CAM

Machining
g Centers

A machining center can be defined as a

machine tool capable of:

Multiple operation and processes in a single setup utilizing multiple axis

Typically has an automatic mechanism to change
tools

Machining
g Centers

Machine motion is programmable

Servo motors drive feed mechanisms for tool
axiss
Positioning feedback is provided by resolvers to
the control system

Machining
g Centers

Example - A turning center capable of OD

turning, external treading, cross-hole drilling,
engraving, and milling. All in machining is
accomplished
p
in one set-up.
p Machine may
y
have multiple spindles.

Programming
g
g Methods

Automatically Programmed Tools (APT)

A text based system

y
in which a programmer
g
defines a series of lines, arcs, and points which
define the overall part geometry locations. These
features are then used to generate a cutter
location (CL) file.

Programming
g
g Methods-APT

Requires excellent 3D visualization skills

Capable of generating machine code for

complicated part programs

5 axis machine tools

Programming
g
g Methods-CAM

Computer Aided Machining (CAM) Systems

Graphic representation of the part

PC based
Integrated CAD/CAM functionality
Some built-in expertise

Speed
p
& feed data based on material and tool specifications
p

Programming
g
g Methods-CAM

Tool & material libraries

Tool path simulation
Tool path editing
Tool path optimization
Cut time calculations for cost estimating

Programming
g
g Methods-CAM

Import / export capabilities to other systems

Examples:

Drawing Exchange Format (DXF)

Initial Graphics Exchange Standard (IGES)

The Process - CAD to NC File

Start with graphic representation of part

Direct input
Import from external system

Example DXF / IGES

2D or 3D scan

Model or Blueprint
p

(At this point you have a graphics file of your

g
geometry)
y)

10

The Process CAD to NC File

Define cutter path by selecting geometry

Contours
Pockets
Hole patterns
Surfaces
Volume to be removed
((At this point
p
the system
y
knows what you
y
want
to cut)

11

The Process CAD to NC File

Define cut parameters

Tool information

T
Type,
Rpm,
R
F
Feed
d

Cut method

Example
E
l - Pocket
P k t mill
ill zig-zag,
i
spiral,
i l iinside-out
id
t
Rough and finish parameters

(At this point the system knows how you want to cut
the part)

12

The Process CAD to NC File

Execute cutter simulation

Visual representation of cutter motion

Modify / delete cutter sequences

(At this point the system has a generic cutter location

(CL) fil
file off th
the cutt paths)
th )

13

The Process CAD to NC File

Post Processing

CL file to machine specific NC code

Filters CL information and formats it into NC

code based on machine specific parameters

Work envelope
Limits - feed rates
rates, tool changer
changer, rpms
rpms, etc.
etc
G & M function capabilities

14

Output:
p NC Code

Numerical Control (NC) Language

A series of commands which direct the cutter

motion and support systems of the machine
tool.

15

CAD to NC Code
Import
File

Post Process

DXF
IGES

CL
File

Geometry
Direct input

Tool Path Generation

What you want to cut
How you want to cut
Tool

Tool Type
Rpms Feeds
Method
Canned cycles
Cut direction

NC Code
N1 G80 G90
N3 G0 T01 M06
N5 G0 X0 Y0

16

Advantages
g of CNC Machine Tools

Ease of part duplication

Flexibility
Repeatability
Quality control through process control

17

Advantages
g of CNC Machine Tools

Accommodates simple to complex parts

geometry
I
Improved
d partt aesthetics
th ti
Increased productivity
Technology costs are decreasing

18

Advantages
g of CNC Machine Tools

Reduced set-up
p time
Reduced lead times
R d
Reduced
d iinventory
t
Better machine utilization
Job advancement opportunities

19

Advantages
g of CNC Machine Tools

CNC machine tools are more rigid

g than
conventional machine tools

Less horsepower vs. conventional cutting, but requires

a ridged machine tool with no backlash
Increased Rpms and feeds

20

Using
g Pro/E
/

FeaturesIndividual
F
t
I di id l geometry
t created
t d one att a titime.
Features include datums, extrusions, holes, rounds,
chamfers,, surface features,, cuts,, patterns,
p
, sweeps,
p , etc.
You can have multiple features in a part.
PartsCollection of geometric features that define the
geometric
t i entity
tit called
ll d th
the part.
t P
Parts
t are referred
f
d tto as
components in an assembly. You can have multiple
components
co
po e s in a
an asse
assembly.
by
AssembliesCollection of components assembled
together to create the model. You can have multiple
assemblies
bli and
d subassemblies
b
bli in
i a hi
hierarchical
hi l order
d
according to their relationships with other assemblies and
the master assembly.
21

Pro/NC
/
Flow Chart

22

Introduction
NC Sequences
An NC sequence
q
is an assembly
y ((or workpiece)
p
)
feature that represents a single tool path.
Gouging
When too much material is removed from the
part, it is said to be gouged or overcut..

23

Gouging
g g

When too
Wh
t much
h material
t i l is
i removed
d from
f
the
th part,
t it is
i said
id tto b
be
gouged or overcut.
The converse of gouging a work-piece is undercutting--not
removing enough material.
Interference between the workpiece and components of the
machining center such as clamps, fixtures, tool cutting surfaces,
toolholders and shanks is called a collision.
Gouging, undercutting and collisions are costly and result in a lot
of scrap and major loss of productivity
productivity.
The word most often associated with machine downtime is
gouging.
Gouging a workpiece or surface is one of the biggest problems
that machinists face today because the number of complex
workpieces is increasing these days.
24

Design
g Model
The Pro/ENGINEER
design model,
representing
ti the
th
finished product, is
used as the basis for all
manufacturing
operations.
operations
1.
1
2.

Holes to be drilled
Surfaces to be milled

25

Workpiece
p

The workpiece
represents the raw
stock
t k that
th t is
i going
i to
t be
b
machined by the
manufacturing
operations

1.
2.
3.

Holes removed - not part of casting

Dimensions increased to allow for
material removal
Dimensions decreased to allow for
material removal
26

Introduction

Fixtures
Fixtures are parts or assemblies that help orient
and hold the workpiece during a
manufacturing operation.

27

Coordinate Systems
y
They define the orientation of the workpiece on the
machine and act as the origin (0, 0, 0) for CL data
generation.

Yw

Machine Coordinate System

Ym
Zw

Xw

Workpiece Coordinate System

Zm

Xm

28

Retract Surface

The retract surface

defines the level to
which
hi h th
the ttooll iis
retracted after a cut.
Depending on your
machining needs, you
can specify the retract
surface to be a plane,
cylinder,
y
, sphere,
p
, or a
custom-made surface.

1.
2.

Retract plane
Retract cylinder

29

Operations
p

An operation is a series of NC sequences performed at a particular

workcell and using a particular coordinate system for CL data output.

Name
Workcell to be used
Coordinate system for CL data output
Retract surface

30

Workcells
A workcell is a workpiece (or assembly) feature
that specifies a machine tool using:
Name
Type
Number of axes
A set of parameters
Associated tool

31

Tools Setup
p
Select Manufacturing Setup->Tooling
NC Manufacturing requires the following
general categories of information about
tools:

Tool Type
Geometry parameters
T l Number
Tool
N b
Offset Number

32

Other Tools Parameters

33

Built in Tools

34

Built in Tools

35

Built in Tools

36

Built in Tools

37

Built in Tools

38

Built in Tools

100
50
0

1st
Qtr

3rd
Qtr

East
West
North

39

Milling/Turning
/
Using
P /E
Pro/E

40

Milling (3-Axis)

41

Mill Geometryy

Mill Wi
Window
d
by projecting the silhouette of the reference part on the Mill
Window start plane, by sketching or by selecting a closed
contour. All surfaces visible within the contour are milled
Mill Volumes

Trim a Mill Volume

Sketch the volume to be machined or excluded,, intersect the volume

with the workpiece or reference model, or offset surfaces (for
example, by tool radius). You can use this set of tools in any
combinations to define a single Mill Volume
Subtracts the reference model from the current volume definition and
only the remaining volume is used for machining.

Mill Surfaces
A Mill surface is a special surface feature, created by the set of
techniques
tec
ques that
t at can
ca be used in Su
Surface
ace milling
g NC
C seque
sequences.
ces
42

Mill Surfaces

A Mill surface is a special surface feature

feature, created by
the set of techniques that can be used in Surface
milling NC sequences.

43

Cut Parameters

TOLERANCE

1.
2.
3.
4.
5.

TOLERANCE
Design Surface
Machined Surface
Tool Centerline path
Tool

44

Feed

CUT_FEED
CUT
FEED
CUT_UNITS

IPM (inches
(i h per minutedefault),
i t
d f lt) FPM (f
(feett per minute),
i t )
MMPM (millimeters per minute), FPR (feet per revolution),
IPR (inches per revolution), MMPR (millimeters per
revolution).

RETRACT_FEED
RETRACT UNITS
RETRACT_UNITS
FREE_FEED
PLUNGE_FEED
G
PLUNGE_UNITS
45

Defining
g Tools

46

Volume Milling

It is a very versatile sequence used not

onlyy to rough
g machine the workpiece
p
but
can also perform finishing and facing
operations.
A Volume milling NC sequence removes
the material inside a Milling Volume slice
sliceby-slice. All slices are parallel to the retract
plane;
l

47

Profile Milling:
g

Profile milling is used to rough

or finish mill vertical or slanted
surfaces.
f
The
Th surfaces
f
selected must allow for a
continuous tool path
path. The
depth of the cut is defined by
the depth of the selected
surfaces.

48

Surface Milling
g

Surface
S
f
milling
illi NC S
Sequence iis generally
ll
used to semi-finish or finish the shallow
surfaces It is a versatile sequence which
surfaces.
can generate a lot of toolpath strategies

49

Trajectory
j
y Milling
g

50

CL Data Generation

Cutter Location (CL) data files are generated from

the cutter paths specified within NC Manufacturing
NC sequences.
Each NC sequence generates a separate CL file.
You can also create a single file for a whole
operation.
These CL data files can then be passed to machinespecific or generic post-processors for NC tape
generation
i or DNC communications
i i

51

CL Data (Continue)
(
)

$$*
Pro/CLfile Version Wildfire 3.0 - M020
$$-> MFGNO / TRAINING
PARTNO / TRAINING
$$-> FEATNO / 892
MACHIN / UNCX01, 1
$$-> CUTCOM_GEOMETRY_TYPE / OUTPUT_ON_CENTER
UNITS / MM
LOADTL / 1
$$-> CUTTER / 2
2.000000
000000
$$-> CSYS / 1.0000000000, 0.0000000000, 0.0000000000, 0.0000000000, $
0.0000000000, 1.0000000000, 0.0000000000, 0.0000000000, $
0.0000000000, 0.0000000000, 1.0000000000, 0.0000000000
SPINDL / RPM, 1000.000000, CLW
RAPID
GOTO / 5.0000000000,, 40.0000000000,, 5.0000000000
RAPID
GOTO / 5.0000000000, 40.0000000000, -1.0000000000
FEDRAT / 10.000000, MMPM
GOTO / 5.0000000000, 40.0000000000, -2.0000000000
CIRCLE / 10.0000000000, 40.0000000000, -2.0000000000, $
0.0000000000, -0.0000000000, -1.0000000000, 5.0000000000
GOTO / 10.0000000000, 45.0000000000, -2.0000000000
GOTO / 90.0000000000, 45.0000000000, -2.0000000000
CIRCLE / 90.0000000000, 40.0000000000, -2.0000000000, $
-0.0000000000, -0.0000000000, -1.0000000000, 5.0000000000
GOTO / 95.0000000000, 40.0000000000, -2.0000000000
GOTO / 95.0000000000, 10.0000000000, -2.0000000000
CIRCLE / 90
90.0000000000,
0000000000 10
10.0000000000,
0000000000 -2.0000000000,
2 0000000000 $
-0.0000000000, 0.0000000000, -1.0000000000, 5.0000000000
GOTO / 90.0000000000, 5.0000000000, -2.0000000000
GOTO / 10.0000000000, 5.0000000000, -2.0000000000
CIRCLE / 10.0000000000, 10.0000000000, -2.0000000000, $
-0.0000000000, -0.0000000000, -1.0000000000, 5.0000000000
GOTO / 5
5.0000000000,
0000000000 10
10.0000000000,
0000000000 -2.0000000000
-2 0000000000
GOTO / 5.0000000000, 40.0000000000, -2.0000000000
GOTO / 5.0000000000, 40.0000000000, 5.0000000000
SPINDL / OFF
$$-> END /
FINI

52

NC Post-Processing
g

NC M
Manufacturing
f t i generates
t cutter
tt location
l
ti
(CL) data files in an ASCII format that need to
b post-processed
be
t
d tto create
t Machine
M hi C
Control
t l
Data (MCD) files before any machining
operation occurs.
occurs
Select which post-processor to use.
Execute post-processors with option to run CL
file.
Execute post-processors with options directly
upon
p output
p of tool p
path.
53

NC Post-Processing
g (Continue)
(
)

UNCL01 Lathe G-Post

G Post
UNCX01 Mill G-Post
Conversion of (ncl)
File to CNC Part
Program
Select CL Data->Post
Processor
Select ncl File
Select the Post
Processor name to get
g
CNC Part Program
File.
54

CNC Part Program

g
of Trajectory
j
y millingg
Sequence.

%
(Date:10/22/08 Time:13:21:01)
N0001G98G80G90G49G17
N0002G54
N0003T1M6
N0004S1000M3
N0005G0X5.Y40.
N0006G43Z5.H1
N0007Z-1.
N0008G1Z-2.F10.
N0009G2X10.Y45.I5.J0.
N0010G1X90.
N0011G2X95.Y40.I0.J-5.
N0012G1Y10
N0012G1Y10.
N0013G2X90.Y5.I-5.J0.
N0014G1X10.
N0015G2X5.Y10.I0.J5.
N0016G1Y40.
N0017Z5.
N0018M5
N0019M30
%

55

Transferring
g CNC Part Program
g
to
CNC Machine

Serial port

COM1 (or any free COM port)

Baud

According to Machine e.g. 2400

Data bits

Parity

Even

Stop bits

56

Output:
p NC Code

G-Codes (G00, G1, G02, G81)

Coordinate data (X,Y,Z)
Feed Function (F)
Miscellaneous functions (M13)
(
)
N - Program sequence number
T - Tool call
S - Spindle command

57

Turning

58

Lathe (Continue)
(
)

AreaDefine the area in the model cross section

where you want the material to be removed.
ProfileInteractively define the cut motion(s) by
either sketching or using surfaces or datum curves.
GrooveTurn narrow grooves using a tool with
cutting edges on both sides and a peck-type motion.
ThreadCut threads on a lathe.
HolemakingDrill, bore, and so on.

59

Stock Boundaryy and Cut Extensions

1.
2.
3.
4.
5.
6.

Reference part
p
Workpiece
Stock boundary sketch
Cut sketch
Cut extensions
Cut area

60

Holder_Type
_ yp
1.
2.

Holder_Type Left
Holder_Type Right

61

Tool Definition

62

Outside Area Turningg

Define the Turn Profile

by selecting surfaces of
th reference
the
f
partt (1)
and specify the cut
extensions as shown in
the following illustration:
Positive X (2) and
Positive Z (3).

63

Inside Area Turningg

To turn the inside surfaces of a cored workpiece, set

the TOOL_ORIENTATION parameter value to 0.
Then define the Turn Profile (1) and cut extensions as
shown in the following illustration
illustration, and specify the cut
extensions: Negative Z (2) and Positive Z (3).

64

Groovingg (Continue)
(
)

65

Groovingg (Continue)
(
)

66