Summer Tanning Presentation Makino India pvt ltd.

CNC

Submitted to: Trinath Mahala

Submitted by; Hari om Maurya

Ken Youssefi

Mechanical Engineering Department

Makino India Pvt Ltd.

1. Makino manufacture products and machine for different field of industries like Aerospace, Automobile, power plant, General production , die casting etc. 2. Some major products are Horizontal Machining Centers (HMC), Vertical Machining Centers (VMC), 5-Axis Machines, Graphite Machines, EDM Machines (Wire and Ram types), Automated Pallet Systems, Grinding Machines, and various services. 3. The tanning at Makino involves on operation of workshop, basics of CNC, operation & handling of CNC machine. 4. Main part of the training is programming CNC.
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Numerical Control
Numerical control is a method of automatically operating a manufacturing machine based on a code of letters, numbers, and special characters. The numerical data required to produce a part is provided to a machine in the form of a program, called part program or CNC program. The program is translated into the appropriate electrical signals for input to motors that run the machine.

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Numerical Control - History

The concept is credited to John Parson (1947). Using punched cards he was able to control the position of a machine in an attempt to machine helicopter blade. US Air Force teamed up with MIT to develop a programmable milling machine (1949). In 1952, a three-axis Cincinnati Hydrotel milling machine was demonstrated. The term Numerical Control (NC) originated. The machine had an electromechanical controller and used punched cards. A new class of machines called machining centers and turning centers that could perform multiple machining processes was developed. Modern NC machine has a computer on board, Computer Numerical Control (CNC). They can run unattended at over 20,000 rpm (spindler speed) with a feed rate of over 600 ipm and an accuracy of .0001
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Computer Numerical Control (CNC)

A CNC machine is an NC machine with the added feature of an on-board computer.

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Hardware Configuration of NC Machine

Machine Control Unit (MCU) the brain of the NC machine. The Data Processing Unit (DPU) reads the part program. The Control Loop Unit (CLU) controls the machine tool operation.

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HAAS CNC Machines

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CNC Machines
Machining Centers, equipped with automatic tool changers, are capable of changing 90 or more tools. Can perform milling, drilling, tapping, boring on many faces.

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CNC Machines
Turning Centers are capable of executing many different types of lathe cutting operations simultaneously on a rotating part.

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CNC Controllers
The NC controller is the brain of the NC system, it controls all functions of the machine. Motion control deals with the tool position, orientation and speed. Auxiliary control deals with spindle rpm, tool change, fixture clamping and coolant.

Many different types of controllers are available in the market (GE, Fanuc, Allen-Bradley, Okuma, Bendix, ). There are two basic types of control systems: point-to-point and continuous path.
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Point-to-point control systems cause the tool to move to a point on the part and execute an operation at that point only. The tool is not in continuous contact with the part while it is moving. Drilling, reaming, punching, boring and tapping are examples of point-to-point operations.

Point-to-Point Tool Movements

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Continuous-Path Tool Movements

Continuous-path controllers cause the tool to maintain continuous contact with the part as the tool cuts a contour shape. These operations include milling along any lines at any angle, milling arcs and lathe turning.

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Loop Systems for Controlling Tool Movement

Open Loop System
Uses stepping motor to create movement. Motors rotate a fixed amount for each pulse received from the MCU. The motor sends a signal back indicating that the movement is completed. No feedback to check how close the actual machine movement comes to the exact movement programmed.

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Loop Systems for Controlling Tool Movement

Closed Loop System
AC, DC, and hydraulic servo-motors are used. The speed of these motors are variable and controlled by the amount of current or fluid. The motors are connect to the spindle and the table. A position sensor continuously monitors the movement and sends back a single to Comparator to make adjustments.

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Flow of Computer-Aided CNC Processing

Develop or obtain the 3D geometric model of the part, using CAD. Decide which machining operations and cutter-path directions are required (computer assisted). Choose the tooling required (computer assisted). Run CAM software to generate the CNC part program. Verify and edit program. Download the part program to the appropriate machine. Verify the program on the actual machine and edit if necessary. Run the program and produce the part.
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Basic Concept of Part Programming

Part programming contains geometric data about the part and motion information to move the cutting tool with respect to the work piece. Basically, the machine receives instructions as a sequence of blocks containing commands to set machine parameters; speed, feed and other relevant information. A block is equivalent to a line of codes in a part program. N135 G01 X1.0 Y1.0 Z0.125 T01 F5.0
Block number G-code Coordinates Tool number
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Special function

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Basic Concept of Part Programming

Preparatory command (G code) The G codes prepare the MCU for a given operation, typically involving a cutter motion. G00 G01 G06 G17 G20 G28 G33 rapid motion, point-to-point positioning linear interpolation (generating a sloped or straight cut) parabolic interpolation (produces a segment of a parabola) XY plane selection circular interpolation automatic return to reference point thread cutting
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Basic Concept of Part Programming

Miscellaneous commands (M code) M00 program stop M03 M06 start spindle rotation (cw) tool change

M07 turn coolant on Feed commands (F code) Used to specify the cutter feed rates in inch per minute. Speed commands (S code) Used to specify the spindle speed in rpm. Tool commands (T code) Specifies which tool to be used, machines with automatic tool changer.
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CNC Machine Axes of Motion

The coordinate system used for the tool path must be identical to the coordinate system used by the CNC machine. The standards for machine axes are established according to the industry standard report EIA RS-267A.
Right hand rule

Vertical milling machine Horizontal milling machine

CNC machines milling machines can perform simultaneous linear motion along the three axis and are called three-axes machines.
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CNC Machine Axes of Motion

Coordinate system for a Lathe

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CNC Machine Axes of Motion

More complex CNC machines have the capability of executing additional rotary motions (4th and 5th axes).

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CNC Machine Axes of Motion

Five-axis machine configurations

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CNC Machine Tool Positioning Modes

Within a given machine axes coordinate system, CNC can be programmed to locate tool positions in the following modes; incremental, absolute, or mixed.

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Example of a part program

N001 G91 (incremental) N002 G71 (metric) Loading tool
Rapid motion Tool change

N003 G00 X0.0 Y0.0 Z40.0 T01 M06 Positioning tool at P1

Start spindle Start coolant

N004 G01 X75.0 Y0.0 Z-40.0 F350 M03 M08

Linear interpolation

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Example of a part program

Moving tool from P1 to P3 through P2 N005 G01 X110 N006 G01 Y70.0 Moving tool from P3 to P4 along a straight line and from P4 to P5 clockwise along circular arc. N007 G01 X-40.86 N008 G02 X-28.28 Y0.0 I-14.14 J-5.0

Tool dia.=10 mm
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Example of a part program

X and Y specify the end point of the arc (P5) with respect to the start point (P4). I and J specify the center of the arc with respect to the start point.

14.14

N008 G02 X-28.28 Y0.0 I-14.14 J-5.0

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Computer-Assisted Part Programming

Automatically Programmed Tools (ATP) language is the most comprehensive and widely used program. The language is based on common words and easy to use mathematical notations

Identify the part geometry, cutter motions, speeds, feeds, and cutter parameter. Code the above information using ATP. Compile to produce the list of cutter movements and machine control information (Cutter Location data file, CL). Use post-processor to generate machine control data for a particular machine. This is the same as NC blocks.
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Part Programming from CAD Database Integrated CAD/CAM Systems

In an integrated CAD/CAM system, the geometry and tool motions are derived automatically from the CAD database by the NC program (Pro/E, Unigraphics, .) No need for manual programming or using APT language.

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Integrated CAD/CAM System

CAD and Cam (Computer Aided Manufacturing) together create a link between product design and manufacturing. The CAD system is used to develop a geometric model of the part which is then used by the CAM system to generate part programs for CNC machine tools. Both CAD and CAM functions may be performed either by the same system or separate systems in different rooms or even countries. Extending the connection between CAD and CAM to its logical limits within a company yields the concept of the computer-integrated enterprise (CIE). In CIE all aspects of the enterprise is computer aided, from management and sales to product design and manufacturing.
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CAD/CAM
CAD/CAM systems allow for rapid development and modifying of designs and documentation. The 3D geometric model produced becomes a common element for engineering analysis (FEA), machining process planning (including CNC part programming, documentation (including engineering drawings), quality control, and so on. The coupling of CAD and CAM considerably shortens the time needed to bring a new product to market. Increased productivity is generally the justification for using CAD/CAM system.
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Product Data Management System (PDM)

Product development cycle includes activities not only in design and manufacturing but also in analysis, quality assurance, packaging, shipping, and marketing. Software systems called product data management (PDM) are available to smooth data flow among all these activities. Some available software; SDRCs Metaphase, Unigraphicss IMAN, Computer Visions Optegra. (web-enabled software).

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Electrical Discharge Machine - EDM

Die-sinking EDM systems, the electrode (cutting tool) and workpiece are held by the machine tool. The power supply controls the electrical discharges and movement of the electrode in relation to the workpiece. During operation the workpiece is submerged in a bath of dielectric fluid (electrically nonconducting). (Die-Sinking EDM is also called Sinker, Ram-Type, Conventional, Plunge or Vertical EDM)

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EDM Die-Sinking (Plunge)

During normal operation the electrode never touches the workpiece, but is separated by a small spark gap. The electrode (plunger) can be a complex shape, and can be moved in X, Y, and Z axes, as well as rotated, enabling more complex shapes with accuracy better than one mil. The spark discharges are pulsed on and off at a high frequency cycle and can repeat 250,000 times per second. Each discharge melts or vaporizes a small area of the workpiece surface. The amount of material removed from the workpiece with each pulse is directly proportional to the energy it contains. Plunge EDM is best used in tool and die manufacturing, or creating extremely accurate molds for injection-molding plastic parts.
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EDM
The dielectric fluid performs the following functions: It acts as an insulator until sufficiently high potential is reached . Acts as a coolant medium and reduces the extremely high temp. in the arc gap. More importantly, the dielectric fluid is pumped through the arc gap to flush away the eroded particles between the workpiece and the electrode which is critical to high metal removal rates and good machining conditions. A relatively soft graphite or metallic electrode can easily machine hardened tool steels or tungsten carbide. One of the many attractive benefits of using the EDM process. 34
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EDM
The EDM process can be used on any material that is an electrical conductor The EDM process does not involve mechanical energy, therefore, materials with high hardness and strength can easily be machined. Applications include producing die cavity for large components, deep small holes, complicated internal cavities Dimensional accuracy of 0.0005 in is achievable. Minimum wall thickness: .01 inch, over 5 inch span Feature to feature positioning: .001
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Wire EDM machines utilize a very thin wire (.0008 to .012 in.) as an electrode. The wire is stretched between diamond guides and carbide that conduct current to the wire and cuts the part like a band saw. Material is removed by the erosion caused by a spark that moves horizontally with the wire.

Wire EDM

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EDM Examples

Intricately detailed automobile part 7075-T6 aluminum back plate latch, EDM cost is less than half the milling cost. These simple, flat shapes, used in food processing, which usually would be stamped, were wire EDMed instead because they required a superior quality edge.
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EDM Examples
To manufacture titanium earring shapes wire EDM proved the most cost effective when compared to stamping and laser cutting.

Turbine blades

Small gear (with insect for scale) shows a capability of EDM micromachining.

Small parts made using EDM

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CNC Machines
Laser Machining and Cutting
The machine utilizes an intense beam of focused laser light to cut the part. Material under the beam experiences a rapid rise in temp. and is vaporized. Laser cuts with a minimum of distortion, no mechanical cutting forces. .

Gas is blown into the cut to clear away molten metals, or other materials in the cutting zone. In some cases, the gas jet can be chosen to react chemically with the workpiece to produce heat and accelerate the cutting speed Mechanical Engineering Department 39

Laser machining and Cutting

The first ever gas-assisted laser cuts were done in1967. Sheet metal cutting has since become, by far, the dominant industrial use of lasers in materials processing. Approximately 12 000 industrial laser cutting systems have been installed world-wide, with a total market value of some 4.5 billion US dollars. Over 60% of this equipment is installed in Japan. Today, laser cutting is used extensively for producing profiled flat plate and sheet, for diverse applications in the engineering industry sectors. Metals, ceramics, polymers and natural materials such as wood and rubber can all be cut using CO2 lasers.
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Laser machining and Cutting

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Laser machining and Cutting

Advantages Excellent control of the laser beam with a stable motion system achieves an extreme edge quality. Laser-cut parts have a condition of nearly zero edge deformation, or roll-off It is also faster than conventional tool-making techniques. Laser cutting has higher accuracy rates over other methods using heat generation, as well as water jet cutting. There is quicker turnaround for parts regardless of the complexity, because changes of the design of parts can be easily accommodated. Laser cutting also reduces wastage.
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Laser machining and Cutting

Disadvantages The material being cut gets very hot, so in narrow areas, thermal expansion may be a problem. Distortion can be caused by oxygen, which is sometimes used as an assist gas, because it puts stress into the cut edge of some materials; this is typically a problem in dense patterns of holes. Lasers also require high energy, making them costly to run. Lasers are not very effective on metals such as aluminum and copper alloys due to their ability to reflect light as well as absorb and conduct heat. Neither are lasers appropriate to use on crystal, glass and other transparent materials.
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Laser machining and Cutting

Laser drilling hole

Laser welding in automobile industry

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