Documente Academic
Documente Profesional
Documente Cultură
76-2
Objectives
Identify types of systems and controls used in computer numerical control
List steps required to produce a part by computer numerical control Discuss advantages and disadvantages of computer numerical control
76-3
Numerical Control
Method of accurately controlling operation of a machine tool by series of coded instructions that the machine control unit (MCU) can understand
Instructions converted into electrical pulses of current which machine motors and controls follow
76-4
Theory of CNC
Enable industry to consistently produce parts to accuracies undreamed of a few years ago Same part can be reproduced to same degree of accuracy any number of times with amazing speed
Computer properly programmed Machine properly set up
76-5
Found many uses in overall manufacturing process Fill three major roles in CNC:
1. Almost all machine control units include or incorporate computer in operation 2. Most of part programming for CNC machine tools done with off-line computer assistance 3. Increasing number of machine tools controlled or supervised by computers that may be in separate control room (direct numerical control-DNC)
76-6
Digital
Accepts input of digital information in numerical form, processes it and develops output data
76-7
Minicomputer
Smaller in size and capacity Dedicated type so performs specific tasks
Microcomputer
One chip contains arithmetic-logic and controllogic functions of the central processing unit
76-8
Computer Functions
To receive coded instructions (input data) in numerical form Process information Produce output data that causes machine tool to function Most common method to input data is directly through computer
76-9
CNC Performance
Great advances since NC introduced in mid 1950s Early machines capable only of point-topoint positioning and very costly Cost has continually lowered
Within financial reach of small manufacturing shops and educational institutions
76-10
CNC Offers
Accuracy
.0001-.0002 in.
Repeatability
Reliability
Productivity
76-11
Advantages of CNC
1. 2. 3. 4. 5. 6. Greater operator safety Greater operator efficiency Reduction of scrap Reduced lead time for production Fewer chances for human error Maximum part accuracy and interchange
76-12
9. Increased productivity
10. Minimal spare parts inventory
76-13
Cartesian Coordinates
Allows any specific point on job to be described in mathematical terms in relation to any other point along three perpendicular axes Machine tool construction based on three axes of motion (X, Y, Z) plus axis of rotation
Example: Vertical milling machine
X axis is horizontal movement (right or left) of table Y axis is table cross movement (to/away from column) Z axis is vertical movement of knee or spindle
76-14
76-15
Coordinate System
Quadrant II (-X, +Y) -X
X Axis
+Y
-Y
76-16
+Y
-X
+X -Y -Z
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
76-17
76-18
Machine Axes
Every CNC machine tool has sliding and rotary controllable axes Letters (addresses) used to identify each direction of table or spindle movement
Combined with number to form word establishes distance axis moves
76-19
76-20
I, J, and K words used for rotary axes when circular interpolation used for programming circles or partial arcs R word represents radius of circle U and W words for incremental movement parallel to X and Z primary axes
Chucking and turning centers
76-21
1. Chucking centers
76-22
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
76-23
3. Machining centers
Developed in 1960s Allow more operations to be done on part in one setup instead of moving from machine to machine Two main types of machining centers
Horizontal Vertical spindle (three axis) X axis controls table movement left or right Y axis controls table movement toward or sway from column Z axis controls vertical movement of spindle or knee
76-24
76-25
Programming Systems
Two types of programming modes
Incremental system Absolute system
Most controls on machine tools capable of handling both by altering code between G90 (absolute) and G91 (incremental) commands
76-26
Incremental System
Program dimensions or positions given from current point Disadvantage
If error made in any location, error automatically carried over to all following locations
76-27
Command codes tell machine to move table, spindle, and knee on vertical milling machine
plus X (+X) causes cutting tool to be located to right of the last point minus X (-X) causes cutting tool to be located to left of the last point plus Y (+Y) causes cutting tool to be located toward column minus Y (-Y) causes cutting tool to be located away from column plus Z (+Z) causes cutting tool or spindle to move up or away from workpiece minus Z (-Z) moves cutting tool down or into workpiece
76-28
Absolute System
All dimensions or positions given from one reference point on job or machine All dimensions given from zero or reference point Errors not carried to any other location G90 command indicates to computer and MCU that program is to be in absolute mode
76-29
minus X (-X)
causes cutting tool to be located to left of zero point
plus Y (+Y)
causes cutting tool to be located toward column (above zero)
minus Y (-Y)
causes cutting tool to be located away from column (below zero)
plus Z (+Z)
causes cutting tool to move above program Z0 (top surface of part)
minus Z (-Z)
causes cutting tool to move below the program Z0
76-30
Both can be handled by most control units Knowledge of both programming methods necessary to understand what application each has in CNC
76-31
Point-to-Point Positioning
Consists of any number of programmed points joined together by straight lines Used to accurately locate spindle, or workpiece mounted on machine table to perform operations Process of positioning from one coordinate (X-Y) position or location to another, perform the operation, clear tool from work, and move to next location
76-32
Rapid Travel
Point-to-point machining moves from one point to another as fast as possible (rapids) while cutting tool above work surface Used to quickly position cutting tool between location points
Rate between 200 and 800 in./min
76-33
Continuous-Path (Contouring)
Involves work produced on lathe or milling machine where cutting tool usually in contact with workpiece as it travels from one programmed point to next Ability to control motions on two or more machine axes simultaneously Information in CNC program must accurately position cutting tool and follow predefined accurate path
76-34
Control Systems
Two main types of control systems
Open loop Closed loop
76-35
76-36
Control unit tells servomotor to adjust until both signal from control unit and signal from servo unit equal (one pulse causes .0001 in. movement)
76-37
Input Media
Early media was 1-in. wide, 8-track punched tape Other types
Magnetic tape, punched cards, magnetic disks, and manual data input (MDI)
Computer keyboard formatted to American Standard Code for Information Interchange (ASCII) standard to input directly to machine control unit
Microcomputer along with communications software becoming preferred input method
76-38
DNC control
Used where six or more CNC machines involved in complete manufacturing program
76-39
76-40
Microcomputers are now incorporated into controls Program stored in computer memory Main advantage is ability to operate in live mode
Enables program changes at machine so programs can be tried, corrected, and revised correctly
76-41
76-42
76-43
Advantages of DNC
Single computer can control many machine tools at same time Time saved in eliminating program errors or revising program Programming faster, simpler, and more flexible Operating costs lower than with NC
76-44
Main control unit can be kept in clean processing room, away from dirty shop conditions
When three or more machines DNCcontrolled, initial cost lower than for conventional NC
76-45
Programming Format
Most common type is word address format
Large number of different codes to transfer program information to machine servos, relays, and micro-switches to carry out machine movements
76-46
Uses words
Address character (letter) such as S, X, Y, T, F, or M Alphabetical character followed by numerical data used to identify specific function or give distance, feed rate or speed value
76-47
Codes
Most common CNC programming codes
G-codes: preparatory commands M-codes: miscellaneous functions
F, S, D, H, P, and T
Used to represent functions: feed, speed, cutter diameter offset, tool length compensation, subroutine call, tool number, etc.
76-48
G-Codes
Refer to some action occurring on X, Y, and/or Z axis of machine tool Grouped into categories with group number G00 used to rapidly position cutting tool from one point to another point G01, G02, and G03
Move axes at controlled feed rate G01 used for linear interpolation G02 (clockwise) and G03 (counterclockwise) used for circular interpolation
76-49
G-Codes
Some classified as modal or nonmodal
Modal codes stay in effect in program until changed by another code from same group Nonmodal codes stay in effect for one operation only and must be programmed again whenever required
Many of the common G-codes that conform to EIA standards shown on next slide and in text in Fig. 76-28
76-50
01
01 01
G01
G02 G03
Linear interpolation
Circular interpolation clockwise (CW) Circular interpolation counterclockwise (CCW)
00
00 02
G04
G10 G17
Dwell
Offset value setting XY plane selection
02
02 06
G18
G19 G20
ZX plane selection
YZ plane selection Inch input (in.)
76-51
M-Codes
Used to turn either on or off different functions that control certain machine tool operations (not grouped by categories) M03 turns machine spindle clockwise M04 turns spindle counterclockwise M05 turns off spindle All three of the codes above are modal Common M-codes in text in Fig. 76-29
76-52
M07
M08 M09
Mist coolant on
Flood coolant on Coolant off
76-53
Block of Information
Should contain only enough information to carry out one step of a machining operation Example:
Tool moves from one point to another, then to third point which is two moves (two blocks)
Cannot give first point and third point as one move so cannot combine blocks
76-54
Interpolation
Generation of data points between given coordinate position of axes Interpolator (device within MCU)
Causes drives to move simultaneously from start of command to completion
76-55
Types of Interpolation
Linear interpolation for straight-line machining between two points Circular interpolation for circles and arcs Helical interpolation for threads and helical forms Parabolic and cubic interpolation used by industries that manufacture parts having complex shapes
76-56
Linear Interpolation
Consists of any programmed points joined together by straight lines Include horizontal, vertical, or angular lines where points may be close together or far apart
76-57
Circular Interpolation
Make process of programming arc and circles easy Basic information required to program circle
Position of circle center Start and end points of arc being cut Direction of cut Feed rate for tool
76-58
The circle center position, radius, start point, end point, and direction of cut are required for circular interpolation.
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
76-59
76-60
Program Planning
Information gathered, analyzed and calculated before writing program Consider capabilities of machine
Capacity Tooling requirements Programming format etc.
76-61
76-62
5. What is the table feed direction? 6. How fast can tool be moved to location: rapid traverse or at feed rate? 7. What will tool do when it reaches its location for example, drill hole or mill pocket? 8. Where will the part zero point, or origin, be located, on part of the machine?
76-63
Tool List
List of all tools required for machining process
Complete with correct speeds and feeds for each tool based
Tool material type Type of material being cut Depth of cut
Some CNC systems require presetting tool length for purpose of offsets
Special gage needed
76-64
Manuscript
Programmer records on prepared form all instructions that machine tool must have to complete job
Contains all machine tool movements, cutting tools, speeds, feeds and any other information Uniform format and clear as possible
76-65
Manuscript Information
1. 2. 3. 4. 5. 6. 7. 8. Part sketch Zero (or reference) point Work-holding device (include setups) Sequence of operations Axes dimensions Tool list and identification Speeds and feeds Operator instructions