Computer Aided Design and Manufacturing

Branch: Mech Engg Topic : CAM Semester: 5

Raghunathan Rajesh

CAD CAM: Introduction

Computer-aided design (CAD) is the use of a wide range of computer-based tools that assist engineers in their design activities. It involves both software and special-purpose hardware. Computer Aided Manufacturing can be defined as the use of computer systems to plan, manage and control the operations of a manufacturing plant through either direct or indirect computer interface with the plants production resources. Things taken care of by cam:
Verification of the data Panelization of the design to fit the raw material Ability to edit Ability to add manufacturing information

CAD CAM: Introduction

Fig : Product cycle in a computerized manufacturing environment

CAD CAM: Introduction

Use of computer systems to assist in the creation, modification, analysis, Computer-Aided Design (CAD) and optimization of a design
Typical tools: Tolerance analysis Mass property calculations Finite-element modeling and visualization Defines the geometry of the design
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CAD CAM: Introduction

Use of computer systems to plan, manage, and control manufacturing operations Direct or indirect computer interface with the plants production resources Numerical control of machine tools Programming of robots
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CAD CAM: Introduction

Use of computer systems to analyze CAD geometry Computer-Aided Engineering (CAE) Allows designer to simulate and study how the product will behave, allowing for optimization
Finite-element method (FEM) Divides model into interconnected elements Solves continuous field problems
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CAD CAM: Introduction

Components CAD/CAM/CAE Systems Major component is of hardware and software allowing shape manipulation

Hardware includes graphic devices and their peripherals for input and output operations
Software includes packages that manipulate or analyze shapes according to user interaction
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CAD CAM: Introduction

The vision of the digital factory. Bracht, U. and Masurat, T. The digital factory between 8 vision and reality. Computers Industry, 2005, 56, 325333

CAD CAM: Introduction

Digital manufacturing links product development, production planning, and facility planning. Woehlke, G. and Schiller, E. Digital planning validation in automotive industry. Computers Industry, 2005, 56, 393405 9

Process Planning
The process plan is documentation determining all machining operations, order of the operations, all machine equipment, conditions and requirements to producing a part.
RAW STOCK PART

Machinery operations type of machine type of cutting tool type of fixture cutting condition time, cost

DESISION

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Process Planning methods

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Process Planning

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Process Planning

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Numerical control
Numerical control is a method of automatically operating a manufacturing machine based on a code of letters, numbers and special characters. The numerical data required to produce a part is provided to a machine in the form of a program, called part program. The program is translated into corresponding electrical signal for input to motors that run the machine.

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Numerical control

Link:video\4 - CNC machining

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Numerical control

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Numerical control

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Numerical control part programming

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Numerical control

simulation

Link: video\3b- CNC simulation

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Numerical control

simulation

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Numerical control part programming example

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Numerical control

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Numerical control
So far A brief overview of CAM

Next An overview of the CNC machines

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An overview of the CNC machines

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CNC machines - Motion Control

A CNC machine takes the commanded position from the CNC program

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CNC machines
CNC system elements Part program, Program input device , Machine control unit, Drive system, Machine tool, Feedback system

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CNC machines
Machine Control Unit - The machine control unit (MCU) is the heart of a CNC system. It is used to perform the following functions: Read coded instructions Decode coded instructions Implement interpolations (linear, circular, and helical) to generate axis motion commands Feed axis motion commands to the amplifier circuits for driving the axis mechanisms Receive the feedback signals of position and speed for each drive axis Implement auxiliary control functions such as coolant or spindle on/off, and tool change
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CNC machines: Components

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CNC machines: Components

Drive system

Linear motion stepping motor & lead screw

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CNC machines: Components

Feed Back System Open Loop Control System Closed Loop Control System CNC feedback Devices Potentiometers are used for position measurement based on voltage ratios. Encoders is a device used to convert linear or rotational position information into an electrical output signal. Resolver is a rotary transformer that produces an output signal that is a function of the rotor position. Tachometers is used for velocity feedback where electrical output is proportional to rate of angular rotation.
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CNC machines - How Axis Motion Is Commanded

Understanding Coordinate Systems
Absolute Versus Incremental Motion Assigning Program Zero Other Points About Axis Motion Assigning Program Zero Other Points About Axis Motion

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CNC machines CNC program

The coded instructions are composed of letters, numbers and symbols and are arranged in a format of functional blocks as in the following example N10 G01 X5.0 Y2.5 F15.0 | | | | | | | | | Feed rate (15 in/min) | | | Y-coordinate (2.5") | | X-coordinate (5.0") | Linear interpolation mode Sequence Number

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CNC machines Sample program

O0001 (Program number) N005 G54 G90 S400 M03 (Select coordinate system, absolute
mode, and turn spindle on CW at 400 RPM)

N10 G00 X1 Y1 (Rapid to XY location of first hole) N015 G43 H01 Z.1 M08 (Instate tool length compensation, rapid in
Z to clearance position above surface to drill, turn on coolant)

N020 G01 Z-1.25 F3.5 N025 G00 Z.1 N030 X.2

(Feed into first hole at 3.5 inches per minute) (Rapid back out of hole) (Rapid to second hole)

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CNC machines Sample program

N035 G01 Z-1.25 N040 G00 Z0.1 M09 N045 G91 G28 Z0 N050 M30
(Feed into second hole)
(Rapid out of second hole, turn off coolant)

(Return to reference position in Z)

(End of program command)

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CNC machines Sample program

O - Program number N - Sequence number G Preparatory function X - X-axis designation Y - Y-axis designation Z - Z-axis designation R - Radius designation F - Feedrate designation S - Spindle speed designation H - Tool length offset designation D - Tool radius offset designation T - Tool Designation M - Miscellaneous function

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CNC machines - Directions Of Motion (Axes)

Fig Axis Designation

Fig (b ) Axis Designation for Vertical & Horizontal Machines

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CNC machines - Directions Of Motion (Axes)

Fig Axis Designation for turning machines

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CNC machines - Directions Of Motion (Axes)

Fig Axis Designation for milling machines

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CNC machines Reference point

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CNC machines Reference point

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CNC machines
Accessories To The Machine - Examples of CNC accessories include probing systems, tool length measuring devices, post process gaging systems, automatic pallet changers, adaptive control systems, bar feeders for turning centers, live tooling and C axis for turning centers, and automation systems.

Programmable functions - The programmer must also know what functions of the CNC machine are programmable (as well as the related commands).
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CNC machine: motion and compensation

CNC Motion
Interpolation Linear, Circular The Three Most Basic Motion Types - Rapid Motion (Also Called Positioning), - Straight Line Motion - Circular Motion

Compensation
Offsets and Organizing Offsets Types of compensation - Tool length compensation, Tool Nose Compensation, Cutter Radius Compensation

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CNC machine: motion and compensation

Fig (a ) Tool Compensation for Milling

(b ) Tool Compensation for Turning

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CNC machines
So far A brief overview of CNC machines

Next An overview of the CNC programming

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An overview of the CNC programming

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CNC programming
CNC Programming Methods Manual Programming Conversational (Shopfloor) Programming CAM System Programming

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CNC programming
Procedure for manual NC programming The procedure for manual programming can be divided into four steps: analysis of workshop drawings definition of work plans choice of clamping devices and necessary tools (set-up sheet) generating the NC program (program sheet)

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CNC programming
Informaton needed by a CNC
Preparatory Information: units, incremental or absolute positioning Coordinates: X, Y, Z, RX, RY, RZ Machining Parameters: Feed rate and spindle speed Coolant Control: On/Off, Flood, Mist Tool Control: Tool and tool parameters Cycle Functions: Type of action required Miscellaneous Control: Spindle on/off, direction of rotation, stops for part movement. This information is conveyed to the machine through a set of instructions arranged in a desired sequence Program.

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CNC programming - Program Structure

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CNC programming - Program Structure

Fig (b) Program Structure ( Block )

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CNC programming - Program Structure

Fig (c) Program Structure ( Word )

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CNC programming - Program Structure

Fig (d) Sequence of words in an NC Block

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CNC programming

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