CNC
Fundamentals of CAD/CAM
Computer-aided design (CAD) is the use of computer systems to aid in the creation,
modification, analysis, or optimization of a design. Computer-aided manufacturing (CAM) is an
application technology that uses computer software and machinery to facilitate and automate
manufacturing processes. Many CAD vendors market fully integrated CAM systems, aptly
called CAD/CAM systems. These CAD/CAM packages deliver many advantages. For starters,
they feature a common user interface that allows CAD operators to quickly learn the software.
Moreover, users can easily transfer CAD data to the CAM system without worrying about
translation errors or other difficulties. And finally, some integrated systems provide full
associatively, which means that any modification to the CAD model will prompt the associated
tool path to be automatically updated. Computer Aided Design (CAD) has completely changed
the drafting business and made the storage and retrieval of projects much easier. However,
manual drawing is still very important and provides the basics of learning to draw.
BENEFITS OF CAD OVER MANUAL DRAWING:
➢ No need for scaling. All drawing is done full size.
➢ Both two and three dimensional drawings can be produced.
➢ The screen drawing area can be set to any size with the click of a button
➢ Work is copied and stored off the computer for security – you may never lose your work
again.
➢ All of the tools needed are supplied by the program.
➢ Drawings are stored on disk rather than in a bulky folder.
➢ Absolute accuracy can be maintained.
➢ Dimensioning is almost automatic.
➢ Production details can be extracted directly from the drawing.
➢ Parts of drawings can be saved and used in other drawings.
➢ Eliminates the need for full size set outs.
➢ Everything you learn about manual drawing technique applies to CAD/CAM drawing
development.
➢ The images are displayed on the PC screen and, with the click of a button, can be put on paper
using printers or plotters.
PRODUCT CYCLE COMPUTER AIDED DESIGN
IMPLEMENT OF CAD/CAM IN PRODUCT LIFE CYCLE
COMPUTER AIDED MANUFACTURING
Computer-aided manufacturing (CAM) is defined as the effective use of computer technology in
manufacturing planning and control. CAM is most closely associated with functions in
manufacturing engineering, such as process planning and numerical control (NC) part
programming. The applications of CAM can be divided into two broad categories:(1)
manufacturing planning and (2) manufacturing control.
CAM applications for manufacturing planning are those in which the computer is used indirectly
to support the production function, but there is no direct connection between the computer and
the process. The computer is used "offline" to provide information for the effective planning and
management of production activities. The following list surveys the important applications of
CAM in this category:
➢ Computer-aided process planning (CAPP). Process planning is concerned with the
preparation of route sheets that list the sequence of operations and work centers required 10
produce the product and its components. CAPP systems are available today to prepare these
route sheets.
➢ Computer-assisted NC part programming. or complex part geometries, computer assisted part
programming represents a much more efficient method of generating the control Instructions for
the machine tool than manual part programming is.
➢ Computerized machinability data systems. One of the problems in operating a metal cutting
machine tool is determining the speeds and feeds that should be used to machine a given work
part. Computer programs have been written to recommend the appropriate cutting conditions to
use for different materials. The calculations are based on data that have been obtained either in
the factory or laboratory that relate tool life to cutting conditions.
➢ Development of work standards. The time study department has the responsibility for setting
time standards on direct labor jobs performed in the factory. Establishing standards have direct
time study can be a tedious and time-consuming task. There are several commercially available
computer packages for setting work standards. These computer programs 'use standard time data
that have been developed for basic work elements that comprise any manual task. By summing
the limes for the individual element, required to perform a new Job, the program calculates the
standard lime for the job.
➢ Cost estimating, The task of estimating the cost of a new product has been simplified in most
industries by computerizing several of the key steps required to prepare the estimate. The
computer is programmed to apply the appropriate labor and overhead rates to the sequence of
planned operations for the components of new products. the program then sums the individual
component costs from the engineering bill of materials to determine the overall product cost.
➢ Production and inventory planning. The computer has found widespread use in many of the
functions in production and inventory planning. These functions include: maintenance of
inventory records, automatic reordering of stock items when inventory is depicted. production
scheduling, maintaining current priorities for the different production orders, material
requirements planning, and capacity planning.
➢ Computer-aided line balancing. Finding the best allocation of work elements among stations
on an assembly line is a large and difficult problem if the line is of significant size. Computer
programs have been developed to assist in the solution of this problem.
Computer Numeric Control (CNC)
Computer Numeric Control (CNC) is the automation of machine tools that are operated by
precisely programmed commands encoded on a storage medium (computer command module,
usually located on the device) as opposed to controlled manually by hand wheels or levers, or
mechanically automated by cams alone. Most NC today is computer (or computerized)
numerical control (CNC), in which computers play an integral part of the control.
In modern CNC systems, end-to-end component design is highly automated using
computeraided design (CAD) and computer-aided manufacturing (CAM) programs. The
programs produce a computer file that is interpreted to extract the commands needed to operate a
particular machine by use of a post processor, and then loaded into the CNC machines for
production. Since any particular component might require the use of a number of different tools
– drills, saws, etc. – modern machines often combine multiple tools into a single "cell". In other
installations, a number of different machines are used with an external controller and human or
robotic operators that move the component from machine to machine. In either case, the series of
steps needed to produce any part is highly automated and produces a part that closely matches
the original CAD design.
Definition
Computer Numerical Control (CNC) is one in which the functions and motions of a machine tool
are controlled by means of a prepared program containing coded alphanumeric data. CNC can
control the motions of the work piece or tool, the input parameters such as feed, depth of cut,
speed, and the functions such as turning spindle on/off, turning coolant on/off.
Applications
The applications of CNC include both for machine tool as well as non-machine tool areas. In the
machine tool category, CNC is widely used for lathe, drill press, milling machine, grinding unit,
laser, sheet-metal press working machine, tube bending machine etc. Highly automated machine
tools such as turning centre and machining centre which change the cutting tools automatically
under CNC control have been developed. In the non-machine tool category, CNC applications
include welding machines (arc and resistance), coordinate measuring machine, electronic
assembly, tape laying and filament winding machines for composites etc.
Advantages and Limitations
The benefits of CNC are (1) high accuracy in manufacturing, (2) short production time, (3)
greater manufacturing flexibility, (4) simpler fixturing, (5) contour machining (2 to 5 –axis
machining), (6) reduced human error. The drawbacks include high cost, maintenance, and the
requirement of skilled part programmer.
ELEMENTS OF A CNC
A CNC system consists of three basic components (Figure 2) : Part Program 1 . Part program
2 . Machine Control Unit (MCU) 3 . Machine tool (lathe, drill press, milling machine etc)
Machine Control Unit
The machine control unit (MCU) is a microcomputer that stores the program and executes the
commands into actions by the machine tool. The MCU consists of two main units: the data
processing unit (DPU) and the control loops unit (CLU). The DPU software includes control
system software, calculation algorithms, translation software that converts the part program into
a usable format for the MCU, interpolation algorithm to achieve smooth motion of the cutter,
editing of part program (in case of errors and changes). The DPU processes the data from the
part program and provides it to the CLU which operates the drives attached to the machine
leadscrews and receives feedback signals on the actual position and velocity of each one of the
axes. A driver (dc motor) and a feedback device are attached to the leadscrew. The CLU consists
of the circuits for position and velocity control loops, deceleration and backlash take up, function
controls such as spindle on/off.
Machine Tool
The machine tool could be one of the following: lathe, milling machine, laser, plasma,
Coordinate measuring machine etc. Figure 3 shows that a right-hand coordinate system is used to
describe the motions of a machine tool . There are three linear axes (x,y,z), three rotational axes
(i,j,k), and other axes such as tilt (9) are possible. For example, a 5-axis machine implies any
combination of x,y,z, i,j,k,and 6.
Coordinate systems:
The machine tool is positioned by describing sets of coordinates. In the case of the VMC
(Vertical Machining Centre) shown on the left, the coordinate will be described by 3 Axes.
When CNC programming the coordinate system must reference from a fixed point; this is called
the origin or more commonly in manufacturing, the datum. The datum is the position where X,
Y, and Z all equal zero. This is usually a point on the component and this position is usually
decided by the manufacturing engineer or CNC programmer. The coordinate system is almost
always an absolute coordinate system. Absolute meaning all coordinates are measured from the
datum. Other coordinate system are found in CNC manufacturing; it is not unusual to find
Incremental (Relative) coordinates used on many machines and it is possible to use Polar
coordinates on most machines.
Incremental coordinates do not refer back to the original datum, the position of the datum moves
with the programmed coordinate. The machine moves towards a programmed position; when it
gets to that position the position becomes X0Y0Z0 (the new datum). The next position is
described from this new datum.
AUTOMATIC TOOL CHANGER (ATC)
An Automatic tool changer or ATC is used in computerized numerical control (CNC) machine
tools to improve the production and tool carrying capacity of the machine. ATC changes the tool
very quickly, reducing the non-productive time. Generally, it is used to improve the capacity of
the machine to work with a numbers of tools. It is also used to change worn out or broken tools.
It is one more step towards complete automation. Simple CNC machines work with a single tool.
Turrets can work with a large number of tools. But if even more tools are required, then ATC is
provided. The tools are stored on a magazine. It allows the machine to work with a large number
of tools without an operator. The main parts of an automatic tool changer are the base, the
gripper arm, the tool holder, the support arm and tool magazines.
NC machine tools:
1. Reduced lead time:
Lead time includes the time needed for planning, design and manufacture ofjigs, etc. This time
may amount to several months. Since the need for special jigs andfixtures is often entirely
eliminated, the whole time needed for their design andmanufacture is saved.
2. Elimination of operator errors:
The machine is controlled by instructions registered on the tape provided thetape is correct and
machine and tool operate correctly, no errors will occur in the [Link], boredom, or
inattention by operator will not affect the quality or duration ofthe machining. Responsibility is
transferred from the operator to the tape, machine settings are achieved without the operator
reading the dial.
3. Operator activity:
The operator is relieved of tasks performed by the machine and is free to attend to matters for
which his skills and ability are essential. Presetting of tools, setting of components and
preparation and planning of future jobs fall into this category. It is possible for two work stations
to be prepared on a single machine table, even with small batches. Two setting positions are
used, and the operator can be setting one station while machining takes place at the other.
4. Lower labor cost
More time is actually spent on cutting the metal. Machine manipulation time ex.:. Gear changing
and often setting time are less with NC machines and help reduce the labor cost per job
considerably.
5. Smaller batches
By the use of preset tooling and presetting techniques downtime between batches is kept at a
minimum. Large storage facilities for work in progress are not required. Machining centers
eliminate some of the setups needed for a succession of operation on one job; time spent in
waiting until each of a succession of machine is free is also cut. The components circulate round
the machine shop in a shorter period, inter department costs are saved and „program chasing‟ is
reduced.
6. Longer tool life
Tools can be used at optimum speeds and feeds because these functions are controlled by the
program.
7. Elimination of special jigs and fixtures
Because standard locating fixtures are often sufficient of work on machines. The cost of special
jigs and fixture is frequently eliminated. The capital cost of storage facilities is greatly reduced.
The storage of a tape in a simple matter, it may be kept for many years and manufacturing of
spare parts, repeat orders or replacements is made much more convenient.
8. Flexibility in changes of component design
The modification of component design can be readily accommodated by reprogramming and
altering the tape. Savings are affected in time and cost.
9. Reduced inspection.
The time spent on inspection and in waiting for inspection to begin is greatly reduced. Normally
it is necessary to inspect the first component only once the tape is proved; the repetitive accuracy
of the machine maintains a consistent product.
10. Reduced scrap
Operator error is eliminated and a proven tape results in accurate component.
11. Accurate costing and scheduling
The time taken in machining is predictable, consistent and results in a greater accuracy in
estimating and more consistency in costing.
DNC
It is also known as distributed numerical control ( DNC), is a common manufacturing term for
networking CNC machine tools. On some CNC machine controllers, the available memory is too
small to contain the machining program (for example machining complex surfaces), so in this
case the program is stored in a separate computer and sent directly to the machine, one block at a
time. If the computer is connected to a number of machines it can distribute programs to
different machines as required. Usually, the manufacturer of the control provides suitable DNC
software. However, if this provision is not possible, some software companies provide DNC
applications that fulfill the purpose. DNC networking or DNC communication is always required
when CAM programs are to run on some CNC machine control.
Direct Numerical Control (DNC) is a system that uses a central computer to control several
machines at the same time. It‟s a 1960s technology, which uses two way communication
systems.
DNC involved the control of a number of machine tools by a single mainframe computer through
direct connection and in real time. The tape reader is omitted in DNC System, thus relieving the
system of its least reliable components. Instead of using the tape reader, the part program is
transmitted to the machine tool directly from the computer memory. The DNC Computer is
designed to provide the instructions to each machine tool on the demand. DNC also involves the
data collection and processing from the machine tool back to the computer. Two types of DNC
System are used: 1. Behind the Tape Reader (BTR) System, 2. Special Machine Control Unit
(SMCU)
1.17 Components of DNC
Input medium: - Part program or instructions needed to drive the machine tool components.
Machine control unit (MCU): - Electronics & control hardware.
Machine tool:
Advantages of Direct Numerical Control (DNC) Systems
There are various advantages provided by DNC system. These are as follows: 1) Easy and
Effective programming using DNC Software. 2) Higher level of decision making. 3) Real time
control of various machine tools. 4) First step which gives hands on experience for future
expansion. 5) Elimination of Punched Tape and Tape Reader. 6) CLFILE- A Convent and more
general way of program storage. 7) Elimination of hardwired controller unit on some system. 8)
Greater Productivity. 9) Convenient Storage of NC Part Program. 10) Greater Computational
ability. 11) Location of central computer in remote and clean environment. 12) Effective support
to management information system. 13) Effective data collection and reporting. 14) Enhanced
manufacturing flexibility by real time rescheduling.
Types of CNC Machines
According to the function or type of CNC machining parts, CNC machining machine tools can
be divided into five types: CNC milling machine, CNC lathe, CNC drilling machine, CNC
plasma cutting machine and CNC grinder.
1、CNC Machining and Milling
Used for CNC machining and manufacturing of shapes, grooves, holes, notches, grooves,
pockets and special surfaces, and execute the machining process of CNC milling parts, that is,
the rotating cutting tool on the grinding machine to take out the CNC from the fixed workpiece
Processing materials.
CNC mills, also known as machining centers, are one of the most common types of CNC
machines. They use rotary cutters to remove material from a workpiece, resulting in the desired
shape or form. CNC mills are highly versatile and can perform a wide range of operations,
including drilling, tapping, milling, and contouring.
2、CNC lathe
It is used in the process of CNC machining and manufacturing of cylindrical objects and CNC
turning parts. When the material block rotates quickly on the spindle, the tool will form the CNC
machining [Link] lathes are ideal for producing symmetrical parts such as shafts, rods, and
rings. They offer excellent precision and can produce intricate designs with ease.
3、CNC drilling machine:
It used to drill holes on CNC machined parts. This tool can quickly and accurately locate the
drilling position. The precision drilling machine can also carry out reaming, back drilling and
tapping.
4、CNC plasma cutting machine
A plasma cutting torch for cutting metal, including the use of thermal plasma accelerated jets to
cut conductive materials.
CNC plasma cutters use a high-velocity jet of ionized gas (plasma) to cut through electrically
conductive materials such as steel, aluminum, and brass. They are commonly employed in metal
fabrication industries, where precision cutting and intricate shapes are required.
5、CNC grinder
The machine uses a rotating wheel to grind or grind the material into the desired shape, which is
easier to program than CNC milling machines and lathes.
6、 CNC EDM Machines
CNC EDM (Electrical Discharge Machining) machines use electrical discharges to remove
material and shape the workpiece. They are highly effective in machining complex and intricate
parts, especially those made of hardened materials. CNC EDM machines are widely used in the
aerospace, automotive, and medical industries.
Classifications of CNC Machines
According to the number of axes, CNC machine tools can generally be divided into five
categories: 2-axis CNC machine tools, 2.5-axis CNC machine tools, 3-axis CNC machine tools,
4-axis CNC machine tools and 5-axis CNC machine tools.
a) 2 Axis CNC Machining Machine
A machine is only allowed to enter two axes, such as a lathe, and the tool moves in two
directions, such as X and Z.
b) 2.5-Axis CNC Machining Machine
It is also a three-axis system, but the movement is not three-dimensional. The X-axis and Y-axis
first move to the position, and then the third axis starts to work, such as drilling machines and
tapping machines.
c) 3-Axis CNC Machining Machine
Three-axis (X, Y, and Z) move simultaneously in three dimensions. It is the most widely used
and most versatile machine tool. It can achieve high precision and high precision, and can be
used for automatic/interactive operations and milling grooves. , Drilling and cutting sharp edges.
d) 4-Axis CNC Machining Machine
A three-axis machine tool that rotates again on the A-axis or B-axis. Common examples are
vertical or horizontal machine tools. In the case of 4-axis CNC machining, milling is performed
on the additional axis, and the operations on X, Y, and Z are the same as the three-axis system,
and the rotation on the A or B axis is performed around the X axis.
e) 5-Axis CNC Machining Machine
A three-axis CNC machining machine tool that additionally rotates in two directions (Y and Z)
on the A-axis and B-axis, respectively, is rotated by the bed and the spindle movement (pivot
point). The 5-axis machine tool is an advanced CNC machining machine. Its multi-dimensional
rotation and tool movement allow the creation of precise and complex CNC machining parts.
This is due to improved access to the bottom and deep pockets, unparalleled finish and speed,
usually used in aviation Advanced applications such as aerospace components, artificial bones,
titanium parts, oil and gas machinery parts, and military products.
f) Multi-Axis CNC Machines
These machines go beyond five axes and can have up to 9 or more axes. Multi-axis CNC
machines are used in advanced aerospace, medical, and automotive applications.