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CAM
MANUFACTURING ENGINEERING
Dr. Maqsood Ahmed Khan
Associate Professor & Co Chairman, IMD

COURSE PLAN
Topic Conventional Numerical Control NC Part Programming Computer Numerical Control Midterm Exam Group Technology and FMS Process Planning CAD/CAM Software Lectures 02 03 02 01 03 02 03

Software: CATIA V5 (R18) ; Matlab R2008a Marks Distribution: 1. Final theory paper = 60 Marks 2. Sessional Marks i. Attendance = 10 ii. Midterm Exam = 15 iii. Project = 15 40 Marks

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BOOKS

CAD/CAM
1.

CAD/CAM is a term which means computer-aided design and computer-aided manufacturing. It is the technology concerned with the use of digital computers to perform certain functions in design and production. It is a bridge between design and manufacturing.

2.

3.

Definition-CAM Computer-aided manufacturing (CAM) 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.

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COMPUTER MONITORING AND CONTROL: (DIRECT INTERFACE)

These are the direct applications in which the computer is connected directly to the manufacturing process for the purpose of monitoring or controlling the process. Computer process monitoring involves a direct computer interface with the manufacturing process for the purpose of observing the process and associated equipment and collecting data from the process.

COMPUTER MONITORING AND CONTROL: (DIRECT INTERFACE)

Computer process control goes one step further than monitoring by not only observing the process but also controlling it based on the observations. Signals are transmitted from the process to the computer, just as in the case of computer monitoring. In addition, the computer issues command signals directly to the manufacturing process based on the control algorithm contained in its software.

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MANUFACTURING SUPPORT APPLICATIONS: (INDIRECT INTERFACE)

These are the indirect applications in which the computer is used in support of the production operations in the plant, but there is no direct interface between the computer and the manufacturing process.

MANUFACTURING SUPPORT APPLICATIONS: (INDIRECT INTERFACE)

Some examples of CAM for manufacturing support are
1. 2. 3. 4. 5. 6.

Numerical control part programming by computers Computer-automated process planning Computer-generated work standard Production scheduling Material requirement planning Shop floor control (detailed management of activities and the flow of materials inside the plant - including the workers, materials, machines and time)

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THE PRODUCT CYCLE AND CAD/CAM

Product Cycle: Various activities and functions that must be accomplished in the design and manufacture of a product is termed as the product cycle.

Figure-1 Product Cycle without CAD/CAM

Figure-1 Product Cycle without CAD/CAM

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Figure-1 Product Cycle with CAD/CAM

Product Cycle with CAD/CAM

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CONVENTIONAL NUMERICAL CONTROL

Definition
Programmable automation in which the mechanical actions of a machine tool are controlled by a program containing coded alphanumeric data that represents relative positions between a work head (e.g., cutting tool) and a work part.

CONVENTIONAL NUMERICAL CONTROL

Motivation
To manufacture complex curved geometries in 2D or 3D was extremely expensive by mechanical means (which usually would require complex jigs to control the cutter motions) Machining components with repeatable accuracy Unmanned machining operations NC technology has been applied to a wide variety of operations, including machining, assembly, inspection, sheet metal pressworking, and spot welding.

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CONVENTIONAL NUMERICAL CONTROL

History
Late 1940s John T. Parsons (contractor of USAF) introduced a method of using punched card containing coordinate points of complex three dimensional profiles to control a machine tool. The machine was directed to move in small increments, thus generating the desire surface of a helicopter blade. 1948 Parsons demonstrated his first concept to the U.S. Air Force. 1951 MIT was involved in the project. 1952 MIT demonstrated first prototype of vertical NC milling machine (punched tape input). 1955 After refinements commercially available NC machines were displayed at National Machine Tool Show

BASIC COMPONENTS OF AN NC SYSTEM

A typical NC system consists of the following three elements
1. 2. 3.

Program of instruction Machine control unit (MCU) Machine tool or other controlled process

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BASIC COMPONENTS OF AN NC SYSTEM

Program of Instruction:
The program of instructions is the detailed step-by-step set of directions which tell the machine tool what to do. It is coded in alphanumerical and symbolic form on some type of input medium that can be interpreted by the controller unit. The most common input medium today is 1-inch wide punched tape.

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BASIC COMPONENTS OF AN NC SYSTEM

There are two other methods of input to the NC system:
1. 2.

Manual data input (MDI) Direct link with the computer (DNC)

Controller Unit
The second basic component of the NC system is the controller unit. This consists of the electronics and hardware that read and interpret the program of instructions and convert it into mechanical actions of the machine.

BASIC COMPONENTS OF AN NC SYSTEM

Typical elements of a conventional NC controller unit Tape reader Data Buffer Signal output channels to the machine tool Feed-back channels from the machine tool Sequence controls

Machine tool
The third basic component of an NC system is the machine tool.

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THE NC PROCEDURE
Process Planning Part Programming
1. 2.

Manual Part programming Computer-assisted part programming

Tape preparation Tape verification Production

NC COORDINATE SYSTEM
In order for the part programmer to plan the sequence of positions and movements of the cutting tool relative to the work-piece, it is necessary to establish a standard axis system. All the machine tools make use of Cartesian coordinate system for the sake of simplicity. The familiar right hand coordinate system is used for designating the axes In addition to the three linear axes, milling machine may have the capacity to control one or more rotational axes.

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FIXED ZERO AND FLOATING ZERO

The Programmer must determine the position of the tool relative to the origin (zero point) of the coordinate system. NC machines have two methods for specifying the zero point. Fixed zero Floating zero

Fixed zero
The origin is always located at the same position on the machine table. Usually, the position is the lower left-hand corner of the table and all tool locations are defined by positive x & y coordinates.

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FIXED ZERO AND FLOATING ZERO

Floating zero
This is more common feature on modern NC machines, which allows the machine operator to set the zero point at any position on the machine table. The part programmer decides the location of zero point The decision is based on part programmers convenience The location of zero point is communicated to the machine operator At the beginning of the job, the operator moves the tool manually to the target point The target point is some convenient place for the operator (corner point, pre drilled hole etc.)

FIXED ZERO AND FLOATING ZERO

The target point has been referenced to the zero point by the programmer. When the tool has been positioned at the target point, the machine operator presses a zero button to define the origin point.

Target point

M/C coordinate system

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NC MOTION CONTROL SYSTEM

There are four basic types of motion control systems.

Point-to-point NC
Sometimes it is also called a positioning system. The objective of machine tool control system is to move the cutting tool to a predefined location.

Straight-cut NC
Straight cut control systems are capable of moving the cutting tool parallel to one of the major axis at a controlled rate suitable for machining.

NC MOTION CONTROL SYSTEM

2-Axis Contouring NC
Contouring is the most complex, the most flexible, and the most expensive type of machine tool control. It is capable of performing both PTP and Straight-cut operations. It has simultaneous control of more than one axis movement of the machine tool.

3-Axis Contouring NC
It can control three axis simultaneously. Suitable for machining 3D complex profiles encountered in industrial practice such as aerospace components, mould and dies etc.

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INTERPOLATION METHODS
The selection of appropriate interpolation method is important for 2 and 3 axis contouring jobs. The paths that a contouring-type NC system is required to machine often consist of circular arcs and other smooth nonlinear shapes. Some of these shapes can be defined mathematically by relatively simple geometric formulas. Whereas others cannot be mathematically defined except by approximation. In any case, a fundamental problem in generating these shapes using NC equipment is that these shapes are continuous, whereas NC is digital. To solve this problem the path (circle or any other free form curve) must be divided into a series of straight line segments that approximate the path.

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INTERPOLATION METHODS
The tool is commanded to machine each line segment in succession so that the machined path closely matches the desired path. The maximum error between the nominal (desired) surface and the actual (machined) surface can be controlled by the lengths of the individual line segments,

INTERPOLATION METHODS
If the programmer were required to specify the endpoints for each of the line segments (to machine along a curve), the programming task would be extremely laborious and likely to errors. Also, the part program would be extremely long because of the large number of points. To ease the burden, interpolation routines have been developed that calculate the intermediate points to be followed by the cutter to generate a particular mathematically defined or approximated path. A number of interpolation methods are available to deal with smooth continuous path in contouring. 1. Linear interpolation 2. Circular interpolation 3. Helical interpolation 4. Parabolic interpolation 5. Cubic interpolation

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INTERPOLATION METHODS
Linear interpolation: This is the most basic and used method when a straight line path is to be generated in continuous path NC. The programmer specifies the beginning point and end point of the straight line and the feed rate to be used along the straight line. The interpolator computes the feed rates for each of the two (or three) axes to achieve the specified feed rate. Circular interpolation: This method permits programming of a circular arc by specifying the following parameters: (1) the coordinates of the starting point, (2) the coordinates of the endpoint, (3) either the center or radius of the arc. The generated tool path consists of a series of small straight line segments calculated by the interpolation module.

INTERPOLATION METHODS
Helical interpolation: This method combines the circular interpolation scheme for two axes described above with linear movement of a third axis. This permits the definition of a helical path in three-dimensional space. Applications Include the machining of large Internal threads. Parabolic and cubic interpolation: These routines provide approximations of free form curves using higher order equations. Most applications are in the aerospace and automotive Industries for free form designs that cannot accurately and conveniently be approximated by combining linear and circular interpolations

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ABSOLUTE AND INCREMENTAL POSITIONING

Another option sometimes available to the part programmer is to use either an absolute system of tool positioning or an incremental system.

Absolute system
It is always defined with respect to the zero point.

Incremental system
It is defined with reference to the previous tool location.

NC PART PROGRAMMING CHAP # 8

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THE PUNCHED TAPE IN NC

TAPE CODING AND FORMAT

NC tape coding
There are eight regular columns of holes. There is also a ninth column of holes between the 3rd and 4th regular columns used as sprocket holes. The coding of the tape is provided by either the presence or absence of a hole, hence it becomes the binary code. It uses the base 2 number system, which can represent any number in the decimal system. Besides numbers, alphabetical letters and other symbols can also be coded. Eight columns provide more than enough binary digits to define any of the required symbols.

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TAPE CODING AND FORMAT

How Instructions are formed
A complete row makes a character, which represents a letter, number, or other symbol. A word is a collection of characters A block is a collection of words. A block of words is a complete NC instruction. To separate blocks, an end-of-block (EOB) symbol is used. The tape reader feeds the data from the tape into the buffer in blocks.

TAPE CODING AND FORMAT

NC words
Sequence number (n-word): N10, N20, N100. Preparatory word (g-word): g00, g01, g02. Coordinates (x-,y-, and z-words): x+9.4625, y-23.6845 Feed rate (f-word): f30. Cutting speed (s-word): s2000 Tool selection (t-word): t05 Miscellaneous function (m-word): m03 (start spindle).

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MANUAL PART PROGRAMMING

To prepare a part program using the manual method, the programmer writes the machining instructions on a special form called a part programming manuscript. Manuscripts come in various forms, depending on the machine tool and tape format to be used. The manuscript is a listing of the relative tool and work-piece positions. It also include other type of data, such as miscellaneous instructions, and speed/feed specifications. Except for complex parts with many holes, manual programming is ideally suited for PTP applications. On the other side, except for the simple jobs, manual programming become quite time consuming for contouring jobs.

EXAMPLE
Suppose that the part to be programmed is a drilling job. The engineering drawings for the part is presented in the figure. Three holes are to be drilled at a diameter of 0.484-in. The close hole size tolerance requires reaming to 0.5-in dia. Recommended parameters are as follows: Speed (rpm) 0.484-in dia. drill 0.5-in dia. reamer 592 382 Feed (in/min) 3.55 3.82

Drill bits are manually changed by the machine operator. The machine has the floating-zero feature and absolute positioning.

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COMPUTER-ASSISTED PART PROGRAMMING

In the more complicated PTP jobs and in contouring applications, manual part programming becomes an extremely tedious task and subject to errors. In these instances it is much more appropriate to use the highspeed digital computer to assist in the part programming process. Many part programming language systems have been developed to perform automatically most of the calculations. In computer assisted part programming the machining instructions are written English-like statements of the NC programming language. These statements are processed by the computer to prepare the tape. The computer automatically punches the tape in the proper tape format for the particular machine.

THE PART PROGRAMMERS JOB

The part programmers responsibility in computer-assisted part programming consists of two basic steps: Defining the work-part geometry Specifying the operation sequence and tool path

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DEFINING THE WORK-PART GEOMETRY

No matter how complicated the work-part may appear, it is composed of basic geometric elements, points, straight lines, planes, circles, cylinders, and other mathematically defined surfaces. It is the part programmers task to identify the elements out of which the part is composed. Each geometric element must be identified and the dimensions and location of the element explicitly defined.

SPECIFYING THE OPERATION SEQUENCE AND TOOL PATH

After defining the work-part geometry, the programmer must next construct the path that the cutter will follow to machine the part. It involves a detailed step-by-step sequence of cutter moves. The moves are made along the geometry elements, which have already been defined. The programmer can use the various motion commands to create these movements.

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THE COMPUTERS JOB

The computers job in computer-assisted part programming consists of the following
1. 2. 3. 4.

Input translation Arithmetic calculations Cutter offset computation Postprocessor

THE COMPUTERS JOB

Input Translation
The part programmer enters the program written in APT or other language The input translation component converts the coded instructions into computer-usable form for further processing.
1. 2. 3. 4.

Syntax check of the input code to identify errors in format, punctuation, spelling etc. Assigning sequence number to each APT statement. Converting geometry elements into suitable form for computer processing Generating intermediate file called PROFIL that is utilized in subsequent arithmetic calculations

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THE COMPUTERS JOB

Arithmetic Calculations
It is a set of subroutines for solving the mathematics required to generate the part surface and generate tool-path. The arithmetic calculations are performed on the PROFIL file. It frees the programmer from the time-consuming and errorprone geometry and trigonometry calculations. The output of this module is CLFILE.

Cutter offset computation

The second task of the part programmer is to construct the tool path. However, the actual tool path is different from the part outline. The actual tool path is achieved by offsetting the path from the desired part surface equal to the radius of the cutter.

THE COMPUTERS JOB

Post-Processor
NC machine systems are different, they have different features and capabilities High-level programming languages are not intended for only one machine tool type. They are designed to be general purpose. The final task of the computer in computer-assisted part programming is post-processing, in which the CLFILE file is converted into low-level code that can be interpreted by the NC controller. The output of post-processing is a part program consisting of G-codes, x-, y-, and z-coordinates, S,F,M, and other functions in word address format. A unique post-processor must be written fro each machine tool system.

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NC PART PROGRAMMING LANGUAGES

APT (Automatically Programmed Tool) ADAPT (Adaption of APT) EXAPT (Extended subset of APT) UNIAPT SPLIT (Sundstrand Processing Language Internally Translated) COMPACT II PROMPT CINTURN II The most widely used NC part programming language is APT.

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APT LANGUAGES
APT is a three dimensional system that can be used to control up to 5-axes. Our discussion is limited to the more familiar axes, x, y, and z, and excluding the rotational coordinates. APT can be used to control a variety of different machining operations, but we will cover only drilling and milling applications. There are four types of statements in APT language:
1. 2. 3. 4.

Geometric Statements Motion Statements Post-processor statements Auxiliary Statements

GEOMETRIC STATEMENTS
These define the geometric elements that comprise the work-part. The general form of an APT geometry statement is Symbol = geometry type / descriptive data Symbol: To identify the geometric element Geometry type: To identify the type of geometric element (should be APT vocabulary word) Descriptive data: To define the geometric element precisely Example: P1 = POINT / 5.0, 4.0, 0.0

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L3 = LINE / P3, P4 L4 = LINE / P5, PARLEL, L3 PL1 = PLANE / P1, P4, P5 PL2 = PLANE / P2, PARLEL, PL1 C1 = CIRCLE / CENTER, P1, RADIUS, 5.0

EXAMPLE

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P0 = POINT / 0, -1.0, 0 P1 = POINT / 6.0, 1.125, 0 P2 = POINT / 0, 0, 0 P3 = POINT / 6.0, 0, 0 P4 = POINT / 1.75, 4.5, 0 L1 = LINE / P2, P3 C1 = CIRCLE / CENTER, P1, RADIUS, 1.125 L2 = LINE / P4, LEFT, TANTO, C1 L3 = LINE / P2, P4 PL1 = PLANE / P2, P3, P4

MOTION STATEMENTS
The general form of motion statement is motion command/ descriptive data Example: GOTO/P1 At the beginning of the motion statements, the tool must be given a starting point. The part programmer keys into this starting position with the following statement FROM/TARG

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POINT-TO-POINT MOTIONS
There are only two basic PTP motion commands:
1. 2.

GOTO GODLTA

The GOTO statement instructs the tool to go to a particular point location. GOTO/2.0, 7.0, 0.0 The GODLTA command specifies an incremental move for the tool. Example: GODLTA/ 2.0, 7.0, 0.0

GODLTA command is useful in drilling and related operations

EXAMPLE
P1=POINT/1.0, 2.0, 0 P2 = POINT/1.0, 1.0, 0 P3 = POINT/3.5, 1.5, 0 P0 = POINT/-1.0, 3.0, 2.0 FROM/P0 GOTO/P1 GODLTA/0, 0, -1.0 GODLTA/0, 0, +1.0 GOTO/P2 GODLTA/0, 0, -1.0 GODLTA/0, 0, +1.0 GOTO/P3 GODLTA/0, 0, -1.0 GODLTA/0, 0, +1.0 GOTO/P0

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