IST / DEEC / ACSDC

MEEC 2007-2008

Industrial Automation
(Automao de Processos Industriais)

CAD/CAM and CNC

htt // http://www.isr.ist.utl.pt/~pjcro/courses/api0708/api0708.html i i t tl t/ j / / i0708/ i0708 ht l
Prof. Paulo Jorge Oliveira pjcro @ isr.ist.utl.pt Tel: 21 8418053 or 2053 (internal)
API P. Oliveira Page 1

IST / DEEC / ACSDC

MEEC 2007-2008

Syllabus:
Chap. 4 - GRAFCET (Sequential Function Chart) [1 weeks] ... Chap. 5 CAD/CAM and CNC [1 semana] Methodology CAD/CAM. Types of CNC machines. Interpolation for trajectory generation. Integration in Flexible Fabrication Cells. Chap. 6 Discrete Event Systems [2 semanas]
API P. Oliveira Page 2

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

Some pointers to CAD/CAM and CNC

History: Tutorial: http://users.bergen.org/~jdefalco/CNC/history.html http://users.bergen.org/~jdefalco/CNC/index.html http://www-me.mit.edu/Lectures/MachineTools/outline.html http://www.tarleton.edu/~gmollick/3503/lectures.htm http://www.cncezpro.com/ http://www.cadstd.com/ http://www.turbocad.com http://www.deskam.com/ http://www.cadopia.com/ * Computer Control of Manufacturing Systems, Yoram Koren, McGraw Hill, 1986. * The CNC Workbook : An Introduction to Computer Numerical Control by Frank Nanfarra, et al.

Editors (CAD):

Bibliography:

API

P. Oliveira

Page 3

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Concept Tool / Methodology

Prototype

API

P. Oliveira

Page 4

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

Brief relevant history NC

1947 US Air Force needs lead John Parsons to develop a machine able to Produce parts describes in 3D. 1949 Contract with Parsons Corporation to implement to proposed method. 1952 Demonstration at MIT of a working machine tool(NC), able to produce parts resorting to simultaneous interpolation on several axes. 1955 First NC machine tools reach the market. market 1957 - NC starts to be accepted as a solution in industrial applications , with first machines starting to produce. 197x Profiting from the microprocessor invention appears the CNC.
API P. Oliveira Page 5

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

Evolution in brief CAD/CAM and CNC Modification M difi i of f existing i i machine hi tools l with i h motion i sensors
and automatic advance systems. Close-loop control systems for axis control. Incorporation of the computational advances in the CNC machines. Development of high accuraccy interpolation algorithms to trajectory interpolation. Resort to CAD systems to design parts and to manage the use of CNC machines.

API

P. Oliveira

Page 6

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM e CNC Objectives:

To augment the accuraccy, reliability, and the ability to introduce changes/new designs. To augment the workload. To reduce prodution costs. To reduce waste due to errors and other human factors factors. To carry out complex tasks (e.g. Simlutaneous 3D interpolation). Augment precision of the produced parts.

API

P. Oliveira

Page 7

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Advantages: To T reduce d the h production/delivery d i /d li time. i

To reduce costs associated to parts and other auxiliary. To reduce storage space. To reduce time to start production. To reduce machining time. To reduce time to market (on the design/redesign and production).

API

P. Oliveira

Page 8

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Limitations:

High initial investment (30.000 (30 000 to 1.500.000 1 500 000 euros) ) Specialized maintenance required Does not eliminates the human errors completely. Requires more specialized operators. Not so relevant l the h advantages d on the h production d i of f small ll or very small series.

API

P. Oliveira

Page 9

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM e CNC Methodology CAD/CAM

To use technical T h i l data d from f ad database b i in the h d design i and d production stages. Information on parts, materials, tools, and machines are integrated. CAD (Computer Aided Design) Allows the design in a computer environment. CAM (Computer Aided Manufacturing) To manage programs and production stages on a computer.

API

P. Oliveira

Page 10

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

API

P. Oliveira

Page 11

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Tools:

API

P. Oliveira

Page 12

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Tools:

Atention to the constraints on the materials used!...

Speed S d of f advance d Speed of rotation Type of tool

API P. Oliveira Page 13

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Tools:

Specific tools to perform different operations.

API P. Oliveira Page 14

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Tools: impact on the quality of finishing (m)

Mtodo
Flame cut Sawing Planeing Drilling Chemical machinning Electrical dischage Milling Augment drilling Electron beam LASER cut Electrochemical cut Lath Electrolitical machining Exctrusion Afiar Polir Quinar 50 25 12 6 3 1.5 .8 .4 .2 .1 .05 .025 .0125

0.5

API

P. Oliveira

Page 15

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Evolution of tools performance:

API

P. Oliveira

Page 16

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Industrial areas of application:

Aerospace A Maquinery Electricity (board production) Automobiles Instrumentation Moulds

API

P. Oliveira

Page 17

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Evolution of Numerical Control

Numerical N i l Control C l (NC)
Data on paper ou received in serial port NC machine unable to perform computations Hardware interpolation

Direct Numerical Control (DNC)

Central computer control a number of machines DNC ou CNC

Computer C t N Numerical i l control t l (CNC)

A computer is on the core of each machine tool Computation and interoplation algorithms run on the machine

Distributive numerical control

scheduling Quality control Remore monitoring

API

P. Oliveira

Page 18

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Numeric Control

A hi Architecture of f a NC system
Open-loop
gear reference step motor transmission table

Close-loop
gear reference controller DA DC motor transmission table encoder

API

P. Oliveira

Page 19

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

p

CAD/CAM and CNC Interpolation Motivation: numerical integration

Area of a function

p(t)
p

z (t ) = p ( )d i =1 pi t
t k 0

Introducing zk, as the value of z at t=kt

z k = i =1 pi t + pk t = z k 1 + z k ,
k 1

z k = pk t

Th integrator The i t t works k at t a rythm th of f f=1/ f 1/t and d the th function f ti p is i given i app. by: b

pk = pk 1 pk
To be able to implement the integrator in registers with n bits, p must verify pk<2n .
API P. Oliveira Page 20

10

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Implementation of a DDA Digital Differential Analyzer

The p register input is +1, 0 ou 1. The q register stores the area integration value
+p p

f q register

adder z p register

qk = qk 1 + pk .
z k = 2 n pk

If th the q register i t value l exceeds d (2n-1), 1) and d overflow fl occurs and d z=1: 1 Defining C=f/2n, and given that f=1/t:

z k = Cpk t
API P. Oliveira Page 21

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC DDA for Linear Interpolation:

Let q=5 and assume 3 bits registers
Passo q z z ------------------------------------------1 5 0 2 2 1 1 3 7 1 4 4 1 2 5 1 1 3 6 6 3 7 3 1 4 8 0 1 5 9 5 5 ...
API

f p t z
where

f0
f 2n

z f 0 = = Cpk , t k

C=

10

12

16

1 P. Oliveira

2 Page 22

11

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Exponential Deacceleration:

Let

p(t ) = p 0 e t

and

z = Cpk = Cp0 e t . t
Example: p(t)=15e-t
15 pk

The differential of p(t) is appr.

p = pk t
Setting C=,

p = z
10 p(t)

p(t)

f +p p
API

f0
0 0 10 20 30 Time iterations 40 50 60

P. Oliveira

Page 23

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Circular Interpolation:

+p p Clock +p p
Rsin(t)dt

Let

( X R )2 + Y 2 = R 2 X = R(1 cos(t )) Y = R sin (t )

or

The differential is X

dX = Rsin (t )dt = d( Rcos(t )) dY = Rcos(t )dt = d(Rsin (t ))

0 pk p(t)

Rcos(t)dt

Y
-5 Y -10

Example: Circunference of radius 15, centered at the origin.

API

-15

5 X

10

15

P. Oliveira

Page 24

12

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Full DDA

circular +p p linear L X C f0 +p p desacceleration L Y C
P. Oliveira Page 25

f +p p

API

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Axes Control

reference controller ll DA DC motor gear transmission table encoder

Dynamics of a control loop

Ts

k2 k1
fref

1 s

k DA

k1 1 + s
P. Oliveira

kg

API

Page 26

13

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

Steps to execute a part

A) Read/interpret the technical drawings

API

P. Oliveira

Page 27

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

B) Choice Ch i of f the h most adequate d machine hi tool lf for the h several l stages of machinning Relevant features:
The workspace of a machine versus the part to be produced The options available on each machine The tools available The mounting and the part handling The operations that each machine can perform

API

P. Oliveira

Page 28

14

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

C) Ch Choice i of f the h most adequate d tools l
Relevant features: The material to be machinned and its characteristics Standard tools cost less The quality of the mounting part is function of the number od parts to p p produce Use the right tool for the job Verify if there are backup tools and/or stored available Take into account tool aging

API

P. Oliveira

Page 29

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

API

P. Oliveira

Page 30

15

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

D) C Cutting i d dataDados D d d de C Corte
Spindle Speed speed of rotation of the cutting tool (rpm) Feedrate linear velocity of advance to machine the part (mm/minute) Depth of Cut deth of machinning in z (mm)

API

P. Oliveira

Page 31

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

E) Choice Ch i of f the h i interpolation l i plane, l in i 2D machines hi

API

P. Oliveira

Page 32

16

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

F1) Unit U i system imperial inches (G70) or international milimeters (G71).

F2) Command mode* Absolut relative to world coordinate system (G90) Relative mouvement relative to the actual position (G91)

* There are other command modes, e.g. helicoidal.

API P. Oliveira Page 33

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC CNC Programming

G) MANUAL DATA INPUT
N G X Y Z R A I J K F S T M Sequence Number Preparatory Functions X Axis Command Y Axis Command Z Axis Command Radius from specified center Angle ccw from +X vector X axis arc center offset Y axis arc center offset Z axis arc center offset Feedrate Spindle speed Tool number Miscellaneous function

API

P. Oliveira

Page 34

17

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Example of a CNC program

N30 G0 T1 M6 N35 S2037 M3 N40 G0 G2 X6.32 Y-0.9267 M8 N45 Z1.1 N50 Z0.12 N55 G1 Z0. F91.7 N60 X-2.82 N65 Y0 Y0.9467 9467 N70 X6.32 N75 Y2.82 N80 X-2.82 N85 G0 Z1.1 ...

API

P. Oliveira

Page 35

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Preparatory functions (inc.)

G00 GO G01 Linear Li Interpolation I t l ti

G02 Circular Interpolation (CW)

G03 Circular Interpolation (CCW)

API

P. Oliveira

Page 36

18

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Other preparatory functions

G04 - A temporary dwell, or delay in tool motion. G05 - A permanent hold, or stopping of tool motion. It is canceled by the machine operator. G22 - Activation of the stored axis travel limits, which are used to establish a safety boundary. G23 - Deactivation of the stored axis travel limits. G27 - Return to the machine home position via a programmed intermediate point G34 - Thread cutting with an increasing lead. G35 - Thread cutting with a decreasing lead. G40 - Cancellation of any previously programmed tool radius compensation G42 - Application of cutter radius compensation to the right of the workpiece with respect to the direction of tool travel. G43 - Activation of tool length compensation in the same direction of the offset value G71 - Canned cycle for multiple-pass turning on a lathe (foreign-made)
API P. Oliveira Page 37

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Miscelaneous functions

M02 - Program end M03 - Start of spindle rotation clockwise M04 - Start of spindle rotation counterclockwise M07 - Start of mist coolant M08 - Start of flood coolant

API

P. Oliveira

Page 38

19

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Canned Cycles

G81 Drilling cycle with multiple holes

API

P. Oliveira

Page 39

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Ciclos Especiais or Canned Cycles

G78 Rectangular pocket cycle, used to clean a square shaped area

API

P. Oliveira

Page 40

20

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Tool change

Note: should be of easy access, when performed manually.

API

P. Oliveira

Page 41

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Example of CNC programming

Ver: http://www.ezcam.com/web/tour/tour.htm http://www ezcam com/web/tour/tour htm

API

P. Oliveira

Page 42

21

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Example of CNC programming

API

P. Oliveira

Page 43

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Advanced CNC programming languages

Automatically A i ll program tool l (APT) Desveloped at MIT in 1954 Derived from APT: ADAPT (IBM) IFAPT (France) MINIAPT (Germany) Compact II Autospot SPLIT
API P. Oliveira Page 44

22

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Machine operation

R l of Rules f Security S i Security is essential! The eyes must be always protected. The tools and parts must be handled and installed properly. Avoid the use of large cloths Cleand the parts with a brush. Never with the hands. Be careful with you and the others.
API P. Oliveira Page 45

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Machine operation

V if tolerances Verify l and d tools l offsets ff for f proper operation i

API

P. Oliveira

Page 46

23

IST / DEEC / ACSDC

Chap. 5 CAD/CAM and CNC

CAD/CAM and CNC Machine operation

Load program

Follow up machine operation Verify carefully the produced part.

API

P. Oliveira

Page 47

24