Beruflich Dokumente
Kultur Dokumente
PATIL S B
Assistant Professor-Mechanical Engineering
College of Engineering, Pune-411 005
sbp.mech@coep.ac.in
History
1949
US Air Force asks MIT to develop a "numerically controlled"
machine.
1952
Prototype NC machine demonstrated (punched tape input)
NC
Numerical Control (NC) - A control system
which primarily processes numeric input
(numbers, letters and symbols). 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.
NC, CNC AND DNC
Introduction
According to Electronic Industries Association (EIA):
The NC Procedure
1. Process planning
2. Part programming
- Manual Part programming
- Computer assisted part programming
3. Tape preparation
4. Tape verification
5. Production
NC, CNC AND DNC
NC Coordinate System
1. Fixed zero- Fixed origin
2. Floating zero- Programmer defines the
position of the origin
1. Absolute programming- tool locations are
always defined in relation to zero point.
2. Incremental programming- next tool
location must be defined with reference
to previous tool location.
NC, CNC AND DNC
10
11
12
Applications of NC-1
- Machining operations such as milling, drilling,
turning, broaching, grinding, etc.
- Other applications-Assembly, testing, welding,
inspection, any repetitive job.
13
Applications of NC-2
1.
2.
3.
4.
5.
6.
7.
8.
14
Advantages of NC
Advantages
Reduced set up time
Reduced fixturing
Reduced inventory
Programming/ training
NC, CNC AND DNC
15
Conventional Vs NC machines
Aspect
Conventional Machine
NC machine
Rate of production
Normal
Comparatively high
Normal
Comparatively high
Less
Additional requirement
Not specific
Usually required
Skill
Type of tooling
Normal
Sophistication
No
High degree
NC, CNC AND DNC
16
17
NC machines
Motion control is done by: servo-controlled motors
Table
Leadscrew
A/C Motor
Encoder
Servo Controller
Counter
Comparator
18
Hardware Configuration of an
NC Machine Tool
A typical NC machine tool contains the Machine
Control Unit (MCU) and the machine tool itself.
19
Hardware Configuration of an
NC Machine Tool
DPU reads the part program, decodes it, processes the information
and passes it to the CLU
20
21
Tape
Reader
for initial
program
entry
Minicomputer or
microcomputer
(Software function and
NC part program storage)
Computer
Hardware
interface
and
Servo system
Machine
tool
22
Functions of CNC
1. Machine tool control
2. In process compensation
3. Improved programming and operating
features
4. Diagnostics
23
Motion
feed back
Motion
Interpolators
And
Sensor system
Tape
reader
Minicomputer/
Interface logic
Microcomputer
(Hard wired)
(soft wired)
Machine
tool
24
Tape
reader
Motion
feed back
Machine
tool
25
2. In process compensation-CNC
- Recommendation of axis position when
inspection probe is used to locate a datum
reference on a work part
- Offset adjustment for tool radius and length
- Adaptive control for processing parameters
- Computation of predicted tool life and selection
of alternative tooling when indicated
NC, CNC AND DNC
26
27
4. Diagnostics
- The system would be able to identify the
reason for down time occurrence, so the
maintenance can be carried out quickly
- Alter to signs that indicate the imminent
failure of a certain component.
28
29
30
CNC terminology
31
Controller components
32
or
Continuous path
or
Closed loop
or
Hydraulic
or
Pneumatic
or
Absolute
33
34
35
table moves
feedback
36
37
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 motor 0.01 is possible
38
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
NC, CNC AND DNC
39
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
40
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
NC, CNC AND DNC
41
42
DNC
43
Components of DNC
1.
2.
3.
4.
Central Computer
Bulk memory, which stores the programs
Telecommunication lines and
Machine tools
44
Types of DNC
1. Behind the tape reader (BTR) system
DNC
Computer
Two
Storage
buffer
Bulk memory
NC
programs
NC
controller
Machine
tool
45
Types of DNC
2. Special machine control unit (MCU)
DNC
Computer
Special
MCU
Bulk memory
NC
programs
Machine
tool
46
Functions of DNC
1.
2.
3.
4.
47
Advantages of DNC
- Elimination of punched tape and tape
readers.
- Greater computational capability and
flexibility
- Convent storage of NC part programs in
computer files.
- Reporting shop performance.
- Establishes the frame work for future
computer automated factory.
NC, CNC AND DNC
48
Machining Centers
A machining center can be defined as a
machine tool capable of:
Multiple operation and processes in a single
set-up utilizing multiple axis
Typically has an automatic mechanism to
change tools
49
Machining Centers
Machine motion is programmable
Servo motors drive feed mechanisms for tool
axiss
Positioning feedback is provided by resolvers
to the control system
50
Machining Centers
Example - A turning center capable of OD
turning, external threading, cross-hole
drilling, engraving, and milling. All in
machining is accomplished in one set-up.
Machine may have multiple spindles.
51
Machining Centers
52
53
Coordinate System
Main 3 Axes forming a right-hand coordinate system, by
convention z axis moves the cutting tool away from the
workpiece, in details:
The z axis, parallel to the spindle for rotating workpiece,
and parallel to the machine tool axis for rotating tool, as
a milling, drilling, or boring machine
The x axis, in the direction of the tool movement for the
first case, and points to the right when some-one is
facing the machine.
54
55
56
Coordinate System
There can be more axes because of secondary slide motions in
addition to the primary x, y and z directions, and the rotary motions
around axes parallel to x, y and z axes.
These axes can be labeled u, v and w (for the first case) and a, b and c
(for the second).
The machine tools can be classified according to the number of axes
they provide to control position and orientation. For example, there
are 2-axis, 3-axis and 5-axis milling machines.
57
58
59
60
61
p2
p3
100
p1
75
50
25
25
50
75
100
62
63
28
24
20
40
20
64
65
66
G91
G71
G00
G01
G01
G01
G01
G01
G02
G01
G01
G01
EOB
EOB
X0.0 Y0.0 Z40.0 T0.1 M06 EOB
X65.0 Y0.0 Z-40.0 F950 S717 M03 EOB
X10.0 F350 M08 EOB
X110.0 EOB
Y70.0 EOB
X-40.86 EOB
X-28.28 Y0.0 I14.14 J5.0 EOB
X-40.86 EOB
Y-70.0 EOB
X-75.0 Y0.0 Z40.0 F950 M30
NC, CNC AND DNC
67
p2
p4
p5
45
(4, 4)
p1
Motion of tool:
p0 p1 p2 p3 p4 p5 p1 p0
p0 (2, 2)
NC, CNC AND DNC
68
p2
p4
p5
Programming in inches
5
p0 (2, 2)
Spindle CCW
NC, CNC AND DNC
69
p2
p4
p5
Feed rate
Spindle speed
45
Tool no.
p0 (2, 2)
Flood coolant ON
NC, CNC AND DNC
70
p2
p4
p5
Linear interpolation
target coordinates
45
(4, 4)
p1
p0 (2, 2)
NC, CNC AND DNC
71
p2
p4
p5
Linear interpolation
5
target coordinates
or
(4, 4)
p1
p0 (2, 2)
X-coordinate
does
it
NC, CNC
AND not
DNCchange no need to program72
p2
p4
Linear interpolation
p5
target coordinates
45
p3
(x, y)
(4, 4)
p1
(6.5, 9)
.125
p0 (2, 2)
NC, 1
CNC AND DNC
73
p2
p4
p5
target coordinates
45
(4, 4)
p1
p0 (2, 2)
NC, CNC AND DNC
74
7. Cut from p4 to p5
5
2.5
p3
p2
p4
p5
Linear interpolation
45
(4, 4)
p1
p0 (2, 2)
NC, CNC AND DNC
75
8. Cut from p5 to p1
5
2.5
p3
p2
p4
p5
Linear interpolation
target coordinates (see step 3)
45
76
p2
p4
p5
Linear interpolation
target coordinates (see step 3)
end of data
N100 M00
program stop
p0 (2, 2)
NC, CNC AND DNC
77
78
79
APT Language
The most comprehensive and widely used language is Automatically
Programmed Tool (APT) the first prototype of the APT system
was developed at MIT in 1956.
The APT statements belong to one of the five types:
Identification statements
Geometry statements
Motion statements
Post-processor statements
Auxiliary statements
80
APT Language
Geometry statements, the general form of geometry
statement is:
Symbol = geometry_word/descriptive data
In the case of points:
P1 = POINT/X, Y, Z
P2 = POINT/L1, L2
P3 = POINT/CENTER, C1
P4= POINT/YLARGE, INTOF,
P5= POINT/XLARGE, INTOF,
P6= POINT/XLARGE, INTOF,
P7= POINT/YLARGE, INTOF,
L1,
L1,
C1,
C1,
C1
C1
C1
C1
81
APT Language
82
APT Language
C1 = CIRCLE/X, Y, Z, R
C2 = CIRCLE/CENTER, P1, RADIOUS, R
C3 = CIRCLE/CENTER, P1, TANTO, L0
C4 = CIRCLE/P1, P2, P3
C5 = CIRCLE/XSMALL, L1, XSMALL, L2, RADIOUS, R
And the same with XLARGE, YLARGE or YSMALL
83
APT Language
Motion statements, with regard to point-to-point operation
there are three motion statements for positioning the
tool at a desired point:
FROM/point_location
GOTO/point_location
GODLTA/x, y, z
84
85
APT Language
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
NC, CNC AND DNC
86
APT Language
Other Motion statements:
Or
GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
Check surface
And the same with PAST or ON instead of TO
GOLFT/
GORGT/
GOUP/
GODOWN/
GOFWD/
GOBACK/
For example:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST, L1, TO, PS, TANTO, C1
NC, CNC AND DNC
87
88
APT Language
Answer:
FROM/SP
GO/TO, L1, TO, PS, ON, L4
GORGT/L1, PAST, L2
GOLFT/L2, PAST, L3
GOLFT/L3, PAST, C1
GOLFT/C1, PAST, L3
GOLFT/L3, PAST, L4
GOLFT/L4, PAST, L1
GOTO/SP
89
APT Language
Example 3:
90
APT Language
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
91
APT Language
Additional statements:
MACHIN/DRILL, 2
COOLNT/
For example: COOLNT/MIST COOLNT/FLOOD COOLNT/OF
FEDRAT/
SPINDL/
For example: SPINDL/ON SPINDL/1250, CCLW
TOOLNO/
TURRET/
END
92
APT Language
Other capabilities of APT, the macro facility, with use variable argument as in a
FORTRAN subroutine, for example:
93
94
APT Language
Example 4 (2/2):
95
APT Language
Answer (1/4):
PARTNO PART11
MACHIN/MILL, 3
;machine selection
CLPRINT
;prints out CL data file
OUTTOL/0.002
SP =POINT/5,0,1
P1 =POINT/1,2,0.5
P2 =POINT/4,2,0.5
P3 =POINT/6,4,0.5
P4 =POINT/8,5,0.5
P5 =POINT/9,7,0.5
P6 =POINT/2,7,0.5
PL1 = PLANE/P1, P2, P3
PS = PLANE/PARALEL, PL1, ZSMALL, 0.5
;define part surface to be z = 0
NC, CNC AND DNC
96
APT Language
Answer (2/4):
C1 = CIRCLE/CENTER, P4, RADIOUS, 1.0
L1 = LINE/P2, P3
L2 = LINE/P3, RIGHT, TANTO, C1
L3 = LINE/P5, LEFT, TANTO, C1
L4 = LINE/P5, P6
L5 = LINE/P6, P1
L4 = LINE/P1, P2
MILL = MACRO/CUT, SPIN, FEED, CLNT
CUTTER/CUT
FEDRAT/FEED
SPINDL/SPIN
COOLNT/CLNT
FROM/SP
NC, CNC AND DNC
97
APT Language
Answer (3/4):
FROM/SP
GO/TO, L1, TO, PS, ON, L6
GORGT/L1, TO, 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
TERMMAC
TURRET/4
NC, CNC AND DNC
98
APT Language
Answer (4/4):
TURRET/4
CALL/MILL, CUT=0.52, SPIN=600, FEED=3.0, CLNT=ON
TURRET/6
CALL/MILL, CUT=0.5, SPIN=900, FEED=2.0, CLNT=ON
SPINDL/0
COOLNT/OFF
END
FINI
99
100
Define Tool
CNC data
Make 3D model
Simulate
cutting
NC, CNC AND DNC
101
102
Programming Methods
Automatically Programmed Tools (APT)
A text based system in which a programmer
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.
103
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
104
Programming Methods-APT
Requires excellent 3D visualization skills
Capable of generating machine code for
complicated part programs
5 axis machine tools
105
Programming Methods-APT
Part definition
P1=Point/12,20,0
C1=Circle/Center,P1,Radius,3
LN1=Line/C1. ATANGL,90
Cutter Commands
TLRT,GORT/LN1.TANTO,C1
GOFWD/C1,TANTO,L5
106
Programming Methods-CAM
Computer Aided Machining (CAM)
Systems
Graphic representation of the part
PC based
Integrated CAD/CAM functionality
Some built-in expertise
Speed & feed data based on material and tool specifications
107
Programming Methods-CAM
Tool & material libraries
Tool path simulation
Tool path editing
Tool path optimization
Cut time calculations for cost estimating
108
Programming Methods-CAM
Import / export capabilities to other systems
Examples:
Drawing Exchange Format (DXF)
Initial Graphics Exchange Standard (IGES)
109
2D or 3D scan
Model or Blueprint
110
111
Cut method
Example - Pocket mill zig-zag, spiral, inside-out
Rough and finish parameters
112
113
114
Output: NC Code
Numerical Control (NC) Language
A series of commands which direct the
cutter motion and support systems of the
machine tool.
115
Output: NC Code
116
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
117
Example of CNC
Programming
What What Must Be Done To Drill A Hole
On A CNC Vertical Milling Machine
118
Tool Home
Top
View
Front
View
NC, CNC AND DNC
119
Top
View
Front
View
NC, CNC AND DNC
120
Top
View
5.) Z Axis Feed Move to
Drill Hole
Front
View
NC, CNC AND DNC
121
Top
View
Front
View
NC, CNC AND DNC
122
Top
View
Front
View
123
Top
View
Front
View
Tool At Home
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
NC, CNC AND DNC
124
Tool At Home
Top
View
O0001
O0001
Number Assigned to this program
Front
View
NC, CNC AND DNC
125
Tool At Home
Top
View
O0001
N005 G54 G90 S600 M03
N005
G54
G90
S600
M03
Sequence Number
Fixture Offset
Absolute Programming Mode
Spindle Speed set to 600 RPM
Spindle on in a Clockwise Direction
Front
View
NC, CNC AND DNC
126
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
NC, CNC AND DNC
127
Top
View
Front
View
O0001
N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
G43
H01
Z.1
M08
128
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
G01
Z-.75
F3.5
129
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
G00
Z.1
M09
Rapid Motion
Z Coordinate .1 in. from Zero
Coolant Off
130
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
G91
Incremental Programming Mode
G28
Zero Return Command
X0, Y0, Z0
X,Y,& Z Coordinates at Zero
131
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
132
133
CAD to NC Code
Import
File
Post Process
NC Code
N1 G80 G90
N3 G0 T01 M06
N5 G0 X0 Y0
Geometry
Direct input
DXF
IGES
CL
File
OEM
Custom
Language
134
135