SlideShare a Scribd company logo
1 of 47
ME8691
COMPUTER AIDED DESIGN & MANUFACTURING
UNIT 4 – FUNDAMENTALS OF CNC
AND PART PROGRAMING
S.BALAMURUGAN
ASSISTANT PROFESSOR
MECHANICAL ENGINEERING
AAA COLLEGE OF ENGINEEERING & TECHNOLOGY
HISTORY & DEVELOPMENT OF TECHNOLOGY
CONVENTIONAL MACHINE
NC MACHINE
(1948 US Air force, MIT 21
Months)
(http://museum.mit.edu/150/86)
1952 - Cincinnati Milacron
Hydrotel Machine
1959: The MIT team showcase
the CNC-milled aluminum
ashtray is handed out as part
of the press kit.
CNC MACHINE
• During the Cold War time, the
development of automation was
addressed.
• At that time, the company Parsons Works
was commissioned by the U.S. Navy to
increase the productivity of its production
line for helicopter blades.
• John T. Parsons then motorized the axes
of the machines for making these blades.
• Working with IBM, he studied the
possibilities of controlling these machines
by computer. This was the starting point
of the CNC machining method.
• In 1952, Richard Kegg, in collaboration
with MIT, developed the first CNC milling
machine: the Cincinnati Milacron
Hydrotel.
• Five years later, in 1958, he filed a patent
for a “Motor Controlled Apparatus for
Positioning Machine Tool”. This was the
commercial birth of this technology.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
NC – NUMERICAL CONTROL MACHINE
• Numerical control is a programmable
automation in which actions are
controlled by means of coded
numbers, letters & other symbols.
• The numerical data is required for
producing a part is maintained on
Punched Tape.
• The data is arranged in the form of
blocks of information.
• The block contains Cutting speed,
Feed, Dimensional information &
Contour form
ELEMENTS OF NC SYSTEM
1. Machine Control Unit
2. Machine Tool
3. Part Program & Drawings
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
ELEMENTS OF NC SYSTEM
MACHINE CONTROL UNIT(MCU) - Data Processing Unit (DPU)
• It consists of Tape Reader, Decoding Circuits, Feed Control Units.
• Tape reader receives the coded data from punched tape.
• The tape reader reads the data & passes data to the Buffer storage through
decoding circuits.
• The buffer storage stores the received information, till it is required & transfers it to
the required area.
• All the operations like Tool movement, Tool change, Speed & Feed Change
can be controlled by MCU.
MACHINE TOOL & NC TOOLING
• It is the manufacturing arm of NC machine
tool system.
• It receives the raw material & perform
different operations like Turning, Milling,
Drilling, Grinding etc.
• Receive the information from MCU. Based
on the information, the desired shape & size
is modified.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
PUNCH CARDS - HOLLERITH CARDS OR IBM CARDS
• Punched Tape – Data is fed by automatic means. – Eliminate the operator errors.
• Punched tape uses a binary coded decimal system for containing operating
information of NC tool.
• Instructions Holes in Binary format Decoded in MCU Electric Pulse
• Electric pulses fed to the servo systems & mechanisms.
• These are paper cards in which holes may be punched by hand or machine to
represent computer data and instructions.
• The cards were fed into a card reader connected to a computer, which converted
the sequence of holes to digital information.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CNC - COMPUTER NUMERICAL CONTROL
• CNC is the numerical control system in which a
dedicated computer is built into the control to
perform basic and advanced NC functions.
• CNC controls are implemented by software
programs.
• CNC is a computer assisted process to control
general purpose machines from instructions
generated by a processor and stored in a
memory system.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
NC MACHINE – DIRECT NUMERICAL CONTROL (DNC)
• In this type, a mainframe computer is used to coordinate the simultaneous
operations of a number NC machines.
• The tasks performed by the computer are to program and edit part
programs as well as download part programs to NC machines.
• Machine tool controllers have limited memory and a part program may
contain few thousands of blocks. So the program is stored in a separate
computer and sent directly to the machine, one block at a time.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
• 1960s technology
• Two way communication.
DISTRIBUTED NUMERICAL CONTROL
• Network consisting of central
computer connected to machine
tool MCUs, which are CNC.
• Present technology
• Two way communication
NC MACHINE – DISTRIBUTED NUMERICAL CONTROL (DNC)
CLASSIFICATION OF CNC – MOTION TYPE
POINT – POINT SYSTEM
• It is used in some CNC machines such as
drilling, boring and tapping machines…etc.
• The control equipment for use with them are
known as point-to-point control equipment.
• Feed rates need not to be programmed.
• In theses machine tools, each axis is driven
separately
CONTINUOUS PATH SYSTEMS
• It is used in CNC machine tools such as milling
machines.
• These machines require simultaneous control
of axes.
• Feed rates need to be programmed.
• Contouring machines can also be used as point
to-point machines, but it will be uneconomical
to use them unless the work piece also requires
having a contouring operation to be performed
on it.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CNC MACHINE AXIS & DIRECTION
MILLING MACHINE TURNING MACHINE
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
FIXED ZERO v/s FLOATING ZERO
FIXED ZERO
• Origin is always located at some position on
M/C table (usually at south west corner/Lower
left-hand) of the tables & all tool location are
defined with respect to this zero.
FLOATING ZERO
• Very common with CNC M/C used now a days.
• Operator sets zero point at any convenient
position on M/C table.
• The Coordinate system is knows as work
coordinate system (WCS)
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CNC – COMPUTERISED NUMERICAL CONTROL
• CNC – Computer + Numerical Control
• Numerical control is a programmable automation in which process is
controlled by Numbers, Letters & Symbols.
• CNC machining is a process used in the manufacturing sector that
involves the use of computers to control machine tools like lathes, Mills &
Grinders.
NEED OF CNC MACHINING
• To manufacture complex curved
geometries in 2D or 3D was extremely
expensive by mechanical means (which
usually would require complex jigs to
control the cutter motions)
• Machining components with high
Repeatability and Precision
• Unmanned machining operations
• To improve production planning and to
increase productivity
• To survive in global market CNC machines
are must to achieve close tolerances.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CNC – COMPUTERISED NUMERICAL CONTROL
INPUT DEVICES
• These are the devices which are used to input the part program in the CNC
machine.
• Commonly used input devices - Punch Tape Reader, Magnetic Tape Reader &
Computer via RS-232-C communication.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CNC MACHINE COMPONENTS
MACHINE CONTROL UNIT (MCU)
It is the heart of the CNC machine. It performs all
the controlling action of the CNC machine, the
various functions performed by the MCU are
• It reads the coded instructions fed into it.
• It decodes the coded instruction.
• It implements interpolation ( linear, circular and
helical ) to generate axis motion commands.
• It feeds the axis motion commands to the
amplifier circuits for driving the axis mechanisms.
• It receives the feedback signals of position and
speed for each drive axis.
• It implements the auxiliary control functions such
as coolant or spindle on/off and tool change.
MACHINE TOOL
• A CNC machine tool always has a slide table and
a spindle to control of the position and speed.
• The machine table is controlled in X and Y axis
direction and the spindle is controlled in the Z
axis direction.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
DRIVING SYSTEM
• The driving system of a CNC machine
consists of amplifier circuits, drive motors
and ball lead screw.
• The MCU feeds the signals (i.e. of
position and speed) of each axis to the
amplifier circuits.
• The control signals are augmented
(increased) to actuate the drive motors &
the actuated drive motors rotate the ball
lead screw to position the machine table.
STEPPER MOTOR SERVO MOTOR
• It is a pulse-driven motor that changes
the angular position of the rotor in
steps.
• Open loop position control systems.
• When switching on an inkjet printer;
the controller will move the ink jet
carrier to the extreme left and right to
establish the end positions. It activates
an end limit switch.
• A servomotor is a rotary actuator or
linear actuator that allows for precise
control of angular or linear position,
velocity and acceleration
• Closed-loop control system.
• A servomotor will immediately turn to
whatever angle the controller instructs it
to, regardless of the initial position at
power up.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
TYPES OF STEPPER MOTOR
PERMANENT MAGNET VARIABLE RELUCTANCE
• Rotor is a permanent magnet.
• PM motor rotor has no teeth and is designed
to be magnetized at a right angle to its axis.
• Figure shows a simple, 90⁰ PM motor with four
phases (A-D).
• Applying current to each phase in sequence
will cause the rotor to rotate by adjusting to the
changing magnetic fields.
• Low speed, relatively high torque
• Low cost motors with typical step angle
ranging between 7.5⁰ to 15⁰
• The cylindrical rotor is made of soft steel and has
four poles
• If 4 rotor teeth, 90⁰ apart and 6 stator poles, 60⁰
apart.
• Electromagnetic field is produced by activating
the stator coils in sequence.
• It attracts the metal rotor. When the windings are
energized in a re occurring sequence of 2, 3, 1,
and so on, the motor will rotate in a 30⁰ step
angle.
• In the non-energized condition, there is no
magnetic flux in the air gap, as the stator is an
electromagnet and the rotor is a piece of soft
iron.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
SERVO MOTOR
• Servomotors are special electromechanical devices that produce precise
degrees of rotation.
• The servomotors are used in a closed-loop servo system as shown in Figure
A reference input is sent to the servo amplifier, which controls the speed of
the servomotor.
• A feedback device is mounted on the machine, which is an encoder.
• This device changes mechanical motion into electrical signals and is used as
a feedback.
• This feedback is sent to the error detector , which compares the actual
operation with that of the reference input.
• If there is an error, that error is fed directly to the amplifier, which will be used
to make necessary corrections in control action.
• DC servo motor
• AC servo motor
• Brushless DC motor.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
OPEN LOOP SYSTEM CLOSED LOOP SYSTEM
• It is a system that involves feeding of
tape, interpretation of information by
Tape reader, Storing the data in buffer
storage, converting it into electrical
signal and sending this signal to the
control unit.
• It is a system that carries an additional
feedback device along with a
transducer, accompanied by a
comparator.
• It is a simpler & Cheaper system • It is more complicated & costly than the
open loop system
• Feedback device is absent • Feedback device is present
• With no feedback device, chance of
error is always present
• As the comparator compares the
obtained slide motion, chance of error
greatly reduced.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
OPEN LOOP VS CLOSED LOOP SYSTEM
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
FEEDBACK SYSTEM
• This system consists of transducers that act as sensors.
• It contains position and speed transducers that continuously monitor the
position and speed of the cutting tool located at any instant.
• The MCU receives the signals from these transducers.
• MCU uses the difference between the reference signals and feedback
signals to generate the control signals for correcting the position and speed
errors.
ROTARY ENCODER LINEAR ENCODER
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
ENCODERS
• Linear Encoder uses a transducer to
measure the distance between two points.
• It consists of a glass disc with accurately
etched lines at regular intervals.
• This line make & break this photoelectric
beam which generates a pulse signal.
• This signal is amplified to give a square
wave output.
• Number of signals generated per revolution
depends on the number of lines on the disc.
• A Rotary Encoder collects data and
provides feedback based on the rotation of
an object.
• Absolute Rotary Encoders - Angular positions
• Incremental Rotary Encoders - Distance, speed,
and position.
SLIDEWAYS
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
HYDROSTATIC SLIDEWAY
• Air or oil is pumped into the small pockets or cavities machined into the
carriage or slides which are in contact with the guide way.
• The pressure of fluid gradually reduces to atmospheric pressure as it
sweeps out from the pockets, through the gap between slide and guide
ways.
• The hydro-static guide way provides almost a friction-less condition for the
movement of the slide.
• For the efficient operation it is very important that the fluids and guide ways
are kept clean.
• Hydro-static guide ways need a very large surface area to provide adequate
support.
RECIRCULATING BALL SCREW
• A recirculating ball screw consists a
screw, a nut and a series of balls.
• In recirculating ball screw, the sliding
friction gets replaced by rolling friction.
• Rolling friction is very less in recirculating
ball screw,
• The threads of screw and nut in
recirculating ball screw are semicircular,
so that they can accommodate rolling
balls.
• Almost no heat generation in recirculating
ball screw due to negligible friction, it can
be used at very high speeds up to 10
m/min.
DISADVANTAGES
• Buckling of screw is serious problem at
critical speed
• It require high degree of cleanliness
Also Known as
• BALL BEARING SCREW
• BALL SCREW.
APPLICATIONS
• Machine tools controls
• Hospital beds adjusters
• Aircraft landing gear retractors
• Automobile steering gears
AUTOMATIC TOOL CHANGER (ATC)
• It is a device which can automatically change the
tool from the tool magazine to the machine spindle
as per the CNC program.
• ATC is used in CNC machine tools to improve
• Tool carrying capacity of the machine.
• Reducing the non-productive time.
• 16 – 24 Tools used, Nowadays 160 – 350 Tools.
• MCU receives the tool change command signal.
• Move the spindle to its fixed tool change
position.(Home Position –Tool post Top Position)
• Same time, Tool magazine indexed to proper
position.
• The tool changer (Gripper Plate) engages the tool
in the spindle & tool in the magazine at that time.
• Both tools are removed from their position by tool
changer, & turns by 180° to swap both tools.
• Old tool sent to Tool magazine
• New tool engaged to Spindle.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
AUTOMATIC TOOL CHANGER (ATC)
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
AUTOMATIC PALLET CHANGER
• Automatic Pallet Changer (APC) is a device which can automatically change the
pallet to/from machine to pallet stand.
• By this Mechanism, the pallet with the finished component and the pallet with a raw
component could be exchanged automatically.
• Pallet is a transferable work table having `T’ slots or tapped holes for
component/fixture clamping.
• Used to avoid the machine waiting time during loading & unloading of component.
• Pallet is held on the machine table by locating pins and clamping mechanism to
ensure repeatability and accuracy
ROTARY PALLET CHANGER SYSTEM INVERTED U-PATH, LINEAR PALLET CHANGER SYSTEM
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
TOOL MAGAZINE
• Tool Magazine is a device which holds number
of tools.
• This magazine can automatically index to
enable ATC to pick the right tool and to replace
the used tool.
• Duplication of tools is possible & a new tool of
same type can be selected when a particular
tool is worn off.
DISC or DRUM TYPE TOOL MAGAZINE
• The disc type tool magazine rotates to get the
desired tool in position with the tool change arm.
• The tools are stored on the periphery of the
drum.
• Capacity – 12 – 30 Tools
CHAIN TYPE TOOL MAGAZINE
• When the number of tools is more than 50,
chain type tool magazine are used.
• The magazine is mounted overhead or as a
separate column.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
MACHINING CENTRE• A machining center can be defined as a sophisticated CNC machine tool
controlled by a computer running programs driven by numerical data, which can
perform multiple machining operations like milling, drilling, tapping and boring
operations at the same location control by making use of several area and a
variety of tools with Automatic Tool Changer (ATC) unit
• ARBOR - A rotating shaft in a machine or power tool on which a milling cutter or
grinding wheel is fitted
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
• The total production time is increased due to the Non–Productive time.
• Total Production time = Non-Production Time + Machining Time
• Non–Productive time – Workpiece handling, Setup time, Tool change time,
Operator Delay
To overcome this, NC, CNC machine developed. It will reduce the Non-
Productive time.
• A part programmer specifies cutting speed, Feed rate, Depth of cut etc., on
the basis of his knowledge & experience to achieve desired levels of
manufacturing objectives such as accuracy, surface finish & productivity.
• This programmed values are offline mode & do not always extract the optimal
from the machine.
ADAPTIVE CONTROL SYSTEM - ACS
• The main idea in adaptive control is the improvement in production rate & part
quality by calculation and setting of the optimal variables during the machining
itself
• The concept of adaptive control aims at reducing the in-process machining time
by a real time control in operating parameters such as cutting speed, Feed rate,
Depth of cut etc., which can be adjusted automatically
DRAWBACK IN CONVENTIONAL MACHINE
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
ADAPTIVE CONTROL OPTIMISATION (ACO)
• The overall performance of the process is indicated by performance index(PI).
PI =
𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝑹𝒆𝒎𝒐𝒗𝒂𝒍 𝑹𝒂𝒕𝒆(𝑴𝑹𝑹)
𝑻𝒐𝒐𝒍 𝑾𝒆𝒂𝒓 𝑹𝒂𝒕𝒆 (𝑻𝑾𝑹)
ADAPTIVE CONTROL SYSTEM - ACS
• The system measures the
process parameters such as
Cutting torque, Tool temperature,
Tool Wear & Vibration by sensors.
• This information's are fed to the
ACO software along with
programmed feed rate, Spindle
speed & other constraints.
• The software computes the real
time performance index(PI) on the
basis of the MRR & TWR.
• This index is compared with the
set value & the software then
recomputes the feed rate &
spindle speed.
• This system used to maximize the
PI without violating the
constraints.
ADVANTAGES OF ADAPTIVE CONTROL
• Increased production rate
• Increased Tool life
• Increased accuracy by making
tolerances as a constraint
• Less Human Interaction
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
ADAPTIVE CONTROL CONSTRAINT (ACC)
ADAPTIVE CONTROL SYSTEM - ACS
• In this control, constraints are
placed on the measured process
variables.
• The system measures the process
parameters such as Cutting torque,
Tool temperature, Tool Wear, Tool
deflection & Vibration by sensors.
• The measured values of these
parameters are compared with the
set values with ACC software.
• It is ensured that at no time the
measured parameters exceed the
set value.
• ACC system is to manipulate the
spindle speed & feed rate to
maintain this into the set values.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
2.5 AXIS VS 3 AXIS MACHINE
• 2.5 axis machining requires that the machine have three axes, but only two
axes must be moving simultaneously at any one time.
• Operations, like drilling and most milling
• 3-axis machining requires that all three axes be moving at the same time.
• More complex operations, like the machining of sculptured surfaces required
in molds and airfoils.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
G90 Absolute Positioning & G91 Incremental Positioning
Absolute Positioning Method (G90) Incremental Positioning Method (G91)
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
ABSOLUTE POSITIONING SYSTEM INCREMENTAL POSITIONING SYSTEM
• In this system, all the positions are
indicated from a reference point, which
is a fixed zero point or set point.
• In this method, the tool positions are
indicated with respect to previous
point.
• The coordinate of each point are
independent of each other.
• The coordinate if each point are
dependent on each other.
• If an error occurs into the dimensions
of any location, then the error will be
restricted to that location only.
• The main disadvantage of this system
is that if an error occurs into the
dimensions of any location, all the
locations marked after that will carry
the same error.
• Here, a reference point is must. • Reference point is not needed.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
G90 Absolute Positioning & G91 Incremental Positioning
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
RAPID MOTION G00 & LINERA MOTION G01
• If there is no contact between tool & work piece, Use Rapid motion to save the time.
CIRCULAR INTERPOLATION MOTION G02 (CW) & G02 (CCW)
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CUTTER COMPENSATION (G41, G42)
G40 – CUTTER COMPENSATION
CANCEL
• This code should be entered in
the separate line at the end of
the required operation.
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CANNED CYCLE
G81 – SPOT DRILLING CANNED CYCLE
A canned cycle is used to simplify programming of a part. Canned cycles are defined for the most common Z-axis
repetitive operation.
• Drilling(G81 – SPOT DRILLING)
• G83 – PECK DRILL
• Tapping (G84) & Boring (G85).
The five operations in a canned cycle are:
1) Positioning of the X and Y axes.
2) Rapid traverse to the R plane.
3) The drilling, tapping, and boring for the canned cycle.
4) Operation at the bottom of hole.
5) Retraction to R plane (G99) or initial starting point (G98).
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
PART PROGRAM - MILLING
G21 G94
G91 G28 X0. Y0. Z0.
T01 M06
G43 H01 Z100.
G90 G54 G41 G00 X0.0 Y0.0 D01
M03 S1000 Z20.
G01 G41 G90 Z-5. F400.
G01 X0. Y125.
G03 X25. Y150. R25.
G01 X125. Y150.
G02 X150. Y125. R25.
G01 X150. Y25.
G03 X125. Y0. R25.
G01 X0. Y0.
G01 Z10.
G00 Z100.
G40
G91 G28 X0. Y0. Z0.
M30
• RADIUS – 25 mm
• Cutter Compensation
Program
• Tool – End Mill – 6 mm
• Diameter Offset – D01 – 3 mm
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
PART PROGRAM - MILLING
G21 G94
G91 G28 X0. Y0. Z0.
T01 M06
G90 G54 G42 G00 X25. Y25. D01
G43 H01 Z100.
M08
M03 S1000
G01 Z20.
G01 G90 Z-5. F400.
G01 X25. Y175.
G01 X175. Y175.
G01 X175. Y25.
G01 X25. Y25.
G01 Z10.
G40
G00 Z100.
M05
M09
G91 G28 X0. Y0. Z0.
M30
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
PART PROGRAM - MILLING
SUB PROGRAM – M98 & M99
G21 G94
T01 M06
G90 G54 G00 X-25. Y-25.
G43 H01 Z100.
M03 S1000
G01 Z0. F400.
M98 P1500 L10
G40
G00 Z100.
M05
G91 G28 X0. Y0.
M30
O1500
G91 Z-2. F400.
G90 G41 G01 X0. Y50. F400. D01
G01 X45. Y150.
G01 X105. Y150.
G01 X150. Y50.
G01 X150. Y25.
G01 X125. Y0.
G01 X25. Y0.
G01 X0. Y25.
M99
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
CANNED CYCLE - DRILLING
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
G21 G94
G91 G28 X0. Y0. Z0.
TO1 M06
G17 G90 G54 G00 X20. Y20.
G43 H01 Z100.
M03 S1000 Z20.
G01 G90 Z-20. F300.
G90 Z5.
G01 G90 X80.
G01 G90 Z-20. F300.
G90 Z5.
G01 G90 Y80.
G01 G90 Z-20. F300.
G90 Z5.
G01 G90 X20.
G01 G90 Z-20. F300.
G90 Z5.
G01 G90 X50. Y50.
G01 G90 Z-20. F300.
G90 Z5.
G00 Z100.
G91 G28 X0. Y0. Z0.
M05
M30
PART PROGRAM - MILLING
G21 G94
G91 G28 X0. Y0. Z0.
TO1 M06
G17 G90 G54 G00 X20. Y20.
G43 H01 Z100.
M08
M03 S1000
G01 G90 Z20.
G90 G83 G99 Z – 20. Q2. R1. F10
G01 X80. Y20.
G01 X80. Y80.
G01 X20. Y80.
G01 X50. Y50.
G80
G00 Z100.
M09
G91 G28 X0. Y0. Z0.
M05
M30
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
PART PROGRAM - TURNING
G21 G95
M06 T01
G18 G54
G00 G90 X40. Z5.0
G73 U0.5 W0.5 R10.
G73 P10 Q70 U0.2 W0.2 F0.2
S1000
N10 G01 X14. Z1.0
N20 G01 Z-15.
N30 G03 X22. Z-19. R4.
N40 G01 X22. Z-34.
N50 G02 X34.0 Z-40. R6.
N60 G01 Z-50.
N70 X50. Z0.
G00 X60.0 Z50.
M05
M09
T02 (TOOL CHANGE)
(FINISH TURN CONTOUR)
G96 S200
M03 S2500
G01 G90 X49.0 Z5.0
M08
G70 P10 Q70 F0.15
G00 X60.0 Z50.0
M05
M09
M30
G73 – Pattern Repeating Cycle
G73 U… W… R…
G73 P… Q… U… W… F... S...
U: X-axis (radius value). This is the amount of material which will be cut in x-axis.
W: Z-axis. This is the amount of material which will be cut in z-axis.
R: Number of divisions. The number the contour will be repeated.
P - Contour Start block number, Q - Contour End block number
U - Finishing allowance in X-axis, W- Finishing allowance in Z-axis
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
PART PROGRAM - TURNINGG21 G95
M06 T01
G18 G54
G00 G90 X40. Z5.0
G73 U0.5 W0.5 R10.
G73 P10 Q70 U0.2 W0.2 F0.2
M03 S1000
N10 G01 X0. Z0.
N20 G03 X16. Z-8. R8.
N30 G01 X16. Z-15.
N40 G01 X26.0 Z-30.
N50 G03 X34.0 Z-35. R5.
N60 G01 X34. Z-50.
N70 X50. Z0.
G00 X60. Z50.
M05
M09
MO6 T02 (TOOL CHANGE)(FINISH TURN CONTOUR)
G96 S200
M03 S2500
G01 G90 X49. Z5.
M08
G70 P10 Q70 F0.15
G00 X60. Z50.
M05
M09
M30
G73 – Pattern Repeating Cycle
G73 U… W… R…
G73 P… Q… U… W… F... S...
U: X-axis (radius value). This is the amount of material which will be cut in x-axis.
W: Z-axis. This is the amount of material which will be cut in z-axis.
R: Number of divisions. The number the contour will be repeated.
P - Contour Start block number, Q - Contour End block number
U - Finishing allowance in X-axis, W- Finishing allowance in Z-axis
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
MACRO – CNC PROGRAMMING
• Macro programming is also known as Parametric
Programming.
• It means, we can control the program by external parameters.
• This program uses the #(variable) sign to represent values.
• Used for making Holes.
G21 G94
G91 G28 X0. Y0. Z0.
TO1 M06 (6 mm Drill)
G17 G90 G54 G00 X20. Y20.
G43 H01 Z100.
M08
M03 S1000
#1 = 10.
#2 = 100.
M98 P500 (Call Subprogram)
M05
M09
G91 G28 Z0.
TO2 M06 (12 mm Drill)
G17 G90 G54 G00 X20. Y20.
M03 S1000
G43 H02 Z100.
M08
#1 = 20.
#2 = 200.
M98 P500 (Call Subprogram)
M05
M09
G00 Z100.
G91 G28 Z0.
M30
#1 variable – Depth
#2 Variable – Feed Rate
O500 (Sub Program)
G90 G83 G99 Z-#1 Q2. R1. F#2
G01 X80. Y20.
G01 X80. Y80.
G01 X20. Y80.
G01 X50. Y50.
G80
M99
ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET

More Related Content

What's hot

Chapter 2 constructional feature of cnc machine
Chapter 2 constructional feature of cnc machineChapter 2 constructional feature of cnc machine
Chapter 2 constructional feature of cnc machineRAHUL THAKER
 
Flexible manufacturing systems (FMS)
Flexible manufacturing systems (FMS)Flexible manufacturing systems (FMS)
Flexible manufacturing systems (FMS)jntuhcej
 
Geometric modeling111431635 geometric-modeling-glad (1)
Geometric modeling111431635 geometric-modeling-glad (1)Geometric modeling111431635 geometric-modeling-glad (1)
Geometric modeling111431635 geometric-modeling-glad (1)manojg1990
 
CNC principle & machining centre
CNC principle & machining centreCNC principle & machining centre
CNC principle & machining centreNirmalRaja3
 
INTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURING
INTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURINGINTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURING
INTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURINGBalamurugan Subburaj
 
Chapter 3 CNC turning and machining centers
Chapter 3 CNC turning and machining centersChapter 3 CNC turning and machining centers
Chapter 3 CNC turning and machining centersRAHUL THAKER
 
CAD/CAM 1 Module-2 18ME72 Part-A
CAD/CAM  1 Module-2 18ME72 Part-ACAD/CAM  1 Module-2 18ME72 Part-A
CAD/CAM 1 Module-2 18ME72 Part-AMohammed Imran
 
Unit 3-ME8691 & COMPUTER AIDED DESIGN AND MANUFACTURING
Unit 3-ME8691 & COMPUTER AIDED DESIGN AND    MANUFACTURINGUnit 3-ME8691 & COMPUTER AIDED DESIGN AND    MANUFACTURING
Unit 3-ME8691 & COMPUTER AIDED DESIGN AND MANUFACTURINGMohanumar S
 
CNC Machines
CNC MachinesCNC Machines
CNC Machinespratik207
 
DNC machines tools
DNC machines toolsDNC machines tools
DNC machines toolsjntuhcej
 

What's hot (20)

CNC machining centers
CNC machining centersCNC machining centers
CNC machining centers
 
CNC machine
CNC machineCNC machine
CNC machine
 
Chapter 2 constructional feature of cnc machine
Chapter 2 constructional feature of cnc machineChapter 2 constructional feature of cnc machine
Chapter 2 constructional feature of cnc machine
 
DNC SYSTEMS
DNC SYSTEMSDNC SYSTEMS
DNC SYSTEMS
 
Flexible manufacturing systems (FMS)
Flexible manufacturing systems (FMS)Flexible manufacturing systems (FMS)
Flexible manufacturing systems (FMS)
 
Geometric modeling111431635 geometric-modeling-glad (1)
Geometric modeling111431635 geometric-modeling-glad (1)Geometric modeling111431635 geometric-modeling-glad (1)
Geometric modeling111431635 geometric-modeling-glad (1)
 
CNC principle & machining centre
CNC principle & machining centreCNC principle & machining centre
CNC principle & machining centre
 
INTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURING
INTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURINGINTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURING
INTRODUCTION TO COMPUTER AIDED DESIGN & MANUFACTURING
 
CNC Machines and its Components
CNC Machines and its ComponentsCNC Machines and its Components
CNC Machines and its Components
 
Ch 2 NC machine
Ch 2 NC machine Ch 2 NC machine
Ch 2 NC machine
 
Apt programming
Apt programmingApt programming
Apt programming
 
Chapter 3 CNC turning and machining centers
Chapter 3 CNC turning and machining centersChapter 3 CNC turning and machining centers
Chapter 3 CNC turning and machining centers
 
CAD/CAM 1 Module-2 18ME72 Part-A
CAD/CAM  1 Module-2 18ME72 Part-ACAD/CAM  1 Module-2 18ME72 Part-A
CAD/CAM 1 Module-2 18ME72 Part-A
 
Drill bushes
Drill bushesDrill bushes
Drill bushes
 
Tool presetting
Tool presettingTool presetting
Tool presetting
 
Unit 3-ME8691 & COMPUTER AIDED DESIGN AND MANUFACTURING
Unit 3-ME8691 & COMPUTER AIDED DESIGN AND    MANUFACTURINGUnit 3-ME8691 & COMPUTER AIDED DESIGN AND    MANUFACTURING
Unit 3-ME8691 & COMPUTER AIDED DESIGN AND MANUFACTURING
 
CNC Machines
CNC MachinesCNC Machines
CNC Machines
 
4 tooling in cnc
4 tooling in cnc4 tooling in cnc
4 tooling in cnc
 
CNC Programming
CNC Programming CNC Programming
CNC Programming
 
DNC machines tools
DNC machines toolsDNC machines tools
DNC machines tools
 

Similar to FUNDAMENTALS OF CNC & PART PROGRAMMING - UNIT - 4 CAD&M

MT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHININGMT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHININGKarthik R
 
M.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.ppt
M.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.pptM.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.ppt
M.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.pptMohanumar S
 
Chapter_2_NC-CNC machine tools.pptx
Chapter_2_NC-CNC machine tools.pptxChapter_2_NC-CNC machine tools.pptx
Chapter_2_NC-CNC machine tools.pptxSankalp Bhatiya
 
Part programming for nc machines
Part programming for nc machinesPart programming for nc machines
Part programming for nc machinesDorothy Kare
 
INTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptx
INTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptxINTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptx
INTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptxMohammadHussain364422
 
Computer Aided Manufacturing.pptx
Computer Aided Manufacturing.pptxComputer Aided Manufacturing.pptx
Computer Aided Manufacturing.pptxDrDineshDhande
 
Cnc ppt by APC Sir
Cnc ppt by APC SirCnc ppt by APC Sir
Cnc ppt by APC SirAnsh Rocker
 
Modern machine
Modern machineModern machine
Modern machineUbaid Shah
 
Unit 3 Computer Numerical Control
Unit 3 Computer Numerical ControlUnit 3 Computer Numerical Control
Unit 3 Computer Numerical ControlSURYAPRAKASH S
 
geometric modelling and PLC
geometric modelling and PLCgeometric modelling and PLC
geometric modelling and PLCDenny John
 
Unit V CNC Machining
Unit V CNC MachiningUnit V CNC Machining
Unit V CNC Machininglaxtwinsme
 
BHEL CNC MACHINE TRAINING REPORT
BHEL CNC MACHINE TRAINING REPORT BHEL CNC MACHINE TRAINING REPORT
BHEL CNC MACHINE TRAINING REPORT piyush singh
 
bhel6-171106130647.pdf
bhel6-171106130647.pdfbhel6-171106130647.pdf
bhel6-171106130647.pdfARYAKUMARNIRAV
 
MT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHININGMT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHININGKarthik R
 
Numerical Control Machines tools....pptx
Numerical Control Machines tools....pptxNumerical Control Machines tools....pptx
Numerical Control Machines tools....pptxsuyogpatil49
 
Numerical control machines
Numerical control machines Numerical control machines
Numerical control machines jntuhcej
 
CNC PROGRAMMING FOR BEGAINER Part 1
CNC PROGRAMMING FOR BEGAINER Part 1CNC PROGRAMMING FOR BEGAINER Part 1
CNC PROGRAMMING FOR BEGAINER Part 1Parveen Kumar
 

Similar to FUNDAMENTALS OF CNC & PART PROGRAMMING - UNIT - 4 CAD&M (20)

CNC MACHINE TOOLS.ppt
CNC MACHINE TOOLS.pptCNC MACHINE TOOLS.ppt
CNC MACHINE TOOLS.ppt
 
MT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHININGMT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHINING
 
M.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.ppt
M.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.pptM.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.ppt
M.P- II-UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING.ppt
 
Chapter_2_NC-CNC machine tools.pptx
Chapter_2_NC-CNC machine tools.pptxChapter_2_NC-CNC machine tools.pptx
Chapter_2_NC-CNC machine tools.pptx
 
Part programming for nc machines
Part programming for nc machinesPart programming for nc machines
Part programming for nc machines
 
INTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptx
INTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptxINTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptx
INTRODUCTION ABOUT CNC MACHINE with G Code and M Code.pptx
 
Computer Aided Manufacturing.pptx
Computer Aided Manufacturing.pptxComputer Aided Manufacturing.pptx
Computer Aided Manufacturing.pptx
 
Cnc ppt by APC Sir
Cnc ppt by APC SirCnc ppt by APC Sir
Cnc ppt by APC Sir
 
Ncmachine (1)
Ncmachine (1)Ncmachine (1)
Ncmachine (1)
 
Modern machine
Modern machineModern machine
Modern machine
 
Unit 3 Computer Numerical Control
Unit 3 Computer Numerical ControlUnit 3 Computer Numerical Control
Unit 3 Computer Numerical Control
 
3 numerical control
3 numerical control3 numerical control
3 numerical control
 
geometric modelling and PLC
geometric modelling and PLCgeometric modelling and PLC
geometric modelling and PLC
 
Unit V CNC Machining
Unit V CNC MachiningUnit V CNC Machining
Unit V CNC Machining
 
BHEL CNC MACHINE TRAINING REPORT
BHEL CNC MACHINE TRAINING REPORT BHEL CNC MACHINE TRAINING REPORT
BHEL CNC MACHINE TRAINING REPORT
 
bhel6-171106130647.pdf
bhel6-171106130647.pdfbhel6-171106130647.pdf
bhel6-171106130647.pdf
 
MT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHININGMT-II UNIT V CNC MACHINING
MT-II UNIT V CNC MACHINING
 
Numerical Control Machines tools....pptx
Numerical Control Machines tools....pptxNumerical Control Machines tools....pptx
Numerical Control Machines tools....pptx
 
Numerical control machines
Numerical control machines Numerical control machines
Numerical control machines
 
CNC PROGRAMMING FOR BEGAINER Part 1
CNC PROGRAMMING FOR BEGAINER Part 1CNC PROGRAMMING FOR BEGAINER Part 1
CNC PROGRAMMING FOR BEGAINER Part 1
 

More from Balamurugan Subburaj

CELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & M
CELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & MCELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & M
CELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & MBalamurugan Subburaj
 
Energy, economic and environmental issues of power plants
Energy, economic and environmental issues of power plantsEnergy, economic and environmental issues of power plants
Energy, economic and environmental issues of power plantsBalamurugan Subburaj
 
DIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT III
DIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT IIIDIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT III
DIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT IIIBalamurugan Subburaj
 
COAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERING
COAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERINGCOAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERING
COAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERINGBalamurugan Subburaj
 
Replacement & Maintenance Analysis Unit IV MG 6863
Replacement & Maintenance Analysis Unit IV MG 6863Replacement & Maintenance Analysis Unit IV MG 6863
Replacement & Maintenance Analysis Unit IV MG 6863Balamurugan Subburaj
 
Cash Flow - Unit III Engineering Economics - MG6863
Cash Flow - Unit III Engineering Economics - MG6863Cash Flow - Unit III Engineering Economics - MG6863
Cash Flow - Unit III Engineering Economics - MG6863Balamurugan Subburaj
 
Introduction to Engineering Economics Unit I MG6863
Introduction to Engineering Economics  Unit I MG6863Introduction to Engineering Economics  Unit I MG6863
Introduction to Engineering Economics Unit I MG6863Balamurugan Subburaj
 

More from Balamurugan Subburaj (18)

CAD STANDARDS
CAD STANDARDSCAD STANDARDS
CAD STANDARDS
 
CELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & M
CELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & MCELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & M
CELLULAR MANUFACTURING & FLEXIBLE MANUFACTURING SYSTEM - UNIT 5 - CAD & M
 
GEOMETRIC MODELING
GEOMETRIC MODELINGGEOMETRIC MODELING
GEOMETRIC MODELING
 
Manufacture of plastic components
Manufacture of plastic componentsManufacture of plastic components
Manufacture of plastic components
 
Sheet metal processes
Sheet metal processesSheet metal processes
Sheet metal processes
 
METAL FORMING PROCESS
METAL FORMING PROCESSMETAL FORMING PROCESS
METAL FORMING PROCESS
 
Welding - Joining Processes
Welding - Joining ProcessesWelding - Joining Processes
Welding - Joining Processes
 
METAL CASTING PROCESSES
METAL CASTING PROCESSESMETAL CASTING PROCESSES
METAL CASTING PROCESSES
 
Energy, economic and environmental issues of power plants
Energy, economic and environmental issues of power plantsEnergy, economic and environmental issues of power plants
Energy, economic and environmental issues of power plants
 
Power from renewable energy
Power from renewable energyPower from renewable energy
Power from renewable energy
 
NUCLEAR POWER PLANT
NUCLEAR POWER PLANTNUCLEAR POWER PLANT
NUCLEAR POWER PLANT
 
DIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT III
DIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT IIIDIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT III
DIESEL, GAS TURBINE & COMBINED CYCLE POWER PLANTS UNIT III
 
COAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERING
COAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERINGCOAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERING
COAL BASED POWER PLANT UNIT 1 - POWER PLANT ENGINEERING
 
DEPRECIATION - UNIT V- MG6863
DEPRECIATION - UNIT V- MG6863DEPRECIATION - UNIT V- MG6863
DEPRECIATION - UNIT V- MG6863
 
Replacement & Maintenance Analysis Unit IV MG 6863
Replacement & Maintenance Analysis Unit IV MG 6863Replacement & Maintenance Analysis Unit IV MG 6863
Replacement & Maintenance Analysis Unit IV MG 6863
 
Cash Flow - Unit III Engineering Economics - MG6863
Cash Flow - Unit III Engineering Economics - MG6863Cash Flow - Unit III Engineering Economics - MG6863
Cash Flow - Unit III Engineering Economics - MG6863
 
Value Engineering Unit 2 MG6863
Value Engineering Unit 2 MG6863Value Engineering Unit 2 MG6863
Value Engineering Unit 2 MG6863
 
Introduction to Engineering Economics Unit I MG6863
Introduction to Engineering Economics  Unit I MG6863Introduction to Engineering Economics  Unit I MG6863
Introduction to Engineering Economics Unit I MG6863
 

Recently uploaded

Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...
Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...
Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...Krashi Coaching
 
Alper Gobel In Media Res Media Component
Alper Gobel In Media Res Media ComponentAlper Gobel In Media Res Media Component
Alper Gobel In Media Res Media ComponentInMediaRes1
 
microwave assisted reaction. General introduction
microwave assisted reaction. General introductionmicrowave assisted reaction. General introduction
microwave assisted reaction. General introductionMaksud Ahmed
 
The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13Steve Thomason
 
mini mental status format.docx
mini    mental       status     format.docxmini    mental       status     format.docx
mini mental status format.docxPoojaSen20
 
Paris 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activityParis 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activityGeoBlogs
 
URLs and Routing in the Odoo 17 Website App
URLs and Routing in the Odoo 17 Website AppURLs and Routing in the Odoo 17 Website App
URLs and Routing in the Odoo 17 Website AppCeline George
 
Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111Sapana Sha
 
“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...
“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...
“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...Marc Dusseiller Dusjagr
 
Micromeritics - Fundamental and Derived Properties of Powders
Micromeritics - Fundamental and Derived Properties of PowdersMicromeritics - Fundamental and Derived Properties of Powders
Micromeritics - Fundamental and Derived Properties of PowdersChitralekhaTherkar
 
Science 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsScience 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsKarinaGenton
 
PSYCHIATRIC History collection FORMAT.pptx
PSYCHIATRIC   History collection FORMAT.pptxPSYCHIATRIC   History collection FORMAT.pptx
PSYCHIATRIC History collection FORMAT.pptxPoojaSen20
 
Concept of Vouching. B.Com(Hons) /B.Compdf
Concept of Vouching. B.Com(Hons) /B.CompdfConcept of Vouching. B.Com(Hons) /B.Compdf
Concept of Vouching. B.Com(Hons) /B.CompdfUmakantAnnand
 
Organic Name Reactions for the students and aspirants of Chemistry12th.pptx
Organic Name Reactions  for the students and aspirants of Chemistry12th.pptxOrganic Name Reactions  for the students and aspirants of Chemistry12th.pptx
Organic Name Reactions for the students and aspirants of Chemistry12th.pptxVS Mahajan Coaching Centre
 
Contemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptx
Contemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptxContemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptx
Contemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptxRoyAbrique
 
Introduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher EducationIntroduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher Educationpboyjonauth
 
Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)eniolaolutunde
 
Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991
Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991
Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991RKavithamani
 
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptxPOINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptxSayali Powar
 
Mastering the Unannounced Regulatory Inspection
Mastering the Unannounced Regulatory InspectionMastering the Unannounced Regulatory Inspection
Mastering the Unannounced Regulatory InspectionSafetyChain Software
 

Recently uploaded (20)

Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...
Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...
Kisan Call Centre - To harness potential of ICT in Agriculture by answer farm...
 
Alper Gobel In Media Res Media Component
Alper Gobel In Media Res Media ComponentAlper Gobel In Media Res Media Component
Alper Gobel In Media Res Media Component
 
microwave assisted reaction. General introduction
microwave assisted reaction. General introductionmicrowave assisted reaction. General introduction
microwave assisted reaction. General introduction
 
The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13The Most Excellent Way | 1 Corinthians 13
The Most Excellent Way | 1 Corinthians 13
 
mini mental status format.docx
mini    mental       status     format.docxmini    mental       status     format.docx
mini mental status format.docx
 
Paris 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activityParis 2024 Olympic Geographies - an activity
Paris 2024 Olympic Geographies - an activity
 
URLs and Routing in the Odoo 17 Website App
URLs and Routing in the Odoo 17 Website AppURLs and Routing in the Odoo 17 Website App
URLs and Routing in the Odoo 17 Website App
 
Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111Call Girls in Dwarka Mor Delhi Contact Us 9654467111
Call Girls in Dwarka Mor Delhi Contact Us 9654467111
 
“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...
“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...
“Oh GOSH! Reflecting on Hackteria's Collaborative Practices in a Global Do-It...
 
Micromeritics - Fundamental and Derived Properties of Powders
Micromeritics - Fundamental and Derived Properties of PowdersMicromeritics - Fundamental and Derived Properties of Powders
Micromeritics - Fundamental and Derived Properties of Powders
 
Science 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its CharacteristicsScience 7 - LAND and SEA BREEZE and its Characteristics
Science 7 - LAND and SEA BREEZE and its Characteristics
 
PSYCHIATRIC History collection FORMAT.pptx
PSYCHIATRIC   History collection FORMAT.pptxPSYCHIATRIC   History collection FORMAT.pptx
PSYCHIATRIC History collection FORMAT.pptx
 
Concept of Vouching. B.Com(Hons) /B.Compdf
Concept of Vouching. B.Com(Hons) /B.CompdfConcept of Vouching. B.Com(Hons) /B.Compdf
Concept of Vouching. B.Com(Hons) /B.Compdf
 
Organic Name Reactions for the students and aspirants of Chemistry12th.pptx
Organic Name Reactions  for the students and aspirants of Chemistry12th.pptxOrganic Name Reactions  for the students and aspirants of Chemistry12th.pptx
Organic Name Reactions for the students and aspirants of Chemistry12th.pptx
 
Contemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptx
Contemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptxContemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptx
Contemporary philippine arts from the regions_PPT_Module_12 [Autosaved] (1).pptx
 
Introduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher EducationIntroduction to ArtificiaI Intelligence in Higher Education
Introduction to ArtificiaI Intelligence in Higher Education
 
Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)Software Engineering Methodologies (overview)
Software Engineering Methodologies (overview)
 
Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991
Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991
Industrial Policy - 1948, 1956, 1973, 1977, 1980, 1991
 
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptxPOINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
POINT- BIOCHEMISTRY SEM 2 ENZYMES UNIT 5.pptx
 
Mastering the Unannounced Regulatory Inspection
Mastering the Unannounced Regulatory InspectionMastering the Unannounced Regulatory Inspection
Mastering the Unannounced Regulatory Inspection
 

FUNDAMENTALS OF CNC & PART PROGRAMMING - UNIT - 4 CAD&M

  • 1. ME8691 COMPUTER AIDED DESIGN & MANUFACTURING UNIT 4 – FUNDAMENTALS OF CNC AND PART PROGRAMING S.BALAMURUGAN ASSISTANT PROFESSOR MECHANICAL ENGINEERING AAA COLLEGE OF ENGINEEERING & TECHNOLOGY
  • 2.
  • 3. HISTORY & DEVELOPMENT OF TECHNOLOGY CONVENTIONAL MACHINE NC MACHINE (1948 US Air force, MIT 21 Months) (http://museum.mit.edu/150/86) 1952 - Cincinnati Milacron Hydrotel Machine 1959: The MIT team showcase the CNC-milled aluminum ashtray is handed out as part of the press kit. CNC MACHINE • During the Cold War time, the development of automation was addressed. • At that time, the company Parsons Works was commissioned by the U.S. Navy to increase the productivity of its production line for helicopter blades. • John T. Parsons then motorized the axes of the machines for making these blades. • Working with IBM, he studied the possibilities of controlling these machines by computer. This was the starting point of the CNC machining method. • In 1952, Richard Kegg, in collaboration with MIT, developed the first CNC milling machine: the Cincinnati Milacron Hydrotel. • Five years later, in 1958, he filed a patent for a “Motor Controlled Apparatus for Positioning Machine Tool”. This was the commercial birth of this technology. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 4. NC – NUMERICAL CONTROL MACHINE • Numerical control is a programmable automation in which actions are controlled by means of coded numbers, letters & other symbols. • The numerical data is required for producing a part is maintained on Punched Tape. • The data is arranged in the form of blocks of information. • The block contains Cutting speed, Feed, Dimensional information & Contour form ELEMENTS OF NC SYSTEM 1. Machine Control Unit 2. Machine Tool 3. Part Program & Drawings ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 5. ELEMENTS OF NC SYSTEM MACHINE CONTROL UNIT(MCU) - Data Processing Unit (DPU) • It consists of Tape Reader, Decoding Circuits, Feed Control Units. • Tape reader receives the coded data from punched tape. • The tape reader reads the data & passes data to the Buffer storage through decoding circuits. • The buffer storage stores the received information, till it is required & transfers it to the required area. • All the operations like Tool movement, Tool change, Speed & Feed Change can be controlled by MCU. MACHINE TOOL & NC TOOLING • It is the manufacturing arm of NC machine tool system. • It receives the raw material & perform different operations like Turning, Milling, Drilling, Grinding etc. • Receive the information from MCU. Based on the information, the desired shape & size is modified. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 6. PUNCH CARDS - HOLLERITH CARDS OR IBM CARDS • Punched Tape – Data is fed by automatic means. – Eliminate the operator errors. • Punched tape uses a binary coded decimal system for containing operating information of NC tool. • Instructions Holes in Binary format Decoded in MCU Electric Pulse • Electric pulses fed to the servo systems & mechanisms. • These are paper cards in which holes may be punched by hand or machine to represent computer data and instructions. • The cards were fed into a card reader connected to a computer, which converted the sequence of holes to digital information. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 7. CNC - COMPUTER NUMERICAL CONTROL • CNC is the numerical control system in which a dedicated computer is built into the control to perform basic and advanced NC functions. • CNC controls are implemented by software programs. • CNC is a computer assisted process to control general purpose machines from instructions generated by a processor and stored in a memory system. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 8. NC MACHINE – DIRECT NUMERICAL CONTROL (DNC) • In this type, a mainframe computer is used to coordinate the simultaneous operations of a number NC machines. • The tasks performed by the computer are to program and edit part programs as well as download part programs to NC machines. • Machine tool controllers have limited memory and a part program may contain few thousands of blocks. So the program is stored in a separate computer and sent directly to the machine, one block at a time. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET • 1960s technology • Two way communication.
  • 9. DISTRIBUTED NUMERICAL CONTROL • Network consisting of central computer connected to machine tool MCUs, which are CNC. • Present technology • Two way communication NC MACHINE – DISTRIBUTED NUMERICAL CONTROL (DNC)
  • 10. CLASSIFICATION OF CNC – MOTION TYPE POINT – POINT SYSTEM • It is used in some CNC machines such as drilling, boring and tapping machines…etc. • The control equipment for use with them are known as point-to-point control equipment. • Feed rates need not to be programmed. • In theses machine tools, each axis is driven separately CONTINUOUS PATH SYSTEMS • It is used in CNC machine tools such as milling machines. • These machines require simultaneous control of axes. • Feed rates need to be programmed. • Contouring machines can also be used as point to-point machines, but it will be uneconomical to use them unless the work piece also requires having a contouring operation to be performed on it. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 11. CNC MACHINE AXIS & DIRECTION MILLING MACHINE TURNING MACHINE ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 12. FIXED ZERO v/s FLOATING ZERO FIXED ZERO • Origin is always located at some position on M/C table (usually at south west corner/Lower left-hand) of the tables & all tool location are defined with respect to this zero. FLOATING ZERO • Very common with CNC M/C used now a days. • Operator sets zero point at any convenient position on M/C table. • The Coordinate system is knows as work coordinate system (WCS) ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 13. CNC – COMPUTERISED NUMERICAL CONTROL • CNC – Computer + Numerical Control • Numerical control is a programmable automation in which process is controlled by Numbers, Letters & Symbols. • CNC machining is a process used in the manufacturing sector that involves the use of computers to control machine tools like lathes, Mills & Grinders. NEED OF CNC MACHINING • To manufacture complex curved geometries in 2D or 3D was extremely expensive by mechanical means (which usually would require complex jigs to control the cutter motions) • Machining components with high Repeatability and Precision • Unmanned machining operations • To improve production planning and to increase productivity • To survive in global market CNC machines are must to achieve close tolerances. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 14. CNC – COMPUTERISED NUMERICAL CONTROL INPUT DEVICES • These are the devices which are used to input the part program in the CNC machine. • Commonly used input devices - Punch Tape Reader, Magnetic Tape Reader & Computer via RS-232-C communication. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 15. CNC MACHINE COMPONENTS MACHINE CONTROL UNIT (MCU) It is the heart of the CNC machine. It performs all the controlling action of the CNC machine, the various functions performed by the MCU are • It reads the coded instructions fed into it. • It decodes the coded instruction. • It implements interpolation ( linear, circular and helical ) to generate axis motion commands. • It feeds the axis motion commands to the amplifier circuits for driving the axis mechanisms. • It receives the feedback signals of position and speed for each drive axis. • It implements the auxiliary control functions such as coolant or spindle on/off and tool change. MACHINE TOOL • A CNC machine tool always has a slide table and a spindle to control of the position and speed. • The machine table is controlled in X and Y axis direction and the spindle is controlled in the Z axis direction. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 16. DRIVING SYSTEM • The driving system of a CNC machine consists of amplifier circuits, drive motors and ball lead screw. • The MCU feeds the signals (i.e. of position and speed) of each axis to the amplifier circuits. • The control signals are augmented (increased) to actuate the drive motors & the actuated drive motors rotate the ball lead screw to position the machine table. STEPPER MOTOR SERVO MOTOR • It is a pulse-driven motor that changes the angular position of the rotor in steps. • Open loop position control systems. • When switching on an inkjet printer; the controller will move the ink jet carrier to the extreme left and right to establish the end positions. It activates an end limit switch. • A servomotor is a rotary actuator or linear actuator that allows for precise control of angular or linear position, velocity and acceleration • Closed-loop control system. • A servomotor will immediately turn to whatever angle the controller instructs it to, regardless of the initial position at power up. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 17. TYPES OF STEPPER MOTOR PERMANENT MAGNET VARIABLE RELUCTANCE • Rotor is a permanent magnet. • PM motor rotor has no teeth and is designed to be magnetized at a right angle to its axis. • Figure shows a simple, 90⁰ PM motor with four phases (A-D). • Applying current to each phase in sequence will cause the rotor to rotate by adjusting to the changing magnetic fields. • Low speed, relatively high torque • Low cost motors with typical step angle ranging between 7.5⁰ to 15⁰ • The cylindrical rotor is made of soft steel and has four poles • If 4 rotor teeth, 90⁰ apart and 6 stator poles, 60⁰ apart. • Electromagnetic field is produced by activating the stator coils in sequence. • It attracts the metal rotor. When the windings are energized in a re occurring sequence of 2, 3, 1, and so on, the motor will rotate in a 30⁰ step angle. • In the non-energized condition, there is no magnetic flux in the air gap, as the stator is an electromagnet and the rotor is a piece of soft iron. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 18. SERVO MOTOR • Servomotors are special electromechanical devices that produce precise degrees of rotation. • The servomotors are used in a closed-loop servo system as shown in Figure A reference input is sent to the servo amplifier, which controls the speed of the servomotor. • A feedback device is mounted on the machine, which is an encoder. • This device changes mechanical motion into electrical signals and is used as a feedback. • This feedback is sent to the error detector , which compares the actual operation with that of the reference input. • If there is an error, that error is fed directly to the amplifier, which will be used to make necessary corrections in control action. • DC servo motor • AC servo motor • Brushless DC motor. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 19. OPEN LOOP SYSTEM CLOSED LOOP SYSTEM • It is a system that involves feeding of tape, interpretation of information by Tape reader, Storing the data in buffer storage, converting it into electrical signal and sending this signal to the control unit. • It is a system that carries an additional feedback device along with a transducer, accompanied by a comparator. • It is a simpler & Cheaper system • It is more complicated & costly than the open loop system • Feedback device is absent • Feedback device is present • With no feedback device, chance of error is always present • As the comparator compares the obtained slide motion, chance of error greatly reduced. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 20. OPEN LOOP VS CLOSED LOOP SYSTEM ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 21. FEEDBACK SYSTEM • This system consists of transducers that act as sensors. • It contains position and speed transducers that continuously monitor the position and speed of the cutting tool located at any instant. • The MCU receives the signals from these transducers. • MCU uses the difference between the reference signals and feedback signals to generate the control signals for correcting the position and speed errors. ROTARY ENCODER LINEAR ENCODER ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 22. ENCODERS • Linear Encoder uses a transducer to measure the distance between two points. • It consists of a glass disc with accurately etched lines at regular intervals. • This line make & break this photoelectric beam which generates a pulse signal. • This signal is amplified to give a square wave output. • Number of signals generated per revolution depends on the number of lines on the disc. • A Rotary Encoder collects data and provides feedback based on the rotation of an object. • Absolute Rotary Encoders - Angular positions • Incremental Rotary Encoders - Distance, speed, and position.
  • 23. SLIDEWAYS ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET HYDROSTATIC SLIDEWAY • Air or oil is pumped into the small pockets or cavities machined into the carriage or slides which are in contact with the guide way. • The pressure of fluid gradually reduces to atmospheric pressure as it sweeps out from the pockets, through the gap between slide and guide ways. • The hydro-static guide way provides almost a friction-less condition for the movement of the slide. • For the efficient operation it is very important that the fluids and guide ways are kept clean. • Hydro-static guide ways need a very large surface area to provide adequate support.
  • 24. RECIRCULATING BALL SCREW • A recirculating ball screw consists a screw, a nut and a series of balls. • In recirculating ball screw, the sliding friction gets replaced by rolling friction. • Rolling friction is very less in recirculating ball screw, • The threads of screw and nut in recirculating ball screw are semicircular, so that they can accommodate rolling balls. • Almost no heat generation in recirculating ball screw due to negligible friction, it can be used at very high speeds up to 10 m/min. DISADVANTAGES • Buckling of screw is serious problem at critical speed • It require high degree of cleanliness Also Known as • BALL BEARING SCREW • BALL SCREW. APPLICATIONS • Machine tools controls • Hospital beds adjusters • Aircraft landing gear retractors • Automobile steering gears
  • 25. AUTOMATIC TOOL CHANGER (ATC) • It is a device which can automatically change the tool from the tool magazine to the machine spindle as per the CNC program. • ATC is used in CNC machine tools to improve • Tool carrying capacity of the machine. • Reducing the non-productive time. • 16 – 24 Tools used, Nowadays 160 – 350 Tools. • MCU receives the tool change command signal. • Move the spindle to its fixed tool change position.(Home Position –Tool post Top Position) • Same time, Tool magazine indexed to proper position. • The tool changer (Gripper Plate) engages the tool in the spindle & tool in the magazine at that time. • Both tools are removed from their position by tool changer, & turns by 180° to swap both tools. • Old tool sent to Tool magazine • New tool engaged to Spindle. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 26. AUTOMATIC TOOL CHANGER (ATC) ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 27. AUTOMATIC PALLET CHANGER • Automatic Pallet Changer (APC) is a device which can automatically change the pallet to/from machine to pallet stand. • By this Mechanism, the pallet with the finished component and the pallet with a raw component could be exchanged automatically. • Pallet is a transferable work table having `T’ slots or tapped holes for component/fixture clamping. • Used to avoid the machine waiting time during loading & unloading of component. • Pallet is held on the machine table by locating pins and clamping mechanism to ensure repeatability and accuracy ROTARY PALLET CHANGER SYSTEM INVERTED U-PATH, LINEAR PALLET CHANGER SYSTEM ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 28. TOOL MAGAZINE • Tool Magazine is a device which holds number of tools. • This magazine can automatically index to enable ATC to pick the right tool and to replace the used tool. • Duplication of tools is possible & a new tool of same type can be selected when a particular tool is worn off. DISC or DRUM TYPE TOOL MAGAZINE • The disc type tool magazine rotates to get the desired tool in position with the tool change arm. • The tools are stored on the periphery of the drum. • Capacity – 12 – 30 Tools CHAIN TYPE TOOL MAGAZINE • When the number of tools is more than 50, chain type tool magazine are used. • The magazine is mounted overhead or as a separate column. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 29. MACHINING CENTRE• A machining center can be defined as a sophisticated CNC machine tool controlled by a computer running programs driven by numerical data, which can perform multiple machining operations like milling, drilling, tapping and boring operations at the same location control by making use of several area and a variety of tools with Automatic Tool Changer (ATC) unit • ARBOR - A rotating shaft in a machine or power tool on which a milling cutter or grinding wheel is fitted ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 30. • The total production time is increased due to the Non–Productive time. • Total Production time = Non-Production Time + Machining Time • Non–Productive time – Workpiece handling, Setup time, Tool change time, Operator Delay To overcome this, NC, CNC machine developed. It will reduce the Non- Productive time. • A part programmer specifies cutting speed, Feed rate, Depth of cut etc., on the basis of his knowledge & experience to achieve desired levels of manufacturing objectives such as accuracy, surface finish & productivity. • This programmed values are offline mode & do not always extract the optimal from the machine. ADAPTIVE CONTROL SYSTEM - ACS • The main idea in adaptive control is the improvement in production rate & part quality by calculation and setting of the optimal variables during the machining itself • The concept of adaptive control aims at reducing the in-process machining time by a real time control in operating parameters such as cutting speed, Feed rate, Depth of cut etc., which can be adjusted automatically DRAWBACK IN CONVENTIONAL MACHINE ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 31. ADAPTIVE CONTROL OPTIMISATION (ACO) • The overall performance of the process is indicated by performance index(PI). PI = 𝑴𝒂𝒕𝒆𝒓𝒊𝒂𝒍 𝑹𝒆𝒎𝒐𝒗𝒂𝒍 𝑹𝒂𝒕𝒆(𝑴𝑹𝑹) 𝑻𝒐𝒐𝒍 𝑾𝒆𝒂𝒓 𝑹𝒂𝒕𝒆 (𝑻𝑾𝑹) ADAPTIVE CONTROL SYSTEM - ACS • The system measures the process parameters such as Cutting torque, Tool temperature, Tool Wear & Vibration by sensors. • This information's are fed to the ACO software along with programmed feed rate, Spindle speed & other constraints. • The software computes the real time performance index(PI) on the basis of the MRR & TWR. • This index is compared with the set value & the software then recomputes the feed rate & spindle speed. • This system used to maximize the PI without violating the constraints. ADVANTAGES OF ADAPTIVE CONTROL • Increased production rate • Increased Tool life • Increased accuracy by making tolerances as a constraint • Less Human Interaction ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 32. ADAPTIVE CONTROL CONSTRAINT (ACC) ADAPTIVE CONTROL SYSTEM - ACS • In this control, constraints are placed on the measured process variables. • The system measures the process parameters such as Cutting torque, Tool temperature, Tool Wear, Tool deflection & Vibration by sensors. • The measured values of these parameters are compared with the set values with ACC software. • It is ensured that at no time the measured parameters exceed the set value. • ACC system is to manipulate the spindle speed & feed rate to maintain this into the set values. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 33. 2.5 AXIS VS 3 AXIS MACHINE • 2.5 axis machining requires that the machine have three axes, but only two axes must be moving simultaneously at any one time. • Operations, like drilling and most milling • 3-axis machining requires that all three axes be moving at the same time. • More complex operations, like the machining of sculptured surfaces required in molds and airfoils. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 34. G90 Absolute Positioning & G91 Incremental Positioning Absolute Positioning Method (G90) Incremental Positioning Method (G91) ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 35. ABSOLUTE POSITIONING SYSTEM INCREMENTAL POSITIONING SYSTEM • In this system, all the positions are indicated from a reference point, which is a fixed zero point or set point. • In this method, the tool positions are indicated with respect to previous point. • The coordinate of each point are independent of each other. • The coordinate if each point are dependent on each other. • If an error occurs into the dimensions of any location, then the error will be restricted to that location only. • The main disadvantage of this system is that if an error occurs into the dimensions of any location, all the locations marked after that will carry the same error. • Here, a reference point is must. • Reference point is not needed. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 36. G90 Absolute Positioning & G91 Incremental Positioning ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 37. RAPID MOTION G00 & LINERA MOTION G01 • If there is no contact between tool & work piece, Use Rapid motion to save the time. CIRCULAR INTERPOLATION MOTION G02 (CW) & G02 (CCW) ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 38. CUTTER COMPENSATION (G41, G42) G40 – CUTTER COMPENSATION CANCEL • This code should be entered in the separate line at the end of the required operation. ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 39. CANNED CYCLE G81 – SPOT DRILLING CANNED CYCLE A canned cycle is used to simplify programming of a part. Canned cycles are defined for the most common Z-axis repetitive operation. • Drilling(G81 – SPOT DRILLING) • G83 – PECK DRILL • Tapping (G84) & Boring (G85). The five operations in a canned cycle are: 1) Positioning of the X and Y axes. 2) Rapid traverse to the R plane. 3) The drilling, tapping, and boring for the canned cycle. 4) Operation at the bottom of hole. 5) Retraction to R plane (G99) or initial starting point (G98). ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 40. PART PROGRAM - MILLING G21 G94 G91 G28 X0. Y0. Z0. T01 M06 G43 H01 Z100. G90 G54 G41 G00 X0.0 Y0.0 D01 M03 S1000 Z20. G01 G41 G90 Z-5. F400. G01 X0. Y125. G03 X25. Y150. R25. G01 X125. Y150. G02 X150. Y125. R25. G01 X150. Y25. G03 X125. Y0. R25. G01 X0. Y0. G01 Z10. G00 Z100. G40 G91 G28 X0. Y0. Z0. M30 • RADIUS – 25 mm • Cutter Compensation Program • Tool – End Mill – 6 mm • Diameter Offset – D01 – 3 mm ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 41. PART PROGRAM - MILLING G21 G94 G91 G28 X0. Y0. Z0. T01 M06 G90 G54 G42 G00 X25. Y25. D01 G43 H01 Z100. M08 M03 S1000 G01 Z20. G01 G90 Z-5. F400. G01 X25. Y175. G01 X175. Y175. G01 X175. Y25. G01 X25. Y25. G01 Z10. G40 G00 Z100. M05 M09 G91 G28 X0. Y0. Z0. M30 ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 42. PART PROGRAM - MILLING SUB PROGRAM – M98 & M99 G21 G94 T01 M06 G90 G54 G00 X-25. Y-25. G43 H01 Z100. M03 S1000 G01 Z0. F400. M98 P1500 L10 G40 G00 Z100. M05 G91 G28 X0. Y0. M30 O1500 G91 Z-2. F400. G90 G41 G01 X0. Y50. F400. D01 G01 X45. Y150. G01 X105. Y150. G01 X150. Y50. G01 X150. Y25. G01 X125. Y0. G01 X25. Y0. G01 X0. Y25. M99 ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 43. CANNED CYCLE - DRILLING ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 44. G21 G94 G91 G28 X0. Y0. Z0. TO1 M06 G17 G90 G54 G00 X20. Y20. G43 H01 Z100. M03 S1000 Z20. G01 G90 Z-20. F300. G90 Z5. G01 G90 X80. G01 G90 Z-20. F300. G90 Z5. G01 G90 Y80. G01 G90 Z-20. F300. G90 Z5. G01 G90 X20. G01 G90 Z-20. F300. G90 Z5. G01 G90 X50. Y50. G01 G90 Z-20. F300. G90 Z5. G00 Z100. G91 G28 X0. Y0. Z0. M05 M30 PART PROGRAM - MILLING G21 G94 G91 G28 X0. Y0. Z0. TO1 M06 G17 G90 G54 G00 X20. Y20. G43 H01 Z100. M08 M03 S1000 G01 G90 Z20. G90 G83 G99 Z – 20. Q2. R1. F10 G01 X80. Y20. G01 X80. Y80. G01 X20. Y80. G01 X50. Y50. G80 G00 Z100. M09 G91 G28 X0. Y0. Z0. M05 M30 ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 45. PART PROGRAM - TURNING G21 G95 M06 T01 G18 G54 G00 G90 X40. Z5.0 G73 U0.5 W0.5 R10. G73 P10 Q70 U0.2 W0.2 F0.2 S1000 N10 G01 X14. Z1.0 N20 G01 Z-15. N30 G03 X22. Z-19. R4. N40 G01 X22. Z-34. N50 G02 X34.0 Z-40. R6. N60 G01 Z-50. N70 X50. Z0. G00 X60.0 Z50. M05 M09 T02 (TOOL CHANGE) (FINISH TURN CONTOUR) G96 S200 M03 S2500 G01 G90 X49.0 Z5.0 M08 G70 P10 Q70 F0.15 G00 X60.0 Z50.0 M05 M09 M30 G73 – Pattern Repeating Cycle G73 U… W… R… G73 P… Q… U… W… F... S... U: X-axis (radius value). This is the amount of material which will be cut in x-axis. W: Z-axis. This is the amount of material which will be cut in z-axis. R: Number of divisions. The number the contour will be repeated. P - Contour Start block number, Q - Contour End block number U - Finishing allowance in X-axis, W- Finishing allowance in Z-axis ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 46. PART PROGRAM - TURNINGG21 G95 M06 T01 G18 G54 G00 G90 X40. Z5.0 G73 U0.5 W0.5 R10. G73 P10 Q70 U0.2 W0.2 F0.2 M03 S1000 N10 G01 X0. Z0. N20 G03 X16. Z-8. R8. N30 G01 X16. Z-15. N40 G01 X26.0 Z-30. N50 G03 X34.0 Z-35. R5. N60 G01 X34. Z-50. N70 X50. Z0. G00 X60. Z50. M05 M09 MO6 T02 (TOOL CHANGE)(FINISH TURN CONTOUR) G96 S200 M03 S2500 G01 G90 X49. Z5. M08 G70 P10 Q70 F0.15 G00 X60. Z50. M05 M09 M30 G73 – Pattern Repeating Cycle G73 U… W… R… G73 P… Q… U… W… F... S... U: X-axis (radius value). This is the amount of material which will be cut in x-axis. W: Z-axis. This is the amount of material which will be cut in z-axis. R: Number of divisions. The number the contour will be repeated. P - Contour Start block number, Q - Contour End block number U - Finishing allowance in X-axis, W- Finishing allowance in Z-axis ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET
  • 47. MACRO – CNC PROGRAMMING • Macro programming is also known as Parametric Programming. • It means, we can control the program by external parameters. • This program uses the #(variable) sign to represent values. • Used for making Holes. G21 G94 G91 G28 X0. Y0. Z0. TO1 M06 (6 mm Drill) G17 G90 G54 G00 X20. Y20. G43 H01 Z100. M08 M03 S1000 #1 = 10. #2 = 100. M98 P500 (Call Subprogram) M05 M09 G91 G28 Z0. TO2 M06 (12 mm Drill) G17 G90 G54 G00 X20. Y20. M03 S1000 G43 H02 Z100. M08 #1 = 20. #2 = 200. M98 P500 (Call Subprogram) M05 M09 G00 Z100. G91 G28 Z0. M30 #1 variable – Depth #2 Variable – Feed Rate O500 (Sub Program) G90 G83 G99 Z-#1 Q2. R1. F#2 G01 X80. Y20. G01 X80. Y80. G01 X20. Y80. G01 X50. Y50. G80 M99 ME 8691 COMPUTER AIDED DESIGN & MANUFACTURING S.BALAMURUGAN, AP/MECHANICAL, AAACET