BA 301 Social Responsibility and Ethics in Engineering: Presentation (Test III)
BA 301 Social Responsibility and Ethics in Engineering: Presentation (Test III)
BA 301 Social Responsibility and Ethics in Engineering: Presentation (Test III)
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Presentation 01 Introduction
Outline
02 Elements of a CNC System
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Introduction Outline
Numerical Control and CNC 05
Components of NC System 06
What is CNC ?
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Components of NC System
01 02 03
1. Machine Tool Control: Controlling the machine tool is the primary function of a CNC. It includes the
conversion of part program instruction into machine tool motions. This conversion is done through a
computer interface and servo system.
2. In-process compensation: It involves the real-time dynamic correction of errors in the machine tools
motion during processing. Some features of in-process compensation are listed below
i. Debugging the problem and adjusting for the error sensed by in-process probes and gauges.
ii. Recalculation of axis positions when inspection probe is locating the reference on work part.
iii. Adaptive control adjustment to the tool speed and feed.
iv. Compute the predicted tool life and select alternative tooling when indicated.
v. Offset adjustment for tool radius and length.
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CNC Features and Functions
3. Improved programming and operating features: The flexibility of soft-wired control of CNC allows
the introduction of many convenient programming and operation features. The main features are
listed below
i. Manual data input and editing of part program at machine - it permits the correction and
optimization of part program.
ii. Graphic display tool path help to verify the tape.
iii. Support more than one system of units.
iv. Use of specially written subroutine program.
v. Types of interpolation technique: Cubic, circular and parabolic interpolation.
vi. Large local storage system that having more than one program.
4. Diagnostic: The CNC machines are often equipped with the diagnostic capability to assist during the
maintenance of system. The diagnostic subsystem has several features. One of the main features is
that it identifies the reason for a problem and guide the maintenance personnel so that he/ she can
repair the system very quickly.
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Advantages and Disadvantages of CNC
Advantages Disadvantages
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Examples of CNC Machines
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Examples of CNC Machines
Electric
Water Jet
Discharge
CNC
CNC Machine
Machine
Plasma
Laser Cutting
Cutting CNC
CNC Machine
Machine
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Elements of a CNC System Outline
Components of a CNC System 13
Input Devices 14
Machine Tool 16
Driving System 17
Feedback System 23
Display Unit 25
CNC System
02 Machine Control Unit
03 Machine Tool
04 Driving System
05 Feedback System
06 Display Unit
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Input Devices
These are the devices which are used to input the part program in the CNC machine.
Some of the commonly used input devices are:
03 Serial Communication
04 Ethernet communication
05 Conversational Programming
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Machine Control Unit (MCU)
It is the heart of the CNC machine. It performs all the controlling action of the CNC machine, the various
functions performed by the MCU are:
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Driving System
• The requirement is that the driving system has to response accurately according to the
programmed instructions.
• The motor is coupled either directly or through a gear box to the machine lead screw to moves
the machine slide or the spindle
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DC Servo motor
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AC Servo motor
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Stepper motor
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What does Stepper means?
• To make the motor shaft turn, first, one
electromagnet is given power, which
magnetically attracts the gear's teeth.
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Feedback System
Two types of feedback systems normally used are:
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Feedback System
2. Velocity Feedback Systems:
• The actual speed of the motor can be measured in terms of voltage generated from a tachometer
mounted at the end of the motor shaft.
• The voltage generated by the DC tachometer is compared with the command voltage corresponding
to the desired speed.
• The difference of the voltages is used to actuate the motor to eliminate the error.
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Display Unit
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Types of CNC and related concepts Outline
Basis of Classification 27
Positions on CNC 37
Coordinate Systems 38
Interpolation Methods 40
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1. Based on Control Point Characteristics
Point to Point Positioning System
• In this method, the cutting tool (or the table) moves from one
point to another point.
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Straight Line System
• Straight line system are capable of moving the cutting moving the
cutting tool parallel to one of the axes (x-y-z) at a controlled feed
rate suitable for machining.
• This system is used in step turning, milling of slots and face milling.
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Contouring (Continuous) System
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2. Based on Positioning Coordinates
Absolute System
• In this system, all the moving commands are referred to
one reference point, which is the origin and is called the
zero point.
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Incremental System
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3. Based on Feedback or type of control system
Open Loop Control System
• It refers to a system using a stepper motor, where the
communication between open loop the controller
system and motor is one way.
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Open Loop Control System
• The computer will relay this information to the controller which then energizes the motor.
What distinguishes open looped from a close looped system is after the motor moves to the
desired position, there is no feedback to the controller system to verify the action.
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Close Loop Control System
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Close Loop Control System
• There are two types of closed loop systems; one where the closed the system returns the
feedback to the CNC controller and another which returns the feedback to the computer. The
closed loop system uses a feedback subsystem primarily to monitor the actual output and
correct any discrepancies from the programmed input. The feedback system could be either
analog or digital.
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Positions on CNC
• A CNC machine tool is provided with a fixed position where
tool changes are normally executed and programming of
absolute zero point is performed, is known as a reference
point or position.
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Coordinate Systems on CNC Machines
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Coordinate Systems on CNC Machines
• Machine Coordinate System: A coordinate system with a
machine zero point set as its origin is referred at as a machine
coordinate system. A machine coordinate system is set by
performing manual reference position return after power-on. A
machine coordinate system, once set, remains unchanged until the
power is turn-off.
Sub Programs 53
Types of G Codes
G Codes are of 2 kinds:
a) Modal G-Code: This G-Code is effective until another G-Code of the same group is
commanded (specified). G00 and G01 are modal G-codes in the same 1 group.
b) Non Modal (One Shot) G-Code: This G-Code is effective only in the block in which it is
specified. Non modal G-codes must be programmed in every block when required. e.g. G04,
G28, G53
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Some Common G Codes
G00: Positioning (Rapid Transverse) G43: Tool length compensation (plus)
G01: Linear Interpolation(Feed) G44: Tool length compensation (minus)
G02: Circulation Interpolation(CW) G49: Tool length compensation cancel
G03: Circular Interpolation (CCW) G50: Work Co-Ordinate change
G10: Offset value setting by program G53: Setting Machine Coordinate Sys.
G20: Inch Data Input G54-59: Setting Workpiece Coordinate Sys.
G21: Metric Data Input G70: Finishing Cycle
G27: Reference Point Return Check G71: Stock Removal in Turning
G28: Reference Point Return G72: Stock Removal in Facing
G29: Return from Reference Point G73: Pattern Repeating Cycle
G30: Skip Function G81: Drilling cycle
G32: Thread Cutting G82: Counter boring cycle
G34: Variable Lead Thread Cutting G83: Deep hole drilling cycle
G40: Tool Nose Radius Compensation Cancel G90: Absolute positioning
G41: Tool Nose Radius Compensation Left G91: Incremental positioning
G42: Tool Nose Radius Compensation Right G94: Setting feed rate mode
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Miscellaneous Codes (M Code)
These are also standardized codes use for miscellaneous functions, the address latter being M
followed by two digits. M-codes execute various NC machine operations not related to
dimensional axial movement. e.g. M06 – Auto Tool Change. These can be used for variety of
operations, depending on the company, but not related to dimensional axial movement.
Types of M Codes
M Codes are of 2 kinds:
a) The first category consists of those which execute with the start of the motion in a block.
e.g. M03 – Spindle Forward.
b) The second category consists of those which execute with the completion of motion
described in the block. e.g. M30 – End of the program.
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Some Common M Codes
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Setting up the Coordinate System
Machine Coordinate System:
A coordinate system with a machine zero point set as its origin is referred at as a
machine coordinate system. A machine coordinate system is set by performing manual
reference position return after power-on. A machine coordinate system, once set,
remains unchanged until the power is turn-off.
Command Format : G53 X__ Z__ ;
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T Word
The T-word is used in the CNC part programming to initiate/cause a tool change and to activate
tool geometry offsets to obtain the desired machining accuracy. There are 2 methods of
specifying a T Code.
Tool Offset
Tool offset is used to compensate for the difference when the tool actually used differs from the
imagined tool used in programming (usually, standard tool). The tool offset is specified by T code.
It is of two types:
• Tool geometry offset: It is used for compensating the tool shape or tool mounting position.
• Tool wear offset: It is used for compensating the tool nose wear.
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N Words O Words
The number for discriminating each block is The number for distinguishing each
called the sequence number. It consists of a program is called the program number.
character “N” followed by a three digit number The address letter “O” followed by 4-
raising from ‘0’ to ‘999’. Generally, the sequence digit numerical value is used to assign a
number are given in ascending order in program number. e.g. O1234
increment of 10. e.g. N010 means “line number
10”.
P Words Q Words
Used in automatic cycles (G70, G71, G72, Used in automatic cycles (G70, G71,
G73, G76) to define the first block of the G72, G73, G76) to define the last block
contour. Used with G10 to define the of the contour. In G32 Threading
offset number in the tool. Used to define Cycle, it is used for multi-start thread
a subroutine number. E.g. M98 P1234; to define the start angle.
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F Word
It is used to program the proper feed rate, to be given in either mm/min or mm/rev (inch/min or
inch/rev) as described by the G-code.
• In G98 mode the F word is used to command feed/min. e.g. G98 F60; (Metric)
• In G99 mode the F word is used to command feed/rev. e.g. G99 F0.1; (Metric)
• In G32 mode the F word specifies the lead of the thread. e.g. G32 Z-25 F3.00;
S Word
The
speed of the cutting tool with respect to the workpiece when the workpiece is cut, is called
the cutting speed. As for the CNC, the cutting speed can be specified by the spindle speed per
minute. It is represented by the address letter S which is followed by the numerical value, e.g.
S450.
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Sub Programs
Normally, the CNC operates according to the main program. However, when a command calling
a subprogram is encountered in the main program, control is passed to the subprogram. When a
command specifying a return to the main program is encountered in a subprogram, control is
returned to the main program.
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Code
G50 S2000 T0300 ; Sets machine datum and max spindle speed to 2000 rpm when
tool is changed to tool number 3 with no offset.
G96 S200 M03 ; Turns constant surface speed on (SFM) and sets spindle speed
200 rpm and spindle forward (CW).
G42 G00 X35.0 Z5.0 T0303; Selects Tool nose radius compensation right, rapid positions tool
to X35 (diameter) and Z5, changes offset of tool number 3 to 3.
M08 ; Turns coolant on.
G01 Z-20.0 F0.2 ; Describes linear feed interpolation till Z2 with feed 0.2 SFM.
G02 X67.0 Z-36.0 R16.0 ; Cuts arc in CW direction till X67 (dia.) and Z36 with arc radius 16.
G01 X68.0 ; Linearly feeds till X68 diameter.
G03 X100.0 Z-52.0 R16.0 ; Cuts an arc in CCW direction till X100 diameter and Z52 with an
arc radius 16.
G01 Z-82.0 ; Linearly feeds till Z82.
G40 G00 X200.0 Z200.0 T0300 ;Cancels tool nose radius compensation, rapid positions tool to
X200, Z200, and sets the offset to 0.
M09; Turns coolant off.
M30 ; Resets and rewinds the program.
Examples
Required
Using codes G94 enable end face turning cycle. This
is also a “box type” cycle. It has 2-feed rate motions
and 2-rapid motions. This useful cycle is used for
stock removal either parallel or at an angle to the
workpiece face.
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