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CNC TECHNOLOGY
and
CNC PROGRAMMING
2004 1
AUTOMATION IN MANUFACTURING
SYSTEMS
TRENDS IN INDUSTRY
THE OBJECTIVE:
TO BE COMPETITIV THROUGH
INCREASING PRODUCTIVITY AND TOTAL
QUALITY ASSURANCE
2004 2
COST = COST OF
MANUFACTURING AND
COST OF MATERIAL
HANDLING
EFFICIENCY OF PRODUCTIVITY =
MANUFACTURING AVERAGE OUTPUT PER
MAN-HOUR
2004 3
PROFIT increases as COST decreases
and as PRODUCTIVITY increases.
2004 4
any means of helping
the workers to perform
their tasks more
efficiently
AUTOMATION
2004 5
Transferred Results
skill
muscle power engine driven First industrial
machine tools revolution
manipulating mechanization hard automation
skill
vision skill use of position increase of
transducers, accuracy, part
cameras recognition
brain power cnc machines, industrial second industrial
robots, soft
automation, revolution
computer control of
manufacturing
2004 systems 6
Utilization of computers in
manufacturing applications has
proved to be one of the most
significant developments over the
last couple of decades in helping to
improve the productivity and
efficiency of manufacturing
systems.
2004 7
The metal cutting operations (also
called machining) is one of the
most important manufacturing
processes in industry today (as it
was yesterday).
2004 8
MACHINING IS THE REMOVAL
OF MATERIALS IN FORMS OF
CHIPS FROM THE WORKPIECE
BY SHEARING WITH A SHARP
TOOL.
2004 9
The main function of a machine
tool is to control the workpiece-
cutting tool positional relationship
in such a way as to achieve a
desired geometric shape of the
workpiece with sufficient
dimensional accuracy.
2004 10
Machine tool provides:
work holding
tool holding
relative motion between tool
and workpiece
primary motion
secondary motion
2004 11
Primary motion
Relative motion
between tool and Secondary motion
workpiece
2004 12
m a c h i n e c o n t r o l u n i t
p o s i t i o n t r a n s d u c e r s
w o r k h o l d i n g d e v i c e
t o o l h o l d i n g d e v i c e
2004 13
CLASSIFICATION OF THE CHIP REMOVING METHODS
ACCORDING TO THE RELATIVE MOTION
2004 14
CLASSIFICATION OF MACHINE TOOLS
2004 15
ISO MACHINE TOOL AXIS DEFINITION
2004 16
ISO MACHINE TOOL AXES DEFINITIONS
AXIS MACHINE TOOL WITH SPINDLE MACHINE TOOL WITH
NO SPINDLE
HORIZONT VERTICAL
AL AXIS AXIS
2004 18
STANDARD LATHE COORDINATE
SYSTEM
2004 19
STANDARD MILLING MACHINE
COORDINATE SYSTEM
2004 20
NUMERICALLY CONTROLLED MACHINE
TOOLS:
An NC machine tool is functionally the same
as a conventional machine tool. The
technological capabilities NC machine tools
in terms of machining are no different from
those of conventional ones. The difference is
in the way in which the various machine
functions and slide movements are
controlled.
2004 21
The functions and motions such as;
2004 22
INTRODUCTION TO CNC
2004 23
HISTORY
US Air Force commissioned MIT to develop the
first "numerically controlled" machine in 1949. It
was demonstrated in 1952.
At 1970-1972 first Computer Numeric Control
machines were developed.
Today, computer numerical control (CNC)
machines are found almost everywhere, from
small job shops in rural communities to
companies in large urban areas.
2004 24
DEFINITION
2004 25
CNC APPLICATIONS
Machining
2.5D / 3D
Turning ~ Lathes, Turning Centre
Milling ~ Machining Centres
Forming
2D
Plasma and Laser Cutting
Blanking, nibbling and punching
3D
Rapid Prototyping
2004 26
SAMPLE
CNC MACHINES
2004 27
CNC TURNING
28
CNC MILLING
29
CNC LASER CUTTING
2004 30
CNC PLASMA CUTTING
2004 31
CNC PRESS
2004 32
CNC RAPID PROTOTYPING
2004 33
INDUSTRIES MOST AFFECTED
by CNC
Aerospace
Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mold making
2004 34
SAMPLE PRODUCTS
OF
CNC MANUFACTURING
2004 35
AUTOMOTIVE INDUSTRY
Engine Block
2004 36
AUTOMOTIVE INDUSTRY(Contd)
Different Products
2004 37
AEROSPACE INDUSTRY
Aircraft Turbine Machined by
5-Axis CNC Milling Machine
2004 38
CNC MOLD MAKING
2004 39
ELECTRONIC INDUSTRY
2004 40
RAPID PROTOTYPING
PRODUCTS
2004 41
ADVANTAGES of CNC
Productivity
Machine utilisation is increased because
more time is spent cutting and less time is
taken by positioning.
Reduced setup time increases utilisation
too.
2004 42
ADVANTAGES of CNC
Quality
Parts are more accurate.
Parts are more repeatable.
Less waste due to scrap.
2004 43
ADVANTAGES of CNC
Reduced inventory
Reduced setup time permits smaller
economic batch quantities.
Lower lead time allows lower stock levels.
Lower stock levels reduce interest charges
and working capital requirements.
2004 44
ADVANTAGES of CNC
2004 45
ADVANTAGES of CNC
Management Control
CNC leads to CAD
Process planning
Production planning
2004 46
DRAWBACKS of CNC
High capital cost
Machine tools cost $30,000 - $1,500,000
Retraining and recruitment of staff
New support facilities
High maintenance requirements
Not cost-effective for low-level production on
simple parts
As geometric complexity or volume increases
CNC becomes more economical
Maintenance personnel must have both
mechanical and electronics expertise
2004 47
CNC SYSTEM ELEMENTS
2004 48
CNC SYSTEM ELEMENTS
A typical CNC system consists of the
following six elements
Part program
Program input device
Machine control unit
Drive system
Machine tool
Feedback system
2004 49
NC SYSTEM ELEMENTS
2004 50
OPERATIONAL FEATURES of CNC
MACHINES
2004 51
PART PROGRAM
A part program is a series of coded instructions required
to produce a part. It controls the movement of the
machine tool and the on/off control of auxiliary functions
such as spindle rotation and coolant. The coded
instructions are composed of letters, numbers and
symbols and are arranged in a format of functional
blocks as in the following example
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number
2004 52
PROGRAM INPUT DEVICE
2004 53
MACHINE CONTROL UNIT
The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:
2004 54
TYPES of CNC CONTROL
SYSTEMS
Open-loop control
Closed-loop control
2004 55
OPEN-LOOP CONTROL SYSTEM
In open-loop control system step motors are
used
Step motors are driven by electric pulses
Every pulse rotates the motor spindle through a
certain amount
By counting the pulses, the amount of motion
can be controlled
No feedback signal for error correction
Lower positioning accuracy
2004 56
CLOSED-LOOP CONTROL
SYSTEMS
In closed-loop control systems DC or AC
motors are used
Position transducers are used to generate
position feedback signals for error
correction
Better accuracy can be achieved
More expensive
Suitable for large size machine tools
2004 57
DRIVE SYSTEM
A drive system consists of amplifier
circuits, stepping motors or servomotors
and ball lead-screws. The MCU feeds
control signals (position and speed) of
each axis to the amplifier circuits. The
control signals are augmented to actuate
stepping motors which in turn rotate the
ball lead-screws to position the machine
table.
2004 58
STEPPING MOTORS
A stepping motor provides open-loop, digital
control of the position of a workpiece in a
numerical control machine. The drive unit
receives a direction input (cw or ccw) and pulse
inputs. For each pulse it receives, the drive unit
manipulates the motor voltage and current,
causing the motor shaft to rotate bya fixed angle
(one step). The lead screw converts the rotary
motion of the motor shaft into linear motion of
the workpiece .
2004 59
STEPPING MOTORS
2004 60
RECIRCULATING BALL SCREWS
Transform rotational motion of the motor
into translational motion of the nut attached to
the machine table.
2004 61
RECIRCULATING BALL SCREWS
Accuracy of CNC
machines depends on
their rigid
construction, care in
manufacturing, and
the use of ball screws
to almost eliminate
slop in the screws
used to move portions
of the machine.
2004 62
2004 63
POSITIONING
The positioning resolution of a ball screw drive
mechanism is directly proportional to the
smallest angle that the motor can turn.
The smallest angle is controlled by the motor
step size.
Microsteps can be used to decrease the motor
step size.
CNC machines typically have resolutions of
0.0025 mm or better.
2004 64
MACHINE TOOL
2004 67
POTENTIOMETERS
2004 68
POTENTIOMETERS
2004 69
ENCODERS
2004 70
ENCODERS
2004 71
INDUSTRIAL APPLICATIONS of
ENCODERS
2004 72
RESOLVERS
A resolver is a rotary
transformer that produces
an output signal that is a
function of the rotor
position.
2004 73
SERVOMOTOR with RESOLVER
2004 74
VELOCITY FEEDBACK
Tachometers:
Electrical output is proportional to rate of
angular rotation.
Encoders, Resolvers, Potentiometers:
Number of pulses per time is proportional
to rate change of position.
2004 75
CNC CUTTERS
2004 76
TURNING CENTER CUTTERS
2004 77
STANDART INSERT SHAPES
V used for profiling, weakest
insert, 2 edges per side.
D somewhat stronger, used for
profiling when the angle allows it,
2 edges per side.
T commonly used for turning
because it has 3 edges per side.
C popular insert because the
same holder can be used for
turning and facing. 2 edges per
side.
W newest shape. Can turn and
face like the C, but 3 edges per
side.
S Very strong, but mostly used
for chamfering because it wont
cut a square shoulder. 4 edges per
side.
R strongest insert but least
commonly used.
2004 78
TYPICAL TURNING,
THREADING and PARTING TOOLS
2004 79
MACHINING CENTER CUTTING
TOOLS
Most machining centers
use some form of HSS or
carbide insert endmill as
the basic cutting tool.
Insert endmills cut many
times faster than HSS,
but the
HSS endmills leave a
better finish when side
cutting.
2004 80
MACHINING CENTER CUTTING
TOOLS (contd)
Facemills flatten large
surfaces quickly and
with an excellent
finish. Notice the
engine block being
finished in one pass
with a large cutter.
2004 81
MACHINING CENTER CUTTING
TOOLS (contd)
Ball endmills (both
HSS and insert) are
used for a variety of
profiling operations
such as the mold
shown in the picture.
Slitting and side
cutters are used when
deep, narrow slots
must be cut.
2004 82
MACHINING CENTER CUTTING
TOOLS (contd)
Drills, Taps, and Reamers
Common HSS tools such as
drills, taps, and reamers are
commonly used on CNC
machining centers. Note that a
spot drill is used instead of a
centerdrill. Also, spiral point or
gun taps are used for through
holes and spiral flute for blind
holes. Rarely are hand taps
used on a machining center.
2004 83
TOOL HOLDERS
All cutting tools must be held in a holder
that fits in the spindle. These include end
mill holders (shown), collet holders, face
mill adapters, etc. Most machines in the
USA use a CAT taper which is a modified
NST 30, 40, or 50 taper that uses a pull
stud and a groove in the flange. The
machine pulls on the pull stud to hold the
holder in the spindle, and the groove in
the flange gives the automatic tool
changer something to hold onto. HSK tool
holders were designed a number of years
ago as an improvement to CAT tapers,
but they are gaining acceptance slowly.
2004 84
CNC PROGRAMMING
2004 85
CNC PROGRAMMING
Offline programming linked to CAD programs.
Conversational programming by the
operator.
MDI ~ Manual Data Input.
Manual Control using jog buttons or
`electronic handwheel'.
Word-Address Coding using standard G-codes
and M-codes.
2004 86
Basics of NC Part Programming:
2004 87
The position of the tool is described
by using a Cartesian coordinate
system. If (0,0,0) position can be
described by the operator, then it is
called floating zero.
2004 88
In defining the motion of the tool
from one point to another,
either
absolute positioning mode or
incremental positioning mode
can be used.
2004 89
1. Absolute positioning. In this mode, the
desired target position of the tool for a
particular move is given relative to the origin
point of the program.
2004 90
Structure of an NC Part Program:
Commands are input into the controller in
units called blocks or statements.
Block Format:
1. Fixed sequential format
2. Tab sequential format
3. Word address format
2004 91
EXAMPLE:
Assume that a drilling operation is to be
programmed as:
2004 92
1. Fixed sequential format
0050 00 +0025400 +0012500 +0000000 0000 00
0060 01 +0025400 +0012500 -0010000 0500 08
0070 00 +0025400 +0012500 +0000000 0000 09
2004 93
Modal commands: Commands issued in the
NC program that will stay in effect until it is
changed by some other command, like, feed
rate selection, coolant selection, etc.
2004 95
INFORMATION NEEDED by a CNC
1. Preparatory Information: units, incremental or absolute
positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. 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.
2004 96
BLOCK FORMAT
Sample Block
N135 G01 X1.0 Y1.0 Z0.125 F5
2004 98
G & M Codes
Example CNC Program
G-codes: Preparatory Functions
N5 G90 G20 involve actual tool moves.
N10 M06 T3
N15 M03 S1250 M-codes: Miscellaneous
N20 G00 X1 Y1 Functions involve actions
N25 Z0.1
N30 G01 Z-0.125 F5 necessary for machining (i.e.
N35 X3 Y2 F10 spindle on/off, coolant on/off).
N40 G00 Z1
N45 X0 Y0
N50 M05
N55 M30
2004 99
G Codes
G00 Rapid traverse
G01 Linear interpolation G40 Cutter compensation
cancel
G02 Circular interpolation,
CW G41 Cutter compensation
G03 Circular interpolation, left
CCW G42 Cutter compensation-
G04 Dwell right
G08 Acceleration G70 Inch format
G09 Deceleration G71 Metric format
G17 X-Y Plane G74 Full-circle programming
G18 Z-X Plane off
G19 Y-Z Plane G75 Full-circle programming
G20 Inch Units (G70) on
G21 Metric Units (G71) G80 Fixed-cycle cancel
G81-G89 Fixed cycles
G90 Absolute dimensions
2004 G91 Incremental dimensions 100
Modal G-Codes
2004 101
Modal G-Code List
G00 Rapid Transverse G43 Tool length compensation
G01 Linear Interpolation (plus)
G02 Circular Interpolation, CW G44 Tool length compensation
G03 Circular Interpolation, (minus)
CCW G49 Tool length compensation
G17 XY Plane cancel
G18 XZ Plane G80 Cancel canned cycles
G19 YZ Plane G81 Drilling cycle
G20/G70 Inch units G82 Counter boring cycle
G21/G71 Metric Units G83 Deep hole drilling cycle
G40 Cutter compensation G90 Absolute positioning
cancel G91 Incremental positioning
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation
(plus)
2004 102
M Codes
M00 Program stop
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps on
M11 Clamps off
M30 Program stop, reset to start
2004 103
N Codes
2004 104
X,Y, and Z Codes
2004 105
I,J, and K Codes
2004 106
F,S, and T Codes
2004 107
Application of Some Codes
G01 Linear Interpolation
Format: N_ G01 X_ Y_ Z_ F_
2004 109
Application of Some Codes
G01 Linear Interpolation
2 5
B C
2 0
1 5
1 0 P o s i t i o n i n g m o t i o n f r o m A t o C
N 1 0 G 0 0 X 3 0 0 0 0 Y 2 0 0 0 0 F 0
A
5
5 1 0 1 5 2 0 2 5 3 0
2004 110
Application of Some Codes
G01 Linear Interpolation
G01 is another preparatory function to specify
that the tool should be moved to a specified
location along a straight line path. It is referred
to as linear interpolation.
2004 111
Application of Some Codes
G01 Linear Interpolation
L i n e a r i n t e r p o l a t i o n f r o m A t o C
2 5 N 1 0 G 0 1 X 3 0 0 0 0 Y 2 0 0 0 0 F 2 5 0 0
C
2 0
1 5
1 0
A
5
5 1 0 1 5 2 0 2 5 3 0
2004 112
G01 Linear Interpolation
N10 G00 X1 Z1
X
N15 Z0.1
N20 G01 Z-0.125 F5
N25 X2 Z2 F10
Z
2004 113
G02 Circular Interpolation
G02 is also a preparatory function to specify that
the tool should be moved to a specified location
along a circular path in a clockwise direction. In
order to specify the path to the MCU, the end
point of the arc and the location of the center of
the arc should be specified. Within the block in
which the G02 code is programmed, the center
of the arc is given by specifying its location
relative to the start of the arc.
2004 114
G02 Circular Interpolation (CW)
2004 115
G02 Circular Interpolation (CW)
C i r c u l a r i n t e r p o l a t i o n f r o m A t o B
a b o u t a c i r c l e c e n t e r e d a t C
N 1 0 G 0 2 X 2 0 0 0 0 Y 1 0 0 0 0
2 5 I 5 0 0 0 J 1 5 0 0 0 F 2 5 0 0
I = 5 A C
2 0
1 5
J = 1 5
1 0 B
C
5
5 1 0 1 5 2 0 2 5 3 0
2004 116
Canned Cycles
The sequence of some machining operations is may be
the same for any part and for any machine. For example,
drilling a hole involves the following steps:
Position the tool above the point where the hole will be
drilled
2004 117
Some Commonly Used Canned Cycle
Code Function Down feed At bottom Retracti
on
G81 Drilling Continuous No action Rapid
feed
G82 Spot face, Continuous Dwell Rapid
counterbore feed
G83 Deep hole drilling Peck No action Rapid
G84 Tapping Continuous Reverse Feed
feed spindle rate
G85 Through boring(in Continuous No action Feed
& out) feed rate
G86 Through boring(in Continuous Stop Rapid
only) feed spindle
2004 118
G81 ILLUSTRATION
2004 119
Three Main parts of a CNC program
2004 121
Three Main parts of a CNC program
2004 122
EXAMPLE OPERATION on CNC
MILLING MACHINE
2004 123
G-CODE PROGRAM
First pass : conventional mill to
a depth of 0.125 around edge
profile. Tool 1 is a inch dia.
end mill.
%
:1002
N5 G90 G20
N10 M06 T1
N15 M03 S1200
N20 G00 X0.125 Y0.125
N30 Z0.125
N35 G01 Z-0.125 F5
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
2004 124
Second pass:
conventional mill to a
depth of 0.25 around
edge profile.
N35 Z-0.250
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
N60 Z0.125
2004 125
Third pass:
conventional mill to a
depth of 0.125
around pocket profile.
2004 126
Fourth pass: climb
mill to a depth of
0.125 across
remaining material.
N100 Y2.125
N105 X2.625
N110 Z0.125
N115 G00 X-5 Y-5 Z5
N120 M05
N125 M30
2004 127
Advanced features:
2004 128
Program Loading:
Through keyboard
Through punched tape reader
Through diskette drive
Through RS 232 serial port
Through network interface card
2004 129
Direct Numerical Control (DNC):
2004 130
Direct Numerical Control (DNC):
2004 131
Distributed Numerical Control (DNC):
2004 132
Distributed Numerical Control (DNC):
2004 133
Computer Aided Part Programming:
2004 134
Advantages of applying computer-aided part
programming include the following:
2004 136
CAD/CAM Based Part Programming: