Introduction to CAM

Definition of CAM
Product Cycle & CAD/CAM
Latest trend of market
Automation & Types of Productions
Advantages of CAM
CNC/NC =
Flexible/Programmable
Automation

eg. Development of lathe to CNC Turning Center

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Definition of CAM

Effective utilization of computer technology

in the MANAGEMENT, CONTROL and
OPERATIONS of the manufacturing facility
through either direct or indirect computer
interface with the physical and human
resources of the company.

Use of computer systems to plan, manage &

control the operations of a manufacturing
plant with the plants production resources.

Product Cycle & CAD/CAM

Modern Product Cycle:

CAD

CAM
Marketing
&
Customer
Feed back
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Product Cycle & CAD/CAM

Traditional Manufacturing:
Process Planning (process?, m/c?)
Tooling & Equip. + Prodn Scheduling
Production
Quality Control

Product Cycle & CAD/CAM

Computer Aided Manufacturing:
CAPP
MRP + CAS
Production (Robots & CNC)
CAQC

Latest Trend of Market

Large varieties & lower product lives requires:

Reduction in inventory, Lower cost of product

Reduce waste, Improve quality
Increase flexibility in manufacturing to achieve
immediate & rapid response to:

Product changes
Production changes
Process changes
Equipment changes &
Change in personnel

Automations & CAM/CIM meet above challenges

in manufacturing.
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Automation & Types of Productions

Automation: Technology concerned with the

application of complex mechanical, electronics &

computer based systems in the operation & control
of production.
To reduce various time elements in product cycle.

Types of Production:
1.
2.
3.
4.

Continuous Flow
Mass Production
Batch Production
Job Shop
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Automation & Types of Productions

1)

Continuous Flow
Common in food & chemical processing
industry,
oil
refinery,
drugs
and
pharmaceutical unit, etc.
Production does not stop & the flow of
output is continuous.
Generally, online control and continuous
system monitoring may be needed.
All such controls are generally automated
and computer controlled. (eg. Transfer lines)
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Automation & Types of Productions

1)

Continuous Flow
High Productivity but less Flexibility

Automation & Types of Productions

2)

Mass Production
Suited for the manufacturing of continuous
identical parts.
Production lot size is very high & production
rate is continuous
Product variety is very low, which may be
one of its kind (e.g. Automobile parts)
i.e. Fixed Automation (Machines with
Robots & M.H.E)
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Automation & Types of Productions

3)

4)

Batch Production
Production lot size is medium (100 1000)
Product variety is medium e.g. bolts, books...
i.e. Flexible or Programmable Automation
(CNC with jigs & fixtures)
Job Shop :
Lot size is generally small
Production variety is generally very high
Production equipments are mostly general
purpose and flexible
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Advantages of CAM
Increase productivity by carrying maximum
operations in one setup.
Flexibility in design change
Operating flexibility
Shorter lead time
Increased reliability (accuracy & precession)
Reduced maintenance & rework
Better management control
High speed machining

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Flexible/Prog. Automation
System

works automatically but on

instructions which can be changed as
desired.
Conventional
automatic equipments
works automatically on prog. a
physical one in the form of cams i.e.
Fixed programming.
Flexible programming == NC/CNC m/cs
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Numeric Control (NC)

Definition:
The control of operation of machine tools by a
series of coded instructions called the program,
which consists mainly of alphanumeric
characters (numbers and letters).
Characteristic: Preplanned and Predictable
NC is a typical form of Programmable
Automation..
1948 U.S Air force, 1952 NC milling (MIT)

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HISTORICAL DEVELOPMENT
15th century - 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

PROBLEM IDENTIFICATI

Automated functions in NC
Starting & stopping of m/c tool spindle
Controlling the spindle speed
Positioning the tool tip at desired location
Guiding the tool along desired path
Controlling Feed Rate
Changing of tools in the spindle
Changing the pallets
Controlling coolant flow

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Suitability of NC
For following characteristic of job:
The components have complex shape
The parts are to be made in small batches
Set-ups are numerous & costly
Repeatability & accuracy is desired
The parts are subjected to design changes
The inspection cost is significantly more
Expensive part & much metal to be removed

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Advantages of NC technology
Accommodates simple to complex parts
geometry
Increased productivity

Reduced no. of setups & its time

Reduce w/p handling & tool changing time

Reduced inventory
Better machine utilization
Ensures accuracy & repeatability of work
Flexibility in manufacturing (design change)

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Limitations of NC technology
High Establishment & Running cost
High maintenance cost
Downtime of NC system is expensive
Skill personnel for hardware & software
Requires conditional environment

Applications of NC:
NC milling, drilling, boring, lathes, grinders,
punches& presses, welding, inspection m/c,
hobbing ..
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Operation of NC/CNC m/c tool

Part

MCU
(CPU+
PLC)

Signal
to
motors

M/C
Tool

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Machined
Part

Components of NC/CNC system

A.
B.
C.
D.
E.
F.

Part program
Program i/p
device
MCU
Drive System
Machine Tool
Feed Back System
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NC SYSTEM ELEMENTS

DPU: Data Processing Unit

CLU: Control Loop Unit

Components of NC system
A.

Part program

A series of coded instructions required to

produce a part.
It controls the movement of the m/c tool and
on/off control of auxiliary functions.
The program are alphanumeric. (NC block)
Program can be written in Higher Level
Language eg. APT, UNIAPT = CAPP
CAPP is converted into std. part program
with the help of processors.

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Components of NC system
B.

Program i/p device

The means for part program to be entered
into the NC control. They are:
Punch Tape Reader (EIA & ISO code tape),
Manual Data I/P (keyboard on MCU),
Magnetic Tape Reader,
Floppy Disc & Computer Disc drive,
Computer via RS-232-C communication.
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Components of NC system
C.

MCU: Machine control unit is the heart of a NC

system. It perform the following functions:
To read & decode the coded instructions. (interpreted)
To implement interpolations (linear, circular, &
helical) to generate axis motion commands.
To feed the axis motion commands to the amplifier
circuits for driving the axis mechanisms.
To receive the feedback signals of position and
speed for each drive axis.
To implement auxiliary control functions such as
coolant or spindle on/off and tool change.
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MCU
Consists of electronics & hardware that read
& interpret the part program & convert into
mech. actions of m/c tool.
Elements:

Tape reader (electro-mechanical device)

Data buffer (store instructions into logical blocks)
Signal o/p channels to m/c (motors & other control)
Feedback channels (to make certainty of instruction)
Sequence controller (to coordinate overall operation)
Control panels (MDI, Inspection)
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Components of NC system
D.

Drive System
It consists of amplifier circuits, drive motors, and
ball lead-screws. The MCU feeds the control signals
(position and speed) of each axis to the amplifier
circuits. The control signals are augmented to
actuate drive motors which in turn rotate the ball
lead-screws to position the machine table.

E.

Machine Tool
NC controls are used to control various types of
m/c tools. M/c tool has a slide table and a spindle to
control of position and speed.
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Components of NC system
F.

Feed Back System

The feedback system is also referred to as
the measuring system.
It uses position and speed transducers to
continuously monitor the position at which
the cutting tool is located at any particular
instant.
The MCU uses the difference between
reference signals and feedback signals to
generate the control signals for correcting
position and speed errors.
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NC MACHINE RATING

Accuracy

Repeatability

Spindle and axis motor horsepower

Number of controlled axes

Dimension of workspace

Features of the machine and the

controller
PROBLEM IDENTIFICATI

NC ACCURACY AND
REPEATABILITY

Accuracy = control instrumentation

resolution and hardware accuracy.

Control resolution: the minimum length

distinguishable by the control unit (BLU).

Hardware inaccuracies are caused by

physical machine errors.

PROBLEM IDENTIFICATI