Beruflich Dokumente
Kultur Dokumente
NC,CNC&Robotics
WhatisNC/CNC?
NC is an acronym for Numerical Control and CNC is an acronym for Computer Numerical Control.
BySKMondal
WhatisthedifferencebetweenNCandCNC?
The difference between NC and CNC is one of age and capability. The earliest NC machines performed limited functions and movements controlled by punched tape or punch cards. cards As the technology evolved, the machines were equiped with increasingly powerful microprocessors (computers) with the addition of these computers, NC machines become CNC machines. CNC machines have far more capability than their predecessor. contd..
WhatisthedifferencebetweenNCandCNC?
Some of the enhancements that came along with CNC include: Canned Cycles, Sub Programming, Cutter Compensation, Work coordinates, Coordinate system rotation, automatic corner rounding, chamfering, and B spline interpolation.
WheredidCNCgetstarted?
1940 Jhon Parson developed first machine able to drill holes at specific coordinates programmed on punch cards. 1951 MIT developed servomechanism 1952 MIT developed first NC machines for milling. 1970 First CNC machines came into picture Nowadays modified 1970s machines are used.
IsitnecessarytohaveaCAD/CAM systemtoprogramaCNCmachine?
No, yes, may be. It all depends on the kind of work you are doing, your customers requirements and your staffs capability. CAM system give the programmer a tool for creating set up sheets and process drawings.
10/1/2011
DoallmachinesspeakthesameCNC language
No, while there is fairly standard set of G and M codes, there is some variation in their application. For example a G0 or G00 command is universally regarded as the command for rapid travel. Some older machines do not have a G00 command. On these machines, rapid travel is commanded by using the F (feed) word address.
WhatisaConversationalControl
CNC machine tool builders offer an option what is known as the conversational control. This control lets the operator/programmer use simple descriptive
language to program the part. The control then displayed a graphical representation of the instructions so the operator/programmer can verify the tool path.
AreCNCmachinesfasterthan conventionalmachines?
Yes, No, Sometimes. When it comes to making a single, simple part it is hard to beat a conventional mill or lathe. lathe CNC machines move faster in rapid travel than conventional machines.
AreCNCmachinesmoreaccurate thanconventionalmachines?
Yes, they can be. But like anything else it depends on who i running th machine, h h is i the hi how well th machines h ll the hi has been maintained, quality of setup and so on.
NC/CNCMachinesAdvantages
High Repeatability and Precision e.g. Aircraft parts Volume of production is very high Complex contours/surfaces need to be machined. E.g. Turbines Flexibility in job change, automatic tool settings, less scrap More safe, higher productivity, better quality Less paper work, faster prototype production, reduction in lead times
NC/CNCMachinesDisadvantages
Costlysetup,skilledoperators Computers,programmingknowledgerequired Maintenanceisdifficult
10/1/2011
NC/CNC/DNC
Direct Numerical Control is a system that uses a central computer to control several machines at the same time Distributed Numerical Control (DNC): the central computer downloads complete programs to the CNC t d l d l t t th machines, which can be workstations or PCs, and can get the information for the machine operations. The speed of the system is increased, large files can be handled and the number of machine tools used is expanded.
13
Directnumericalcontrol
14
DNC
BasicLengthUnit(BLU)
In NC machine, the displacement length per one pulse output from machine is defined as a Basic Length Unit (BLU). In the CNC computer each bit (binary digit) represents 1 BLU. BLU Bit = BLU Example: If one pulse makes a servo motor rotate by one degree and the servo motor moves the table by 0.0001 mm, one BLU will be 0.0001 mm. The lead of a ball screw is related to the displacement unit of the machine tool table.
15
StepperMotor
The stepper motor is special type of synchronous motor which is designed to rotate through a specific angle (Called step) for each electrical pulse received from the control unit.
10/1/2011
ControlSystemspossibleinCNCMachine
Point to point mode:
Pointtopointstraightlinemode
Coordinatesystem
All the machine tool use Cartesian Coordinate system. The first axis to be identified is the Z axis, This is followed by X and Y axes respectively.
Righthandcoordinatesystems
10/1/2011
5axesCNCverticalaxismachiningcentreconfiguration
Thefollowingarethestepstobefollowed whiledevelopingtheCNCpartprograms.
Processplanning Axesselection Toolselection Cuttingprocessparametersplanning Jobandtoolsetupplanning Machiningpathplanning Partprogramwriting Partprogramproving
10/1/2011
BasicCNCPrinciples
For a CNC machine control unit (MCU) decides cutting speed, feed, depth of cut, tool selection , coolant on off and tool paths. The MCU issues commands in form of numeric data to motors that position slides and tool accordingly.
PartProgramming
FANUCCONTROLL SIEMENSCONTROLL
CNCprogramming
Importantthingstoknow:
ProgrammingKeyLetters
O Programnumber(Usedforprogramidentification) N Sequencenumber(Usedforlineidentification) G Preparatoryfunction X Xaxisdesignation Y Yaxisdesignation g Z Zaxisdesignation R Radiusdesignation F Feedratedesignation S Spindlespeeddesignation H Toollengthoffsetdesignation D Toolradiusoffsetdesignation T ToolDesignation M Miscellaneousfunction
ExplanationofcommonlyusedGcodes
G00 Preparatory code to control final position
of the tool and not concerned with the path that is followed in arriving at the final destination. G01 Tool is required to move in a straight line connecting current position and final position. Used for tool movement without any machining point to point control. (linear interpolation) G02 Tool path followed is along an arc specified by I, J and K codes.( circular interpolation)
10/1/2011
CNCProgrammingBasics
Each letter address relates to a specific machine function. G and M letter addresses are two of the most common. A G letter specifies certain machine preparations such as inch or metric modes, or absolutes versus incremental modes. A M letter specifies miscellaneous machine functions and work like on/off switches for coolant flow, tool changing, or spindle rotation. Other letter addresses are used to direct a wide variety of other machine commands.
TableofImportantGcodes
G00RapidTransverse G01LinearInterpolation G02CircularInterpolation,CW G03CircularInterpolation,CCW G17XYPlane,G18XZPlane,G19YZPlane G XYPl G XZPl G YZPl G20/G70Inchunits G21/G71MetricUnits G40Cuttercompensationcancel G41Cuttercompensationleft G42Cuttercompensationright
TableofImportantGcodes
G43Toollengthcompensation(plus) G44Toollengthcompensation(minus) G49Toollengthcompensationcancel G80Cancelcannedcycles G81Drillingcycle G82Counterboringcycle G83Deepholedrillingcycle G90Absolutepositioning G91Incrementalpositioning
Rapidtraverse:G00
G00:
tomakethemachinemoveatmaximumspeed. Itisusedforpositioningmotion. G90G00X20.0Y10.0 G90G00X20 0Y10 0
G90: absolute coordinate s
Start End
(20,10) (10,10)
(0,0)
Linearinterpolation:G01
G01:
linearinterpolationatfeedspeed. G91G0lX200.0Y100.0F200.0
G91: incremental coordinates Y 100.0 End
Circularinterpolation:G02,G03
G02,G03: Forcircularinterpolation,thetooldestinationandthecircle centerareprogrammedinoneblock G02isclockwiseinterpolation,G03iscounterclockwise interpolation
G 02 R G17 X __ Y __ G 03 I __ G 02 R G18 X __ Z __ G 03 I __ G 02 R G19 Y __ Z __ G 03 J __ F __; J __ F __; K __ F __; K __
Start
200.0
End point
Circlecenter,radius
10/1/2011
Circularinterpolation:G02,G03
Y X R=-50mm End
Circularinterpolation:G02,G03
Y End
SpecifyCenterwithI,J,K
I,J,Karetheincremental distancefromthestartof thearc; Start Viewingthestartofarcas theorigin,I,J,Khave positiveornegativesigns.
SpecifyRwith signbeforeit:
180 +R >180 R
Start
R=50mm
Circularinterpolation:G02,G03
N0010G92X200.0Y40.0Z0; N0020G90G03X140.0Y100.0I60.0F300 N0030G02X120.0Y60.0I 50.0
Or G92: Todefineworking coordinate
Circularinterpolation:G02,G03
AnnotationforCircularInterpolation
I0.0,J0.0,andK0.0canbeomitted. IfX,Y,Zareallomittedintheprogram,thatmeans startandendofarcaresamepoints. startandendofarcaresamepoints
N0020G02I20.0(afullcircle)
IfI,J,K,andRallappearsincircularinterpolation instruction,RisvalidandI,J,andKareinvalid
R50 R60 X
90 120 140
200
ToolCompensation
ToolRadiusCompensation
LefthandG41 RighthandG42 CanceltoolradiuscompensationG40 C l l di i G
ToolRadiusCompensation
Toolradiuscompensationsmakeitpossibleto programdirectlyfromthedrawing,andthuseliminate thetooloffsetcalculation
G41(G42)H
H:theradiusoftooltocompensateissavedinamemoryunitthat H th di ft lt t i di itth t isnamedH G41/G42isdirectlyrelatedwithdirectionoftoolmovementand whichsideofpartiscut.
ToolHeightCompensation
PositiveG43 NegativeG44 CanceltoolheightcompensationG49
10/1/2011
CancelToolCompensation:G40
Notethedifferencebetweentwoways
N0060G40G01 X2.000Y1.700M02 N0060G01 X2.000Y1.700 7 4 N0070G40 M02
ToolHeightCompensation
G43(G44)H
H:specifiedmemoryunitusedtosaveheight compensationoftool. Positivecompensation(G43):
realposition=specifiedposition+valuesavedinH
Negativecompensation(G44):
realposition=specifiedposition valuesavedinH
rampoffblock effectivetotheendpoint
ToolHeightCompensation
Example:
N0010G91G00X12.0Y80.0 N0020G44Z32.0H02 Ifweput0.5mmintoH02, realposition=32.0 0.5=32.5
G91: incremental coordinates
TableofImportantMcodes
M00Programstop M01Optionalprogramstop M02Programend M03Spindleonclockwise M04Spindleoncounterclockwise M05Spindlestop M06Toolchange M08Coolanton M09Coolantoff M10Clampson M11Clampsoff M30Programstop,resettostart
Canceltoolheightcompensation:G49
Rulesforprogramming
Block Format N135 G01 X1.0 Y1.0 Z0.125 F5 Sample Block Restrictions on CNC blocks Each may contain only one tool move Each may contain any number of non-tool move G-codes Each may contain only one feed rate Each may contain only one specified tool or spindle speed The block numbers should be sequential Both the program start flag and the program number must be independent of all other commands (on separate lines) The data within a block should follow the sequence shown in the above sample block
ExampleofCNC Programming
WhatMustBeDoneToDrillAHoleOnACNC VerticalMillingMachine g
10/1/2011
ToolHome
Top View
Top View
1.)X&YRapidToHolePosition
Front View
Front View
.100
Top View
5 5.)ZAxisFeedMoveto DrillHole
Top View
6.)RapidZAxisMove OutOfHole
Front View
Front View
HeresTheCNCProgram!
ToolAtHome
Top View
Top View
Front View
Front View
10
10/1/2011
ToolAtHome
ToolAtHome
Top View
O0001
O0001 NumberAssignedtothisprogram
Top View
O0001 N005G54G90S600M03
N005 G54 G90 S600 M03 SequenceNumber FixtureOffset AbsoluteProgrammingMode SpindleSpeedsetto600RPM SpindleoninaClockwiseDirection
Front View
Front View
Top View
Top View
Front View
Front View
Top View
Top View
Front View
Front View
11
10/1/2011
Top View
Top View
Front View
Front View
O0001 N005G54G90S600M03 N010G00X1.0Y1.0 N015G43H01Z.1M08 N020G01Z .75F3.5 N020G01Z.75F3.5 N025G00Z.1M09 N030G91G28X0Y0Z0 N035M30
M30 EndofProgram
APTLanguage
APT (Automatically Programmed Tools) TheAPTlanguageconsistsofmanydifferenttypesof statementsmadeupofthefollowingvalidletters,numerals andpunctuationmarks. Letters: ABCDEFGHIJKLMNOPQRSTWWXYZ Numerals: 0123456789 / Aslashdividesastatementintotwosections.eg., GO/PAST, , Acommaisusedasaseparatorbetweentheelementsin astatementgenerallytotherightoftheslash. = Anequalsisusedforassigninganentitytoasymbolic name,e.g.,CI=CIRCLE/25,50,30.
Words
The words to be used in the statements are built up from one to six letters or numerals with the first one being a letter. No special character is allowed in the words.
ThecompleteAPTpartprogramconsistsof thefollowingfourtypesofstatements
Geometry Motion Postprocessor Compilationcontrol
12
10/1/2011
APTLanguage
Additionalstatements:
MACHIN/DRILL, 2 COOLNT/ p Forexample: COOLNT/MIST COOLNT/FLOOD COOLNT/OF FEDRAT/ SPINDL/ Forexample: SPINDL/ON SPINDL/1250, CCLW TOOLNO/ TURRET/ END
APTLanguage
OthercapabilitiesofAPT,themacrofacility,withusevariableargumentasina FORTRANsubroutine,forexample:
P0 = POINT/0.0, 0.3, 0.1 FROM/P0 CALL/DRILL, X=1.0, Y=1.0, Z=0.1, DEPTH=0.7 CALL/DRILL, X=2.0, Y=1.0, Z=0.1, DEPTH=0.7 GOTO/P0
whenthedefinitionofthemacroDRILLis:
73
74
OtherPartProgramming Languages
Point (POINT)
PTA = POINT/ 3,4,5
y (3, 4, 5) PTA z
ADAPT (ADaptationAPT)wasthefirstattempttoadaptAPT programmingsystemforsmallercomputers AUTOSPOT (AUTOmaticSytemforPOsitioningTools)was developedbyIBMandfirstintroducedin1962 EXAPT (EXtendedsubsetofAPT)wasdevelopedjointlyin Germaninabout1964byseveraluniversitiestoadaptAPTfor Europeanuse.ItiscompatiblewithAPTandthuscanusethe E I i ibl i hAPT d h h sameprocessorasAPT COMPACT wasdevelopedbyManufacturingDataSystems,Inc. (MDSI) SPLIT (SundstrandProcessingLanguageInternallyTranslated) wasdevelopedbySundstrandCorporation,intendedforitsown machinetools MAPT (MicroAPT)isasubsetofAPT,toberunonthe microcomputers
75
Point (POINT)
PTB = POINT/ INTOF, LIN1, LIN2
Point (POINT)
PTD = POINT/ YSMALL, INTOF, LIN3, C1 PTD = POINT/ XSMALL, INTOF, LIN3, C1 PTC = POINT/ YLARGE, INTOF, LIN3, C1 PTC = POINT/ XLARGE, INTOF, LIN3, C1 y
PTC
LIN2
13
10/1/2011
Point (POINT)
PTE = POINT/ YLARGE, INTOF, C1, C2 PTE = POINT/ XLARGE, INTOF, C1, C2 PTF = POINT/ YSMALL, INTOF, C1, C2 PTF = POINT/ XSMALL, INTOF, C1, C2
Point (POINT)
PT7 = POINT/ CENTER, C6
y
y PTE C6
C1
PT7
PTF
C2
Line (LINE)
LIN1 = LINE/ P1, P2
y
Line (LINE)
LIN4 = LINE/ PT6, 15, -30, 3
y PT6 P2
P1 L4 LIN1 x x (15,30,3)
Line (LINE)
L12 = LINE/ PT4, ATANGL, 20, XAXIS L14 = LINE/ PT1, ATANGL, 40 L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS L16 = LINE/ PT3, ATANGL, 40, YAXIS
y PT3 40 L16 PT1 PT4 L14 L L12
Line (LINE)
LIN = LINE/ POINT, ATANGL, ANGLE (in degrees), LINE
y LINE2
P1
30
LINE1
LINE2=LINE/P1,ATANGL,30,LINE1
40 L15 20 15 (32,3,2) x
x
14
10/1/2011
Line (LINE)
LIN = LINE/ SLOPE, SLOPE VALUE, INTERC, MODIFIER, d where the slope value is y/x. The modifier options are [XAXIS, YAXIS], and d is the corresponding intercept value on the selected axis (i.e., modifier).
y
Line (LINE)
LIN = LINE/ ATANGL, DEGREES, INTERC, MODIFIER, d The modifier options are [XAXIS, YAXIS], and d is the corresponding intercept value on the selected axis (i.e., modifier).
LINE1
LINE1
LINE1=LINE/SLOPE,1,INTERC,xaxis,6
=30 x
LINE1=LINE/ATANGL,30,INTERC,d
x
(6,0)PointofXIntercept
Line (LINE)
The LEFT & RIGHT modifier indicates whether the line is at the left or right tangent point, depending on how one looks at the circle from the point. L1 = LINE/ PT51, LEFT, TANTO, C11
Line (LINE)
L2 = LINE/ PT51, RIGHT, TANTO, C11 L3 = LINE/ PT40, RIGHT, TANTO, C11 L4 = LINE/ PT40, LEFT, TANTO, C11
L3 Right
PT40
Line (LINE)
LN3 = LINE/ PNT6, PARLEL, LN15 LN4 = LINE/ PNT5, PERPTO, LN13
y PNT6 LN3 LN4 PNT5
Plane (PLANE)
LN5 = LINE/ INTOF, PLAN1, PLAN2
LN5
LN15
LN13
PLAN1 PLAN2
15
10/1/2011
Plane (PLANE)
PLAN10 = PLANE/ PT6, PT12, PT15
Plane (PLANE)
PLAN14 = PLANE/ PT4, PARLEL, PLAN10 PLAN14 = PLANE/ PARLEL, PLAN10, YSMALL, 3.0
PLAN10 PT15 PT15 PLAN10
PT6 y
PT4 z PLAN14 z
PT4
PLAN14 x
Circle (CIRCLE)
Circle (CIRCLE)
C3 = CIRCLE/ CENTER, PT6, TANTO, LN4 C7 = CIRCLE/ CENTER, PT8, PT5
y C1 4.3 PT3 (3,6,5) LN4 PT5 y
PT6 C3
PT8 C7
Drivesurface
y
Checksurface
cutter
x
Directionof cuttermotion
Partsurface
16
10/1/2011
CS
CS
CS
: Move left along the drive surface : Move right along the drive surface : Move up along the drive surface : Move forward from a tangent position
DS
DS
DS
GODOWN/ : Move down along the drive surface GOFWD/ GOBACK/ : Move backward from a tangent position
TO
ON
PAST
Machining Specifications
Postprocessor commands for a particular machine tool are: MACHIN/ : used to specify the machine tool and call the postprocessor for that tool: , MACHIN/ DRILL, 3 COOLNT/ : allows the coolant fluid to be turned on or off: COOLNT/ MIST COOLNT/ FLOOD COOLNT/ OFF
Machining Specifications
FEDRAT/ : specifies the feed rate for moving the tool along the part surface in inches per minute: FEDRAT/ 4.5 SPINDL/ : gives the spindle rotation speed in revolutions per minute: SPINDL/ 850 TURRET/ : can be used to call a specific tool from an automatic tool changer: TURRET/ 11
Machining Specifications
TOLERANCE SETTING: Nonlinear motion is accomplished in straight-line segments, and INTOL/ and OUTTOL/ statements dictate the number of straight-line segments to be generated. INTOL/ 0.0015 OUTTOL/ 0.001
Machining Specifications
PARTNO: identifies the part program and is inserted at the start of the program. CLPRINT: indicates that a cutter location printout is desired. CUTTER: specifies a cutter diameter for offset (rough versus finish p ( g cutting). If a milling cutter is 0.5 in. in diameter and we have CUTTER/ 0.6 then the tool will be offset from the finish cut by 0.05 in.
17
10/1/2011
Machining Specifications
FINI: specifies the end of the program.
APT Program
MACHIN/ MILL P0 = POINT/ 0, 0, 3 P1 = POINT/ 1, 0 L1 = LINE/ P1, SLOPE, 0 L2 = LINE/ P1, SLOPE, 90 L3 = LINE/ PARLEL, L1, YLARGE, 2 L4 = LINE/ (POINT/ 4, 2), SLOPE, 1, L3 L5 = LINE/ (POINT/ 6, 4), ATANGL, 270, L4 10, 0), PEPTO, L6 = LINE/ (POINT/ 10 0) PEPTO L3 P2 = POINT/ INTOF, L3, L4 P3 = POINT/ INTOF, L4, L5 P4 = POINT/ INTOF, L5, L3 PL = PLANE/ P1, P2, P3 CUTTER/ 60 TOLER/ 0.1 SPINDL/ 200 COOLNT/ ON FEDRAT/ 20 P0 L2 P1 L1 L3 L4 P2 P3 L5 P4 L3 L6
APT Program
MACHIN/ MILL P0 = POINT/ 0, 0, 3 P1 = POINT/ 1, 0 L1 = LINE/ P1, SLOPE, 0 L2 = LINE/ P1, SLOPE, 90 L3 = LINE/ PARLEL, L1, YLARGE, 2 L4 = LINE/ (POINT/ 4, 2), SLOPE, 1, L3 L5 = LINE/ (POINT/ 6, 4), ATANGL, 270, L4 L6 = LINE/ (POINT/ 10, 0), PEPTO, L3 10 0) PEPTO P2 = POINT/ INTOF, L3, L4 P3 = POINT/ INTOF, L4, L5 P4 = POINT/ INTOF, L5, L3 PL = PLANE/ P1, P2, P3 CUTTER/ 60 TOLER/ 0.1 SPINDL/ 200 COOLNT/ ON FEDRAT/ 20 P0 L6 L1 L5 L4 L3 L2
APT Program
FROM/ P0 GOTO/ L1, TO, PL, TO, L2 GOFWD/ P1, PAST, L3 GORGT/ L3, TO, P2 GOLFT/ P2, TO, P3 GORGT/ P3, TO, P4 GORGT/ P4, PAST, L6 GORGT / L6, PAST, L1 GORGT / L1, TO, P1 COOLNT/ OFF END FINI P0 L2 P1 L1 L3 L4 P2 P3 L5 P4 L3 L6
APTLanguage Example:
APTLanguage Answer:
FROM/SP GO/TO, L1, TO, PS, ON, L6 GORGT/L1, PAST, L2 GORGT/L2, TANTO, C1 GOFWD/C1, TANTO, L3 GOFWD/L3, PAST, L4 GOLFT/L4, PAST, L5 GOLFT/L5, PAST, L6 GOLFT/L6, PAST, L1 GOTO/SP
107 108
18
10/1/2011
APTLanguage Example1:
APTLanguage Answer:
P0 = POINT/0.0, 3.0, 0.1 P1 = POINT/1.0, 1.0, 0.1 P2 = POINT/2.0, 1.0, 0.1 FROM/P0 GOTO/P1 GODLTA/0, 0, -0.7 GODLTA/0, 0, 0.7 GOTO/P2 GODLTA/0, 0, -0.7 GODLTA/0, 0, 0.7 GOTO/P0
109 110
APTLanguage
OtherMotionstatements:
GO/{TO}, Drive surface, {TO} Part surface, {TO}, Check surface Or GO/{TO}, Drive surface, {TO} Part surface, {TANTO}, Check surface AndthesamewithPASTorONinsteadofTO GOLFT/ GORGT/ GOUP/ GODOWN/ GOFWD/ GOBACK/ Forexample: GO/TO, L1, TO, PS, TANTO, C1 GO/PAST, L1, TO, PS, TANTO, C1
111
APTLanguage Example2:
112
APTLanguage Answer:
FROM/SP GO/TO, L1, TO, PS, ON, L4 GORGT/L1, PAST, L2 GOLFT/L2, PAST, L3 GOLFT/L2 PAST GOLFT/L3, PAST, C1 GOLFT/C1, PAST, L3 GOLFT/L3, PAST, L4 GOLFT/L4, PAST, L1 GOTO/SP
113
19
10/1/2011
20
10/1/2011
21