Unit 3
Unit 3
CAD/CAM
using various methods available
UNIT – III
Lecture Plan
CO3: Develop a programming for NC operations
MODULE
TOPIC
NO
INTRODUCTION
Introduction to NC/CNC (NC, NC modes, NC elements,
1
CNC machine tools, Coordinate Systems)
Structure of CNC machine tools (Classification, MCU and
using various methods available
2
its organization, CNC Control systems and its functions)
Structure of CNC machine tools (Tape Reading, Tooling,
3
Feedback components – Resolvers and Encoders)
Features of CNC Machines (Machining and Turning
4
centers)
Part Programming – Methods and Computer Aided Part
5
Programming, APT Language - 1
6 APT Language - 2
7 APT Language - 3
8 APT Language - 4
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 2
Topic : Numerical Control Introduction Course : CAD/CAM
Why Automation?
CO3: Develop a programming for NC operations
labour
Of the entire spectrum on 15 – 20 % require mass production. Rest
all is being done either in job-shop or batch production. This is
because
• High variety of products required
• Discontinuous demand for the product
• Batch sizes required are either small or medium
• Human intervention is another factor leading to inconsistency
and unpredictable delays in schedules
• Changes in parts may result in high setup costs
Basic Definition
CO3: Develop a programming for NC operations
• Fixed Automation: This is also called as Hard Automation. Here once the
sequences are defined, a lot of setup costs are required so as to change the
sequence.
using various methods available
• Both NC and CNC (computerized NC) are used to describe this category.
• The term was coined in the 1950s when the instructions to the tool were
numeric codes. Just like the computer industry, symbolic languages were
soon developed, but the original term remained.
Disadvantages of NC machines:
• High setup costs
• Special skills in programming and maintenance required.
• Downtime of NC machine is costly.
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 6
Topic : Numerical Control Introduction Course : CAD/CAM
Coordinate Systems
CO3: Develop a programming for NC operations
using various methods available
SUMMARY
CO3: Develop a programming for NC operations
CNC Classification
CO3: Develop a programming for NC operations
Machining
Mechanism
Open loop
operation
Based on
Based on
feedback
center
types
NC Machines
Turning center Closed loop
Program input
(from a tape MCU
reader)
using various methods available
NC Machine
Servo
Drives
controls
M/C tool
feed
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 13
Topic : NC/CNC system architecture Course : CAD/CAM
Mini
Hardwire
computer
d
and
modules
storage
NC
Machin
actuatio
e tool
using various methods available
n areas
INTERFACE
Control
panel
Management Information like the running
CRT
Manual Information job, tool status, machine
display
data input System status etc.
Tape Tape
reader punch
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 14
Topic : NC/CNC system architecture Course : CAD/CAM
✔ Program storage
✔ Program modification/editing
✔ Pattern program storage
✔ Expanded tool offsets
using various methods available
✔ Control flexibility
✔ Sending control signals for interpolation
✔ Digitizing
✔ Management Information
✔ Maintenance
Tape Readers
CO3: Develop a programming for NC operations
• Paper tape is common. Although its cost is low, it is not durable and
therefore not appropriate for repeated use.
• Paper is often used for the initial preparation and testing of the part
program.
Punched Tape
CO3: Develop a programming for NC operations
Tape Reading
CO3: Develop a programming for NC operations
Method 1
• The tape passes over a light source
• The light pulses produced due to presence of
punches will be detected by photodiodes
• These pulses are then decoded
using various methods available
http://www.decodesystems.com/ce-punched-readers.html
Preset Tooling
CO3: Develop a programming for NC operations
• The tools whose offsets are specified using presetting are called as preset tools
using various methods available
Qualified Tooling
CO3: Develop a programming for NC operations
Tool which fits into a location on the machine, where its cutting edge is accurately
positioned within close limits relative to a specified datum on the tool holder or
slide, is known as qualified tool. The cutting tools satisfy the following
requirements :
• Tools need not be measured individually.
• No pre-setting device is used.
using various methods available
• The dimensions of the tool holder which are fixed and known.
• Set up time is reduced.
• Control dimensions of the tool are nominal and fixed.
• Higher control on resharpening e.g. drills, reamers.
• Cutter for better size control e.g. end mills, teamers.
• Chip breaking facilities incorporated in tool.
• Improved designs
Feedback Components
CO3: Develop a programming for NC operations
Linear transducers
Transducers
Rotary transducers
using various methods available
Resolvers Encoders
Resolvers
CO3: Develop a programming for NC operations
multiplied by the sine or cosine of the input shaft’s angle from a zero
point.
• The ratio of the voltages represents the absolute position of the input
shaft, and a resolver to digital converter (RDC) compares the two
voltages to determine the shaft position.
Encoders
CO3: Develop a programming for NC operations
Linear Encoder
using various methods available
Encoders
Rotary Encoder
Incremental Absolute
Rotary Encoder
CO3: Develop a programming for NC operations
Rotary Encoders
CO3: Develop a programming for NC operations
using various methods available
Linear Encoder
CO3: Develop a programming for NC operations
Incremental
Linear Encoders
Absolute
using various methods available
A machining center is the most capable and versatile NC metal cutting tool which can
perform milling, drilling, boring, reaming and tapping operations.
FEATURES:
• General design features
using various methods available
• Rugged Construction
• Guideways and Lubrication
• Recirculating ball bearings
• Ease of access
using various methods available
YAMA fmv99
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 30
Topic : Features of CNC Course : CAD/CAM
Pallet changers
CO3: Develop a programming for NC operations
using various methods available
Multi-Axis Machine
CO3: Develop a programming for NC operations
using various methods available
Index G220
using various methods available
FEATURES:
• Bed construction
• Drive
• Bar feeds
• Parting – off slide
• Work auto-gauge system and auto tool offsets
SLIDE No: 36
DEPARTMENT OF MECHANICAL ENGINEERING
Topic : Features of CNC Course : CAD/CAM
Bed Construction
CO3: Develop a programming for NC operations
• Tool information
• Speed and feed of operation
• Miscellaneous information like on/off of spindle, CCW/CW rotation
direction, coolant on/off
Miscellaneous function
The information given by a word which is prefixed by the letter M followed by
the numerical code for the operation for which the control unit is to instruct the
machine tool. Operations like spindle start/stop, spindle CW/CCW, coolant
ON/OFF etc. are given by miscellaneous functions. These are also called as
Auxiliary functions and prefixed by M.
Tool information (Tool location and offset information is given by data prefixed
by T)
Speed & Feed data (Speed is given by data prefixed by S and feed is given by data
prefixed by F)
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 41
Course : CAD/CAM
Interpolation
CO3: Develop a programming for NC operations
Linear Interpolation
CO3: Develop a programming for NC operations
will be:
N24 G01 X30000 Y30000 F100 …
Circular Interpolation
CO3: Develop a programming for NC operations
Canned Cycles
CO3: Develop a programming for NC operations
Example 1
CO3: Develop a programming for NC operations
Operation sheet
S.No Operation Tool Speed Feed
(rpm) (mm/min)
1. End milling edges T01 1500 100
using various methods available
(20,30)
N012 Z2000;
N013 G00 X-50000 Y-2500 Z50000 M05;
N014 T02 M06;
N015 G00 X20000 Y30000 S600 M03;
N016 G81 Z-18000 R2000 F60;
(-50,-2.5) (-2.5,-2.5) (72.5,- N017 G80;
2.5)
N018 G00 X-50000 Y-2500 Z50000 M05;
Note: If a preparatory function is specified, N014 T03 M06;
the same preparatory function is carried N015 G00 X50000 Y40000 S600 M03;
on for the next block until another N016 G81 Z-18000 R2000 F60;
preparatory function is called
N017 G80 G00 X-50000 Y-2500 Z50000 M05;
N018 M30;
Tool Offsets
CO3: Develop a programming for NC operations
offset
APT PROGRAMMING
using various methods available
L2
C1
C2
L1
• Need
• Computer aided part programming system
• APT like languages
• APT language
using various methods available
Need
CO3: Develop a programming for NC operations
accuracy.
• Input language & Error Checking
• Writing a complicated program in G & M codes is a difficult
task
• To check the program syntactically, it will be a difficult task
for the codes are not simple English to understand.
• Part programming time
• Manually writing the part program takes a lot of time
COMPUTER SYSTEM
Part program
Translator
input
PROCESSOR
Arithmetic element
using various methods available
INTERFACE
the first NC machine tool in 1952. (CL Data)
Machine tool
specific
IFAPT
ADAPT GNC
ELAN
Special systems GTL
VNC
NUFORM
GENESIS
COMPACT II
TOOLPATH
TAPE-PREP
QUICK-PATH
GETURN
= - assignment
() – for enclosing nested definitions
$ - For indicating line break
$$ -comment
• Key words
The words having reserved meanings.
Eg: LINE, CIRCLE, IN, OUT, TANTO, XLARGE, XSMALL, YLARGE, YSMALL, INTOF, PARLEL,
PERPTO
• Symbols
The word to which the variable defined is assigned.
Should start with a letter
Eg: c1 = CIRCLE/10,10,10
• Labels
• Numbers
• Angles (Should be specified in decimals only)
• Arithmetic
using various methods available
+ - / * ** - Operators
ABS, SQRT, SIN, COS, TAN, ATAN, ACOS, LOG, EXP - Functions
APT Commands
CO3: Develop a programming for NC operations
APT PROGRAMMING
using various methods available
Geometry
L2
C1
C2
L1
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 59
Topic : APT Language Course : CAD/CAM
• Point
• Line
• Circle
• Plane
using various methods available
• Pattern
• Vector
• Matrix
• General Format
<Symbol> = Geometry Type/ Definitional Modifiers
Point Definitions
Point (POINT)
CO3: Develop a programming for NC operations
<symbol>=POINT/<x, y, z>
PTA = POINT/ 3,4,5
using various methods available
Point (POINT)
CO3: Develop a programming for NC operations
LIN2
PTB
LIN1
Point (POINT)
CO3: Develop a programming for NC operations
PTC
using various methods available
Point (POINT)
CO3: Develop a programming for NC operations
C1
using various methods available
PTE
PTE = POINT/ YLARGE, INTOF, C1, C2
Point (POINT)
CO3: Develop a programming for NC operations
Y
C6
PT7 = POINT/ CENTER, C6
PT7
X
using various methods available
Line (LINE)
CO3: Develop a programming for NC operations
L10=LINE/PT1,PT2
P2 (or)
L10 = LINE/ 20, 3.5, 0.2, 31, 6.2, 1.3
(or)
L10= LINE/ PT1, 31, 6.2, 1.3
P1
Line (LINE)
CO3: Develop a programming for NC operations
LINE2
P1
L14
L12 = LINE/ PT4, ATANGL, 20, XAXIS PT3
40° L12
L14 = LINE/ PT1, ATANGL, 40 PT1
L16
L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS
PT4
L16 = LINE/ PT3, ATANGL, 40, YAXIS
LINE2 = LINE/ P1, ATANGL, 30, LINE1
40° 20°
X
15°
L15
(32, -3, 2)
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 68
Topic : APT Language Course : CAD/CAM
Line (LINE)
CO3: Develop a programming for NC operations
where the slope value is y/x and d is the corresponding intercept value on the
selected axis (i.e., modifier).
using various methods available
LINE1
X
(6,0) Point of X-Intercept
Line (LINE)
CO3: Develop a programming for NC operations
•
using various methods available
LINE1
Line (LINE)
CO3: Develop a programming for NC operations
Line (LINE)
CO3: Develop a programming for NC operations
using various methods available
Line (LINE)
CO3: Develop a programming for NC operations
using various methods available
Line (LINE)
CO3: Develop a programming for NC operations
Circle (CIRCLE)
CO3: Develop a programming for NC operations
<symbol>=CIRCLE/<x>,<y>,<z>,<r>
<symbol>=CIRCLE/CENTER, <point>, RADIUS, <radius>
<symbol>=CIRCLE/CENTER, <point1>, <point2>
using various methods available
C1 = CIRCLE/ 3, 6, 5, 4.3
C1 = CIRCLE/ CENTER, PT3, RADIUS, 4.3
C7=CIRCLE/CENTER, PT8, PT5
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 75
Topic : APT Language Course : CAD/CAM
Circle (CIRCLE)
CO3: Develop a programming for NC operations
Circle (CIRCLE)
CO3: Develop a programming for NC operations
using various methods available
CIRCLE
CO3: Develop a programming for NC operations
using various methods available
CIRCLE
CO3: Develop a programming for NC operations
using various methods available
Plane (PLANE)
CO3: Develop a programming for NC operations
•
using various methods available
PATTERN
CO3: Develop a programming for NC operations
•
For pattern angle of 360ꞏ
using various methods available
Example 1
CO3: Develop a programming for NC operations
PARTNO/ EXAMPLE 1
P2 = POINT/ 0, 0
L1 = LINE/ 20, 20, 20, (20 + 80)
L2 = LINE/ (POINT/ 20, (20 + 80)), ATANGL, 45
P1 = POINT/ (20 + 30 + 40 + 20), 20
C2 = CIRCLE/ CENTER, P1, RADIUS, 20
using various methods available
Example 2
CO3: Develop a programming for NC operations
using various methods available
PARTNO/ EXAMPLE 2
L4 = LINE / XAXIS
C1 = CIRCLE/ 24, 20, 12.5
L1 = LINE/ (POINT/ 0,0), ATANGL, 15
L2 = LINE/ PARLEL, L4, YLARGE, 32
L7 = LINE/ YAXIS
L5 = LINE/ PARLEL, L7, XLARGE, (24 – 12.5)
L6 = LINE/ PARLEL, L5, XLARGE, (12.5 + 12.5)
L3 = LINE/ PARLEL, L7, XLARGE, 100
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 83
CO3: Develop a programming for NC operations Course : CAD/CAM
L
2
C
APT
C
1 2
using various methods available
L
1
PROGRAMMING
Motion Commands
Motion Commands
CO3: Develop a programming for NC operations
Start Point
In general, the position of the tool at the end of a motion is treated as the starting point
for the subsequent motion.
But to set the start point of tool path for a new program will be specified by using the
command FROM.
The format is
using various methods available
FROM/ point
FROM/ x1, y1
FROM/ x1, y1, z1
When no Z value is specified, it is derived from the current ZSURF in force.
Cutter
Cutter specification is given by using this command
CUTTER/ dia
CUTTER/ dia, radius
CUTTER/ dia, radius, e, f, …, h
SURFACES
CO3: Develop a programming for NC operations
Tolerances
CO3: Develop a programming for NC operations
GODLTA/ vector
GOTO/ pattern
Pattern modifiers such as INVERS, OMIT, RETAIN, AVOID, THRU and CONST can be used
with this command.
INVERS reverses the order in which the tool visits the locations
OMIT tool will not visit the specified points
RETAIN tool will visit only the specified points
Example
GOTO/ patern, INVERS, OMIT, 9, THRU, 4
Where patern is the defines the pattern of holes shown
Below are the action verbs that are used to specify the motion
• GOLFT/ ds, TO, cs Contour motion command to go left
• GORGT/ ds, TO, cs Contour motion command to go right
• GOFWD/ ds, TO, cs Contour motion command to go
forward
• GOBACK/ ds, TO, cs Contour motion command to go back
• GOUP/ ds, TO, cs Contour motion command to go up
using various methods available
FROM/ SETPT
GO/ L1, PS, L4
GOLFT/ L1, PAST, L2
GORGT/ L2, PAST, L3
GORGT/ L3, PAST, L4
GORGT/ L4, PAST, L1
GOTO/SETPT
Example 1
PARTNO/ EXAMPLE 1
P2 = POINT/ 0, 0
CO3: Develop a programming for NC operations
CUTTER/ 20
TOLER/ 0.01
GO/L1, (PL1 = PLANE/ 0, 0, 1, 3), L5
AUTOPS
GODLTA/ -8
GOLFT/ L1, PAST, L2
GORGT/ L2, PAST, L3
GORGT/ L3, TANTO, C1
GOFWD/ C1, TANTO, L4
GOFWD/ L4, PAST, 1, INTOF, C2
GORGT/ C2, PAST, L5
GORGT/ L5, PAST, L1
GODLTA/ 8
GOTO/ 0, 0, 50
INTOL/ 0.01
GO/L4, (PL1 = PLANE/ 0, 0, 1, 2), L1
AUTOPS
GODLTA/ -7.5
GORGT/ L4, PAST, L3
GOLFT/ L3
GOLFT/ L2
GOLFT/ L8
GORGT/ L1
GORGT/ L6, TANTO, C1
GOFWD/ C1, TANTO, L5
GOFWD/ L5
GORGT/ L1, PAST, L7
GODLTA/ 7.5
GOTO/ -50, -50, 50
DEPARTMENT OF MECHANICAL ENGINEERING SLIDE No: 95
Topic : APT Language Course : CAD/CAM