Beruflich Dokumente
Kultur Dokumente
R. A. Wysk, Ph.D.
Agenda
Introduction
Types of NC Machines
Components of a NC Machine
Control Mechanisms
Interpolation
Software Components
Readings
Chapters 9-10 of Computer Aided
Manufacturing, Wang, H.P.,
Chang, T.C. and Wysk, R. A., 2rd
Edition ,1991.
http://www.engr.psu.edu/cim/ie450
/mllwrkbk.pdf
Exercise
Readiness Assessment Test
A.K.A. RAT
AS A INDIVIDUAL,
INDIVIDUAL prepare a detailed
response for the Readiness Assessment test
found on the web
http://www.engr.psu.edu/cim/ie450/ie450rat3.
doc
(ratNC.doc in this module directory)
Objectives
To be able to read and interpret an NC part
program
To be able to create NC part programs for
milled parts
To understand the difference between
world, machine and part coordinates
To understand how to set machine offsets
To execute an NC part program
HISTORICAL
15th century DEVELOPMENT
- machining metal.
18th century - industrialization, production-type machine tools.
20th century - F.W. Taylor - tool metal - HSS
Automated production equipment Screw machines
Transfer lines
Assembly lines
using cams and preset stops
Programmable automation NC
PLC
Robots
NC
Computer control
MACHINES
Servo axis control
Tool changers
Pallet changers
On-machine programming
Data communication
Graphical interface
Group Exercise
As a group, discuss how you could justify the
purchase of an NC machine.
What are the downsides for purchasing an
NC machine?
Besides direct labor reductions, what other
benefits come from NC machines?
NC
MCU - Machine control
MACHINES unit
Machine
Tool
MCU
NC MOTIONCONTROL
NC Program
Execution
Syst em
Commands
Dimensions
Interpolator &
Servo-cont rol
Mechanism
Control
Linear
Logic
Motion
T ranslat or
Power
Relay
Solenoid
NC MACHINE
1. MotionCLASSIFICATIONS
control:
point to point (PTP)
continuous (contouring) path
2. Control loops:
open loop
closed loop
3. Power drives:
hydraulic, electric,or pneumatic
NC MACHINE
CLASSIFICATIONS
4. Positioning
systems:
incremental
absolute positioning
POINT TO
Moving at maximum ratePOINT
from point to point.
Accuracy of the destination is important but not the path.
Drilling is a good application.
CONTINUOUS
Controls both the displacement and the velocity.
PATH
Machining profiles.
Precise control.
COMPONENTS OF AN NC MACHINE
TOOL
Position
transducer
Controller
Machine table
Gear
box
Tachometer
Motor
Leadscrew
Servo
drive
Magnetics control
cabinet
NC MACHINE
Accuracy RATING
Repeatability
Spindle and axis motor horsepower
Number of controlled axes
Dimension of workspace
Features of the machine and the
controller.
NC
ACCURACY
Accuracy = control instrumentation
resolution and hardware accuracy.
HARDWARE
Component tolerances:
INACCURACIES
inaccuracies in the machine elements,
Machine operation:
Tool deflection (a function of the cutting
force), produces dimensional error and
chatter marks on the finished part.
HARDWARE
Thermal INACCURACIES
error:
heat generated by the motor operation,
cutting process, friction on the ways and
bearings, etc. Use cutting fluids, locating
drive motors away from the center of a
machine, and reducing friction from the
ways and bearings
REPEATABILIT
Y
Programmed position
Repeat abilit y
Avg. error
T est result
LEADSCRE
WS
Leadscrew
Pitch
CONTROL
Open loop - No position feedback.
LOOPS table
pulses
motor
CONTROL
A machine has 1 BLU = 0.001".To move the
LOOPS
table 5" on X axis at a speed (feed rate) of
6 ipm.
pulse rate = speed/BLU = 6 ipm/0.001
ipp= 6,000 pulse/min
pulse count = distance/BLU
= 5/0.001 = 5,000 pulses
CLOSED
LOOP
Differential
amplifier
_
Up-down
counter
DAC
Amp
Shaft
DC
Motor
Tachometer
+
Reference pulses
Encoder
INTERPOLATIO
Control multiple axes simultaneously to move
on a line, a circle, orN
a curve.
(10,5)
(10,5)
(3,2)
(3,2)
X
Linear path
INTERPOLATOR
Most common : linear and circular
S
COORDINATE
SYSTEMS
y
y
z
x
MACHINE
COORDINATES
Z
PROGRAM
Paper tape STORAGE
Paper or Mylar coated paper.
Diskettes
From other computers through RS 232 or
local area network (LAN)
ASCII
SYMBOLIC
or ISO,
use even parity
CODES
TAPE INPUT
EIA RS-274 standard
FORMATS
Resources
Primary Reference:
Chang T-C., Wysk, R. A., and Wang, H-P., Computer
Aided Manufacturing, Prentice Hall International Series
in Industrial and Systems Engineering, Upper Saddle
Valley, NJ 07458. ISBN 0-13-754524-X
Agenda
Introduction
Absolute and Incremental Programming
Elements of NC Program
NC Words (G, M, T, S, Codes)
Examples
Cutter Compensation and Offsets
Examples
Conclusions
Introduction to NC programming
Manual part programming
Computer-assisted part programming
Formats
Fixed-Address
Tab-Sequential
Word-Address
Manual NC programming
Absolute Programming
Incremental Programming
Example (on Board)
NC WORDS
A G-code program consists the following
words:
N, G, X, Y, Z, A, B, C, I, J, K, F, S, T, R, M
An EIA standard, RS-273 defines a set of
standard codes.
NC WORDS G codes
Table 9.1 G codes
N code.
sequence
number
g00
Rapid traverse
g40
g01
Linear interpolation
g41
g02
Circular interpolation, CW
g42
g70
Inch format
Dwell
g71
Metric format
Acceleration
g74
Deceleration
g75
g80
example: g03
N0010 g04
g08
G code.
preparatory
g09
word.
g17
X-Y Plane
*g18
Z-X Plane
g19
Y-Z Plane
g90
g33
* lead g91
Thread cutting, constant
g34
Absolute dimension
programming
Incremental deimension
programming
NC WORDS- BLU
X, Y, Z, A, B, C Codes. coordinate positions of the tool.
The coordinates may be specified in decimal number (Decimal
Programming), or integer number (BLU Programming).
BLU programming: leading zero, trailing zero.
NC
WORDS
Circular
Interpolation
Circular Interpolation:
Full circle ON
(5.000,4.000)
sequence no.
destination
(5.000,2.000)
(7.000,2.000)
center
F code must be given before either G01, G02, or G03 can be used.
Example:
N0100 G02 X7.000 Y2.000 I5.000 J2.000 F6.00
S Code. cutting speed code.
Programmed in rpm.
S code does not turn on the spindle, spindle is turned on by a M code.
N0010 S1000
(1,2,2)
Initial height
2
0.7"
R plane
0.3"
1"
Z point
NC WORDS M Codes
M Code. miscellaneous word.
m06
Tool change
m07
Flood coolant on
m08
Mist coolant on
m03 Spindle CW
m09
Coolant off
m30
End of tape
MANUAL PART
Example 9.1
PROGRAMMING
Machined from a 5" x 4" x 2" workpiece. low carbon steel.
The process plan:
1. Set the lower left bottom corner of the part as the machine zero point
(floating zero programming).
2. Clamp the workpiece in a vise.
3. Mill the slot with a 3/4" four flute flat end mill made of carbide. From the
machinability data handbook, the recommended feed is 0.005
inch/tooth/rev, and the recommended cutting speed is 620 fpm.
4. Drill two holes with a 0.75" dia twist drill. Use 0.18 ipr feed and 100 fpm
speed.
PART
DRAWING
2 holes 0.750.001
.75
0.001 M
MA BC
4.000
R1.000
3.000
2.000
1.000
1.75
3.000
5.000
.500
2.000
C
All dimension in inches. A ll tolerance 0.001"
SOLUTION TO
Solution:
EXAMPLE
The cutting parameters
need be converted into rpm and ipm.
Milling:
Drilling:
12 V
RPM =
=
D
12 x 100 fpm
0.75 inch = 509 rpm
p3
p6
H2
p8
H1
p4
p7
p5
p9
p1
(0,0,0)
Drill
End mill
Vise jaw
(0,0,0)
CUTTER
The coordinates of each point (cutter location) are calculated below:
LOCATIONS
p1': ( 1.75+0.375, -0.1-0.375, 4.00) = (2.125, -0.475, 4.000)
p1: (2.125,-0.475, 2.000-0.500) = (2.125,-0.475,1.500)
p2: (2.125,4.000+0.100,1.500) = (2.125,4.100,1.500)
p3: (3.000-0.375,4.100,1.500) = (2.625,4.100,1.500)
p4: (2.625,1.375,1.500)
p5: (3.000,2.000-1.000+0.375,1.500) = (3.000,1.375,1.500)
p6: (3.000,2.625,1.500)
p7: (3.000,2.000,1.500)
p8: (2.625,2.000,1.500)
p9: (2.625,-0.100,1.500)
p9': (2.625,-0.100,4.000)
PART PROGRAM
Part program
N0010 G70 G 90 T08 M06
and absolute dimension
Explanation
Set the machine to inch format
programming.
Feed to p2.
To p3.
To p4.
PART PROGRAM
Part program
Explanation
CNCS
VERIFICATION
CNCS 3D
DRAWING
Offsets
Fixture
G10, G54, G54.1
Diameter
Tool
Length compensation
Part-Edge compensation
Cutter Compensation Next Slides
Others Discussed in Lab Exercises (Simulators)
G41 (or G42) and G01 in the same block ramp takes place at block N0010.
N0010 G01 G42 X0.500 Y1.700
N0020 G01 X1.500
(b) G42
(0.5, 1.7)
(1.5, 1.7)
G41
G42
G41 (or G42) and G01 in separate blocks the compensation is effective from the start.
N0010 G41
N0020 G01 X0.500 Y1.700
G41
N0010 G41
G42
(0, 1.6)
G41
M96
G41
M97
TOOL-RADIUS
COMPENSATION
Cancel Tool Compensation.
G41
G40
G42
(2.000, 1.700)
G41
(2.000, 1.700)
EXAMPL
A square 2.0 in. x 2.0 in. is to be milled using a 1/2 in. end milling cutter. Write
an NC part program to make the square.
E
Solution
Let us set up the lower left corner of the square at (6.0,6.0). Using toolradius compensation, the square can be produced.
2.000
2.000
(6,6)
PART PROGRAM
Part Program
N0010 G41 S1000 F5 M03
N0020 G00 X6.000 Y6.000
N0030 G01 Z-1.000
N0040 Y8.000
N0050 X8.000
N0060 Y6.000
N0070 X6.000
N0080 Z1.000
N0090 G40 M30
Explanation
Begin compensation, set feed and speed, spindle on
Move to lower left corner
Plunge down the tool
Cut to upper left corner
Cut to upper right corner
Cut to lower right corner
Cut to lower left corner
Lift the tool
End compensation, stop the machine
Exercise
Complete the exercise on setting up an NC
machine. The exercise can be found at
http://www.engr.psu.edu/cim/ie450/ie450as2.doc
2.875
TURNIN
G
.250
.625
1.125
R.125
1.000
2.125
2.875
Part design
Cutter path
Cutter path
Tool
TURNIN
G
No compensation needed.
Surfaces cut
Programmed
tool path
Surface created
calculations
Post processing
Language
Processor
CL data
Post
Processor
N-G code
RS-273
Summary
NC can reduce machining skill
NC can reduce the time required to machine
a part
NC provides sophisticated contour
capability
NC is a flexible method for manufacture of
sophisticated machined components
Questions