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CAM Systems & CNC Machine
History
1955 - John Parsons and US Air Force define a need to develop a machine tool capable of machining complex and close tolerance aircraft parts with the same quality time after time (repeatability). MIT is the subcontractor and builds the machine for the project
1959 - MIT announces Automatic Programmed Tools (APT) programming language
1960 - Direct Numerical Control (DNC). This eliminates paper tape punch programs and allows programmers to send files directly to machine tools
1968 - Kearney & Trecker machine tool builders market first machining center
1970’s - CNC machine tools & Distributed Numerical Control
1980’s - Graphics based CAM systems introduced. Unix and PC based systems available
1990’s - Price drop in CNC technology
1997 - PC- Windows/NT based “Open Modular Architecture Control (OMAC)” systems introduced to replace “firmware” controllers.
Control Systems
Open-Loop Control
– Stepper motor system
– Current pulses sent from control unit to motor
– Each pulse results in a finite amount of revolution of the motor001” is possible
Open-Loop Limitations
– Control unit “assumes” desired position is achieved
– No positioning compensation
– Typically, a lower torque motor
Open-Loop Advantages
– Less complex, Less costly, and lower maintenance costs
– Control Systems
Closed-Loop Control
– Variable DC motors - Servos
– Positioning sensors -Resolvers
l Feedback to control unit
l Position information compared to target location
l Location errors corrected
Closed-Loop Advantages
– DC motors have the ability to reverse instantly to adjust for position error
– Error compensation allows for greater positional accuracy (.0001”)
– DC motors have higher torque ranges vs.. stepper motors
Closed-loop limitations
– Cost
– Three Basic Categories of Motion Systems
l Point to Point - No contouring capability
l Straight cut control - one axis motion at a time is controlled for machining
Contouring - multiple axis’s controlled simultaneously
Three Basic Categories of Motion Systems
CNC vs. NC Machine Tools
Computer Numerical Control (CNC) - A numerical control system in which the data handling, control sequences, and response to input is determined by an on-board computer system at the machine tool.
CNC
Advantages
– Increased Program storage capability at the machine tool
– Program editing at the machine tool
– Control systems upgrades possible
– Option -resident CAM system at machine tool
– Tool path verification
NC
Numerical Control (NC) - A control system which primarily processes numeric input. Limited programming capability at the machine tool. Limited logic beyond direct input. These types of systems are referred to as “hardwire controls” and were popular from the 1950’s to 1970’s.
Machining Centers
A machining center can be defined as a machine tool capable of:
Multiple operation and processes in a single set-up utilizing multiple axis
Typically has an automatic mechanism to change tools
Machine motion is programmable
Servo motors drive feed mechanisms for tool axis’s
Positioning feedback is provided by resolvers to the control system
l Example - A turning center capable of OD turning, external treading, cross-hole drilling, engraving, and milling. All in machining is accomplished in one “set-up.” Machine may have multiple spindle
Programming Methods
Automatically Programmed Tools (APT)
– A text based system in which a programmer defines a series of lines, arcs, and points which define the overall part geometry locations. These features are then used to generate a cutter location (CL) file.
– Programming Methods-APT
– Developed as a joint effort between the aerospace industry, MIT, and the US Airforce
– Still used today and accounts for about 5 -10% of all programming in the defense and aerospace industries
l Programming Methods-APT
– Requires excellent 3D visualization skills
– Capable of generating machine code for complicated part programs
l 5 axis machine tools
Programming Methods-APT
Part definition
l P1=Point/12,20,0
l C1=Circle/Center,P1,Radius,3
l LN1=Line/C1. ATANGL,90
Cutter Commands
l TLRT,GORT/LN1.TANTO,C1
l GOFWD/C1,TANTO,L5
Programming Methods-CAM
computer Aided Machining (CAM) Systems
– Graphic representation of the part
– PC based
– Integrated CAD/CAM functionality
– “Some” built-in expertise
Speed & feed data based on material and tool specifications
Programming Methods-CAM
– Tool & material libraries
– Tool path simulation
– Tool path editing
– Tool path optimization
– Cut time calculations for cost estimating
Programming Methods-CAM
– Import / export capabilities to other systems
l Examples:
l Drawing Exchange Format (DXF)
l Initial Graphics Exchange Standard (IGES)
The Process CAD to NC File
Start with graphic representation of part
– Direct input
– Import from external system
l Example DXF / IGES
– 2D or 3D scan
l Model or Blueprint
(At this point you have a graphics file of your geometry)
The Process CAD to NC File
Define cutter path by selecting geometry
– Contours
– Pockets
– Hole patterns
– Surfaces
– Volume to be removed
(At this point the system knows what you want to cut)
l The Process CAD to NC File
l Define cut parameters
– Tool information
» Type, Rpm, Feed
– Cut method
» Example - Pocket mill zig-zag, spiral, inside-out
» Rough and finish parameters
(At this point the system knows how you want to cut the part)
l The Process CAD to NC File
l Execute cutter simulation
l Visual representation of cutter motion
l Modify / delete cutter sequences
(At this point the system has a “generic” cutter location (CL) file of the cut paths)
l The Process CAD to NC File
l Post Processing
– CL file to machine specific NC code
l Filters CL information and formats it into NC code based on machine specific parameters
– Work envelope
– Limits - feed rates, tool changer, rpm’s, etc.
– G & M function capabilities
l Output: NC Code
l Numerical Control (NC) Language
– A series of commands which “direct” the cutter motion and support systems of the machine tool.
l Output: NC Code
l G-Codes (G00, G1, G02, G81)
l Coordinate data (X,Y,Z)
l Feed Function (F)
l Miscellaneous functions (M13)
l N - Program sequence number
l T - Tool call
l S - Spindle command
l Output: NC Code
l NC Program Example
– N01G90 G80
– N03 GOO T12 M06
– N05 GOO X0 Y0 Z.1 F10 S2500 M13
– N07 G1Z-.5
– N09 G02 X-10. I0J0F20
– N13 X0Y10
– N17 X10Y0
– N19 X0Y-10
– N21 X-10Y0
– N23 M2
Example of CNC Programming
What What Must Be Done To Drill A Hole On A CNC Vertical Milling Machine
l Output: NC Code - Canned Cycles
l CAD to NC Code
l Advantages of CNC Machine Tools
l Ease of part duplication
l Flexibility
l Repeatability
l Quality control through process control
l Advantages of CNC Machine Tools
l Accommodates simple to complex parts geometry
l Improved part aesthetics
l Increased productivity
l Technology costs are decreasing
l Advantages of CNC Machine Tools
l Reduced set-up time
l Reduced lead times
Reduced inventory
Better machine utilization
Job advancement opportunities
Advantages of CNC Machine Tools
CNC machine tools are more rigid than conventional machine tools
– $$$- Climb milling requires about 10 - 15 % less horsepower vs. conventional cutting, but requires a ridged machine tool with no backlash
– Increased Rpm’s and feeds