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WORKSHOP WORK SHOP ASSIGNMENT ASSIGNMEN T
ON
ADVANCED CNC MILLING
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MILLING MACHINES
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A milling machine is a machine tool used to machine solid materials. Mill machines exist in two basic fo rms: horizontal a nd vertical, which t erms ref er er the orientation of the cutting tool spindle. Unlike a drill press , in which th workpie ce is held stationary and the drill is moved vertically to penetrate th material, milling also involves movement of the workpiece against th e rotating cutter, the latter of which is able to cut o n its flanks as well as its t Workpiece and cutter movement are precisely controlled t o l ess than 0.001 (0.025 mm), u sually by means of precision ground slides and leadscrews analogous technology. Milling machines may be manuall y operated, mechanically automated, digitally automated via computer numerical co ntrol (CNC). Milling machines ine can per form a vast number of o perations, some very complex, such as slot a keyway cutting, planing, drilling, diesinking, rebating, routing, etc. Cutting flu is often pumped to the cutting site to cool and lubricate the cut, a nd to slu away the resulting swa rf . Most CNC milling machines (also called machining centers ) are comput controlled vertical m ills with the ability to move the spindle verticall y along th Z-axis. This extra degree of f reed reedom permits their use in diesinking, engraving applications, a nd 2.5D surfaces such as relief sculptures. When combined w the use of conical tools or a ball nose cutter, it also signif ica ntly improv milling precision without impacting speed, providing a co st -eff icient alternat to most flat- surface hand-engraving work. CNC machines can exist in virtuall any of the forms of manual mach inery, like horizontal mills. The mo advanced CNC millingmach ines, the multiaxis machine, add two more axes addition to the three normal a xes (XYZ). Horizontal m illing machines also hav a C or Q axis, allowing the horiz ontally moun tedupFree wo cthis to rkpie eDays Read Foron 30 Sign to vote titlebe rotated TheNotf iuseful fth axis (B axis essentially allowing asymmetric a nd eccentrictuUseful rning. Cancel anytime. contOnly the tilt of the tool itself . Wh en all of these axes are used rols$4.99/month. Special offer for students: conjunction with each other extremely complicated geometries even orga
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INTRODUCTION TO NUMERICAL CONTROL Numerical co ntrol (NC) ref ers to the automation of machine tools that are operated by ab stractly programmed commands en coded on a storage Reading a Preview medium, as opposed to ma nYou're ually co or mechanically automated via ntrolled cams alone. The f irs t NC mach ines were built in the 1940 s and '50s, based on Unlock full access with a free trial. exis ting tools that were modif ied with motors that moved the controls to follow points f edDownload tem onTrial into the sys paper tape. These early With Free servomechanisms were rapidly augmen ted with analog and digital computers creating the modern computer numerical controlled (CNC) machine tools that have revolutionized the design process. In modern CNC systems, end -to-end com ponent design is highly automated using CAD/CAM programs. The nds ted to tron act thtitle programs produce a computer f ile that is interpre ex e comma Read Free For 30this Days Sign up to vote loaded needed to operate a particular machine, and th en Useful into e CNC Notth useful Cancel anytime. mach for product ion. Since any particular component might require the ines Special offer for students: Only $4.99/month. use of a number of diff eren t tools, mo dern machines often combine multiple
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enough f rom the working piece for saf e operation. Mechanical ma nual contr disappeared long ago. CNC-like systems are now u sed for any pr ocess that can be described as a series of movements and operations. These include laser cutting, welding, f riction stir welding , ultraso welding , flame and plasma cutting, bending, spinning, pinning, gluing, fabri c cutt ing, sewing, tape and f iber placement, routing, picking and placing (PnP), and saw ing.
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Download With Free Trial FEATURES
OF CNC CNC systems include additional f eatures beyond what is f easible w conven tional hardwired Read Free Foron 30this Days Sign up to vote title nt NC. These f eatures , ma ny of which a re standard of most CNC mach ine co Useful Not useful Cancel anytime. units Special offer for students: Only $4.99/month. (MCU) where others are optional, include the following:
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testing and correcting a program ca n be done entirely at the machin e si rather than returning to the programming off ice to edit the tape.
4. Fixed cycles and programm ing subroutines. The increased memory ca pac and the ability to program th e control computer provide the opportu nity store f requently used machining cycles as macros that ca n be called by the p program. Instead of writing the full instructions for the particular cycle in every program, a call statement is included in the part program to indi cate tha the macro cycle should be executed. 5. Interpolation. Linear and circular interpolation is sometimes hard -wired in the control unit, but helical, parabolic and cubic interp olations are usuall executed in a stored program algorithm. 6. Positioning f eatures for set up. Setting up the machine tool for a giv workpart involves installing and aligning a f ixture on the machine tool tabl The alignment task can be facilitated using certain f eatures made possible software option in CNC system. Position set is one of these f eatures. W position set, the operato r is not required to locate the f ixture on the mach table with extreme accuracy.You're Reading a Preview Unlock full access with a free trial.
7. Cutter length and size compensation. In older style controls, cutt ly toFree agree with the tool path def ined dimensions had to be set very preciseWith Download Trial the part pr ogram. 8. Acceleration and deceleration calculation. This f eature is applicable wh the cutt er moves at high f eed rates. It is designed to avoid tool marks on th en th work surface that would be generated due to mach am ine dyn ics wh Read Free Foron 30this Days Sign up totool vote title cutter path changes abruptly. Useful Not useful
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9 Communicat ion interface. Most modern CNC controllers are equipped w
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ADVANTAGES OF CNC MACHINE CNC machine has several advantages with emphasis on mach ine too applicat ions. When the production application satisf ies the charact erist needed, CNC yields many bene f its over manual production methods. Th benef its translate into economic saving for the user company. Some of th advantages are: i. Nonpr oduct ive time is reduced through f ewer setu p, less setup time, l workpie ce handling time, and automatic tool changes. ii. Greater accurancy and repeatab ility. iii. Lower scrap rates. iv. Inspe ctions requiremen ts are reduced. v. More complex part geomet ries are possi ble vi. Enginnering changes ca n be accommodated more gracefully. vii. Simple f ixture are needed. viii. Shorter manufacturung lead times. ix. Red uced parts inventory. x. Less floorspac e required You're Reading a Preview menfull ts access are red xi. O perator skill level req uire e d.trial. Unlock withuc a free Download With Free Trial
MACHINE CONTROL UNIT (MCU) CNC machine is f itted with MCU which is performs the various controlling functions under the program control. The MCU ma y be generally hou sed in seperated cabinet l ike cabinet body or may be mounted on the machine itse Read Free Foron 30this Days Sign up to vote title Apperance wise it looks like a computer with a display panel generally of smal Useful Not useful Canceline anytime. tool along with size and a number of button to control th e mach Special offer for students: Only $4.99/month. keyboard. This control unit control the motion of cutting tool, spindle speeds
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NUMERICAL CONTROL MODE The controller have number of modes in which the can operate. There could four possible modes in which the controller ca n function in re lation to machine centre. 1. Termed as point to point mode. In this, the control has the capability operate all the three axes, but not necessarily simultaneously. It would possible to move the tool to any point (in X a nd Y a xes) and carry out th machining operation in one axis (Z axis) at that point. 2. Improvement ov er point to point mo de. The machine tool has the ca pabil to carry out a continuous motion in each of the axis dire ction.
3. A control system, which has simulta neous motion ca pability in any two axes.
4. The highest form of co ntrol that gives the ca pability of simultaneous three or more axes You're Reading a Preview motion. Unlock full access with a free trial.
PART PROGRAM
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Part program is a very important software element in the NC manufacturing system. It is a detailed plan of manufacturing instruct ions required machining the part as per drawing. The format standardized by ISO. For exam ple, Read Free Foron 30this Days Sign up to vote title N30 G00 X12 0 Y45 Z 85 Useful Not useful Cancel anytime. N40 G90 Special offer for students: Only $4.99/month. N50 G03 X200 I-100 J0 F200
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ISO standards for coding
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FO R
CHARACTER
ADDRESS
A
Angular N dimension around X axis O Angular dimension around Y axis P Angular dimension around Z axis Angular Q dimension around rd 3 f eed function Angular R dimension around nd 2 f eed function Feed funYou're ction ReadingS a Preview
B
C
D
E
F
CHARACTER
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G H
Preparatory T functionDownload With Free Trial Unassigned U
DistancScribd I semester with e to arc Master your centre to X & The New York Times Special offer for students: Only $4.99/month. J
Distance
to
V
arc W
FO R Sequence numb ADDRESS
Ref erences rewind sto p
Third ra traverse dimension Second ra traverse dimension First ra traverse dimension Spindle speed function Tool function
Secondary mot dimension parallel to X* Secondary mot Read Free Foron 30 Days Sign up to vote this title on mensi di Not useful Useful parallel to Y* Cancel anytime. Secondary mot di
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PREPARATORY FUNCTIONS This is denoted by G. It is a pre - set fu nction associated with the movement o machine axes and the associated geometry. It has two digits as per ISO specif ications. Some examples are show n: CODE
FUNCTION rapid traverse line interpolation circular interp olation, clockwise
G00 G01 G02 G03 G04 G05 G06 G33 G53 G64 G80
circular interp olation, anti -clockwise dwell hold/delay parabolic interpolation thread cutting, constant lead deletion of zero off set cha nge in f eed rate or speed canned cycle cancelled
You're Reading a Preview MISCELLANEOUS FUNCTIONS CODE
M00 M01 M02 M03 M04 M09 M10 M31Only $4.99/month. Special offer for students: M68
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program stop, spindle and coolant off Download With Free Trial optional programmable sto p end of program
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spindle on, clockwise spindle on, anticlockwise coolanRead tSign off upFree Foron 30this Days to vote title clamp Useful Not useful Cancel anytime. interlock by-pass unclamp piece art
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CNC SYSTEM LAYTOUT
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PROGRAMMING SYSTEMS Two types of programming modes, the incremental system and the ab solut system, are used for CNC. Both systems have applications in CNC programming, and no system is either right or wrong all the time. Mo controls on mach ine tools today are capable of handling either incremen tal o absolute programm ing. Incremental program locations are always given as the distan ce and direct f rom the immediately preceding point (Fig. 6). Comma nd codes which tell th machine to move the table, spindle, and knee are explained here using vertical m illing machine as an example:
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Download With Free Trial A X plus (X+) comma nd will cau se the cutting tool to be located to the rig of the last point. A X m inus (X-) comma nd will cau se the cutt ing tool to be located to the l of the last point. A Y plus (Y+) comma nd will cause the cutting tool tovote beon locat ed Read Free For 30this Days Sign up to titletoward th column. Not useful Useful Cancel anytime. A Only Y m inus (Y-) will cause the cutting tool to be located away f rom th Special offer for students: $4.99/month. column.
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Absolute program locat ions are always given f rom a single f ixed zero or origin
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point (F ig. 7). The zero o r origin point ma y be a position on the mach ine tabl such as the corner of the worktable or at any specif ic point on the workpie
In absolute dimensioning and programm ing, each point or location on th workpie ce is given as a cer tain distance f rom the zero o r ref erence point.
You're Reading a Preview A X plus (X+) comma nd will cau se the cutting tool to be located to the rig Unlock full access with a free trial. of the zero or origin point. A X m inus (X-) comma nd will cau se the cutt ing tool to be located to the l Download With Free Trial of the zero or origin point. A Y plus (Y+) comma nd will cause the cutting tool to be located toward th column. A Y minus (Y-) comma nd will cau se the cutting tool to be located awa f rom the column. Read Free Foron 30this Days Sign up to vote title
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In ab solut e programming, the G90 command indicates to the computer a Special offer for students: Only $4.99/month. MCU that the programming is in the absolute mode.
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In Fig point 1 to point 2 is a straight line, and the machine moves only alo the X a xis; but points 2 a nd 3 require that motion along both the X a nd Y a xes takes place. As the distance in the X direction is greater than in the Y directio Y will reach its position f irst, leaving X to travel in a straight line for th remaining distance. A similar motion takes place between points 3 and 4. You're Reading a Preview Unlock full access with a free trial.
CONTINIOUS PATH Contouring, or continuousDownload path mach involves work such as tha Withining Free,Trial produced on a lathe or milling machine, where the cutting tool is in contact with the workpiece as it travels f rom one programmed point to the nex Continuous path positioning is the abi lity to control motions on two or mo machine axes simultaneously to keep a constant cutter -workpiece relationsh The programmed information in the CNC program accu tion th stvote rat eltitle y posi Read Free Foron 30 Days Signmu up to this cutt ing tool f rom one point to the next and follow a prede f Not accurate path ined useful Useful Cancel anytime. at a Only ammed f eed rate in order to produce the form or contour required. progr Special offer for students: $4.99/month.
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INTERPOLATION The method by which contouring mach ine tools move f rom one programm point to the next is called interpolation. This ability to merge individual a points into a predef ined tool path is built into most of todays MCU s. There a f ive methods of interp olat ion: linear, circular, helical, parabolic, and cubic. contouring controls provide linear interpolation, and most controls are capabl of both linear and circular interpolation. Helical, parabolic, and cub interpolation are used by industries that ma nufacture parts which hav com plex shapes, such as aerospace parts and dies for car bodies. LINEAR INTERPOLATION Linear I nterp olation consists of any programmed points linked together straight lines, wh ether the points are close together or far apart. Curves can produced with linear interpolation by breaking them into short, straight-l segments. This method has limitations, because a ve ry large number of poin would have to be programmed to describe the curve in order to produce contour shape. A contour programmed in linear interpolation requires th coo rdinate positions (XY posi tionsReading work) for the start and f inish in two-a You're a xis Preview each line segment. Therefore, the end point of one line or segment becom Unlock full access with a free trial. the start point for the next segment, and so on, throughout the en t program. Download With Free Trial
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CNC MILLING CENTRES Vertical machining centers and turning centers are the most common CNC machines used in industry. For tea ching purposes, two types of CNC Ben ch-To machines, th e lathe and the mill, will be used because they use the same ba programming f eatures and the Fanuc compatible controls as indust You're Reading a Preview machines. Mo st of the G and M codes are the same for CNC Bench -t accessines. with aSfree teaching machines and induUnlock mach strialfull inctrial. e pr ogramm ing codes do va slightly with manufacturers, it is always wise to consult the programm ing Download With manual for each specif ic mach ine to avo id cFree rashTrial es or scrap work. The 3-a xes bench-top CNC vertical machining cen tre (mill) with the Fan com patible controller, is ideal for teaching the basics of CNC mill programming. It includes all important G and M codes, milling cycles, subroutines, etc. a can be programmed in inch or metric dimensions in both incremental a Read Free For 30 Days Sign up on this absolute programming. Some models are equipped w thvote a ap hictitle ito gr s displa y that Useful Not useful allows the operator to test- run the program o comanytime. n th eCancel puter screen withou Special offer for students: Only $4.99/month. cutt ing a part. This is a saf e way to check the accurac y of a program, to preven
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CNC PART PROGRAMMING
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We ass ume that the machining is a contouring operation alo ng the out boundary of a simple part, who ominal age ometry is as show n on Fig.3. se nReading You're Preview Unlock full access with a free trial. The tool size is 0. 25 inch, a nd the f eed rate of 6 inch per minute is used.
Download The cutt ing speed is required to be With 300 Free rpmTrial . To simplif y the program, w
ignore the Zaxis motions, and that the home position of the tool is at th
correct height, centered on the point located in the machine tool coordinat as (2, 2).
Master your semester with Scribd Read Free Foron 30this Days Sign up to vote title n order to specif y the geometry of the motion, we need to comput e th & The NewIlocat York Times Useful Not useful ion of 5 points f rom p1 to p5 (later, w e shall see that additional points w Special offer for students: Only $4.99/month.
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NOTE: we could use M14 instead of M04 and M08 that w e shall use in the nex
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block. // Block 2: cutting on XY plane, set f eed, spindle speed, N020 G17 F6.0 S300 T1001 M08 [EOB] // Block 3: move to f irst point in a straight line (linear interp olation). We n need to compute the coordinates of p1, as shown in f igure below:
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N050 G01 X5 .635 Y9.125 [EOB]
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// blocks 6, 7, 8: now we need to cut alo ng a circular arc. Most NC controllers cannot cut along a full circle directl y they need to
programmed once FOR EACH QUADRANT of the arc. In our ca se, the circula
path of the tool goes through tree quadrants, so we need to f ind two
additional points, p31, a nd p32. Programming for circular interp olat ion (moving the tool along a circular ar Circular arcs are machined only in main planes. The plane is selected by th preparatory functions (G17, G18, G19). The dire ction of the tool along the a
must be specif ied (G02, G03, G20 G21, G30, G31) . Four dimension words are needed per block. Two dimension words specif y th distance to the end of the arc f rom current position. Two circular dimensi
words specif y the distance to the arc center. Usually, I, J, K specif y th
distances parallel to the X, Y, Z a xes, respe ctively. You're Reading a Preview The I, J, K valu es are absolutUnlock e valu es (unless there is ambiguity). The following full access with a free trial.
f igure shows the computat ions of the next three blocks of motion: Download With Free Trial
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Figure 6 : Circular movement f rom p3 to p4
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The corresponding blocks are: *NOTE : EOB stands for End Of Block N060 G03 X5 .625 Y9.0 I0.866 J0.125 [EOB] N070 G03 X6 .5 Y8.125 I0.875 J0.0 [EOB] N080 G03 X7 .375 Y9.0 I0.0 J0.875 [EOB] // block 9: the next move is to point p4 (coordinates computed similar to p3) N090 G03 X7 .366 Y9.125 I0.875 J0.00[EOB] // blocks 10, 11, 12 : all linear interpolation. Computations for the point p5 are as follows: p4: y = 9.125; x = 9 + 0 .125 ta n 67.5 = 9.302 You're Reading a Preview
N100 G01 X9 .302 [EOB]
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NOTE: here we did not specif y the Y coordinate, so it will be kept constant. Download With Free Trial N110 G01 X3 .875 Y3.698 [EOB] N120 G01 X2 .0 Y2. 0 M30 [EOB]
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REFERENCES
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y
Wikipedia
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Computer Numeric control basics by Steve Krar and Arthur Gill
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P.N. Rao, CAD/CAM Principles and Applications
y
Serope Kalpakjian, W.R.Schmid, Manufacturing Technology and Fundamentals.
y
www.scribd.com
y
http://www.technologystudent.com
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