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Overview to Computer Aided Manufacturing ENGR-2963 - Fall 2005 Class Manager - Sam Chiappone
History
1955 - John Parsons and US Air Force define a need to develop a machine tool capable of machining complex and close tolerance aircraft parts with the same quality time after time (repeatability). MIT is the subcontractor and builds the machine for the project.
History: Continued
1959 - MIT announces Automatic Programmed Tools (APT) programming language 1960 - Direct Numerical Control (DNC). This eliminates paper tape punch programs and allows programmers to send files directly to machine tools
History: Continued
1968 - Kearney & Trecker machine tool builders market first machining center 1970s - CNC machine tools & Distributed Numerical Control 1980s - Graphics based CAM systems introduced. Unix and PC based systems available
History: Continued
1990s - Price drop in CNC technology 1997 - PC- Windows/NT based Open Modular Architecture Control (OMAC) systems introduced to replace firmware controllers.
Control Systems
Open-Loop Control
Stepper motor system Current pulses sent from control unit to motor Each pulse results in a finite amount of revolution of the motor001 is possible
Control Systems
Open-Loop Limitations
Control unit assumes desired position is achieved No positioning compensation Typically, a lower torque motor
Open-Loop Advantages
Less complex, Less costly, and lower maintenance costs
Control Systems
Closed-Loop Control
Variable DC motors - Servos Positioning sensors -Resolvers
Feedback to control unit Position information compared to target location Location errors corrected
Control Systems
Closed-Loop Advantages
DC motors have the ability to reverse instantly to adjust for position error Error compensation allows for greater positional accuracy (.0001) DC motors have higher torque ranges vs.. stepper motors
Closed-loop limitations
Cost
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Intro to CAM Chiappone
Point to Point - No contouring capability Straight cut control - one axis motion at a time is controlled for machining Contouring - multiple axiss controlled simultaneously
Computer Numerical Control (CNC) - A numerical control system in which the data handling, control sequences, and response to input is determined by an on-board computer system at the machine tool.
CNC
Advantages
Increased Program storage capability at the machine tool Program editing at the machine tool Control systems upgrades possible Option -resident CAM system at machine tool Tool path verification
NC
Numerical Control (NC) - A control system which primarily processes numeric input. Limited programming capability at the machine tool. Limited logic beyond direct input. These types of systems are referred to as hardwire controls and were popular from the 1950s to 1970s.
Machining Centers
Machining Centers
Machine motion is programmable Servo motors drive feed mechanisms for tool axiss Positioning feedback is provided by resolvers to the control system
Machining Centers
Example - A turning center capable of OD turning, external treading, cross-hole drilling, engraving, and milling. All in machining is accomplished in one set-up. Machine may have multiple spindles.
Machining Centers
Programming Methods
Programming Methods-APT
Developed as a joint effort between the aerospace industry, MIT, and the US Airforce Still used today and accounts for about 5 -10% of all programming in the defense and aerospace industries
Programming Methods-APT
Requires excellent 3D visualization skills Capable of generating machine code for complicated part programs
5 axis machine tools
Programming Methods-APT
Part definition
Cutter Commands
TLRT,GORT/LN1.TANTO,C1 GOFWD/C1,TANTO,L5
Programming Methods-CAM
Programming Methods-CAM
Tool & material libraries Tool path simulation Tool path editing Tool path optimization Cut time calculations for cost estimating
Programming Methods-CAM
Import / export capabilities to other systems
Examples: Drawing Exchange Format (DXF) Initial Graphics Exchange Standard (IGES)
2D or 3D scan
Model or Blueprint
Contours Pockets Hole patterns Surfaces Volume to be removed (At this point the system knows what you want to cut)
Cut method
Example - Pocket mill zig-zag, spiral, inside-out Rough and finish parameters
(At this point the system knows how you want to cut the part)
(At this point the system has a generic cutter location (CL) file of the cut paths)
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, tool changer, rpms, etc. G & M function capabilities
Output: NC Code
Output: 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
Output: NC Code
NC Program Example
N01G90 G80 N03 GOO T12 M06 N05 GOO X0 Y0 Z.1 F10 S2500 M13 N07 G1Z-.5 N09 G02 X-10. I0J0F20 N13 X0Y10 N17 X10Y0 N19 X0Y-10 N21 X-10Y0 N23 M2
What What Must Be Done To Drill A Hole On A CNC Vertical Milling Machine
Tool Home
Top View
Front View
Rensselaer Polytechnic Institute
Intro to CAM Chiappone
Top View
Front View
.100
Top View
5.) Z Axis Feed Move to Drill Hole
Front View
Rensselaer Polytechnic Institute
Intro to CAM Chiappone
Top View
Front View
Rensselaer Polytechnic Institute
Intro to CAM Chiappone
Top View
Front View
Tool At Home
Top View
Front View
O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09 N030 G91 G28 X0 Y0 Z0 N035 M30
Rensselaer Polytechnic Institute
Intro to CAM Chiappone
Tool At Home
Top View
O0001
O0001 Number Assigned to this program
Front View
Rensselaer Polytechnic Institute
Intro to CAM Chiappone
Tool At Home
Top View
Front View
Rensselaer Polytechnic Institute
Intro to CAM Chiappone
Top View
O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0
G00 X1.0 Y1.0 Rapid Motion X Coordinate 1.0 in. from Zero Y Coordinate 1.0 in. from Zero
Front View
Rensselaer Polytechnic Institute
Intro to CAM Chiappone
Top View
O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08
G43 H01 Z.1 M08 Tool Length Compensation Specifies Tool length compensation Z Coordinate .1 in. from Zero Flood Coolant On
Front View
Top View
O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5
G01 Z-.75 F3.5 Straight Line Cutting Motion Z Coordinate -.75 in. from Zero Feed Rate set to 3.5 in./min.
Front View
Top View
O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09
G00 Z.1 M09 Rapid Motion Z Coordinate .1 in. from Zero Coolant Off
Intro to CAM Chiappone
Front View
Top View
O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09 N030 G91 G28 X0 Y0 Z0
G91 Incremental Programming Mode G28 Zero Return Command X0, Y0, Z0 X,Y,& Z Coordinates at Zero
Front View
Top View
Front View
O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09 N030 G91 G28 X0 Y0 Z0 N035 M30
M30 End of Program
Intro to CAM Chiappone
CAD to NC Code
Import File DXF IGES Geometry Direct input
Post Process
CL File
Tool Path Generation What you want to cut How you want to cut Tool Type Rpms Feeds Method Canned cycles Cut direction
Ease of part duplication Flexibility Repeatability Quality control through process control
Accommodates simple to complex parts geometry Improved part aesthetics Increased productivity Technology costs are decreasing
Reduced set-up time Reduced lead times Reduced inventory Better machine utilization Job advancement opportunities
CNC machine tools are more rigid than conventional machine tools
$$$- Climb milling requires about 10 - 15 % less horsepower vs. conventional cutting, but requires a ridged machine tool with no backlash Increased Rpms and feeds