UNIT – IV FUNDAMENTALS OF COMPUTER AIDED

MANUFACTURING(CAM)
Course Outcome(CO) – Maintain CNC machine to produce components effectively

CURRICULUM

• CAM concept, NC(Numerical Control),CNC (Computerized

Numerical Control) and DNC (Direct Numerical Control)-
concept, features and differences.
• CNC machines : Types, Classification, working and
constructional features, Advantages, limitations and
selection criteria.
• Elements of CNC machines – Types, sketch, working and
importance of : slide ways, Recirculating ball screw,
Feedback devices (transducers, encoders),Automatic tool
changer(ATC), Automatic pallet changer(APC)
 UNIT – IV FUNDAMENTALS OF COMPUTER AIDED
MANUFACTURING(CAM)
CURRICULUM

• CNC tooling : Tool presetting-concept and

importance, Qualified tools – definition need and
advantages. Tool holders – types and applications.
• CNC turning centers : Types, Features, Axes
nomenclature, specification, work holding device-
types, working and applications.
• CNC machining centers : Types, Features, Axes
nomenclature, specification, work holding device-
types, working and applications.
 DEFINITON OF COMPUTER AIDED
MANUFACTURING(CAM)
• CAM can be simply stated as any
manufacturing process that uses computer
software to facilitate, assist or automate parts
of the manufacturing processes.
• CAM can be defined as the use of computer
software applications to create instructions
that drive a machine tools for manufacturing
of parts.
 Limitations of Conventional Machines
 It requires skill operators to perform various
operations.
 The production time increases if the work piece is
complex and precision manufacturing.
 Operator may get fatigue and committed mistakes.
 Rate of production is low, not suitable for mass
production.
 Limited tools can be mounted on tool post
 Longer set up times for machine and tool
adjustments.
 NUMERICAL CONTROL
• Numerical control can be
defined as a form of
programmable
automation in which the
process is controlled by
numbers, letters and
symbols.
• Basic components of NC
Machines :
1. Programme of
instructions
2. Machine control unit
3. Machine tool
 NUMERICAL CONTROL
• Programme of instructions :
It is the detailed step by step set of instructions
in which machine tool has to perform the
operations.
The part programme is the set of instructions
which is fed through input media –
 Punched card
 Magnetic tapes and floppy disks
 Paper tape
 NUMERICAL CONTROL
• Machine Control Unit:
This consists of electronics and hardware that read
and interpret the programme of instructions and
convert into mechanical action of the machine tool.
Machine tool :
In a numerically controlled machine all the
movements of the tool and the machine table are
done automatically with the help of electric motor.
The machine tool consist of servo motors, tool
magazine, tool changer machine and coolant
ON/OFF control etc.
 COMPUTER NUMERICAL CONTROL (CNC)
• In CNC machines, a dedicated computer is
used to perform all the basic NC functions to
complete part programme to produce a
component is input and stored in the
computer memory.
• In simple words the machine tool which is
operated and controlled by using a dedicated
computers is known as computerized
numerical control machine.
 FEATURES OF CNC MACHINE
 The part programme can be input to the controller unit
through keyboard.
 The part programme once entered into the computer
memory can be used again and again.
 The part programme can be edited and optimized at the
machine tool itself.
 The CNC machines have facility to check the programme
without actual running it on the machine. The shape of
the component to be produced after machining is also
shown on the screen without actual machining taken
place. It is known as DRY RUN.
 CNC control unit allows tool length compensation for any
changes in the dimensions of the cutting tool.
 ADVANTAGES OF CNC MACHINE
 Reduced lead time : the time required before
actual production starts is called as lead time.
 Elimination of operator error
 Lower labour cost
 High accuracy
 Flexibility : The modifications or changes in
component design can be easily accommodated
by reprogramming.
 Reduced inspection
 Less scrap
 DISADVANTAGES OF CNC MACHINE
 High investment cost
 Higher maintenance cost
 Costlier CNC personnel
 The CNC machine operator needs basic training
and skills.
 Direct Numerical Control (DNC)
 DNC can be defined as a manufacturing system
in which a number of machines are controlled by
computer through direct connection and in real
time.
 CLASSIFICATION OF CNC MACHINES
 BASED ON CONTROL SYSTEM CHARACTERISTICS
1. Point to point position system
2. Straight line system
3. Contouring (continuous path system)
 BASED ON POSITIONING CO-ORDINATES
1. Absolute system
2. Incremental system
 BASED ON FEEDBACK OR TYPE OF CONTROL SYSTEM
1. Open loop system
2. Closed loop system
CLASSIFICATION OF CNC MACHINES
CLASSIFICATION OF CNC MACHINES
CLASSIFICATION OF CNC MACHINES
 OPEN LOOP CONTROL SYSTEM

• In open loop control system, there is no

feedback device.
• It is simple in design, less expensive and less
accurate as compared to closed loop control
system.
 OPEN LOOP CONTROL SYSTEM
• It consists of an input device which loads the program in the
machine.
• The program is decoded in the machine understandable format
and the required signals are send to the control unit (MCU).
• The MCU sends the series of electrical pulses to the drive unit
(stepper motor).
• This results in the motion of the slides through a desired
distance.
• The stepper motor is used to drive the worktable of machine.
Thus the stepper motor converts digital electrical signals into
proportional movement of the slide.
• However there is no provision to ensure that the slide has
actually moved through the desired distance only and that is
actually acquired the desired portion as a result of this
movement.
 CLOSED LOOP CONTROL SYSTEM

• In closed loop control system, there is

feedback device is used.
• It is complicated in design, expensive and
more accurate as compared to closed loop
control system.
 CLOSED LOOP CONTROL SYSTEM
• This system is similar to open loop control system.
But it consists of two additional device in the form
of feedback transducer and a comparator as shown
in fig.
• The transducer feedbacks the actual slide
displacement to the comparator. The comparator
compares the actually achieved slide movement
with the command signal. If there is any error then
it is feedback to the MCU.
• The MCU then sends the corrective commands to
the drive unit and the cycle repeats until there is
no error signal from the comparator.
 DIFFERENCE BETWEEN OPEN AND CLOSED LOOP CONTROL
SYSTEM
Sr. PARAMMETER OPEN LOOP CONTROL CLOSED LOOP CONTROL
No. SYSTEM SYSTEM

1. Definition When there is no feedback When feedback devices are

is present in the system it is present to detect error and
known as open loop control action is taken to remove it. It is
system. known as closed loop system.

2. Design It is simple in design. It is complex in design.

3. Feedback There is no feedback A feedback element present in
element. this system.

4. Input & output No comparison between Error is determined to between

input and output. input and output and removed.

5. Accuracy Less due to friction, wear High due to error correction

and vibration. system.

6. Cost It is less costly due to simple It is costly due to feedback

construction device used in the system.
 Absolute co-ordinate system
• In this system, all co-ordinates
of various points are calculated
with respect to fixed reference
point which is the origin (also
called as zero point)
• This system is known as fixed Co-ordinates

zero system. Hole X Y

No.
• The G code used for this system 1 10 10
is G90 2 30 20
3 50 30
• E.g. Drilling of holes in a given
part at 1,2,3.
 Incremental co-ordinate system
In this system, the co-ordinates of
any point is calculated with
reference to previous point
It means that the reference point
is not fixed but it moves from one
point to the next point, it is called
as floating zero system. Hole X Y
No.
The G code used for this system is 4 10 10
G91 5 20 10
E.g. Drilling of holes in a given 6 20 10

part at 4,5,6.
DIFFERENCE BETWEEN ABSOLUTE AND INCREMENTAL SYSTEM
Sr. PARAMMETER ABSOLUTE COORDINATE INCREMENTAL COORDINATE
No. SYSTEM SYSTEM
1 Reference The coordinates will be The coordinates of any point
measured with respect to will be calculated with reference
fixed origin to previous point
2 Origin It is always fixed and never It is always changed and
changed preceding point is taken as
reference
3 Changes of Minimum chances of error As reference changes every time
Error error may occur
4 G code G90 is used in program G91 is used in program
5 Example
 CONSTRUCTIONAL FEATURES OF CNC MACHINES
 Machine Structure
 Slideways
 Spindle mounting
 Drive units
 Elements of transmission and positioning slides
 Location of transducers
 Tool and work holding devices
 Swarf removal
 safety
 ELEMENTS OF CNC MACHINES
 Slideways – hydrostatic, antifriction type
 Re-circulating ball screw
 Feedback devices – transducers
 Automatic Tool Changer
 Tool magazine – drum and chain type
ELEMENTS OF CNC MACHINES
ELEMENTS OF CNC MACHINES
ELEMENTS OF CNC MACHINES
ELEMENTS OF CNC MACHINES
ELEMENTS OF CNC MACHINES
 ELEMENTS OF CNC MACHINES –SLIDEWAYS
 A slide is a moving element providing a straight line movement to a work
piece or tool holder a prescribed feed rate.
 Slideways are provided on the machine tools to withstand heavy loads
encountered during cutting action. Their purpose is also to maintain the
alignment of the guided parts at respective positions.
The Slideways may be integral with structure and thus made by casting

or joined separately the top face of the structure.

 It is usual to provide the slide ways either in vertical or inclined plane
so that falling chips not rest over it. It contains some form of adjustment
to eliminate lay between the two members on which wear takes place.
Usually semi-steel with nickel and chromium is a suitable Slideways
material capable of resisting wear and bending stresses
TYPES:-
1.Hydrostastic type slide ways
2.Anti-friction type of slide ways
ELEMENTS OF CNC MACHINES –SLIDEWAYS
 ELEMENTS OF CNC MACHINES –Hydrostatic Slide Ways
• Hydrostatic Type Slide Ways -The slide-ways of CNC machines are subjected to varying
cutting conditions and eventual varying forces on the sliding surface.
• It will lead to increase friction and wear along with loss accuracy.
• Hence, a constant film of some fluid prevents metallic contact between the sliding members
an thus reduces wear to a minimum.
• This film can be in the form of air or oil.
• Accordingly it can be called as oil lubricated or air lubricated Slideways.
• In case of air lubricated Slideways, compressed air is used instead of oil.
• Hydrostatic Type Slide Ways
• During the actual displacement of the slides, the table and saddle are raised on the cushion
of compressed air which entirely separates the slide and slide ways are only suitable for
positioning work such as drilling, because machining does not take surfaces.
• These bearings have a drawback that there may be misalignment due to lifting of slides.
ELEMENTS OF CNC MACHINES –Antifriction Slide Ways
 FEEDBACK DEVICES – INDUCTOSYN
• The inductosyn is a precision feedback
device for the accurate measurement and
control of angles or linear distances with
inductive coupling between conductors
separated by a small air gap.
• Accuracy of better than one second of arc
and linear accuracy of better than 0.5
microns is achieved.
• There are two forms in inductosyns.
• Rotary form is used in precision servo
systems on machine tools and other
equipment as a primary signal generator for
shaft digitizers.
• The linear form provides means for accurate
control of elements moving in translation
and widely used in automatic machine tool
controls. Figure shows rotary and linear
inductosyn.
FEEDBACK DEVICES – ENCODERS
ELEMENTS OF CNC MACHINES
ELEMENTS OF CNC MACHINES
ELEMENTS OF CNC MACHINES
 AUTOMATIC TOOL CHANGER (ATC)
• ATC are used on machines where number
of tools is used for machining operations.
• They allow tool changing without the
intervention of the operator.
• The tool is automatically selected and
changed by the T-word and use of
miscellaneous function (M06)
• An ATC grips the tool in the spindle, pulls
it out and replaces it with another tool.
• An ATC is provided to pick-up the
programmed tool from the tool magazine
and mount it on the spindle. The
removed tool is put back in the magazine
and the ATC picks-up the next tool.
• An ATC consists of a tool magazine for
storing the tools and a tool change unit
for transferring the tool from the tool
magazine to machine spindle.
 TOOL MAGAZINE
• The tool magazine is used
to store the tools required
during the machining
operations
• Storage capacity of tool
magazine starts with about
12 tools or even more.
• The tools in the tool
magazine are identified by
the tool number using the
same number as in the
part program.
 TYPES OF TOOL MAGAZINE
• Drum Type :- The tool are
arranged around a drum
which is generally circular in
shape. The drum rotates for
the purpose of tool change to
bring the required tool to the
tool change arm.
• The number of tools which the
drum can hold depends on it
diameter.
• This type is used for storing
lower number of tools.
 TYPES OF TOOL MAGAZINE
• Chain Type :- The chain type
magazine is used for storing
large number of tools with the
required flexibility.
• The tools are held in a sprocket.
• The pockets are attached to a
chain which moves on the
sprockets.
• The chain can be arranged to
follow any path, thereby
increasing the capacity of the
magazine
 METHODS OF TOOL SELECTION
The tool can be arranged in the tool magazine In two ways,
(1) Random tool selection
(2) Sequential tool selection
• Random tool Selection:-In this type the tools do not have to be loaded into the
magazine in the order in which they are called for in the program. The tools are
loaded in the tool magazine in their regular locations. When program calls for tool,
the controller knows where to find the tool. For example, In a program, the tools
are called in the following order 5-3-1-2-4-6. But the tools may be loaded in the
magazine in the order, such as 1-2-3-4-5-6 as shown in Fig.
In sequential tool selection:- the tools must be loaded in the exact order in which
they are called for In the program. Even if the wrong tool is loaded in the
sequence, the controller will select the tool automatically whether or not it is
suitable for the next machining operation. When a tool has to be used twice, then
another tool has to be loaded in the sequence as shown in fig.
 Automatic Pallet Changer
• A number of operations are performed
on a component machined in a
machining centre. So the setting time
and operating time of the components
machined in machining centre are
usually high.
• When a component and toolings are
set-up on a machining centre the
machine and operator are idle, resulting
in heavy loss.
• A solution to avoid this is to have a
second table on which the next work
piece can be set-up while one
component on table is being machined.
The worktables are called pallets.
• The automatic pallet changer system on
the machine reduces such unproductive
time during machining. The palletizing
system consists of two or more pallets.
 Types of Pallet Changer
• Manual pallet systems: The operator has to physically load and
unload the pallet, with the raw / finished part, to from a machining
station located and mounted on top of the machine table. Of the
three options, this is the most laborious and least automated
version.
• Automated pallet systems: These are normally built-into the
machine and operated automatically by the machine it self The
human intervention comes from the loading and unloading of parts
at the pallet station .
• Robotic pallet systems: These usually utilize a robot to load and
unload pallets.
• The robot is often able to serve one to multiple machines. However,
these are fairly costly and are often sought in locations with high
labour costs or insufficient skilled manpower. Difficulties for such
systems may arise whenever customized and very specific
manufacturing needs are required.
 Types of Pallet Changer
• Shuttle type pallet changers:- A pallet with parts
after completion that would leave the inside of a
machine on rails. A second pallet is then pushed
into the machine. This system is considered more
traditional and may take a longer time for pallet
exchange to be made.
• Swing type pallet changers:-The pallet with the
finished part is lifted up together with the pallet
with the raw (unfinished) part. It is then rotated
180 degrees and placed onto the CNC Index or
rotary table. At the same time, the first pallet is
placed on the loading and unloading stations.
 TOOL PRESETTING
• Most of the CNC machines have no built-in
tool measurement mechanism, so to
measure CNC machine tools external tool
measuring devices are used.
• These tool measuring devices are called
Tool Presetters or Tool Presetting Devices.
• A CNC tool presetter is a highly accurate
device which is used to measure the CNC
machine tools.
• As the machining is carried out by the tool
tip, it is important to know the exact
dimensions of the tool when it is placed in
the spindle.
• It is therefore becomes necessary to know
precisely the deviation of the tool tip from
the gauge point on the spindle. Hence tool
setting equipment is generally used.
 TOOL PRESETTING
• A simple mechanical type tool setting device as shown
in fig.
• In this system, the base is provided with the exact
taper as used in the actual machine tool. The
assembled tool is therefore placed in the spindle taper.
• The measurement is done with the help of a
micrometer head, which is attached to a U-clamp.
• The U-clamp can be moved manually on a post, which
has precise location slots that are separated by an
exact distance(for example, 25 mm) . The length of the
tool can therefore be measured by the measurement
of the micrometer plus the slots along the post.
 QUALIFIED TOOL

• Tool which fits into a location on the machine, where its cutting edge is
accurately positioned within close limits relative to a specific datum on the tool
holder or slide is known as qualified tool.
• In qualified tool the cutting tool or edge is maintained at a fixed distance within
a tolerance of + 0.05 with respect to the reference surface of the holder.
• Qualified tools are the tools on which the position of the cutting edge is
guaranteed within close limits of accuracy from a specific datum on the tool
holder.
• The qualified dimensions are applied to the tool tip from the three datum.
Usually the datum are formed by the tool holder. Since dimensions of the tool
holder are fixed and known, precise position of tool tip is known and accurate
positioning on the machine tool is possible.
 Advantages of Qualified Tool
 No presetting device is used so the investment
is less
 The tools need not be measured individually
 Set-up time is reduced as detailed planning as
in tool presetting is not needed.
 There is no need of trial cuts before taking
rough cuts
 Programming is easy with respect to qualified
tool.
 Types of Tool Holder
 A tool holder is a machining component that holds the
cutting tool in place.
 Its purpose is to hold the tool in place as precisely and
firmly as possible, so that any cutting force or vibrations
will not run out or break the cutting tool.
 It is essential that the insert be supported in a strong,
rigid manner to minimize deflection and possible
vibration.
Types of Tool Holder
 Machining Center
 A machining center is a computer-controlled
machine tool with automatic tool changing
capability.
 The machining center is designed to perform a
variety of cutting operations on different
surfaces of the work piece.
 Any machining center is capable of carrying out
milling, drilling, reaming, tapping, boring, facing
and other operations without operator
intervention for change of tools.
 NEED OF Machining Center
 To reduce the non-productive time and thereby
reduce the lead time
 To increase the productivity
 To reduce the work in process
 To obtain a versatile machine capable of
performing different operations.
 To reduce the number of skilled operator.
 TYPES OF Machining Center
1) Horizontal Machining
Center (HMC)
2) Vertical Machining Center
(VMC)
 Horizontal Machining
Center (HMC)
These machines generally have
a single spindle aligned
horizontally
This is the redesign of CNC
milling machine with ability to
perform variety of operations
They are suitable for large
work piece requiring
machining on all the surfaces.
This requires number of tools
making the tool magazine
heavier
 TYPES OF Machining Center
 Vertical Machining Center
(HMC)
As the name suggests these
machines have a vertical
spindle mounted in the
vertical machining head.
The vertical head can also be
swiveled either in one or two
axes (about X or Y axis)
They are suitable for
machining vertical surfaces of
long work pieces with deep
cavities such as mould and
die making.
AXIS OF CNC MACHINES
CO-ORDINATE SYSTEM USED IN CNC MACHINES
CO-ORDINATE SYSTEM USED IN CNC MACHINES
CO-ORDINATE SYSTEM USED IN CNC MACHINES
CO-ORDINATE SYSTEM USED IN CNC MACHINES
NC WORDS
NC WORDS
G-CODES
G-CODES
M-CODES
M-CODES
PROGRAMMING FORMATS
PROGRAMMING FORMATS
PROGRAMMING FORMATS
PROGRAMMING FORMATS
Program