computer aided manufacturing - psna cet - psna...

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IMLIML 332332EE: CAM Introduction: CAM Introduction

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COMPUTER AIDED MANUFACTURINGCOMPUTER AIDED MANUFACTURINGIML 332EIML 332E CAD&MCAD&MLECTURE NOTESLECTURE NOTES

by: H. Livatyalby: H. Livatyalıı

SpringSpring 20020055--20020066ITU Dept. of MEITU Dept. of ME

GGüümmüüşşsuyu, ISTANBULsuyu, ISTANBUL


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COMPUTER AIDED MANUFACTURING TOPICS

• Numerical Control Systems (NC,CNC) and Machine Tools• Numerical Part Programming (Manual and Automatic/CAPP)• CAD-CAM-CNC Systems Integration• Automation in Manufacturing and Computer Integrated

Manufacturing (CIM)• Flexible Manufacturing Cells (FMC) and Systems (FMS) • Sensors and Process Monitoring Systems• Rapid Prototyping Methods• Computer Aided Special and Nontraditional Manufacturing

Methods

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COMPUTER AIDED MANUFACTURINGCOMPUTER AIDED MANUFACTURING

DEFINITION:DEFINITION:EffectiveEffective utilizationutilization of of computercomputer technologytechnology in in thetheMANAGEMENT, CONTROL MANAGEMENT, CONTROL andand OPERATIONS of OPERATIONS of thethemanufacturingmanufacturing facilityfacility throughthrough eithereither directdirect oror indirectindirect computercomputerinterfaceinterface withwith thethe physicalphysical andand humanhuman resourcesresources of of thethecompanycompany ((afterafter CAMI).CAMI).

Dominant Dominant OperationOperation::NumericalNumerical ControlControl (NC) (NC) partpart programmingprogramming

CommonCommon ((andand narrowernarrower)) conceptconcept forfor CAM:CAM:ComputerComputer assistedassisted partpart programmingprogramming

LogicalLogical StartingStarting pointpoint::ManualManual partpart programmingprogramming


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NUMERICAL CONTROL (NC)NUMERICAL CONTROL (NC)

DEFINITION:DEFINITION:TheThe controlcontrol of of operationoperation of of machinemachine toolstools (M/T) ((M/T) (ororotherother sheetsheet--workingworking andand weldingwelding machinesmachines)) byby aaseriesseries of of codedcoded instructionsinstructions calledcalled thethe program, program, whichwhich consistsconsists mainlymainly of of alphanumericalphanumeric characterscharacters((nembersnembers andand lettersletters).).

MainMain CharacteristicsCharacteristics::PreplannedPreplanned andand predictablepredictable

ThereforeTherefore, NC is a , NC is a typicaltypical form of:form of:ProgrammableProgrammable AutomationAutomation..

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BRIEF HISTORY OF CNC M/TBRIEF HISTORY OF CNC M/T

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ParsonsParsons’’ NC NC proposalproposal forfor millingmillinghelicopterhelicopter rotor rotor bladesblades

11st st modern modern conceptconcept19471947

MITMIT’’ss firstfirst NC NC MillingMilling machinemachine11stst effectivelyeffectively functioningfunctioningversionversion19521952

USAFUSAF’’ss contractcontract forfor 100 NC 100 NC MillingMillingmachinesmachines toto 88 coco.s.s11stst industrialindustrial contractcontract19561956

PointPoint--toto--pointpoint controlcontrol drilldrill pressedpressed11stst industrialindustrial successsuccess19611961

BigBig oppositionopposition againstagainst NC M/T in NC M/T in thethecontractorscontractors of USAFof USAFDifficultDifficult yearsyears19561956--19621962

StoringStoring thethe programsprograms on a on a computercomputer in in addadd.. toto tapestapes..11stst CNCCNC19701970

ParsonParson’’ss 22--DD CoordinateCoordinate tabletableoperatedoperated byby twotwo peoplepeople2D 2D ManualManual ApplicationsApplications22ndnd WorldWorld WarWar

J.JackardJ.Jackard’’s method to control textile s method to control textile looms by using punched cards.looms by using punched cards.Basic ConceptBasic ConceptEarly Industrial Early Industrial

RevolutionRevolution

DescriptionDescriptionCharacteristicCharacteristicTimeTime


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ADVANTAGES OF NCADVANTAGES OF NC

•• NC M/T NC M/T ensureensure positioningpositioning accuracyaccuracy andand repeatibilityrepeatibility withwith theirtheirDESIGN, CONSTRUCTION DESIGN, CONSTRUCTION andand CONTROLS: CONTROLS: GoodGood forfor makingmaking manymanyof of thethe samesame partpart..

•• ComplexComplex shapedshaped componentscomponents can be can be mademade automaticallyautomatically,, withwith highhighprecisionprecision andand reliabilityreliability..

•• PartsParts thatthat requirerequire aa longlong seriesseries of of operationoperation can be can be mademade withwith minimal minimal accumulatedaccumulated errorerror..

•• NC M/T can NC M/T can operateoperate in in hostilehostile andand hazardoushazardous environmentsenvironments..•• Since Since mostmost workwork is is shiftedshifted toto officesoffices fromfrom thethe shopshop--floorfloor,, productionproduction can can

be be monitoredmonitored byby thethe managementmanagement directlydirectly..•• NC M/T NC M/T mostlymostly areare capablecapable of of conductingconducting moremore thanthan oneone machiningmachining

operationoperation at a time at a time oror in a in a sequencesequence withoutwithout repeatingrepeating thethe partpart setset--upup..•• Minimum idle time Minimum idle time andand increasedincreased productivityproductivity..•• InterchangeabilityInterchangeability of of workwork betweenbetween differentdifferent productionproduction plantsplants..

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NC MACHINE MOTIONSNC MACHINE MOTIONS


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TYPES OF NC SYSTEMSTYPES OF NC SYSTEMS

PointPoint--toto--pointpoint controlcontrol systemsystem ((NumericalNumerical positioningpositioning controlcontrol, NPC), NPC)NC NC DrillDrill pressespresses usedused in in drillingdrilling preciseprecise patternspatterns of of holesholes..

StraightStraight cutcut systemsystemFeedFeed raterate at at eacheachAxisAxis is is controlledcontrolledİİndependentlyndependently,, oneone atatA time. A time. UsedUsed in in facefacemillingmilling,, PocketingPocketing etcetc..

ContouringContouring systemsystem ((continuouscontinuous pathpath systemsystem))•• EachEach servoservo motor can be motor can be controlledcontrolled in in varyingvarying speedsspeeds in in coordinationcoordination toto

produceproduce angularangular lineslines andand curvescurves..•• SomeSome simplersimpler systemssystems of of thisthis typetype useuse thethe methodmethod of of breakingbreaking downdown thethe

curvedcurved intointo smallersmaller linearlinear segmentssegments whichwhich areare connectedconnected toto eacheach otherother in a in a tiptip--toto--tailtail fashionfashion..

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PointPoint--toto--PointPoint vs. vs. ContouringContouring ControlControl


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COMPUTERIZED NUMERICAL CONTROL (CNC) COMPUTERIZED NUMERICAL CONTROL (CNC)

CNC CNC waswas firstfirst introducedintroduced in 1970 in 1970 byby replacingreplacing thethe hardwiredhardwired MCU of a MCU of a conventionalconventional NC NC systemsystem byby aa microcomputermicrocomputer whichwhich accomplishesaccomplishes allall thethe functionsfunctions of an MCU of an MCU withwithitsits softwaresoftware..

WhatWhat is is newnew??•• FeedFeed raterate controlcontrol,, bufferingbuffering,, positionposition looploop controlcontrol ......•• AbilityAbility toto editedit andand storestore programsprograms•• AbilityAbility toto produceproduce punchedpunched ((oror magneticmagnetic)) tapestapes,, diskettesdiskettes etcetc..•• ExpandedExpanded tooltool offsetsoffsets•• ExpandedExpanded controlcontrol of of machinemachine--sequencesequence operationsoperations•• DigitizingDigitizing•• CircularCircular andand moremore advancedadvanced (NURBS (NURBS etcetc.) .) interpolationinterpolation•• ParametricParametric programmingprogramming•• Do Do loopsloops•• RoughneningRoughnening toto aa defineddefined shapeshape•• SubroutinesSubroutines•• DiagnosticDiagnostic capabilitycapability•• OnOn--screenscreen geometricgeometric programmingprogramming•• ......

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CNC Machining CNC Machining -- LatheLathe


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CNC Machining CNC Machining -- Horizontal Milling CenterHorizontal Milling Center

1,575 in/min(40 m/min) feed rate

22”x 22”x 22” envelope1,000 psi

through spindle coolant

14,000 rpm spindlewith HSK-63A adapter

FANUC 16MB controllerwith Makino software


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ELEMENTS ELEMENTS OF NCOF NC

•• TapeTape ((MediaMedia)) ReaderReader ((electromechanicalelectromechanical,, electromegneticelectromegnetic,, opticaloptical etcetc.).)•• MachineMachine ControlControl UnitUnit (MCU, (MCU, sendssends conrolconrol signalssignals toto servomechanismservomechanism))•• ServomechanismServomechanism(s) (s) ((amplifyamplify signalssignals fromfrom thethe MCU, MCU, andand sendsend themthem toto servomotorsservomotors))•• ControlledControlled element element ((tooltool,, turretturret, M/T , M/T tabletable:: thethe numericallynumerically controlledcontrolled partpart of M/T)of M/T)•• FeedbackFeedback unitunit ((recordsrecords thethe achievedachieved tooltool movementmovement andand sendsend themthem toto thethe MCU)MCU)

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•• nnnn

BallBall ScrewScrew vs. vs. LeadLead ScrewScrew


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CNC Machining CNC Machining -- TurningTurning

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CNC Machining CNC Machining ––TurningTurning


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CNC MCNC Millingilling -- Cutting ToolsCutting Tools

Cutting Tool Cutting Tool GeometryGeometry

Flat end millBall-nose end mill

Kinds of Kinds of Cutting EdgeCutting Edge

Solid cutting toolsIndexableinserts


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CNC CNC MillingMilling andand CAM: CAM: GenerationGeneration of of CuttingCutting ToolTool PathsPaths andandPartPart ProgramsPrograms

UNIGRAPHICS

UNIGRAPHICS

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USE OF USE OF (CAD &) (CAD &) CAM TECHNOLOGYCAM TECHNOLOGY

MicrochipsMicrochips,, PrintedPrinted circuitcircuit boardsboards,,MicroelectronicMicroelectronicDevicesDevices

Sheet blanking and bending in Punch Press, Sheet blanking and bending in Punch Press, Plasma Arc Cutting, Sheet bending in CNC Plasma Arc Cutting, Sheet bending in CNC Press Brake, Spinning, etc...Press Brake, Spinning, etc...

Metal FormingMetal Forming

CMM (Computerized Measurement Mach.)CMM (Computerized Measurement Mach.)Measurement &Measurement &ReRe--engineeringengineering

Welding, painting, finish, hoisting and Welding, painting, finish, hoisting and conveying, sheet formingconveying, sheet forming

Robot programmingRobot programmingSLA, SLS, FDM, LOM, SGC, SLA, SLS, FDM, LOM, SGC, MillinMillinggRapid PrototypingRapid Prototyping

Electric Discharge (EDM: Wire & Plunge), Electric Discharge (EDM: Wire & Plunge), Electro Chemical (ECM), Water Jet, PCB & Electro Chemical (ECM), Water Jet, PCB & Micro chip ManufacturingMicro chip Manufacturing

Nontraditional Nontraditional ProcessesProcesses

Milling, Turning, Drilling, Grinding, FinishingMilling, Turning, Drilling, Grinding, FinishingMachiningMachining


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Commercial CAM SoftwareCommercial CAM Software

•• II--DEASDEAS•• CATIACATIA•• PROPRO--EngineerEngineer•• UnigraphicsUnigraphics•• CimatronCimatron•• WorkWork--NCNC•• PowerPower MillMill•• HyperHyper MillMill•• CAMCAM WorksWorks•• Master CAMMaster CAM•• SurfSurf--CAMCAM•• NCNC--GibbsGibbs•• AutoAuto--CAD based CAM programsCAD based CAM programs•• ........

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CAM IN MACHINING OPERATIONSCAM IN MACHINING OPERATIONS

Basic AdvantagesBasic AdvantagesIn mass productionIn mass production•• Better geometric repeatabilityBetter geometric repeatability•• Combining many operations in one machineCombining many operations in one machine•• Flexibility: Many different parts on one machineFlexibility: Many different parts on one machine•• Flexibility: Quick and easy implementation of design Flexibility: Quick and easy implementation of design

modificationsmodificationsIn production of tools, dies and moldsIn production of tools, dies and molds•• Quick and hassleQuick and hassle--free production of complex 3free production of complex 3--DD

surfacessurfaces•• Drastic Time reduction in part programmingDrastic Time reduction in part programming•• Accurate production of the geometry developed during Accurate production of the geometry developed during

the CAD stage and verified in the CAE stagethe CAD stage and verified in the CAE stage


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Realization of a Realization of a Product via Product via

Computer Aided Computer Aided Processes Processes

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Phases in Die & Mold ProductionPhases in Die & Mold Production•• Design (CAD & CAE)Design (CAD & CAE)

• Selection of support components and design of functional components Tool Path Generation

•• Tool Path Generation (CAM)Tool Path Generation (CAM)• NC programs are needed for machining of EDM electrodes or for direct

machining of functional components•• Machining (CAM)Machining (CAM)

• Typical processes: electro-discharge machining and CNC machining (turning and/or milling)

•• BenchingBenching• The tooling is assembled• Critical dimensions are checked: Coordinate Measuring Machine (CMM)• Hand finishing: Grinding and polishing.

•• TryoutTryout• During tryout, a limited number of parts are produced with the die or mold• Minor changes on the tooling may be necessary for required performance


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Die & Mold ComponentsDie & Mold Components

•• Functional ComponentsFunctional Components– Die– Punch– Blank holder– Cavity inserts– Ejector pins– etc.

•• Support ComponentsSupport Components– Guide pins and bushings– Holding plates– etc.

ERC/NSM

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Milling of Sculptured SurfaceMilling of Sculptured Surface

CAMAX

FIDIA


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Die & Mold Production Information FlowDie & Mold Production Information Flow

Part Design forManufacturing

Die / MoldInitial Design

Process Modellingand

Structural Analysis

Die / MoldDesign

Satisfactory ?N

Prototypes / Models

Part FileDigitized PartData Part Drawing

a

Data for CMM

bY

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Die / MoldDetail Design

CNC MachiningCavities / Cores

EDMCavities / Cores

CNC MachiningEDM Electrodes

Polishing( Manual, Mechanical, Electro-Chemical )

EDM ElectrodesInspection

Data for CMM

b

c

Data for CMM

d

Satisfactory Design


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Cavities / CoresInspection

Die / MoldAssembly

Die / MoldTry out

Try outParts Inspection

Inspected Parts

a

Data for CMM

c d

Data for CMMPolished Cavities / Cores

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Business Card Holder Business Card Holder -- Design PhaseDesign Phase

Part DesignPart Design

Process SimulationProcess Simulation ERC/NSM


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Die & Mold Production Die & Mold Production ––Design PhaseDesign Phase

Filament

Supply

HeatedFDM Head

MoltenFilament

Fused Deposition ModelingFused Deposition Modeling(FDM)(FDM)

PrinciplePrinciple

ExampleExample

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Business Card Holder Business Card Holder --Design PhaseDesign Phase

Cavity Plate

Gas NozzleSupport

Glass Window Ejector

Plate

MoldBase

LogoInsert

ERC/NSM PRO-E


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Business Card Holder Business Card Holder --Machining PhaseMachining Phase

ERC/NSM

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Business Card Holder Business Card Holder --Tryout PhaseTryout Phase

ERC/NSM


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Business Card Holder Business Card Holder --Tryout PhaseTryout Phase

ERC/NSM

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