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Conventional machines section
Some of the machines in this section are :
Bandsaw - The bandsaw is useful for cutting stock to size and roughing
out shapes. It cuts curved shapes very well.
Belt sander A belt sander is used to remove rough edges. It makes use
of an abrasive riding belt. Effective on wood, plastic and most metals.
Drilling machine
The drill press is mostly
used for drilling holes,
reaming, boring,
countersinking etc.
Power hacksaw A
type of hacksaw powered
either by its own electric
motor or connected to an
engine.
Power hacksaw Drilling machine
Surface grinder It is a machine tool used to
provide high precision surface finish. The
grinding wheel rotates in the spindle head, its
height adjustable. The workpiece is fed by a
horizontal table positioned below the grinding
wheel.
Surface grinder
Slotting machine - Similar to
a vertical shaper. The most
common use is to machine
straight, flat surfaces.
Slotting machine
And several other machines for sheet metal work, electroplating etc. , as
well as callipers, micrometers etc. for measurement and testing.
The 2 principal conventional machines on which we are focusing are the
lathe and milling machines.
Lathe Machine
Lathes are designed for precisely machining relatively hard materials. With
their inherent versatility, they are used in a wide range of applications, and can
machine a broad range of
materials.
Threading - External threads can be cut with a die and internal threads
can be cut with a tap.
Types of lathe
Centre lathe / bench lathe / engine lathe - The most basic type of lathe.
Toolroom Lathe - Lathe optimized for toolroom work. It has all of the
best optional features that may be omitted from less expensive models, such
as a collet closer, taper attachment, and others.
Multispindle lathe - Multispindle lathes have more than one spindle and
automated control.
CNC lathe - CNC lathes are rapidly replacing the older production lathes
due to their ease of setting and operation. The part may be designed by the
Computer-aided manufacturing (CAM) process, the resulting file uploaded
to the machine, and once set and trialled the machine will continue to turn
out parts under the occasional supervision of an operator.
Types of milling cutters
In vertical mills, milling cutters
with solid shafts are usually used.
Roughing
Finishing
Drilling
Boring (a) Rough (b) Finish (c) Counter boring
Slotting
Key way cutting
Gear cutting
Spur
Bevel
Worm
Helical
Computer and Numerically Controlled
Machines
Numerically Controlled (NC)
NC is the operation of M/c tool by a series of coded instructions consisting of
numbers, letters of the alphabets and symbols, which the MCU (Machine Control
Unit) can understand.
For both NC and CNC systems, working principles are the same. Only the way in
which the execution is controlled is different. Normally, new systems are faster,
more powerful, and more versatile.
Comparison between NC, CNC and DNC machine tools
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CNC MILLING
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CNC LASER CUTTING
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CNC PLASMA CUTTING
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CNC PRESS
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CNC RAPID PROTOTYPING
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INDUSTRIES MOST AFFECTED
by CNC
Aerospace
Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mold making
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Various popular CNC control systems
1. ECS
2. LECS
3. NUM
4. SELCA
5. MARPOSS
6. Z-16
7. FANUC
8. FAGOR
9. FIDIA
10. DECKEL
11. SINUMERIC
12. HINUMERIC
13. HEIDENHAIN A CNC Milling center by DECKEL
14. GILDEMEISTER
The construction of CNC machines
1. Elements of motion transmission
The drive motors control machine slide movement on CNC equipment. Types used :
1. Stepper motors (convert a digital pulse into a small rotation, mostly used in
applications where low torque is required )
2. DC servo motors (rotate in response to the applied voltage, used to drive lead
screw and gear mechanisms, provide higher-torque output)
3. AC servo motors (controlled by varying the voltage frequency to control speed,
more power than a DC servo, used to drive a lead screw and gear mechanism )
4. Fluid servo motors (variable speed motors, produce more power, in the case of
pneumatic motors, than electric servomotors)
5. Tool changers
Several different cutting tools are used to produce a part. The tools must be replaced
quickly for the next machining operation. For this reason, the majority of NC/CNC
machine tools are equipped with automatic tool changers. They allow tool changing
without the intervention of the operator.
An automatic tool changer grips the tool in the spindle, pulls it out, and replaces it
with another tool. Tool changers are equipped for either random or sequential
selection.
In random tool selection there is no specific pattern of tool selection.
In sequential tool selection, the tools must be loaded in the exact order in which
they are called for in the program.
CNC PROGRAMMING
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INFORMATION NEEDED by a
CNC
1. Preparatory Information: units, incremental or
absolute positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle
speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. 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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BLOCK FORMAT
Sample Block
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WORD-ADDRESS CODING
Example CNC Program
Each instruction to the machine
N5 G90 G20
N10 M06 T3 consists of a letter followed by a
N15 M03 S1250 number.
N20 G00 X1 Y1
N25 Z0.1 Each letter is associated with a
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 specific type of action or piece of
N40 G00 Z1 information needed by the
N45 X0 Y0 machine.
Letters used in Codes
N50 M05
N55 M30 N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
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G & M Codes
Example CNC Program
G-codes: Preparatory
N5 G90 G20
N10 M06 T3 Functions involve actual tool
N15 M03 S1250 moves.
N20 G00 X1 Y1
N25 Z0.1 M-codes: Miscellaneous
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 Functions involve actions
N40 G00 Z1 necessary for machining (i.e.
N45 X0 Y0 spindle on/off, coolant on/off).
N50 M05
N55 M30
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G Codes
G00 Rapid traverse G40 Cutter compensation
G01 Linear interpolation cancel
G41 Cutter compensation
G02 Circular interpolation, left
CW
G42 Cutter compensation-
G03 Circular interpolation, right
CCW
G70 Inch format
G04 Dwell
G71 Metric format
G08 Acceleration
G74 Full-circle programming
G09 Deceleration off
G17 X-Y Plane G75 Full-circle programming
G18 Z-X Plane on
G19 Y-Z Plane G80 Fixed-cycle cancel
G20 Inch Units (G70) G81-G89 Fixed cycles
G21 Metric Units (G71) G90 Absolute dimensions
G91 Incremental dimensions
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Modal G-Codes
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Modal G-Code List
G43 Tool length
G00Rapid Transverse compensation (plus)
G01Linear Interpolation G44 Tool length
G02Circular Interpolation, CW
G03Circular Interpolation,
compensation (minus)
CCW G49 Tool length
G17XY Plane compensation cancel
G18XZ Plane
G19YZ Plane G80 Cancel canned
G20/G70 Inch units cycles
G21/G71 Metric Units G81 Drilling cycle
G40 Cutter compensation
cancel G82 Counter boring
G41 Cutter compensation cycle
left
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N Codes
Gives an identifying number for each
block of information.
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X,Y, and Z Codes
X, Y, and Z codes are used to
specify the coordinate axis.
Number following the code defines
the coordinate at the end of the
move relative to an incremental or
absolute reference point.
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I,J, and K Codes
I, J, and K codes are used to specify
the coordinate axis when defining
the center of a circle.
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F,S, and T Codes
F-code: used to specify the feed rate
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