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PROCEDURE MANUAL
Computer-aided manufacturing
The use of computers in converting engineering designs into finished products. Computers assist
managers, manufacturing engineers, and production workers by automating many production tasks,
such as developing process plans, ordering and tracking materials, and monitoring production
schedules, as well as controlling the machines, industrial robots, test equipment, and systems that
move and store materials in the factory. Abbreviated CAM.
It is a form that helps designers to prepare drawings, specifications, parts lists, and other design-
related elements using special graphics- and calculations-intensive computer programs. The
technology is used for a wide variety of products in such fields as architecture, electronics, and
aerospace, naval, and automotive engineering. Although CAD systems originally merely automated
drafting, they now usually include three-dimensional modeling and computer-simulated operation of
the model. Rather than having to build prototypes and change components to determine the effects of
tolerance ranges, engineers can use computers to simulate operation to determine loads and
stresses.
Numerical control
(NC)
Control of a system or device by direct input of data in the form of numbers, letters, symbols, words,
or a combination of these forms. It is a principal element of computer-integrated manufacturing,
particularly for controlling the operation of machine tools. NC is also essential to the operation of
modern industrial robots. The two basic types of NC systems are point-to-point, in which a device is
programmed to perform a series of motions with fixed starting and stopping points, and continuous-
path, in which a point-to-point programmed device has sufficient memory to be aware of its former
actions and their results and to act in accordance with this information.
The method of controlling machines by the application of digital electronic computers and circuitry.
Machine movements that are controlled by cams, gears, levers, or screws in conventional machines
are directed by computers and digital circuitry in computer numerical control (CNC) machines.
Computer numerical control provides very flexible and versatile control over machine tools. Most
machining operations require that a cutting tool be fed at some speed against a workpiece. In a
conventional machine such as a turret lathe, the turning tool is mounted on a slide with hand-
operated infeed and crossfeed slides. The operator manually turns a crank that feeds the cutting tool
into the workpiece (infeed) to the desired diameter. Another crank then moves the turning tool along
the longitudinal axis of the machine and produces a cylindrical cut along the workpiece. The feed rate
of the turning tool is sometimes controlled by selecting feed gears. These gears move the axis slide at the
desired feed. A CNC machine replaces the hand cranks and feed gears with servomotor systems.
Computer numerical controls allow the desired cut depths and feed rates to be dialed in rather than controlled
by cranks, cams, and gears. This provides precise, repeatable machine movements that can be programmed
for optimal speeds, feeds, and machine cycles. All cutting-tool applications, whether on a lathe, drill press, or
machining center, have optimum speeds and feeds, which are determined by carefully weighing the economics
of tool life, required production rates, and operator attentiveness. With computer numerical control these
parameters are set once, and then they are repeated precisely for each subsequent machine cycle.
In computer-aided manufacturing (CAM), computers are used to assist in programming CNC machines. In
sophisticated CNC manufacturing operations, machined parts are first designed on computer-aided-design
(CAD) equipment. The same electronic drawing is then used to create the CNC part program automatically. A
less advanced version of CAM is the use of high-level part programming languages to write part programs.
Computer numerical control machines are used mainly when flexibility is required or variable and complex part
geometries must be created. They are used to produce parts in lot sizes of a few pieces to several thousand.
Extremely large manufacturing lot sizes frequently call for more product-specific machines, which can be
optimized for large production runs.
CNC MACHINE:
A machine tool that uses programs to automatically execute a series of machining operations. CNC
machines offer increased productivity and flexibility.
WORK OFFSET:
An offset used to adjust the location of every tool loaded in the machine. On the mill, the
work offset changes the position of the spindle in both the X- and Y-axes, and often the Z-axis as
well.
An offset used on the mill that accounts for variations in tool length along the Z-axis. Each
tool requires its own offset, which is measured from the tip of the tool to the gage line.
Normal screen
Indicated in picture
Screen indicated in
machine
Note
After pressing input the curser automatically jumps
Metalworking lathes
In a metalworking lathe, metal is removed from the workpiece using a hardened cutting tool, which is
usually fixed to a solid moveable mounting, either a toolpost or a turret, which is then moved against
the workpiece using handwheels and/or computer controlled motors. These (cutting) tools come in a
wide range of sizes and shapes depending upon their application. Some common styles are diamond,
round, square and triangular.
The toolpost is operated by leadscrews that can accurately position the tool in a variety of planes. The
toolpost may be driven manually or automatically to produce the roughing and finishing cuts required
to turn the workpiece to the desired shape and dimensions, or for cutting threads, worm gears, etc.
Cutting fluid may also be pumped to the cutting site to provide cooling, lubrication and clearing of
swarf from the workpiece. Some lathes may be operated under control of a computer for mass
production of parts (see "Computer Numerical Control").
Manually controlled metalworking lathes are commonly provided with a variable ratio gear train to
drive the main leadscrew. This enables different thread pitches to be cut. On some older lathes or more
affordable new lathes, the gear trains are changed by swapping gears with various numbers of teeth
onto or off of the shafts, while more modern or expensive manually controlled lathes have a quick
change box to provide commonly used ratios by the operation of a lever. CNC lathes use computers
and servomechanisms to regulate the rates of movement.
On manually controlled lathes, the thread pitches that can be cut are, in some ways, determined by the
pitch of the leadscrew: A lathe with a metric leadscrew will readily cut metric threads (including BA),
while one with an imperial leadscrew will readily cut imperial unit based threads such as BSW or UTS
(UNF,UNC). This limitation is not insurmountable, because a 127-tooth gear, called a transposing
gear, is used to translate between metric and inch thread pitches. However, this is optional equipment
that many lathe owners do not own. It is also a larger changewheel than the others, and on some lathes
may be larger than the changewheel mounting banjo is capable of mounting.
The workpiece may be supported between a pair of points called centres, or it may be bolted to a
faceplate or held in a chuck. A chuck has movable jaws that can grip the workpiece securely.
There are some effects on material properties when using a metalworking lathe. There are few
chemical or physical effects, but there are many mechanical effects, which include residual stress,
microcracks, workhardening, and tempering in hardened materials.
CNC PROGRAMMING
3
R
7 6
5 c3
3
R3
4 2
1
25
10
20 20
PROGRAM NO:1
Line1-----------> G28U0.W0.;
Line2-----------> T202;
Line3-----------> G97M4S2000;
Line4-----------> G0X29.Z4.;
Line5-----------> G71U0.5R0.5;
Line6-----------> G71P10Q15U0.25W0.1F0.1;
Line7-----------> N10G0X7.0;
Line8-----------> G1Z0.0;
Line9-----------> G1X10.0Z-3.0;
Line10-----------> G1Z-15;
Line11-----------> G2X16.0Z-20.0R3.0;
Line12-----------> G3X22.0Z-25.0R3.0;
Line13-----------> G1Z-40.0;
Line14-----------> N15G1X29.0;
Line15-----------> G70P10Q15F0.05;
Line16-----------> G0Z10.0M5;
Line17-----------> G28U0.W0.;
Line18-----------> M30;
PROGRAM NO:2
6 5
3 c4
4
2
50
30 1
20 20
G-codes:
G00 Positioning
G04 Dwell
M-codes:
M03 Spindle CW
M10 Clamp
M11 Unclamp
M12 Unassigned
M15 Motion +
M16 Motion -
M17 Unassigned
M18 Unassigned
M32-35 Unassigned
M46-47 Unassigned
M50-89 Unassigned