cam lab manual_new.pdf

COMPUTER AIDED MANUFACTURING LABORATORY MANUAL

DEPARTMENT OF MANUFACTURING ENGINEERING

CENTRAL INSTITUTE OF PLASTICS ENGINEERING & TECHNOLOGY

T.V.K. Industrial Estate, Guindy, Chennai- 600 032

C.SANTHANAKUMAR, TOOLROOM - CIPET, CHENNAI- 32

E Mail: [email protected]

Computer Aided Manufacturing Laboratory Manual

C.Santhana kumar CIPET, Chennai. 2

STUDY OF CNC MACHINES

CNC - Definition:(Computer Numerical Control) CNC may be defined as the NC system that utilizes a dedicated, stored computer program

to perform some or all the basic numerical control functions. In CNC, a mini computer is used to control machine tool functions from stored in

information's or punched tape input or computer terminal input. Therefore CNC system replaces some or all of the hard work functions previously

perforations or punched by MCU with a dedicated computer i.e., computer assigned to control a single NC machine.

CONFIGURATION OF CNC SYSTEM:

FUNCTIONS OF CNC:

The principle functions of CNC are:

1. Machine tool control,

2. In-process compensation,

3. Improved programming & operating features, and

4. Diagnostics

CLASSIFICATION OF CNC SYSTEM:

1. Based on feedback control

(a) Open loop system(b) Closed loop system (c) Semi closed loop system 2. Based on feedback control

(a) Positional system (b) Paraxial system and (c) Continuous path system



3. Based on power drive (a) Hydraulic system (b) Electric system and (c) Pneumatic system 4. Based on circuit technology

(a) Analog system and (b) Digital system 5. Based on position system

(a) Absolute positioning system and (b) Incremental positioning system 6. Based on position system

(a) 2-Axis system (b) 3-Axis system (c) 4-Axis system and (c) 5-Axis system

CLASSIFICATIONS BASED ON MOTION CONTROL: (1.) Point-to-point position control: Travel of axes in rapid traverse separately or simultaneously, but without correlated functions. Application: boring, welding and punching machines.

(2.) Linear path control:

Travel of axes individually/parallel to the machine axes with programmable feed. Machining parallel to axes. Application: simple turning and milling machines



(3.)Continuous path control:

2 D (dimensional) continuous path control: Straight line and arc interpolation in one plane only. Application: turning, milling.

2 1/2 D continuous path control: Straight line and arc interpolation individually in each plane. Conversion of interpolation plane possible via part program. Application: turning, milling.

3 D continuous path control: Controlled travel is possible to all three axes simultaneously; spatial interpolation. Application: universal tool milling machines, wire erosion machines, machining centers, etc.



TYPES OF INTERPLOATIONS: Linear, Circular, Helical, Parabolic and Cubic

ADVANTAGES / DIS ADVANTAGES OF CNC MACHINE: Advantages,

1. Reduced Lead Time

2. Elimination of Operator Errors

3. Operator Activity

4. Lower Labour Cost

5. Smaller Batches

6. Longer Tool Life

7. Elimination of Special Jigs and Fixtures

8. Reduced Inspection

9. Less Scrap

10. Accurate Costing and Scheduling

Disadvantages,

1. Higher Investment Cost

2. Higher Maintenance Cost

3. Costlier CNC Personnel

4. Planned Support Facility

APPLICATIONS OF CNC MACHINE: The CNC machines can be applied to many manufacturing processes and machine tools like milling machines, lathes, grinding machines, drilling machines, bending machines, presses, EDM, laser cutting, flame cutting and co-ordinate measuring machines, etc.

Result:

Thus the Study of CNC machines has been studied.



STUDY OF CNC MILLING MACHINE:

CNC machining centers, The centre which consists of multifunction CNC equipped with ATCs, which are capable of carrying out milling, drilling, reaming, taping, boring, counter boring and allied operations without operator intervention is called as machining centers.

Classifications of CNC machining centers: 1. Horizontal machining center,

2. Vertical machining center,

3. Universal machining center.

Components of CNC machining centers: The main components of machining centers are,

1.Bed, 2.Saddle, 3.Spindle, 4.ATC, 5.MCU, 6.Column, 7.Table, 8.Ball screw and 9.Servo system.

Machining Axis:

1. X,Y,Z axis for linear movements,

2. A axis for rotary table,

3. B axis for Indexing head.

Work Holding Techniques:

1. Direct clamping, and 2. Indirect clamping

Work Holding Devices:

1. Machine vice, 2.Universal vice, 3.Chuck, 4.Fixture, 5.V- blocks, 6.Step blocks, 7.Clamps, 8. Angle plate, and 9.Support jacks.

Cutting Tools:

Classifications of cutting tools:

Single point cutting tools

Multi point cutting tools

Single point cutting tools,

Form tools like knife tools , V-tools, and grooving tools.



Multi point cutting tools, 1. Drills,

2. Reamers,

3. Tapes,

4. End mill cutter (Flat E/M, Bull nose E/M and Ball nose E/M), and 5. Face mill cuter.

Types of cutting tools: 1. Solid type,

2. Inserted type.

Cutting Tool Material: 1. High speed steel(HSS) 2. Carbide

3. Diamond

4. Ceramic

Cutting Tool Holding Devices: 1. Collet adaptor,

2. Drill chuck,

3. Side lock adaptor,

4. Taper shank adaptor,

5. Spring type collet.

Cutting Tool Selection Factors: 1. Based on machining material,

2. Based on size,

3. Based on shape,



Part programming: The part diagram is converted into part program. The part program consists of

instructions written in numerical codes , which constitutes the operations to be carried out while machining the part.

Part program is the planned and documented procedure by which the sequence of processing steps to performed on the NC machine.

Types of part programming: a. Manual part programming, and

b. Computer aided part programming.

Cycle: A set of operations which is repeated regularly in same sequence.

Types of cycles: Canned cycles,

Special cycles (Transformation cycles). Canned cycles:

Fixed sequence of operations, which are permanently stored in the control system.

The fixed cycles can be called and used by a single command in the part program.

1. Drilling,

2. Boring,

3. Taping,

4. Pocketing,

5. Slotting.

Special cycles (Transformation cycles). This cycles are used for operations transformation like,

1. Mirroring,

2. Scaling,

3. Rotation.



Machine Languages: Machine language is nothing but control system, it is used to communicate the machine.

FANUC

ISO,

HEIDENHEIN,

SINUMERIC.

Machine Functions: Preparatory functions,

Miscellaneous functions.

Preparatory functions: Function for control of the machine that involves actual tool moves. It is denoted as G -Code. There are two types G-Code,

1.Modal and 2.Non- modal.

Miscellaneous functions: In this functions necessary for machine, but it not involves any dimensions movements. like spindle and coolant On/off. It is denoted as M -Code.

Block: A group of NC words ,characters or digits used to describe one instruction in a part program. That is one line is nothing but block, it is consist of following:

Block No. (N), Preparatory functions (G), Dimension instructions (X,Y,Z, and etc.), Feed (F), Speed (S), Miscellaneous functions (M), End of block (;)



Dimensioning methods: 1.Absolute dimensioning,

2.Incremental dimensioning.

Absolute Dimensioning, In an absolute system all references are made to the origin of the coordinate system. All commands of motion are defined by the absolute coordinate referred to the origin.

Example of Absolute Dimensioning:

POINTS

CO-ORDINATES

X Y

1 +30.0 +30.0

2 +70.0 +60.0

3 +110.0 +90.0



Incremental Dimensioning, This type of control always uses as a reference to the preceding point in a sequence of points. The disadvantage of this system is that if an error occurs, it will be accumulated.

Example of Incremental Dimensioning:

POINTS

CO-ORDINATES

X Y

1 +30.0 +30.0

2 +40.0 +30.0

3 +40.0 +30.0

Co-Ordinate systems: 1.Cartesian / Rectangular co-ordinate system,

It is based on X and Y positions

2.Polar co-ordinate system,

It is based on Angle() and radius(R)



Cutter Radius Compensation:

G40 Cutter Comp Cancel G40 will cancel G41 or G42 cutter compensation.

G41 2D Cutter Compensation Left / G42 2D Cutter Comp. Right G41 will select cutter compensation left; that is, the tool is moved to the left of the programmed path to compensate for the size of the tool. A D address must be programmed to select the correct tool radius or diameter offset. If the value in the selected offset is negative, cutter compensation will operate as though G42 (Cutter Comp Right.) was specified. The right or left side of the programmed path is determined by looking at the tool as it moves away from you. If the tool needs to be on the left of the programmed path as it moves away from you, Use G41. If it needs to be on the right of the programmed path as it moves away from you, use G42.Refer to the Cutter Compensation section for more information.

Tool Length Compensation:

G43 Tool Length Compensation + (Add) / G44 Tool Length Comp - A G43 code selects tool length compensation in the positive direction; the tool length in the offsets page is added to the commanded axis position. A G44 code selects tool length compensation in the negative direction; the tool length in the offsets page is subtracted from the commanded axis position. A non-zero H address must be entered to select the correct entry from the offsets page.



Cutting Speed & Feed

As you proceed to the process of metal cutting, the relative `speed' of work piece rotation and `feed' rates of the cutting tool coupled to the material to be cut must be given your serious attention. This relationship is of paramount importance if items are to be manufactured in a cost-effective way in the minimum time, in accordance with the laid down specifications for quality of surface finish and accuracy. You, as a potential supervisory / management level engineer, must take particular note of these important parameters and ensure that you gain a fundamental understanding of factors involved.

Cutting Speed

All materials have an optimum Cutting Speed and it is defined as the speed at which a point on the surface of the work passes the cutting edge or point of the tool and is normally given in meters/min. To calculate the spindle Speed required,

Cutting Speed (v) = pidn / 1000 meters/min.

Where: N = Spindle Speed (RPM) CS = Cutting Speed of Metal (m/min) d = Diameter of Tool

Table 01 shows the cutting speed recommended for some common metals. It may be possible to exceed these speeds for light finishing cuts. For heavy cuts they should be reduced.

Metal meters /min

Cast Iron 20-28

Mild Steel 18-25

High Speed Steel 12-18

Brass 45-90

Bronze 15-21

Aluminium up to 300 Table 01. Cutting Speed

Feed: The term `feed' is used to describe the distance the tool moves per revolution of the work piece and depends largely on the surface finish required. Finishing requires a finer feed then what is recommended.

Feed = (rpm X Feed per tooth X no. of flute) mm/min.



List of G - Codes: G00 Rapid Motion Positioning G01 Linear Interpolation Motion G02 CW / G03 CCW Circular Interpolation Motion G04 Dwell G12 Circular Pocket Milling CW / G13 Circular Pocket Milling CCW G20 Select Inches / G21 Select Metric G28 Return to Machine Zero Thru Optional G29 Reference Point G40 Cutter Comp Cancel G41 2D Cutter Compensation Left / G42 2D Cutter Comp. Right G43 Tool Length Compensation + (Add) / G44 Tool Length Comp - G50 Cancel Scaling G51 Scaling G54-59 Select Work Coordinate System #1 - #6 G68 Rotation G69 Cancel G68 Rotation G70 Bolt Hole Circle G71 Bolt Hole Arc G72 Bolt Holes Along an Angle G73 High-Speed Peck Drilling Canned Cycle G74 Reverse Tap Canned Cycle G76 Fine Boring Canned Cycle G77 Back Bore Canned Cycle G80 Canned Cycle Cancel G81 Drill Canned Cycle G82 Spot Drill Canned Cycle G83 Normal Peck Drilling Canned Cycle G84 Tapping Canned Cycle G85 Boring Canned Cycle G90 Absolute Position Commands G91 Incremental Position Commands G94 Feed Per Minute Mode G95 Feed per Revolution G98 Canned Cycle Initial Point Return G99 Canned Cycle R Plane Return G100 Cancel Mirror Image G101 Enable Mirror Image G150 General Purpose Pocket Milling



List of M - Codes: M00 Stop Program M01 Optional Program Stop M02 Program End M03 turns spindle on in the forward direction M04 turns spindle on in the reverse direction M05 Stops the spindle M06 Tool Change M08 Coolant On M09 Coolant Off M30 Program End and Reset M97 Local Sub-Program Call M98 Sub Program Call M99 Sub-Program Return or Loop

Address characters as per HAAS machine: % Beginning / End of program A Rotary axis B Rotary axis D Diameter of the tool F Feed rate G Preparatory functions H Tool length compensation location I X co ordinate center J Y co ordinate center L Loop M Miscellaneous function N Block No. O Beginning address of file P Sub-Program No. R Radius of the circle S Spindle speed T Tool No. X Longitudinal axis Y Cross axis Z Vertical axis

Result:

Thus the Study of CNC milling machine has been studied.



STUDY OF CNC LATHE MACHINE:

Classifications of CNC machining centers: 1. Horizontal turning center,

2. Vertical turning center, and

3. Universal turning center

Components of CNC machining centers: The main components of machining centers are,

1.Bed, 2.Saddle ,3.Spindle , 4.Turret, 5.MCU, 6.Head stock, 7.Tail stock, and 8.Servo system.

Machining Axis: Z - Longitudinal axis

X - Cross axis

Work Holding Devices: 1.Chuck 2.Turret sleeve 3.Jaws 4.T- Nut and 5.Spring type collet

Cutting Tools: Classifications of cutting tools:

Single point cutting tools

Multi point cutting tools

Single point cutting tools,

Form tools like knife tools , Threading (v) tools, and grooving tools Multi point cutting tools,

1. Drills,

2. Reamers,

3. Tapes,

Types of cutting tools: 1. Solid type,

2. Inserted type.



Cutting Tool Material: 1. High speed steel(HSS), 2. Carbide,

3. Diamond,

4. Ceramic.

Cutting Tool Holding Devices: 1. Turning tool holder,

2. Boring tool holder,

3. Grooving tool holder,

4. Drill chuck,

5. Sleeve.

Cutting Tool Selection Factors: 1. Based on machining material,

2. Based on size,

3. Based on shape,

Part programming: Part program is the planned and documented procedure by which the sequence of processing steps to performed on the NC machine.

Types of part programming: Manual part programming, and

Computer aided part programming.

Machine Languages: Machine language is nothing but control system, it is used to communicate the machine.

FANUC ISO, HEIDENHEIN,

SINUMERIC.



Cycle: A set of operations which is repeated regularly in same sequence.

Types of cycles: Canned / Fixed cycles,

Machining cycles.

Canned cycles: Fixed sequence of operations, which are permanently stored in the control system. The fixed cycles can be called and used by a single command in the part program.

1. Turning,

2. Facing

3. Boring,

4. Drilling,

5. Thread cutting,

Machine Functions: Preparatory functions,

Miscellaneous functions.

Preparatory functions: Function for control of the machine that involves actual tool moves. It is denoted as G -Code. There are two types G-Code,

(i) Modal and (ii) Non- modal. Miscellaneous functions: In this functions necessary for machine, but it not involves any dimensions movements. like spindle and coolant On/off. It is denoted as M -Code.

Block: A group of NC words ,characters or digits used to describe one instruction in a part programme.That is one line is nothing but block, it is consist of following:



Block No. (N), Preparatory functions (G), Dimension instructions (X, Z, and etc.), Feed (F), Speed (S), Miscellaneous functions (M), End of block (;)

Dimensioning methods:

Absolute dimensioning, Incremental dimensioning.

Absolute Dimensioning With this type of dimensioning the position of target point is always given in relation to the work piece zero point. In this all coordinate values have positive signs. This is not always necessarily so: if the work piece were to be selected in the centre of the piece the coordinate values will be both positive and negative for X and Y, points would be obtained in all four quadrants of the X Y coordinate system.

Incremental Dimensioning

With this type of dimensioning (Relative Dimensioning) the path of the tool is given from the first position to the next target point, taking signs into account.

Tool Nose Compensation:



Cutting Speed & Feed

As you proceed to the process of metal cutting, the relative `speed' of work piece rotation and `feed' rates of the cutting tool coupled to the material to be cut must be given your serious attention. This relationship is of paramount importance if items are to be manufactured in a cost-effective way in the minimum time, in accordance with the laid down specifications for quality of surface finish and accuracy. You, as a potential supervisory / management level engineer, must take particular note of these important parameters and ensure that you gain a fundamental understanding of factors involved.

Cutting Speed

All materials have an optimum Cutting Speed and it is defined as the speed at which a point on the surface of the work passes the cutting edge or point of the tool and is normally given in meters/min. To calculate the spindle Speed required,

Cutting Speed (v) = pidn / 1000 meters/min.

Where: N = Spindle Speed (RPM) CS = Cutting Speed of Metal (m/min) d = Diameter of Work piece

Table 01 shows the cutting speed recommended for some common metals. It may be possible to exceed these speeds for light finishing cuts. For heavy cuts they should be reduced.

Metal meters /min

Cast Iron 20-28

Mild Steel 18-25

High Speed Steel 12-18

Brass 45-90

Bronze 15-21

Aluminium up to 300 Table 01. Cutting Speed

Feed

The term `feed' is used to describe the distance the tool moves per revolution of the work piece and depends largely on the surface finish required. For roughing out a soft material a feed of up to 0.25 mm per revolution may be used. With tougher materials this should be reduced to a maximum of 0.10 mm/rev. Finishing requires a finer feed then what is recommended.



List of G - Codes: G00 Rapid Motion Positioning G01 Linear Interpolation Motion G02 CW / G03 CCW Circular Interpolation Motion G04 Dwell G09 Exact Stop G17 XY Plane G20 Select Inches G21 Select Metric G28 Return To Machine Zero, G29 Return from Reference Point G31 Skip Function G32 Thread G40 Tool Nose Compensation Cancel G41 Tool Nose Compensation (TNC) Left G42 TNC Right G50 Spindle Speed Clamp G51 Cancel Offset G52 Set Local Coordinate System G53 Machine Coordinate Selection G54-59 Select Coordinate System #1 - #6 G70 Finishing Cycle G71 O.D./I.D. Stock Removal Cycle G71 I.D. Stock Removal Example G72 End Face Stock Removal Cycle G73 Irregular Path Stock Removal Cycle G74 End Face Grooving Cycle G75 O.D./I.D. Grooving Cycle G76 Threading Cycle, Multiple Pass G80 Canned Cycle Cancel G81 Drill Canned Cycle G82 Spot Drill Canned Cycle G83 Normal Peck Drilling Canned Cycle G84 Tapping Canned Cycle G85 Boring Canned Cycle G86 Bore and Stop Canned Cycle G87 Bore and Manual Retract Canned Cycle G88 Bore and Dwell and Manual Retract Canned Cycle G89 Bore and Dwell Canned Cycle G90 O.D./I.D. Turning Cycle G92 Threading Cycle G94 End Facing Cycle G95 Live Tooling Rigid Tap (Face) G96 Constant Surface Speed ON G97 Constant Surface Speed OFF G98 Feed Per Minute G99 Feed Per Revolution



List of M - Codes: M00 Stop Program M01 Optional Program Stop M02 Program End M03 Spindle Forward M04 Spindle Reverse M05 Spindle Stop M08 Coolant On M09 Coolant Off M10 Clamp Chuck M11 Unclamp Chuck M14 Main Spindle Brake On M15 Main Spindle Brake Off M17 Turret Rotation Always Forward M18 Turret Rotation Always Reverse M19 Orient Spindle M21 Tailstock Forward M22 Tailstock Reverse M30 Program End and Reset M43 Turret Unlock M44 Turret Lock M97 Local Sub-Program Call M98 Sub Program Call M99 Sub-Program Return or Loop

Result:

Thus the Study of CNC lathe machine has been studied.



Experiment:01

DRILLING

Note:

1. All dimensions are in mm.

2. Don`t measure the drawing.



DRILLING

Aim:- To write and simulate part programming for the given component to the required

dimensions by using CNC HAAS simulator.

Required Raw Material & Cutting Tool:-

100.0 x 100.0 x 25.0 mm 10.0 mm Drill (HSS- material)

Equipment Required:-

HAAS VF2 MILL Travel X axis 762 mm Spindle speed - 40-12000 rpm

Travel Y axis 500 mm Tool holders - 24 stations ATC

Travel Z axis 500 mm

Algorithm:-

Start the program with file name, Set the unit systems, either metric or inches,

Indicate the reference point,

Change the tool for required operation,

Give the spindle speed, Transverse motion of tool to X0.0 Y0.0 Z2.0, Choose the appropriate cycle and carry out milling operation, Give linear interpolation motion of tool and feed rate,

Move the tool to ref. point,

Move the tool in X, Y and Z direction to obtain the required size,

Stop the program.



G 83 - Peck Drilling Canned cycle

CYCLE USED: G 83 - Peck Drilling Canned cycle

Format:

G83 - Z_ Q_ R_ F_ X_ Y_ Where, G 83 - Peck Drilling Canned cycle Z - Total depth of the hole Q - Depth of cut R - Retraction in Z plane

F - Feed rate X,Y - Position



Source Code:- % O10001 ; N01 T01 M06 ; N02 G00 G90 G43 H01 Z50.0 ; N03 S500 M03 ; N04 G00 G90 G54 X0.0 Y0.0 ; N05 G01 Z2.0 F500.0 M08 ; N06 G83 Z-25.0 Q2.5 R2.0 F25.0 X10.0 Y20.0 ; N07 X90.0 Y20.0 ; N08 X90.0 Y80.0 ; N 09 X10.0 Y80.0 ; N10 G00 G80 Z50.0 ; N11 G28 G90 Y0.0 Z0.0 ; N12 M30 ; %

Result:-

Thus the programming for drilling operation has been written and simulated using CNC HAAS simulator.



Experiment:02

CIRCULAR POCKET MILLING

Note:





CIRCULAR POCKET MILLING




100.0 x 100.0 x 25.0 mm 10.0 mm End mill cutter (Carbide- material)





Algorithm:-






Move the tool in X, Y and Z direction to obtain the required size, Stop the program.



G 12 - Circular pocket milling (CW) Canned cycle

CYCLE USED: G 12 - Circular pocket milling (CW) Canned cycle

Format:

G12 Z_ I_ Q_ K_ D_ F_L_ Where, G 12 - Circular pocket milling (CW) Canned cycle Z - Depth of cut

I - First circle radius Q - Horizontal step over K - Finish circle radius D - Diameter of the tool

F - Feed rate L - No. of loop



Source Code:- % O10002 ; N01 T01 M06 ; N02 G00 G90 G43 H01 Z50.0 ; N03 S2000 M03 ; N04 G00 G90 G54 X0.0 Y0.0 ; N05 G00 X50.0 Y50.0 ; N06 G01 Z0.0 F500.0 M08 ; N07 G12 G91 Z-0.5 I7.5 Q5.0 K40.0 D01 F250.0 L30 ; N08 G00 G90 G80 Z50.0 ; N09 G40 X0.0 Y0.0 ; N10 G28 Y0.0 Z0.0 ; N11 M30 ; %

Result:-

Thus the programming for circular pocketing operation has been written and simulated using CNC HAAS simulator.



Experiment:03

RECTANGULAR POCKET MILLING

Note:





RECTANGULAR POCKET MILLING









Algorithm:-









G 150 - General purpose pocket milling cycle

CYCLE USED: G 150 - General purpose pocket milling cycle

Format:

G150 P_ Z_ Q_ R_ J_ K_ D_ F_

Where, G 150 - General purpose pocket milling cycle P - Sub program No. Z - Total depth of the pocket Q - Depth of cut R - Retraction in Z plane

J - Horizontal step over in Y axis

K - Finish pass allowance

D - Diameter of the tool

F - Feed rate



Source Code:- % O10003 ; N01 T01 M06 ; N02 G00 G90 G43 H01 Z50.0 ; N03 S2000 M03 ; N04 G00 G90 G54 X0.0 Y0.0 ; N05 G01 Z0.0 F500.0 ; N06 G150 P10004 Z-10.0 Q0.25 R2.0 J5.0 K0.0 G42 D01 F500.0 ; N07 G00 Z50.0 ; N08 G40 X0.0 Y0.0 ; N09 G28 G90 Y0.0 Z0.0 ; N10 M30 ; % % O10004 ; N01 G01 X0.0 Y-30.0; N02 G01 X-40.0 Y-30.0 ,R5.0 ; N03 G01 X-40.0 Y30.0 ,R5.0 ; N04 G01 X40.0 Y30.0 ,R5.0 ; N05 G01 X40.0 Y-30.0 ,R5.0 ; N06 G01 X0.0 Y-30.0 ; N07 M99 ; %

Result:-

Thus the programming for rectangular pocket milling operation has been written and simulated using CNC HAAS simulator.



Experiment:04

HEXAGONAL MILLING

Note:





HEXAGONAL MILLING









Algorithm:-









Source Code:- % O10005 ; N01 T01 M06 ; N02 G00 G90 G43 H01 Z50.0 ; N03 S2000 M03 ; N04 G00 G90 G54 X0.0 Y0.0 ; N05 G01 Z0.0 F500.0 ; N06 M98 P10006 L60 ; N07 G00 G90 Z50.0 ; N08 G40 X0.0 Y0.0 ; N09 G28 Y0.0 Z0.0 ; N10 M30 ; % % O10006 ; N01 G01 G90 G41 X0.0 Y-35.0 D01 F500.0; N02 G01 G91 Z-.25 F50.0 ; N03 G01 G90 X-20.2 Y-35.0 F500.0 ; N04 G01 X-40.4 Y0.0 ; N05 G01 X-20.20 Y35.0 ; N06 G01 X20.2 Y35.0 ; N07 G01 X40.4 Y0.0 ; N09 G01 X20.20 Y-35.0 ; N10 G01 X0.0 Y-35.0 ; N11 M99 ; %

Result:-

Thus the programming for hexagonal milling operation has been written and simulated using CNC HAAS simulator.



Experiment:05

CONTOUR MILLING

Note:





CONTOUR MILLING









Algorithm:-









Source Code:- % O10007 ; N 01 T01 M06 ; N02 G00 G90 G43 H01 Z50.0 ; N03 S2000 M03 ; N04 G00 G90 G54 X0.0 Y0.0 ; N05 G01 Z0.0 F500.0 ; N06 M98 P10008 L40 ; N07 G00 G90 Z50.0 ; N08 G40 X0.0 Y0.0 ; N09 G28 Y0.0 Z0.0 ; N10 M30 ; % % O10008 ; N01 G01 G90 G41 X17.5 Y42.5 D01 F500.0 ; N02 G01 G91 Z-.25 F50.0 ; N03 G01 G90 X17.5 Y107.5 F500.0 ; N04 G02 X47.5 Y107.5 R17.5 ; N05 G01 X47.5 Y99.5; N06 G03 X67.5 Y99.5 R10.0 ; N07 G01 X67.5 Y107.5; N09 G02 X97.5 Y107.5 R50.0 ; N10 G01 X97.5 Y57.5.0 ; N11 G02 X67.5 Y57.5 R-25.0 ; N12 G03 X47.5 Y57.5 R10.0 ; N13 G01 X47.5 Y42.5 ,C8.0 ; N14 G01 X17.5 Y42.5 ; N15 M99 ; %

Result:-

Thus the programming for contour milling operation has been written and simulated using CNC HAAS simulator.



Experiment:06

PLAIN TURNING

Where,

X - Diameter of Work piece, mm.

Z - Length of Work piece, mm.

F - Feed rate, mm/rev.

Note:





PLAIN TURNING




30.0 x 125.0 mm " Inserted type turning tool (Insert - Carbide material)


HAAS OL 1 Travel X axis 300 mm Spindle speed - 40 - 6000 rpm.

Travel Z axis 200 mm Tool holders - 04 stations

Algorithm:-




Give the spindle speed, Transverse motion of tool to X0.0 Z0.0, Choose the appropriate cycle and carry out milling operation, Give linear interpolation motion of tool and feed rate,


Move the tool in X, and Z direction to obtain the required size, Stop the program.



Source Code:- % O20001 ; N01 G21 ; N02 T0101 ; N03 G00 G28 W0.0; N04 G28 U0.0; N05 G97 S500 M03; N06 G00 X31.0 Z1.0 M08 ; N07 G01 G40 X29.0 Z0.0 F1.0 ; N08 G01 Z-100.0 F.1 ; N09 G00 X31.0 Z0.0 ; N10 G01 X28.0 F.1; N11 G01 Z-100.0 ; N12 G00 X31.0 Z0.0 ; N13 G01 X27.0 F.1 ; N14 G01 Z-100.0 ; N15 G00 X31.0 Z0.0 ; N16 G01 X26.0 F.1 ; N17 G01 Z-100.0 ; N18 G00 X31.0 Z0.0 ; N19 G01 X25.0 F.1 ; N20 G01 Z-100.0 ; N21 G00 X31.0 Z1.0 ; N22 G28 W0.0; N23 G28 U0.0; N24 M30 ; %

Result:-

Thus the programming for plain turning operation has been written and simulated using CNC HAAS simulator.



Exprement:07

STEP TURNING

Where,



Note:





STEP TURNING








Algorithm:-









G 70 - Finish Turning cycle

G 71 - Rough Turning cycle



CYCLE'S USED: G 70 - Finish Turning cycle G 71 - Rough Turning cycle

Format:

G70 P_ Q_ S_ F_ ( I ) G71 U_ R_ ( II ) G71 P_ Q_ U_ W_ F_ Where, G 70 - Finish Turning cycle P - Starting Block number Q - Ending Block number S - Spindle speed F - Feed rate,

( I ) G 71 - Rough Turning cycle U - Depth of cut in Z axis

R - Relief at both axis

( II ) G 71 - Rough Turning cycle P - Starting Block number Q - Ending Block number U - Finish allowance in X axis

W - Finish allowance in Z axis

F - Feed rate,



Source Code:-

% O20002 ; N01 G21 ; N02 T0101 ; N03 G00 G28 W0.0; N04 G28 U0.0; N05 G97 S500 M03; N06 G00 X31.0 Z1.0 M08 ; N07 G71 U0.5 R0.25 ; N08 G71 P09 Q15 U0.5 W0.1 F0.2 ; N09 G42 G01 X18.0 ; N10 G01 Z0.0 ; N11 G01 X18.0 Z-25.0 ; N12 G01 X22.0 Z-25.0 ; N13 G01 X22.0 Z-45.0 ; N14 G01 X25.0 Z-45.0 ; N15 G01 X25.0 Z-70.0 ; N16 G00 G40 X31.0 Z1.0; N17 G70 P09 Q15 S1200 F0.1 ; N18 G00 G28 W0.0; N19 G28 U0.0; N20 M30 ; %

Result:-

Thus the programming for step turning operation has been written and simulated using CNC HAAS simulator.



Experiment:08

TAPER TURNING

Where,



Note:





TAPER TURNING








Algorithm:-









CYCLE'S USED: G 70 - Finish Turning cycle G 71 - Rough Turning cycle Format:






F - Feed rate,



Source Code:-

% O20003 ; N01 G21 ; N02 T0101 ; N03 G00 G28 W0.0; N04 G28 U0.0; N05 G97 S500 M03; N06 G00 X31.0 Z1.0 M08 ; N07 G71 U0.5 R0.25 ; N08 G71 P09 Q12 U0.5 W0.1 F0.2 ; N09 G42 G01 X15.0 ; N10 G01 Z0.0 ; N11 G01 X25.0 Z-30.0 ; N12 G01 X25.0 Z-75.0 ; N13 G00 G40 X31.0 Z1.0; N14 G70 P09 Q12 S1200 F0.1 ; N15 G00 G28 W0.0; N16 G28 U0.0; N17 M30 ; %

Result:-

Thus the programming for taper turning operation has been written and simulated using CNC HAAS simulator.



Experiment:09

MULTIPLE TURNING

Where,



Note:





MULTIPLE TURNING








Algorithm:-









CYCLE'S USED: G 70 - Finish Turning cycle G 71 - Rough Turning cycle Format:






F - Feed rate,



Source Code:-

% O20004 ; N01 G21 ; N02 T0101 ; N03 G00 G28 W0.0; N04 G28 U0.0; N05 G97 S500 M03; N06 G00 X33.0 Z1.0 M08 ; N07 G71 U0.5 R0.25 ; N08 G71 P09 Q12 U0.5 W0.1 F0.2 ; N09 G42 G01 X0.0 ; N10 G01 Z0.0 ; N11 G03 X10.0 Z-5.0 R5.0 ; N12 G01 X10.0 Z-15.0 ; N13 G02 X20.0 Z-20.0 R5.0 ; N14 G01 X20.0 Z-30.0 ; N15 G01 X26.0 Z-40.0 ; N16 G01 X26.0 Z-50.0 ; N17 G01 X30.0 Z-50.0 ; N18 G01 X30.0 Z-65.0 ; N19 G00 G40 X33.0 Z1.0; N20 G70 P09 Q18 S1200 F0.1 ; N21 G00 G28 W0.0; N22 G28 U0.0; N23 M30 ; %

Result:-

Thus the programming for multiple turning operation has been written and simulated using CNC HAAS simulator.



Experiment:10

THREAD CUTTING

Where,



Note:





THREAD CUTTING




32.0 x 100.0 mm " Inserted type threading ( V ) tool (Insert - Carbide material)




Algorithm:-









G 76 - Threading cycle

CYCLE USED: G 76 - Threading cycle, Multiple pass

Format:

G76 X_ Z_ K_ D_ F_ Where, G 76 - Threading cycle, Multiple pass X - Thread cutting (Minor Dia.) Z - Thread length K - Thread height, defines thread depth, radius measure D - Depth of cut

F - Feed rate,



Source Code:- % O20005 ; N01 G21 ; N02 T0101 ; N03 G00 G28 W0.0; N04 G28 U0.0; N05 G97 S500 M03; N06 G00 X21.0 Z1.0 M08 ; N07 G01 X20.0 Z1.0 F.1; N08 G76 X18.05 Z-40.0 K0.975 D0.05 F1.5; N09 G80 G01 X21.0 Z2.0; N10 G00 G28 W0.0; N11 G28 U0.0; N12 M30 ; %

Result:-

Thus the programming for thread cutting operation has been written and simulated using CNC HAAS simulator.



Experiment:11

DRILLING

Where,



Note:





DRILLING Aim:-

To write and simulate part programming for the given component to the required dimensions by using CNC HAAS simulator.


50.0 x 100.0 mm 10.0 mm Drill ( HSS - Material )




Algorithm:-



Change the tool for required operation, Give the spindle speed, Transverse motion of tool to X0.0 Z0.0, Choose the appropriate cycle and carry out milling operation, Give linear interpolation motion of tool and feed rate,





G 83 - Normal Peck Drilling Canned Cycle

CYCLE USED: G 83 - Normal Peck Drilling Canned Cycle

Format:

G83 X_ Z_ Q_ R_ F_ Where,

G 83 - Normal Peck Drilling Canned Cycle X - Position of the hole

Z - Total depth of the hole Q - Depth of cut in Z axis R - Retraction in Z axis

F - Feed rate,



Source Code:-

% O20006 ; N01 G21 ; N02 T0101 ; N03 G00 G28 W0.0; N04 G28 U0.0; N05 G97 S500 M03; N06 G00 X0.0 Z2.0 M08 ; N07 G83 X0.0 Z-50.0 Q2.5 R2.0 F0.1; N08 G80 G01 Z2.0; N09 G00 G28 W0.0 U0.0 M05 ; N10 M30 ; %

Result:-

Thus the programming for drilling operation has been written and simulated using CNC HAAS simulator.



Experiment:12

GROOVING

Where,



Note:





GROOVING Aim:-

To write and simulate part programming for the given component to the required dimensions by using CNC HAAS simulator.


25.0 x 60.0 mm 4.0 mm Inserted type grooving tool (Insert - Carbide material)




Algorithm:-



Change the tool for required operation, Give the spindle speed, Transverse motion of tool to X0.0 Z0.0, Choose the appropriate cycle and carry out milling operation, Give linear interpolation motion of tool and feed rate,


Move the tool in X, and Z direction to obtain the required size,

Stop the program.



CYCLE USED: G 75 - O.D./I.D. Grooving Cycle Format:

G75 X_ Z_ I_ K_ F_ Where,

G 75 - O.D./I.D. Grooving Cycle X - Minor diameter of the groove Z - Total length of the groove

I - Depth of cut in X axis

K - Incremental movement in Z axis

F - Feed rate,



Source Code:- % O20007 ; N01 G21 ; N02 T0101 ; N03 G00 G28 W0.0; N04 G28 U0.0; N05 G97 S500 M03; N06 G00 X21.0 Z1.0 M08 ; N07 G01 G40 X20.0 Z-11.5 F0.1; N08 G75 X15.0 Z-12.5 I0.2 K0.5 F0.1; N09 G80 G00 X21.0 Z2.0; N10 G00 G28 W0.0; N11 G28 U0.0; N12 M30 ; %

Result:-

Thus the programming for grooving operation has been written and simulated using CNC HAAS simulator.



Experiment:13

PROFILE MACHINING



PROFILE MACHINING

Aim:- To generate and simulate the computer aided part programming for the given component to

the required dimensions by using UNIGRPHICS NX- 4 CAD/CAM software.

Part Size & Cutting Tool:-


Operation Used:-

CAVITY_MILL Procedure:-

Create/open the 3D part file, Select the manufacturing mode,

Create the operation,

Choose the appropriate method (Type), Cavity mill method was selected, Set the cutting tool and machine co-ordinate system on groups, Select the part and blank geometry, Select the cut method by follow part,

Select the cutter step over by 50% - 70%,

Set the cut level (depth of cut) in tool axis by 0.25mm, Set the cut parameters like stock allowances ,cut directions and cut order, Set the avoidance (clearance plane) on Z axis more than 10.0mm from part height, Set the spindle speed and cutting feed rate parameters, Generate the operation and save it, Doing the post processing for the suitable machine control with unit system and file

location ,

Get the .NC codes (file) and save it, Then execute the .NC file from computer to machine tool by using Cimcoedit4

software with RS232 connection.



TOOL PATH SIMULATION



Source Code:-

% O30001 N1G17(CAVITY_ROUGH_P1) N2G90(TOOL DIA 20.00 CORNER RADIUS .80) N3G17 N4(OPERATION NAMECAVITY_MILL) N5G54T01 N6G43H01 N7G90S3000M03 N8G1Z10.F5000. N9G1X-21.184Y14.742Z10.F5000. N10G1X-21.184Y14.742Z3.F5000. N11G40X-22.271Y14.252Z2.938F1250.M08 N12X-23.279Y13.615Z2.875 N13X-24.194Y12.849Z2.813 N14X-25.Y11.969Z2.75 N15X-25.683Y10.991Z2.688 N16X-26.23Y9.931Z2.625 N17X-26.633Y8.808Z2.563 N18X-26.883Y7.641Z2.5 N19X-26.977Y6.452Z2.438 N20X-26.914Y5.261Z2.375 N21X-26.693Y4.088Z2.313 N22X-26.32Y2.955Z2.25 N23X-25.8Y1.881Z2.188 N24X-25.142Y.886Z2.125 N25X-24.359Y-.014Z2.063 N26X-23.464Y-.803Z2. N27X-22.473Y-1.467Z1.938 N28X-21.402Y-1.994Z1.875 N29X-20.272Y-2.374Z1.813 N30X-19.101Y-2.602Z1.75 N31X-17.91Y-2.674Z1.688 N32X-16.72Y-2.587Z1.625 N33X-15.552Y-2.344Z1.563 N34X-14.426Y-1.948Z1.5 N35X-13.363Y-1.408Z1.438 N36X-12.38Y-.732Z1.375

-to be continued-



N96X-1.893Y-15.884 N97G3X0.0Y-16.025R12.85 N98X1.893Y-15.884 N99G2X3.051Y-15.812R9.35 N1X5.049Y-16.028 N2G3X6.158Y-16.148R5.218 N3X6.311Y-16.145 N4X6.886Y-16.177R5.277 N5X7.573Y-16.132 N6G2X8.771Y-16.074R12.426 N7X11.991Y-16.498 N8G3X13.604Y-16.598R13.138 N9X14.515Y-16.566 N10G2X14.566R12.485 N11X18.302Y-17.138 N12G3X20.195Y-17.333R14.707 N13G2X20.594Y-17.326R11.565 N14X24.613Y-18.047 N15G3X25.339Y-18.182R15.225 N16X26.448Y-18.27R7. N17X31.486Y-16.13 N18G1X31.486Y-16.13Z10.F5000. N19M02(; MACHINING TIME 17.8 MINUTES) %

Result:-

Thus the computer aided part programming for profile machining has been generated and simulated using UNIGRPHICS NX- 4 CAD/CAM software.



Experiment:14

CONTOUR MACHINING



CONTOUR MACHINING

Aim:- To generate and simulate the computer aided part programming for the given component to

the required dimensions by using UNIGRPHICS NX- 4 CAD/CAM software.

Part Size & Cutting Tool:-

120.0 x 100.0 x 36.0 mm 6.0 mm Ball nose end mill cutter (Carbide- material)

Operation Used:-

CONTOUR_AREA

Procedure:- Create/open the 3D part file, Select the manufacturing mode, Create the operation,

Choose the appropriate method (Type), Contour area method was selected, Set the cutting tool and machine co-ordinate system on groups, Select the part and cut area geometry, Select the cut method by pattern - parallel and cut type- Zigzag,

Select the cutter step over constant by 0.2mm Set the cut parameters like stock allowances and cut angle, Set the avoidance (clearance plane) on Z axis more than 10.0mm from part height, Set the spindle speed and cutting feed rate parameters, Generate the operation and save it, Doing the post processing for the suitable machine control with unit system and file

location ,

Get the .NC codes (file) and save it, Then execute the .NC file from computer to machine tool by using Cimcoedit4

software with RS232 connection.



TOOL PATH SIMULATION



Source Code:-

% O30002 N1G17(CORE_FINISH_P1) N2G90( TOOL DIA 6.00 CORNER RADIUS 3.00) N3G17 N4(OPERATION NAMECONTOUR AREA) N5G54T01 N6G43H01 N7G90S3000M03 N8G1Z10.0F5000. N9G1X-38.189Y-33.086Z10.0F5000. N10G40Z-6.02F1250.M08 N11X-38.115Z-5.875 N12X-38.041Z-5.779 N13X-37.894Z-5.631 N14X-37.599Z-5.345 N15X-37.451Z-5.236 N16X-37.304Z-5.169 N17X-37.009Z-5.054 N18X-36.714Z-4.955 N19X-36.419Z-4.905 N20X-36.124Z-4.856 N21X-35.829Z-4.853 N22X-35.534Z-4.864 N23X-35.239Z-4.898 N24X-34.648Z-5.043 N25X-34.353Z-5.176 N26X-34.058Z-5.35 N27X-33.911Z-5.471 N28X-33.763Z-5.628 N29X-33.616Z-5.796 N30X-33.468Z-6.075 N31X-33.101Y-33.019Z-6.056 N32X-32.735Y-32.941Z-6.071 N33X-32.502Y-32.886Z-6.029 N34X-32.71Z-5.657 N35X-32.918Z-5.343 N36X-33.126Z-5.114

-to be continued-



N69X-38.913Y32.943Z-6.021 N70X-38.672Y32.995Z-6.059 N71X-38.429Y33.043Z-6.057 N72X-38.186Y33.086Z-6.014 N73X-38.113Z-5.872 N74X-38.041Z-5.778 N75X-37.895Z-5.632 N76X-37.603Z-5.349 N77X-37.457Z-5.24 N78X-37.312Z-5.172 N79X-37.02Z-5.058 N80X-36.728Z-4.958 N81X-36.437Z-4.908 N82X-36.145Z-4.859 N83X-35.854Z-4.852 N84X-35.27Z-4.891 N85X-34.687Z-5.031 N86X-34.396Z-5.155 N87X-34.104Z-5.319 N88X-33.958Z-5.427 N89X-33.813Z-5.575 N90X-33.667Z-5.734 N91X-33.594Z-5.827 N92X-33.521Z-5.96 N93G1X-33.521Y33.086Z10.0F5000. N94M02(; MACHINING TIME 28.4 MINUTES) %

Result:-

Thus the computer aided part programming for contour machining has been generated and simulated using UNIGRPHICS NX- 4 CAD/CAM software.

cam lab manual_new.pdf

Documents

position system

loop system c

analog system

c pneumatic system

configuration of cnc

axis system b

b digital system

computer numerical control