as the brain of the machine. It reads the part program and controls the machine tool operation. It consists of two units. (1) Data processing unit (2) Control loop unit.
CONTROL LOOP UNIT: The control loop unit receives the data from data processing unit and converts it into control signals. The data usually provides the control information such as the new required position of each axis, its direction of motion and velocity and auxiliary control signals to relays.
MACHINE TOOL: The machine which performs the machining operation is called machine tool. The machine tool consists of workable and spindle as well as the motor. It also includes the cutting tool work fixture and other auxiliary equipment needed in the operation. 6
CNC Systems: y Point-to-point control is the positioning of the tool from one point to another within a coordinate system. Most often used for positioning to a point where a manual machining operation such as drilling or boring would occur. y Straight-cut control has the ability move a tool, while engaged, straight in all axes of the machine and has the ability to do angles of 45 degrees. y Contouring control systems generate a continuously controlled tool path by interpolating intermediate points or coordinates. Interpolating means the ability to generate the points that make up a path. Cutting Data and Formulae: Here are some of the most common terms used for expressing cutting data:
y Spindle speed - Spindle speed is the rotational speed of the spindle and tooling. This value is usually expressed in RPM. (Revolutions per Minute).
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y Feed rate value - The feed rate value is the numerical value at which a tool will traverse a work piece. It is usually expressed in either IPM (Inches per Minute) or IPR (Inches Per Revolution).
y Cutting speed - Cutting speed is the rotational speed of the cutting tool or work piece. It can be stated as either RPM or SFM. (Surface Feet Per Minute).
y Depth of Cut - Depth of cut is the distance the tool tip is engaged into the wor piece. It is incorporated into the X, Y, and Z values in a CNC program. Separate from the program, it can be expressed in inches or mm.
Tooling Requirements: Tooling requirements and selection are based on part restrictions and industry manufacturing practices. Most of these ideas are common sense thoughts. Good CNC programmers and operators should be aware of them. y Know the material to be machined and its characteristics. y Use industry standard catalog tooling to cut costs. y Make use of technical services offered by tooling manufacturers. 8
y Quality of the fixture should be based on the number of pieces that will eventually be produced. y Always use the right tool for the right machining operation. y Keep spares or backups of tooling in the event resharpening is needed or tool breakage occurs. y Keep an assortment of tooling in case one type does not perform the job as desired. y Use high speed steel tools on easily machined materials. y Use carbide tools on difficult to cut materials. y Use cobalt or oxide coated tools for exotic alloys. y Use insert type tooling where possible to cut costs. y Consider using reamers, instead of boring bars, on lathe applications where chatter and chip control may be a problem. y Be aware of the flexing that occurs with long length tools. Extra passes may be required to eliminate tapering and chattering. Unit Systems and Input Modes: y Unit Systems are the units of measurement to be used for the CNC program. All machines understand both English and Metric standards. When programming in english units you are using inches. And in metric its the millimeter (mm.). The CNC machine needs to be told which units are being used. Some 9
machines are automatically set-up at the factory for inches or mm. Normally at the beginning of a CNC program you will see either; G70 to specify inches or G71 to specify mm.. y Input modes refer to the type of coordinate information that is input into the program for the CNC machine. There are two types. y Absolute input, designated by the G90 code, specifies distances from the origin or program zero point. Absolute is the most common mode. y Incremental input, designated by the G91 code, specifies distances and directions based on the previous point as an origin. Incremental input is sometime called point-to-point. All CNC systems can be switched from absolute to incremental mode and back unlimited times within a program. Other input modes such as Helical also exist
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CHARACTER MEANING A ROTATION ABOUT X AXIS B ROTATION ABOUT Y AXIS C ROTATION ABOUT Z AXIS D&E ROTATION ABOUT ADDITIONAL AXIS F FEED G PREPARATION FUNCTION IDENTIFYING THE ACTION OF EXCUTED H UN ASSIGNED I INTERPOLATION PARAMETER THREAD PITCH PARALLEL J THREAD PITCH PARALLEL TO Y AXIS K THREAD PITCH PARALLEL TO Z AXIS L UN ASSIGNED M AUXILARY FUNCTION N BLOCK NUMBER O NOT USED P,Q,R THREAD MOVEMENT PARALLEL TO X,Y AND Z AXIS. P AND Q ARE ALSO USED AS PARAMETERS IN CYCLES S SPINDLE SPEED T TOOL U,V,W SECOND MOVEMENT PARALLEL TO X,Y,Z AXIS 11
X MOVEMENT IN X AXIS Y MOVEMENT IN Y AXIS Z MOVEMENT IN Z AXIS
MISCELLANIOUS FUNCTION (M CODES): M codes are instructions describing miscellaneous functions like calling the tool, spindle rotation, coolant supply etc. CODES FUNCTION M00 PROGRAM STOP M01 OPTIONAL STOP M02 PROGRAM END M03 SPINDLE FORWARD (CLOCK WISE) M04 SPINDLE FORWARD (COUNTER CLOCK WISE) M05 SPINDLE STOP M06 TOOL CHANGE M08 COOLANT ON M09 COOLANT OFF M10 CHUCK OPEN M11 CHUCK CLOSED M98 SUB PROGRAM CALL M99 SUB PROGRAM EXIT M 30 PROGRAM END AND REPEAT
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PREPARATORY FUNCTIONS (G CODES):
CODES FUNCTION G00 RAPID TRAVERSE G01 LINEAR INTERPOLATION G02 CIRCULAR INTERPOLATION (CLOCK WISE) G03 CIRCULAR INTERPOLATION ( COUNTER CLOCK WISE) G20 INCH DATA INPUT G21 METRIC DATA INPUT G28 REFERENCE POINT RETURN G32 THREAD CUTTING G40 TOOL NOSE RADIUS COMPENSATION CANCEL G41 TOOL NOSE RADIUS COMPENSATION LEFT G42 TOOL NOSE RADIUS COMPENSATION RIGHT G73 PATTERN REPEATING G74 PECK DRILLING IN Z AXIS G76 THREAD CUTTING CYCLE G98 FEED PER MINUTE G99 FEED PER REVOLUTION
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SPECIAL CYCLES y Special Cycles or Canned Cycles are a preprogrammed sequences of repetitive tool motion that are built into the control system for common operations such as drilling, tapping, boring, and pocketing. Its purpose is to reduce the amount of program code that would normally have to be written. Canned cycles are G codes that are options purchased with a CNC, but some are standard equipment depending on the manufacturer. y Drilling cycle (G81, G82 or G83) are used to drill multiple holes without programming each move separately. Using this cycle reduces the amount of code that would normally have to be written. y Facing cycle (G77) is used to clean up rough stock material (normally on top of the part) which can be located within a rectangular area. Using this cycle reduces the amount of code that would normally have to be written. y Rectangular pocket cycle (G78) is used to clear out material which is located within a rectangular area. Using this cycle reduces the amount of code that would normally have to be written. y Circular pocket cycle (G79) is used to clear out material which is located within a circular area. Using this cycle reduces the amount of code that would normally have to be written.
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SPECIAL CODES: Special codes are used to perform functions in the CNC's control and enhance the programmers ability to write smart programs. Most of these codes are standard in today's CNCs, others may be optional. The machine builder sets these codes but some standardization does exist. y / - Block Delete - A code used in a CNC program to allow the operator to ignore a given block or blocks of code, depending on the setting of the Block delete switch on the operators control panel. y EOB - End Of Block - A special character used to signify the end of one block. Normally this character is the carriage return. y . - Period - A period before a block tells the control to execute system mode changes during the search mode also.(ie. a line with G70,G90 will have a . in front .) y % - Rewind Stop y = - Execute (or Do) - When looping; or running macros; = means execute.(ie. =N25/6 - run line number 25 6 times then continue) y E - Rewind Tape 15
y $ - End of Macro - The $ specifies the end of a definition of a macro. y # - The begining of the definition of a macro will have the # sign followed Programming Considerations y Develop a programming style that will be used by all programmers at your facility. y Proofread all programs for typographical errors before they are sent to the shop. y Keep all programs as simple as possible to perform the desired functions. y Be aware of modal and non-modal codes. Modal codes are commands that remain in effect until they are cancelled by another code. This makes it possible for you to not have to repeat them, line after line, for repetitive tasks; such as drilling, boring, etc. . y Choose feeds and speeds that will give you a balance between tool life and short cycle times. y Use your own previous experience and the experiences of others for programming feeds, speeds, and depth of cut. But do not guess. 16
y Optimizing cycle time is accomplished after a program has begun producing dimensionally acceptable parts. y A fully optimized cycle time can be thought of as one that produces the most finished parts per day. y "Error on the side of caution". In CNC programming, it's a good idea to have an extra degree of safety. Examples include longer dwell cycles, higher plunge distances and clearance planes, slower feedrates and lighter depths of cut. Normally this practice would be used on a new program. Later after the program is proofed, these safeties would be optimized out for efficiency.
RESULT:
Thus the part programming fundamentals of CNC turning is studied 17
PROGRAM FOR
CNC LATHE
PLAIN FACING AND TURNING
EXPT. NO: 3 18
DATE :
AIM:
To machine a given work piece for given dimension using turning and facing operations.
RESULT: Thus the work piece is machined as per the dimensions.
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TOOL COMPENSATION AND PROGRAM OFFSET
All dimensions are in mm Material - Aluminum
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STUDY OF CNC WIRE CUT EDM
EXPT. NO: 12 DATE :
AIM: To study about the working principle of the CNC wire cut EDM.
WEDM: In wire electrical discharge machining (WEDM), also known as wire- cut EDM and wire cutting, a thin single-strand metal wire, usually brass, is fed through the work piece, submerged in a tank of dielectric fluid, typically de ionized water
Wire-cut EDM is typically used to cut plates as thick as 300mm and to make punches, tools, and dies from hard metals that are difficult to machine with other methods.
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The wire, which is constantly fed from a spool, is held between upper and lower diamond guides. The guides, usually CNC-controlled, move in the xy plane. On most machines, the upper guide can also move independently in the zuv axis, giving rise to the ability to cut tapered and transitioning shapes (circle on the bottom square at the top for example). The upper guide can control axis movements in x yuvijkl. This allows the wire-cut EDM to be programmed to cut very intricate and delicate shapes The wire, which is constantly fed from a spool, is held between upper and lower diamond guides. The guides, usually CNC-controlled, move in the xy plane. On most machines, the upper guide can also 48
move independently in the zuv axis, giving rise to the ability to cut tapered and transitioning shapes (circle on the bottom square at the top for example). The upper guide can control axis movements in x yuvijkl. This allows the wire-cut EDM to be programmed to cut very intricate and delicate shapes. The upper and lower diamond guides are usually accurate to 0.004 mm, and can have a cutting path or kerf as small as 0.12 mm using 0.1 mm wire, though the average cutting kerf that achieves the best economic cost and machining time is 0.335 mm using 0.25 brass wire. The reason that the cutting width is greater than the width of the wire is because sparking occurs from the sides of the wire to the work piece, causing erosion. This "overcut" is necessary, for many applications it is adequately predictable and therefore can be compensated for (for instance in micro-EDM this is not often the case). Spools of wire are longan 8 kg spool of 0.25 mm wire is just over 19 kilometers in length. Wire diameter can be as small as 20 micrometres and the geometry precision is not far from +/- 1 micrometre. The wire-cut process uses water as its dielectric fluid, controlling its resistivity and other electrical properties with filters and de-ionizer units. The water flushes the cut debris away from the cutting zone. Flushing is an important factor in determining the maximum feed rate for a given material thickness. 49
Along with tighter tolerances, multi axis EDM wire-cutting machining center have added features such as multi heads for cutting two parts at the same time, controls for preventing wire breakage, automatic self-threading features in case of wire breakage, and programmable machining strategies to optimize the operation. Wire-cutting EDM is commonly used when low residual stresses are desired, because it does not require high cutting forces for removal of material. If the energy/power per pulse is relatively low (as in finishing operations), little change in the mechanical properties of a material is expected due to these low residual stresses, although material that hasn't been stress-relieved can distort in the machining process. The work piece may undergo a significant thermal cycle, its severity depending on the technological parameters used. Such thermal cycles may cause formation of a recast layer on the part and residual tensile stresses on the work piece.
RESULT: Thus, the construction, working principle of the CNC Wire Cut EDM was studied and understood. 50
STUDY OF CAM PACKAGES
EXPT. NO: 13 DATE : Computer-aided manufacturing (CAM): The computer-aided manufacturing is the use of computer software to control machine tools and related machinery in the manufacturing of work pieces. This is not the only definition for CAM, but it is the most common CAM may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage. Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumption. CAM is a subsequent computer-aided process after computer-aided design (CAD) and sometimes computer-aided engineering (CAE), as the model generated in CAD and verified in CAE can be input into CAM software, which then controls the machine tool
Over time, the historical shortcomings of CAM are being attenuated, both by providers of niche solutions and by providers of high-end solutions. This is occurring primarily in three arenas: 51
1. Ease of use 2. Manufacturing complexity 3. Integration with PLM and the extended enterprise Ease in use: For the user who is just getting started as a CAM user, out-of- the-box capabilities providing Process Wizards, templates, libraries, machine tool kits, automated feature based machining and job function specific tailor able user interfaces build user confidence and speed the learning curve. User confidence is further built on 3D visualization through a closer integration with the 3D CAD environment, including error-avoiding simulations and optimizations.
Manufacturing complexity: The manufacturing environment is increasingly complex. The need for CAM and PLM tools by the manufacturing engineer, NC programmer or machinist is similar to the need for computer assistance by the pilot of modern aircraft systems. The modern machinery cannot be properly used without this assistance. Today's CAM systems support the full range of machine tools including: turning, 5 axis machining and wire EDM. Todays CAM user can easily generate streamlined tool paths, optimized tool axis tilt for higher feed rates and optimized Z axis 52
depth cuts as well as driving non-cutting operations such as the specification of probing motions.
Integration with PLM and the extended enterprise: Todays competitive and successful companies have used PLM to integrate manufacturing with enterprise operations from concept through field support of the finished product. To ensure ease of use appropriate to user objectives, modern CAM solutions are scalable from a stand-alone CAM system to a fully integrated multi-CAD 3D solution-set. These solutions are created to meet the full needs of manufacturing personnel including part planning, shop documentation, resource management and data management and exchange.
According to the latest analysis of the CAM software market produced by CIM data, Inc., Master CAM from CNC Software Inc. with more than 135,000 installations, is more than twice as popular as its nearest competitor. Master cam is a Windows based CAD/CAM package for 2-axis through 5-axis milling and turning, 2-axis and 4-axis wire EDM, 2D and 3D design, surface and solid modeling, and 2D and 3D routing. 53
`The CAD functions are more advanced than what is needed to do simple editing of part files for use with the CAM function. Some users say that it is more than they need and that the CAD function is more design-oriented than machinist oriented. This made the package harder for them to learn than other packages with only simple editing functions. Other users say that the extended design- oriented functionality of the CAD package gives them the ability to create complex designs without having to buy a stand-alone CAD package.
RESULT: Thus, the various features of CAM packages were studied and understood.