xyz moving drill machine with 90*
TRANSCRIPT
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PROJECT TOPIC
Xyz moving drill machine
PERSONAL TRANSPORTER
SHRI RAM COLLEGE OF ENGINEERING AND MANAGEMENT
(AFFILIATED TO MAHARSHI DAYANAND UNIVERSITY, ROHTAK)
NH2, AURANGABAD (PALWAL), HARYANA.
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CANDIDATE DECLARATION
We the students of Bachelor Of Technology in Mechanical discipline, Session: 200812, Facultyof Engineering and Technology(SRCEM); hereby declare that the work presented in this
dissertation entitled Segway- a Personal Transporter is the outcome of ourwork, is bonafide
and correct to the best of our knowledge and this work has been carried out taking care of
engineering ethics. The work presented does not infringe any patented work and has not been
submitted to any other university or anywhere else for the award of any degree or any
professional diploma.
Chirag Gupta (83009)
Mohit Chaudhary (83026)
Pawan Malik (83033)
Sachin Sharma (83041)
Vinod Chauhan (83053)
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CERTIFICATE
This is to certify that Mr. Vinod Chauhan student of B.Tech (Mechanical) from SHRI RAM
COLLEGE OF ENGINEERING AND MANAGEMENT, Maharishi Dayanand University,
Rohtak, have completed his project as per partial fulfillment of the requirement for the award of
the Degree of Bachelor Of Engineering (ME) of M.D. University in a record of bonafied work
carried out under the guidance of Mr. Surender Kumar.
The project work entitled SEGWAY- A PERSONAL TRANSPORTER embodies the original
work done by him during his final year. He have successfully completed the project work up to
our full satisfaction. We wish him success in his future life.
Mr. Surender Kumar Dr. D.S. Sharma
Professor & Head of Department (Dean, Mech.)Mech. Department
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ACKNOWLEDGMENT
I would like to express my gratitude to Mr. Surender Kumar (Professor & HOD), Department
Mechanical who was instrumental in the formulation of the project. I am very grateful to him for
his encouragement and dedication in making this project a successful one.
I express my sincere regards to other staff of the college for their constant support and
suggestions during the making of this project and for all the facilities provided.
I extend my thanks to all my friends and well wishers for their instant and efficient co-operation
whose efforts resulted in the timely development of the project. I also thank the technical staff of
the computer labs who provided the facilities required during development.
Finally I am indebted to my parents who have constantly provided us the opportunity and
support to rise to higher levels in life.
Vinod Chauhan (83053)
SemesterVIII
B.Tech. (Mechanical)
SRCEM,AURANGABAD(PALWAL)
Introduction
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Congratulations! Your XYZ Bed Mill with the ProtoTRAK SMX CNC is an
excellent tool room machine. It features an easy-to-use interface and dozens of
features that maximize machinists productivity for any kind of toolroom job.
Manual machining is always available and made easier with features like power
feed, rapid positioning, tool offsets and all the best features of sophisticated
DROs. Two-axis machining is available at the touch of a button for prototyping
and moderately complex, low volume work.
Three-axis machining is programmed and run with unprecedented flexibility.
Programs may be entered at the control or imported from CAD/CAM files.
Advanced color graphics show program features.
The ProtoTRAK SMX CNC allows you to chose the CNC configuration that is
right for you. The base system is a powerful CNC for toolroom work. You may
add options for additional features and capabilities.
This manual will describe the operation of all basic and optional features in the
appropriate context. Where optional features are discussed, a note will explain in
which option the particular feature is found.
1.1 Manual Organization
Section 2 of this manual provides important safety information. It is highly
recommended that all operators of this product review this safety information.
Section 3 provides a description of the XYZ Bed Mill and the ProtoTRAK SMX
CNC.
Machine Control Options are described in this section.
Section 4 describes the operation of the milling machine and some basic operations
of
the ProtoTRAK SMX CNC.
Section 5 defines some terms and concepts useful in learning to program and
operate
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the ProtoTRAK SMX CNC.
The ProtoTRAK SMX CNC is organized into six Modes of operation that are
described in the following sections.
Section 6 DRO: Digital Readout, jog, and powerfeed operations.
Section 7 Programming, Part 1: covers some general programming information and
instructions on starting new programs.
Section 8 Programming, Part 2: Program Events - instructions for the canned
cycles, or events, used to program the ProtoTRAK SMX CNC.
Section 9 Programming, Part 3: the A.G.E., or Auto Geometry Engine, so powerful
it
gets its own section. Section 10 Edit: for routines to make large-scale changes to
programs in current
memory, including the powerful Spreadsheet Editing
Section 11 Set-Up: Tool information, part graphics and special codes.
Section 12 Run: Instructions on running a program to machine your part.
Section 13 and 14 Program In/Out: Storing and managing your programs.
Section 15: Sample programs for practice.
EVENT 1 Bolt Hole NOTEScenter drill
DRILL O R BORE
# OF HOLES
X CENTER
Y CENTER
Z RAPID
Z END
RADIUS
ANGLE
# OF PECKS FOR DRILL
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Z FEEDRATE
TOOL #
1
5 ABS SET
0 ABS SET
0 ABS SET
3 ABS SET
-3 ABS SET
33 SET
45 SET
1 SET
125 SET
1 SET
Drill Function
Known print value
Use the center as the reference
Sets the rapid to 3mm above the part
Sets the drill depth to -1
The radius of the bolt hole circle
Angle of first hole from zero (0) degrees
Sets 1 peck
Sets Z plunge rate to 125 mmpm
Selects Tool # 1 as the Center drill
145
XYZ Machine Tools Ltd.
XYZ Bed Mills and ProtoTRAK SMX CNC Safety, Programming, Operating &
Care Manual
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EVENT 2 Bolt Hole NOTESdrill to final size
DRILL OR BORE
# OF HOLES
X CENTER
Y CENTER
Z RAPID
Z END
RADIUS
ANGLE
# OF PECKS FOR DRILL
Z FEEDRATE
TOOL #
1 SET
5 ABS SET
0 ABS SET
0 ABS SET
3 ABS SET
-9 ABS SET
33 SET
45 SET
3 SET
125 SET
2 SET
Drill Function
Known print value
Use the center as the reference
Sets the rapid to 3mm above the part
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Sets the drill depth to9 (through)
The radius of the bolt hole circle
Angle of first hole from zero (0) degrees
Sets 3 peck
Sets Z plunge rate to 125 mmpm
Selects Tool # 2 as the M7 drill
EVENT 3 CIRC PCKT NOTES
X CENTER
Y CENTER
Z RAPID
Z END
RADIUS
DIRECTION
# OF PASSES
ENTRY MODE
FIN CUT
Z FEEDRATE
XYZ FEEDRATE
FIN FEEDRATE
TOOL #
0 ABS SET
0 ABS SET
3 ABS SET
-5 ABS SET
19 SET
2 SET
2 SET
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1 SET
.25 SET
100 SET
250 SET
200 S ET
3 SET
Sets the pocket center to X zero
Sets the pocket center to Y zero
Sets the Rapid
Sets the pocket depth
Sets radius of pocket
Makes the cut direction CCW
Cuts the pocket using two (2) depths
Selects tool ramp into the material
Sets finish cut for the wall of the pocket
Sets the ramp feedrate in mmpm
Sets the pocket cutting feedrate
Sets the finish pocket feedrate.
Sets mill tool #
EVENT 4 RECTANGULAR
PROFILE
NOTESselect PROFILE and then
IRREG PROFILE
X1
Y1
X3
Y3
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Z RAPID
Z END
CONRAD
DIRECTION
TOOL OFFSET
# PASSES
FIN CUT
Z FEEDRATE
XYZ FEEDRATE
FIN FEEDRATE
TOOL #
-50 ABS SET
-50 ABS SET
50 ABS SET
50 ABS SET
3 ABS SET
-7.5 ABS SET
0 SET
1 SET
2 SET
2 SET
.25 SET
100 SET
250 SET
INC SET
3 SET
Start at lower left corner
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Through the p late
Sets tool offset LEFT
Machined at 2 depths
No change of federate
Intro to CNC Machining
CNC stands for computer numeric controlled. It refers to any machine tool
(i.e. mill, lathe, drill press, etc.) which uses a computer to electronically control the
motion of one or more axes on the machine.
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The development of NC machine tools started from a task supported by the
US Air Force in the early 1950s, involving MIT and several machine-tool
manufacturing companies. The need was recognized for machines to be able to
manufacture complex jet aircraft parts.
As computer technology evolved, computers replaced the more inflexible
controllers found on the NC machines; hence the dawn of the CNC era.
CNC machine tools use software programs to provide the instructions
necessary to control the axis motions, spindle speeds, tool changes and so on.
CNC machine tools allow multiple axes of motion simultaneously, resulting
in 2D and 3D contouring ability.
CNC technology also increases productivity and quality control by allowing
multiple parts to be produced using the same program and tooling.
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Basics of CNC Programming
There are two ways to program modern CNC machine tools.
1. Conversational Programming. This is the simpler of the two methods. In effect,this is a macro programming language used to instruct the machine to perform
pre-programmed cycles (i.e. facing, drilling holes in arrays, etc.). When writing
a conversational program, you simply enter the appropriate parameters
associated with each machining cycle. This is analogous to using the polar array
function in SolidWorks or Pro/E; you dont have to do the layout or trig to find
the location of the features; you just specify the essential parameters and the
software does the rest for you.
1. CAM Programming. This is the more powerful of the two methods. Using thismethod, you import your part model into a CAM (computer aided
manufacturing) program and define the parameters associated with each and
every machined feature on the part. These parameters include tool diameter and
length, depth of cut, tool path geometry, etc.
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Conversational CNC Programming
The following cycles are typical of the machining operations available when
programming a 3-axis CNC milling machine.
Position. Used to move the XYZ coordinates at rapid feedrate.
Drill_one. Used to position the tool at a specific XYZ coordinate position in order
to automatically drill a hole. The automatic drill cycles allow for simple drilling,
peck drilling, spot-facing and bore cycles.
Drill_pattern. Used to define polar or rectangular hole arrays for automatic drilling.
Line. Used to cut straight lines along an axis or a diagonal at the desired feedrate.
Arc. Used to cut a circle or partial circle that is part of a series of cuts that usually
includes lines as well.
Face. Used to define a rectangular zig-zag pattern used to clean off a part surface.
Pocket. Used to clear the material out of a rectangle, circle or polygon.
Frame. Used to cut the inside or outside outline of a rectangle, circle or polygon.
Tool. Used to enter tool parameters, machine function parameters and program
pause/stop codes.
Scale/mirror. Used to scale and/or mirror other part features.
Rotate. Used to repeat other part features around a specific center of rotation.
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Conversational CNC Programming Example #1
Drill Pattern Bolt Circle Variables (G121):
X = X center
Y = Y center
R = Radius
A = Start angle (absolute)
N = # of holes
H = # of holes to drill
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Conversational CNC Programming Example #2
Arcs and Lines (dashed line is tool path for 1/8 diameter endmill)
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Conversational CNC Programming Example #2 (cont)
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Below is the actual tool path code for the previous example. After the user enters
the basic parameters, this is the program that is generated by the conversational
interface to run on the CNC.
An analogy to software programming is that conversational programming is
similar to programming using a compiler (ie C, Fortran, VB, etc.) and the actual
tool path code generated is equivalent to the final compiled machine code or
instructions.
G90 G0 X0 Y-0.75 Z1 F5 [G90=absolute; G0=rapid; F=XY feed]
Z0 M3 [M3=spindle on, CW]
G1 Z-0.1 E2 [G1=linear motion; E=Z feedrate]
Y-0.5625
G2 J0.5625 X0 Y0.5625 [G2=CW circular motion]
G1 X0.6507 [G1=linear motion]
X1.5625 Y0.03608
Y-0.3
G2 I-0.2625 X1.3 Y-0.5625 [G2=CW circular motion]
G1 X0 [G1=linear motion]
G0 Y-0.75 Z1 [G0=rapid]
M30 [M30=end of program/rewind]
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CNC CAM Programming
Once the part has been designed using conventional mechanical design methods
(structural analysis, FEA, fatigue study, etc.), the part is manufactured using the
following method.
1. Create a solid 3D model of the part to be produced. Any standard CAD formatis acceptable.
1. Import the solid model into the CAM (computer aided manufacturing)software. (this demonstration uses MasterCAM)
1. Input the raw material stock size and set theparts coordinate origin.
1. Input the necessary information for each tool used in machining the partfeatures. Typically, a tool library will exist, which is simply a database of tools
and their related parameters.
1. For each part feature, select the appropriate tool from the library and set theparameters necessary for machining that feature. Typical parameters include
spindle speed, depth of cut, feedrate, number of passes, tool path pattern, etc.
1. Verify the programmed tool path(s) by running the CAM softwares virtualmachining cycle.
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Final Facts about CNC Machining
CNC manufacturing offers advantages on two types of parts: (1) simple parts
that are mass produced and/or (2) complex parts with features requiring multiple
axes of simultaneous motion. For simple parts in low quantity, it is often quicker to
produce the parts on manual machines (as in lab).
CNC does not inherently imply increased part accuracy. An old CNC with a
lot of hours of use will produce less accurate features than a new quality manual
machine and vise-versa; so dont automatically associate higher accuracy with
CNC machines. (Accuracy has more to do with machine design, component
selection and mechanical wear.)
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Modern CNC machines offer increased productivity due to stiffer machineand spindle designs, more powerful motors, high pressure coolant (up to 1000 psi)
that floods the cutting zone, automatic tool changers, digital workpiece and tool
probing, and/or horizontally mounted spindles.
Downsides to CNC machines are higher initial cost, larger space and
electrical requirements, increased maintenance cost, required programming skillset
and their inherent complexity means theres a higher probably of component
failure during the useful lifespan.