PART PROGRAMMING

IN CNC MACHINES
 CNC PART PROGRAMMING

PART PROGRAMMING USING CAD/CAM

A CAD/CAM system is a computer interactive graphics system equipped

with software to accomplish certain tasks in design and manufacturing

functions. One of the important tasks performed on a CAD/CAM system

is NC part programming. In this method of part programming, portions

of the procedure usually done by the part programmer are instead

done by the computer. The two main tasks of a part programmer in a

computer assisted programming are (a) defining the part geometry and (b)

specifying the tool path. The proposed methodology is used to automate

both of these tasks.

Part geometry definition: The fundamental objective of CAD/CAM

system is to integrate the design engineering and manufacturing

engineering functions. Certainly one of the important design functions is to

design the individual components of the product. If a CAD/CAM system

is used, a computer graphics model of each part is developed by the

designer and stored in the CAD/CAM database. That model contains all of

the geometric, dimensional and material specifications for the part. When

the same CAD/CAM system, or a CAM system that has access to the same

CAD database in which the part model resides, is used to perform NC

part programming it makes little sense to recreate the

geometry of the part during the programming procedure. Instead, the

programmer has the capability to retrieve the part geometry model from

the storage and to use that model to construct the appropriate cutter

path. The significant advantage of using CAD/CAM in this way is that it

eliminates one of the time-consuming steps in computer-assisted part

programming geometry definition. After the part geometry has been

retrieved, the usual procedure is to label the geometric elements that will

be used during part programming. These labels are the variable names

(symbols) given to the lines circles and surfaces that comprise the part.

Most systems have the capacity to automatically label the geometry

elements of the part and to display the labels on the dias.

If the NC programmer does not have access to the data base, then the

NC Programming must be defined. This is done by using similar

interactive graphics techniques that the product designer would use to

design the part. Points are defined in a coordinate system using the

computer graphics system, lines and circles are defined from the points,

surfaces are defined, and so forth, to construct a geometric model of the

part. The advantage of using the interactive graphics system over

conventional computer-assisted part programming is that the

programmer receives immediate visual verification of the definitions being

created. This tends to improve the speed and accuracy of the geometry

definitionprocess.
Tool path generation using CAD/CAM: The second task of the NC

programmer in computer-assisted part programming is tool path

specification. The first step in specifying the tool path is to select the

cutting tool for the operation. Most CAD/CAM systems have tool libraries

that can be called by the programmer to identify what tools are available in

the tool crib. The programmer must decide which of the available tools is

most appropriate for the operation under consideration and specify it for

the tool path. This permits the tool diameter and other dimensions to be

entered automatically for tool offset calculations. If the desired cutting tool

is not available in the library, an appropriate tool can be specified by the

programmer. It then becomes part of the library for future use.

The next step is tool path definition. There are differences in

capabilities of the various CAD/CAM systems, which result in different

approaches for generating the tool path. The most basic approach

involves the use of the interactive graphics system to enter the motion

commands one-by-one, similar to computer-assisted part programming.

Individual statements in APT or other part programming language are

entered and the CAD/CAM system provides an immediate graphic display of

the action resulting from the command, thereby validating the

statement.

A more-advanced approach for generating tool path commands is to

use one of the automatic software modules available on the CAD/CAM

system. These modules have been developed to accomplish a number of

common machining cycles for milling, drilling and turning. They are

subroutines in the NC programming package that cane be called and the

required parameters given to execute the machining cycle.

Computer-Automated part programming:

In the CAD/CAM approach to NC part programming, several aspects of

the procedure are automated. In the future, it should be possible to

automate the complete NC part programming procedure. The proposed

system is an automated system where the input is a geometric model of a

part that bas been defined during product design and the output is a NC

part program. The system possesses sufficient logic and decision-making

capability to accomplish NC part programming for the entire part without

human assistance.

This can most readily be done for certain NC processes that involve

well-defined, relatively medium complex part geometries. Special

algorithms have been developed to process the design data and generate

the NC program.

INTRODUCTION

The proposed CNC module is based on the process sequence made in

the previous module and on the parameters of the features as derived

from the feature recognition module. The CNC code contains the geometry of

the tool path and the motion of the tool specified in a definite syntax as

demanded by the type of controller. The overall tool path generated for

the part is a union of the individual tool paths for each feature/ operation
and combined in a logical sequence. To avoid any collisions, a suitable tool

retraction plane is used.

Each type of operation or feature is associated with a particular

type of path and motion patterns and these are stored in parametric form

and are instanced whenever necessary. Once the tool path is defined it is

only a matter of issuing the motion statements to describe the motion.

These are also standard per feature/operation type and are stored with

the parametric tool path data. The user is also provided with a choice of

selecting process parameters.

The NC code generated in this module is suitable for the FANUC

controllers. Simulation runs are carried out on the CNC machine, for the

sequence of operations, for collision free tool paths and few components

are also produced, to validate the proposed system. The results were

found to be satisfactory.
FUNDAMENTALS OF PROGRAMMING

The CNC machine tool receives the directions for operation through a

CNC program. The program is generated as per the program

manuscript written for the job/operations to be carried out on the CNC

machine. The program is prepared by listing the coordinate values(x, y

and z) of the entire tool paths as suited to machine the complete

component. The coordinate values are prefixed with preparatory codes to

indicate the type of movement required like point-to-point, straight, and

circular, along with coordinate values for tool path generation. Also, the

co-ordinates are suffixed with miscellaneous codes for initiating

spontaneous machine tool functions like start/stop, spindle/coolant,

program/optional stops. In addition to these coded functions the

coordinate values are supplemented with feed rate figures, spindle speed

codes and tool codes, for proper selection of speeds, feeds and required

cutting tools, during a particular operation. All these elements in a line of

information form one meaningful command for the system/machine to

execute, and is called a block of information. A number of such blocks

sequentially written form a program for the particular component.

Part Program:

A part program contains all the information for machining a

component which is given as a input to the control unit. The control unit

provides the control signals at the correct time and in the correct

sequence to the various drive units of the machine.

 The input information required is a series of blocks; one operation

requires one block. Within each block there may be different types of

data.

PREPARATION OF PROGRAM

During the preparation of program for any particular component,

some amount of data processing is required in making the mathematical

computations for achieving the dimensional accuracy of the component

produced and in making the logical decisions like coolant on or off,

spindle on CCW or CW etc.

While making the part program for a component, the programmer

first studies the drawing and decide upon the sequence of operations, the

cutting tools, the path of cutter/tool, speeds and feeds at various points,

other necessary information like starting and stopping of machine etc.

The information is entered in a program sheet in a particular format

acceptable by the machine tool-control unit combination. In the proposed

system the programming is done with the help of a computer which

replaces a programmer and performs the above tasks based on some

logics and instructions given to it in the form of a software program.

CODE GENERATION OF THE PART

After the recognition of manufacturing features/operations and

their sequence from the previous module i.e. the feature recognition

module, the output file of the previous module is taken as an input file for

this module. After mapping the features, the algorithms in the proposed
program initiate the corresponding CNC code. Each manufacturing

feature has a pre-structured CNC code. The proposed system reads the

strings in the feature recognition module and their corresponding

coordinate values to select an equivalent code. It is to be noted that the

initial and final commands of CNC code (called the Head and tail of the

program) remains same irrespective of the component to be produced

(commands like G21, G40, G28, M05, M30). Hence, the proposed system

generates the CNC code by taking this fact in to consideration. Thus, the

body of the code is part specific and changes as per the component. The

important feature of this module is that, the user can check the

generated CNC code and can make any alterations if required. The edited

output file can be given as an input to the CNC machine tool, the

simulations runs are to be made to assure an error free program. If the

simulations runs are satisfactory the component may be produced.

The main challenge in the process of CNC code generation is the

process of converting the coordinate values of the component (expressed

in terms of X and Y) to their equivalent terms in the CNC code. For

instance, in the feature recognition module the coordinate values of the

features are given in terms of X and Y. And the difference of any two

consecutive X ordinate values gives the value of length and that of Y

ordinates gives the value of diameter, where as in the CNC programming

the X ordinate values are to be expressed in terms of Z (length) and Y

ordinate values are to be expressed in terms of X (diameter). Therefore,

the system has to initially transfer all the coordinate values in to their

respective lengths and diameters, suitable for the generation of CNC code.

Thus each of the manufacturing feature details is to be transferred to

their respective points, lengths and diameters.

The coordinate values are rearranged as per the requirements of

the code. For instance, in the feature recognition module the coordinate

values of the features are given in terms of X and Y where as in the CNC

programming the X ordinate values are to be

Another important factor being considered in the generation of the

CNC code is the concept of Reference point. The reference point for

manufacturing feature module represents the right most point on the

outer profile of the component on the axis line or that could be present on

it in case if the component has internal features (for the TEST1

component it is (154.000000, 5.000000). In connection with CNC code

this reference point is to be taken as initial point (0.00000, 0.000000) and

the length and diameters are to be expressed in relation to this reference

point. Hence all the coordinate values from the feature recognition

module need to be expressed in relation to this reference point. And also,

the value of Z (length) is to be converted into negative values as the tool

moves away from this reference point.

And as per the sequence of the processes is considered the

individual codes are placed in an order, to form the final code with a

logical connectivity among them. In doing so the system takes in to

consideration, the initial position to which the tool is to be brought with

fast traverse, for each of the processes. The other basic variables in the

code are speed, feed and depth of cut which may be provided by the user

or they may be selected from the data provided in the system.

CNC SAMPLE CODES:

Given below are some of the CNC codes that are developed as part of

the proposed work. These are given to explain the methodology by which

the codes are generated.

CODE FOR STEP TURNING:

The essential data required for the code generation of step turning

operation, is the length of the step (C) and the reduction in the diameter

of the component (D) for that step whose values are obtained from the

manufacturing feature details provided in the output file of feature

recognition module. The value of the depth of the cut (d.o.c) may be given

by the user and is used to calculate the number of times through which

this operation is to be performed to complete the step. The machine

capabilities are to be taken in to consideration while giving the value of the

depth of cut. The proposed system reads the concerned data from the

output of the previous module and correlates it with process parameters

before it generate the CNC code for that operation.

 ODR1 CD

C 154.000000 29.000000 100.000000 29.000000 ((x1, y1) (x2, y2)) D

100.000000 29.000000 100.000000 35.000000 ((x2, y2) (x3, y3))

Reference value 154.000000, 5.000000 (refx, refy)

Let the feed (F), speed (S) and depth of cut (doc) are given by the user.

For this operation CD the required calculations are made as following.

1) Number of cuts n = (y3-y1)/doc

If doc is 2 then, in this case n= (35.000000-29.000000)/2 = 3

2) Starting diameter (initial value of X)= (y3-refy)*2

In this case it is (35.000000-5.00000)*2= 60.000000

3) The length of cut = (x3-refx)

In this case it is (100.000000-154.00000)= -54.000000

 4) Final diameter = (y2-refy)*2

In this case it is (29.000000-5.00000)*2= 48.000000

5) Initial position for the tool ((y3-refy)*2+1),((x1-refx)+1)

In this case it is (61.000000, 1.00000) i.e. the tool comes to this

position with fast traverse. And this value is followed by the G00

code.

6) As the number of cuts is three, the initial diameter (60) is

reduced to the final diameter (48) in three steps (56,52,48). And

the same is incorporated in to the CNC code.

The same logic is used to generate the code for the other step

turning operations of the component.

CODE FOR GROOVE ELEMENTS:

There may be different types of groove profiles on the outer

surface of a component. Let us consider the groove element BCD, that is

being present on the given component. In such case, the following data

will be obtained from feature extraction module.

B 112.0000000 29.0000000 112.0000000 27.0000000 ((x1, y1) (x 2, y 2)) C -

112.0000000 27.0000000 106.0000000 27.0000000 ((x2, y2) (x3, y 3)) D

106.0000000 27.0000000 106.0000000 29.0000000 ((x3, y3) (x 4, y 4))

Reference value 154.000000, 5.000000 (refx , refy)

Let the feed (F), speed (S) and depth of cut (doc) be the same as given by

the user.

For this operation BCD the required calculations are made as following.
1) Number of cuts n = (y2-y1)/doc

If doc is 2 then, in this case n= (29.000000-27.000000)/2 = 1

2) Starting diameter (initial value of X)= (y1-refy)*2

In this case it is (29.000000-5.00000)*2= 48.000000

3) The length of cut = (x3-x2)

In this case it is (106.000000-112.00000)= -6.000000

4) Final diameter = (y2-refy)*2

In this case it is (27.000000-5.00000)*2= 44.000000

5) Initial position for the tool ((y1-refy)*2+1),((x1-refx)+1)

 Command for Facing operation
Command for plain turning

Command for internal hole

Code for STEP turning

operation (CD) with a
depth of cut of 1mm

Command for groove cutting

Figure1 Sample CNC Part Program

VARIOUS SCREENS GENERATED DURING SIMULATION RUN

Figure4 Screen showing the Step turning operation

Figure3 Screen showing the grooving operation

RESULTS & DISCUSSION

This module is used to generate the automated part program for

the rotary components. The part program for the TEST1 component is

presented in the Figure1 shown above. The same program is being given

as an input for the simulation package and tested for the process

sequence, process parameters and for tool collisions. Upon the

satisfactory results from the simulation runs the program is executed in a

real environment and the component was produced.

The proposed system thus, shows the integration of feature

recognition and CNC code generation for the axi-symmetric rotary parts.
 REFERENCES

http://nptel.ac.in/courses/112102103/Module%20F/Module%20F(1)/p1.htm

https://en.wikipedia.org/wiki/Part_program

http://www.brainkart.com/article/Manual--Part-Programming_6402/

http://user.engineering.uiowa.edu/~mie032/support/labs/nc_machining/

https://rdmitnu.files.wordpress.com/2015/04/computer-assisted-part-programming/

https://www.researchgate.net/publication/297676937_Intelligent_CADCAM_system_

for_programming_of_CNC_machine_tools

https://www.researchgate.net/publication/303370721_Study_on_computer_numeric

al_control_CNC_machines

http://www.ijsimm.com/Full_Papers/Fulltext2016/text15-1_109-120.pdf