Professional Documents
Culture Documents
R. A. Wysk, Ph.D.
Agenda
Introduction
Types of NC Machines
Components of a NC Machine
Control Mechanisms
Interpolation
Software Components
Readings
Chapters 12-13 of Computer Aided
Manufacturing, Wang, H.P., Chang, T.C. and
Wysk, R. A., 3rd Edition ,2006. Chapter 9.
Objectives
To be able to know when and what type of NC
should be used
To be able to read and interpret an NC part
program
To be able to create NC part programs for milled
parts
To understand the difference between world,
machine and part coordinates
To understand how to set machine offsets
To execute an NC part program
HISTORICAL
15th century DEVELOPMENT
- machining metal.
18th century - industrialization, production-type machine tools.
20th century - F.W. Taylor - tool metal - HSS
Automated production equipment Screw machines
Transfer lines
Assembly lines
using cams and preset stops
Programmable automation NC
PLC
Robots
NC
Computer control
MACHINES
Servo axis control
Tool changers
Pallet changers
On-machine programming
Data communication
Graphical interface
Group Exercise
As a group, discuss how you could justify the
purchase of an NC machine.
What are the downsides for purchasing an
NC machine?
Besides direct labor reductions, what other
benefits come from NC machines?
Justification
Variance reduction
Time and quality
NC
MCU - Machine control
MACHINES unit
Machine
Tool
MCU
NC MOTIONCONTROL
NC Program
Execution
Syst em
Commands
Dimensions
Interpolator &
Servo-cont rol
Mechanism
Control
Linear
Logic
Motion
T ranslat or
Power
Relay
Solenoid
NC MACHINE
1. MotionCLASSIFICATIONS
control:
point to point (PTP)
continuous (contouring) path
2. Control loops:
open loop
closed loop
3. Power drives:
hydraulic, electric or pneumatic
NC MACHINE
CLASSIFICATIONS
4. Positioning
systems:
incremental
absolute positioning
POINT TO
Moving at maximum ratePOINT
from point to point.
Accuracy of the destination is important but not the path.
Drilling is a good application.
CONTINUOUS
Controls both the displacement and the velocity.
PATH
Machining profiles.
Precise control.
COMPONENTS OF AN NC MACHINE
TOOL translation axis control
Position
resolver
Controller
Machine table
Gear
box
Tachometer
Motor
Leadscrew
Servo
drive
Magnetics control
cabinet
NC MACHINE
Accuracy RATING
Repeatability
Spindle and axis motor horsepower
Number of controlled axes
Dimension of workspace
Features of the machine and the
controller.
NC
ACCURACY
Accuracy - control instrumentation
resolution and hardware accuracy.
HARDWARE
INACCURACIES
Component
tolerances:
inaccuracies in the machine elements,
machine-tool assembly errors, spindle
runout, and leadscrew backlash.
Machine operation:
Tool deflection (a function of the cutting
force), produces dimensional error and
chatter marks on the finished part.
HARDWARE
INACCURACIES
Thermal error:
heat generated by the motor operation,
cutting process, friction on the ways and
bearings, etc. Use cutting fluids, locating
drive motors away from the center of a
machine, and reducing friction from the
ways and bearings
REPEATABILIT
Y
Programmed position
Repeat abilit y
Avg. error
T est result
LEADSCREW
Converting the rotational motion of the motors to a linear motion.
S
Nut
Leadscrew
Pitch
Example
number of teeth per inch (n) = 20
n = 1 / p (teeth/in) = 0.05 in/rev
Resolver gain - N (sensor points/rev) = 200
pulses/rev
BLU = p (inch/rev)) / N (sensor points/rev)
= 0.05 in/rev / 200 pulses/rev
= 0.00025 inch
CONTROL
LOOPS
motor
CONTROL
LOOPS
A machine has 1 BLU = 0.001".To move the
CLOSED
LOOP
Differential
amplifier
_
Up-down
counter
DAC
Amp
Shaft
DC
Motor
Tachometer
+
Reference pulses
Encoder
INTERPOLATION
Control multiple axes simultaneously to move
on a line, a circle, or a curve.
Y
(10,5)
(10,5)
(3,2)
(3,2)
X
Linear path
INTERPOLATOR
Most common : linear and circular
S
COORDINATE
SYSTEMS
y
y
z
x
MACHINE COORDINATES
Z
PROGRAM
Paper tape STORAGE
Paper or Mylar coated paper.
Diskettes
From other computers through RS 232 or
local area network (LAN)
ASCII
SYMBOLIC
or ISO,
use even parity
CODES
Configurations
Machining centers
Turning centers
Machining Centers
High-Speed Spindles
30,000-rpm Spindle: The Haas 30K
spindle uses BT 30-taper tooling and
accepts tools up to 0.5" max diameter.
Hybrid ceramic angular-contact
bearings, an air/oil spot lubrication
system, and a spindle chiller ensure
superior accuracy and long bearing life.
The 30K spindle is available on VF-1
through VF-4 models. 10,000- and
15,000-rpm Spindles: A variety of 10K
spindles are available for Haas VF
models for 40- or 50-taper models,
with or without a gearbox. A 15K
spindle option is available for all 40taper, direct-drive VF models.
Machining Centers
Through-Spindle Coolant
Optional TSC supplies coolant at up to 300 psi to the cutting edge, for
longer tool life, higher speeds, and improved deep hole drilling and
blind pocket milling as well as reduced cycle times. The exclusive
Haas design includes a special seal that disengages when the system is
not in use, which extends the life of the system. (Note: This system
provides 300 psi at a flow rate of 1.5 gallons per minute and 250 psi at
4 gpm. The actual pressure will vary with the diameter of the coolant
passages in the tool).
High-Pressure (1000 psi) TSC
Available on the VF Super Speed models and all 50-taper VF models,
high-pressure TSC makes it easier to perform deep-hole drilling and
heavy cuts, allows faster feedrates and provides better surface finishes.
Max flow rate is 6 gal/min at 1000 psi; max spindle speed is 10,000
rpm with the high-pressure TSC option enabled.
Machining Centers
Linear Scales
When absolute positioning accuracy is
necessary, linear scales are the only way to
ensure exact axis positioning under the
fluctuating conditions that exist in todays
machine shops. Linear scales ensure
positioning accuracy along X, Y and Z axes
by compensating for the thermal variations
inherent in all machine tools. With 2-micron
resolution, these scales deliver high
accuracy for the type of precision that mold
making and other high-tolerance machining
applications demand.
Machining Centers
Full 4th- and 5th-Axis Capabilities
Add a fully integrated Haas rotary table to your
VMC to create a supercharged machining
center: Program any angle, perform circular
cuts on the outside of your parts, or machine
complex contours such as impellers.
From the original HA5C collet indexer to the
HRT series to the TR series trunnion tables, a
Haas rotary is the industry benchmark. For
superior accuracy, Haas cuts the worm gear
while it's attached to the spindle, rather than
assembling the finished worm gear to the
spindle. And Haas rotary products run directly
from the machines control, for seamless
operation and uncomplicated programming.
Machining centers
Programmable Coolant Nozzle
P-Cool is a multi-position programmable
nozzle that automatically directs coolant
precisely at the part without having to open
the doors. The position of the nozzle is
controlled via the part program, saving
operator time by eliminating constant
adjustments and allowing unattended
operation. The nozzle can also be fine-tuned
from the control pendant while a program is
running.
Machining Centers
Auto Door
With this option, the machine doors open and close automatically via the part
program. This reduces operator fatigue during repetitive machining which
can increase operator productivity by up to 25% and allows for unattended
operation when used with a robotic loader.
Machining Center
Machining Center
Machining Centers
Turning Centers
Workpiece rotates and tool stays stationary normally
horizontal.
Turning Centers
Turning Centers
Live Tooling
The live tooling option for Haas lathes
allows you to use standard VDI 40 axial
or radial driven tools to perform
secondary operations such as milling,
drilling, flatting and tapping both on
the face of the part and around the
diameter. This option includes a full C
axis, which provides interpolated
bidirectional motion at precise speeds
and feeds for part positioning and
repeatability. A powerful hydraulic
brake locks the main spindle during
secondary operations, and disengages
for turning and indexing.
Live tooling is not available with a
standard bolt-on style tool turret. It is
only available with the VDI or VB
Hybrid turret.
Turning Centers
Turning Center
Parts Catcher
For bar feed applications,
or when using a bar puller,
the parts catcher rotates
into position to catch the
finished part and direct it
into a bin located on the
front door. Theres no
need to stop the machine
and open the door to
retrieve parts.
Turning Centers
Tool Presetter
The manual tool-probe
arm swings down for
fast tool setting. Touch
the tool tip to the
probe and offsets are
automatically entered.
Turning Centers
Turning Centers
Resource
PrimarysReference:
http://www.haascnc.com/
Agenda
Introduction
Absolute and Incremental Programming
Elements of NC Program
NC Words (G, M, T, S, Codes)
Examples
Cutter Compensation and Offsets
Examples
Conclusions
Introduction to NC programming
Manual part programming
Computer-assisted part programming
Formats
Fixed-Address
Tab-Sequential
Word-Address
MANUAL PART
Example 9.1
PROGRAMMING
Machined from a 5" x 4" x 2" workpiece. low carbon steel.
The process plan:
1. Set the lower left bottom corner of the part as the machine zero point
(floating zero programming).
2. Clamp the workpiece in a vise.
3. Mill the slot with a 3/4" four flute flat end mill made of carbide. From the
machinability data handbook, the recommended feed is 0.005
inch/tooth/rev, and the recommended cutting speed is 620 fpm.
4. Drill two holes with a 0.75" dia twist drill. Use 0.18 ipr feed and 100 fpm
speed.
PART
DRAWING
2 holes 0.750.001
.75
0.001 M
MA BC
4.000
R1.000
3.000
2.000
1.000
1.75
3.000
5.000
.500
2.000
C
All dimension in inches. A ll tolerance 0.001"
SOLUTION TO
Solution:
EXAMPLE
The cutting parameters
need be converted into rpm and ipm.
Milling:
Drilling:
12 V
RPM =
=
D
12 x 100 fpm
0.75 inch = 509 rpm
p3
p6
H2
p8
H1
p4
p7
p5
p9
p1
(0,0,0)
Drill
End mill
Vise jaw
(0,0,0)
CUTTER
The coordinates of each point (cutter location) are calculated below:
LOCATIONS
p1': ( 1.75+0.375, -0.1-0.375, 4.00) = (2.125, -0.475, 4.000)
p1: (2.125,-0.475, 2.000-0.500) = (2.125,-0.475,1.500)
p2: (2.125,4.000+0.100,1.500) = (2.125,4.100,1.500)
p3: (3.000-0.375,4.100,1.500) = (2.625,4.100,1.500)
p4: (2.625,1.375,1.500)
p5: (3.000,2.000-1.000+0.375,1.500) = (3.000,1.375,1.500)
p6: (3.000,2.625,1.500)
p7: (3.000,2.000,1.500)
p8: (2.625,2.000,1.500)
p9: (2.625,-0.100,1.500)
p9': (2.625,-0.100,4.000)
PART PROGRAM
Part program
N0010 G70 G 90 T08 M06
and absolute dimension
Explanation
Set the machine to inch format
programming.
Feed to p2.
To p3.
To p4.
PART PROGRAM
Part program
Explanation
CNCS
VERIFICATION
CNCS 3D
DRAWING
Offsets
Fixture
G10, G54, G54.1
Diameter
Tool
Length compensation
Part-Edge compensation
Cutter Compensation Next Slides
Others Discussed in Lab Exercises (Simulators)