Module (3)/week (6) Review of CAM / CIM process.

NC part programming : part programming fundamentals manual programming NC co-ordinate systems and axes tape format sequence number, preparatory functions, dimension words, speed word, feed world, tool world, miscellaneous functions programming exercises. Assignment I and evaluation.

3.6 (a) CAM process

Fig. 3.1: A snapshot of the CAM process

Video demo of CAM process Video demo of CNC machining

Module (3)/week (6) 3.6 (b) Computer Integrated Manufacturing process

Fig. 3.2: A schematic layout of a CIM environment

Module (3)/week (6) 3.6.1 Part programming fundamentals

The following are the basic steps in NC procedure: Process planning Part programming Part program entry Proving the part programs or Production a) Process planning The part programmer will often carryout the task of process planning. Process planning is the procedure of deciding what operations are to be done on the component, in what order, and with what tooling and work holding facilities. Both the process planning and part programming aspects of manufacture occur after the detail drawings of a component have been prepared .The following procedure may be used as a guide to assist the programmer, by describing each step required in preparing the method of production. Receive the part drawing. From part drawing check suitability of part to be machined against the machine capacity. Determine a method of driving the component (chuck type, chuck size, type of jaw, collet size, face driver etc,) and the method of machining. Determine the tooling required to suit the method of machining and utilize as much as possible the tools which are permanently in the turret set upon the machine Determine the order of machining and the tooling stations Determine planned stops (cycle interrupt procedure, incorporating block delete codes) for checking dimensional sizes where required by operator. Determine cutting speeds based on - Component material, method of driving, rigidity of component - The tooling selected for roughing and finishing: tool carbide with carbide drills, high speed steel drills, and ceramics. Determine the depths of cut and feeds for roughing operations based on - Horsepower available for cutting and rigidity of the part Determine from surface finish requirements the cutter nose radius most suited for finishing operations and determine feed rates. Allocate tool offsets as required. Complete planning sheet.

b) Part Programming After completing the planning sheet, draw the component showing the cutter paths Select a component datum and carryout the necessary calculations at slopes and arcs. Prepare tooling layout sheet showing tools to be used in the program and indicate the station number for each tool. Indicate the ordering code for each tool and the grade and type of inserts to be used. 3

Module (3)/week (6) Write the part program according to the sequence of operations. c) Part Program Entry or Tape Preparation The part program is prepared/punched on a 25 mm (1-inch) wide paper tape with 8 tracks and is then fed to MCU in order to produce a component of interest on machine tool. Other forms of input media include, punched cards, magnetic tape, and 35 mm motion picture film. The input to the NC system can be in two ways: 1) manual data input, 2) Direct Numerical Part Program Formats Fixed block format Fixed sequential format, Tab sequential format Word address format

d) Proving Part program It is a safe practice to check the programmed path for any interference between the tool and the work before using the part program for production. This process known as Proving Part Program is done in several ways: Visual Inspection Single Step Execution Dry run Graphical Simulation Part Programming Geometry

3.6.2

a) Coordinate System for a CNC Lathe Machining of a work piece by an NC program requires a coordinate system to be applied to the machine tool. There are three planes in which movement can take place - Longitudinal, Vertical, Transverse and each plane is assigned a letter and is referred to as an axis, i.e., axis X, axis Y, axis Z. The coordinate system used for the tool path must be identical to the coordinate system used by the CNC machine.

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Fig. 3.3: Coordinate system for turning operations {Tool positioned behind center line)

Fig. 3.4: Coordinate system for milling operations 5

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Within a given machine axes coordinate system, CNC can be programmed to locate tool positions in the following modes; incremental, absolute, or mixed.

Fig. 3.5: Coordinate system used absolute (top) and increment mode (above) b) Zero Points & Reference Points On CNC machines tool traverses are controlled by coordinating systems. Their accurate position within the machine tool is established by 'Zero points' as shown in Fig. . Machine zero M is specified by the manufacture of the machine. This is the zero point for the coordinate systems and reference points in the machine. On turning lathes, the machine zero is generally at the centre of the spindle nose face. The main spindle axis (center line) represents the Z axis, the face determines the X axis. The directions of the positive X and Z axes point toward the working area. When the tool traverses in the positive direction, it moves away from the workpiece.

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Fig. 3.6: Position of reference point on a lathe Reference Point (R) point serves for calibrating and for controlling the measuring system of the slides and tool traverses. The position of the reference point as shown in fig is accurately predetermined in every traverse axis by the trip dogs and limit switches. Therefore, the reference point coordinates always have the same, precisely known numerical value in relation to the machine zero point. After initiating the control system, the reference point must always be approached from all axes to calibrate the traverse measuring system. If current slide and tool position data should be lost in the control system as, for example, through an electrical failure, the machine must again be positioned to the reference point to re-establish the proper positioning values. Workpiece Zero Point (W) determines the workpiece coordinate system in relation to the machine zero point. The workpiece zero point is chosen by the programmer and input into the CNC system when setting up the machine. The position of the workpiece zero point can be freely 7

Module (3)/week (6) chosen by the programmer within the workpiece envelope of the machine. It is, however, advisable to place the workpiece zero point in such a manner that the dimensions in the workpiece drawing can be conveniently converted into coordinate Values and orientation when clamping/chucking, setting up and checking, the traverse measuring system can be effected easily. Occasionally, the workpiece zero point is also called the 'Program zero point'.

Fig. 3.7: Examples of workpiece zero point position for turned parts Tool Point is essential to control the tool cutting edges in precise relationship to the workpiece along the machining path. Since tools have different shapes and dimensions, precise tool dimensions have to be established beforehand and input into the control system. The tool dimensions are related to a fixed tool setting point during pre-setting.

Fig. 3.8: Tool reference point c) Tool offset The Tool Length Offset value is the distance from the tip of the tool with the spindle in the home position, to the Z0 plane. TLOs must be set for each tool used in the current job. They can be set using a height gage, reference tool, fixture location, or on the stock to be machined. Once the values are determined, they are stored in the controller for use during program operation. A more efficient way to set TLOs is to measure from the spindle to each tool tip. This is better method because the values need only be set once regardless of each different type and size of part being manufactured. Of course, tool breakage or replacement requires a reset of the individual TLO when using either method.

Module (3)/week (6) 3.6.3 Part program structure

Part programming contains geometric data about the part and motion information to move the cutting tool with respect to the work piece. Basically, the machine receives instructions as a sequence of blocks containing commands to set machine parameters, speed, feed and other relevant information. A block is equivalent to a line of codes in a part program.

Fig. 3.9: (a) General structure of a part program

Fig. 3.9: (b) Block format of part programming

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Fig. 3.9: (c) Word format of part programming Table 3.1: Sequence of words in a NC block

When an NC program is input, the control system checks whether the formal rules of the programming language have been kept to an instruction. However input of wrong coordinate values by the programmer can only be found during the program run. 3.6.4 Procedure for manual NC programming

The procedure for manual programming can be divided into four steps: analysis of workshop drawings definition of work plans choice of clamping devices and necessary tools (set-up sheet) generating the NC program (program sheet) 10

Module (3)/week (6) Information needed by a CNC Preparatory Information: units, incremental or absolute positioning Coordinates: X, Y, Z, RX, RY, RZ Machining Parameters: Feed rate and spindle speed Coolant Control: On/Off, Flood, Mist Tool Control: Tool and tool parameters Cycle Functions: Type of action required Miscellaneous Control: Spindle on/off, direction of rotation, stops for part movement. This information is conveyed to the machine through a set of instructions arranged in a desired sequence Program. Demo and simulation of CNC program

3.6.4

CNC machine demo

Visual inspection and demo of CNC machine (STARTURN) G and M codes as applicable to the demonstrated machine

STAR TURN
Mechanical features
Spindle power Swing over bed Swing over cross slide Distance between centres Spindle speed (stepless) Spindle bore Spindle taper Tailstock taper Machine Resolution 1/2 HP 140 mm 38 mm 250 mm 0-1800 RPM 10 mm No.1 No.1 0.01mm 660 mm 425 mm 430 mm 70 Kg 500 mm 220 mm 600 mm 35 Kg

Dimension
Machine Length Machine Depth Machine Height Machine Weight Power Box Length Power Box Depth Power Box Height Power Box Weight

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Module (3)/week (6) Miscellaneous Function (M codes) M Codes are instructions describing miscellaneous functions like calling the tool, spindle rotation, coolant on etc. M100 M02 M03 M04 M05 M06 M08 M09 M10 Program Stop Optional Stop Spindle Forward (CW) Spindle Reverse (CCW) Spindle Stop Tool Change Coolant on Coolant on Vice open M11 M62 M63 M64 M65 M67 M68 M98 M99 Vice close Output 1 on Output 2 on Output 1 off Output 2 off wait input 1 on wait input 1 off subprogram call subprogram exit

Preparatory Function (G Codes) two types: G00 G01 G02 G03 G04 G20 G21 G28 G32 G40 G41 G42 G50 Positioning (rapid traverse) Linear Interpolation (feed) Circular Interpolation (CW) Circular Interpolation (CCW) Dwell Inch data input Metric data input Reference point return Thread cutting

A 2-digit number following address G determines the

meaning of the command of the block concerned. The G codes are divided into the following

G70 G71 G72 G73 G74 G75 G76 G90 G92 G94 G96 G97 G98 G99

Finishing cycle Stock removal in turning Stock removal in facing Pattern repeating Peck drilling in Z axis Grooving in X axis Thread cutting cycle Cutting cycle A Thread cutting cycle Cutting cycle B Constant surface speed control Constant surface speed controls cancel Feed per minute Feed per revolution

Tool nose radius compensation cancel Tool nose radius compensation left Tool nose radius compensation right Work co-ord. change / Max. Spindle speed setting

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