Professional Documents
Culture Documents
10/30/2011
NeedforUnconventionalProcesses
y New materials having high strength and hardness, such as
NTMM
BySKMondal
for development of
processes
which
utilize
nontraditional
other
machining
methods
such
as
NeedforUnconventionalProcesses
InUnconventionalMachining
y Different forms of energy directly applied to the
y Complex shapes.
y A very high accuracy is desired besides the complexity of
ClassificationofNTMM
1.ThermalEnergyMethods
y Electricaldischargemachining(EDM)
y LaserbeamMachining(LBM)
1.ThermalEnergyMethods
y PlasmaArcMachining(PAM)
g
2.Electro ChemicalEnergyMethod
y ElectronBeamMachining(EBM)
3.ChemicalEnergyMethods
y IonBeamMachining(IBM)
4.MechanicalEnergyMethods
Page 2 of 45
10/30/2011
3. ChemicalEnergyMethods
2.Electro ChemicalEnergyMethod
y ElectroChemicalMachining(ECM)
y ElectroChemicalgrinding(ECG)
y ElectroChemicalHoning(ECH)
El t Ch i lH i (ECH)
y ElectroChemicalDeburring (ECD)
4. MechanicalEnergyMethods
SomeObservations
y EDM has the lowest specific power requirement and can
y UltraSonicMachining(USM)
y AbrasiveJetMachining(AJM)
g
y WaterJetMachining(WJM)
g
tool wear,, are used for nonmetal cutting.
y LBM and EBM have high penetration rates with low
ShapesCuttingCapability
LimitationsofNTMM
USM
3. Fine hole drilling and Contour Machining: ECM
Page 3 of 45
10/30/2011
ElectrochemicalMachining
y Electrochemical machining is the reverse of electro
plating
ECM
BySKMondal
ElectrochemicalMachining
y Variation in the current density will result in work
ECMEquipment
ECMEquipment
y Supply Voltage 2 to 35 V DC and Current 500 to 40,000 A
y The tooltowork gap needs to be maintained at a very
Page 4 of 45
10/30/2011
ECMEquipment
Electrolyte
Tool
The properties of tool materials should be:
ForECMofsteelNaCl isusedastheelectrolyte.
1.
2.
Easy machinability
3.
Good shiffness
4.
Advantages
Disadvantages
1.
2.
3.
4.
5.
6.
7.
Page 5 of 45
10/30/2011
Applications
PSU
ECMcannotbeundertakenfor
(a)steel
(b)Nickelbasedsuperalloy
(c)Al2O3
(d)Titaniumalloy
ECMCalculations
PSU
m=
Where
It E
F
m
I
t
E
F
ECMCalculations
yMRR =
EI
F
g/s =
AI
F. V
=weight(g)ofamaterial
=current(A)
=time(sec)
=gramequivalentweightofthe
material
=constantofproportionality
Faraday(96,500coulombs)
ECMCalculations
g/s
3
IfyouputE=equivalentweightinCGSi.e.g/mole
IfyouputE=equivalentweightinCGSi
e g/mole
IinAmpere(A)
F=96500columb/molei.e.As/mole
TheMRRwillbeing/s
Page 6 of 45
10/30/2011
ECMCalculations
Example
UsingECMremove5cm3/minfromanironworkpiece,
whatcurrentisrequired?
Atomicweightofiron56,density7.8g/cm3 valency,2
AI cm3 EI cm3
vF sec F sec
y MRR for Alloy
Eeq I cm3
eq F sec
100
x
= i
eq
i i
and
100
x v
= i i
Eeq
i Ai
Example
Example(GATE2009)
Electrochemicalmachiningisperformedtoremove
materialfromanironsurfaceof20mmx20mmunder
thefollowingconditions:
Interelectrodegap
=
0.2mm
SupplyVoltage(DC)
12V
S
l V lt (DC) =
V
Specificresistanceofelectrolyte
=2cm
AtomicweightofIron =
55.85
Valency ofIron =
2
Faraday'sconstant
=
96540Coulombs
Thematerialremovalrate(ing/s)is
Example
Flowanalysis
l2R = q e ce (B o )
Page 7 of 45
10/30/2011
Example
Overvoltage
Example
DynamicsofElectrochemicalMachining
ElectrochemicalGrinding(ECG)
y In ECG, the tool electrode is a rotating, metal bonded,
diamond grit grinding wheel.
y As the electric current flows between the workpiece and the
wheel, through the electrolyte, the surface metal is changed
to a metal oxide, which is ground away by the abrasives. As
the oxide film is removed,
removed new surface metal is oxidized and
removed.
y ECG is a lowvoltage highcurrent electrical process.
y The purpose of the abrasive is to increase the efficiency of the
ECG process and permit the continuance of the process.
y The abrasive particles are always nonconductive material
such as aluminum oxide, diamond, or borazon (CBN). Thus
they act as an insulating spacer maintaining a separation of
from 0.012 to 0.050 mm between the electrodes.
Equipmentsetupandelectricalcircuitforelectrochemicalgrinding.
Page 8 of 45
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ElectrochemicalGrinding(ECG)
OtherElectrochemicalprocesses
y Electrochemicalpolishing
y Electrochemicalholedrilling
g
y ElectrochemicalDeburring
PhysicalPrinciple
y Basic process
EDM
PhysicalPrinciple
PhysicalPrinciple
resistance.
Page 9 of 45
10/30/2011
PhysicalPrinciple
PhysicalPrinciple
CharacteristicsofEDM
CharacteristicsofEDM
EDMTool
EDMTool
Theusualchoicesfortool(electrode)materialsare
y Copper,
y brass,
y alloysofzincandtin,
y hardenedplaincarbonsteel,
y coppertungsten,
y silvertungsten,
y tungstencarbide,
y coppergraphite,andgraphite.
Page 10 of 45
10/30/2011
WearRatio
ServoMechanism
electrode.
DielectricFluid
IES2011Conventional
debris.
Relaxationcircuit
[5 Marks]
Advantages
1.
2.
3.
4.
5.
6.
Page 11 of 45
10
10/30/2011
Disadvantages
Applications
2.
33.
4.
5.
6.
Applications
Applications
y In EDM method,
method small holes,
holes about 0.13
0 13 mm,
mm in
WireEDM
IES2009Conventional
[15marks]
electrode.
y The electrode wire is typically made with a 0.05 to 0.25
Page 12 of 45
11
10/30/2011
WireEDM
y This process is much faster than electrode EDM.
y This process is widely used for the manufacture of
ElectricDischargeGrinding(EDG)
y EDG is similar to EDM except that the electrode is a
ElectricDischargeGrinding(EDG)
y The spark gap is normally held at 0.013 to 0.076 mm
y The graphite wheel is rotated at 0.5 to 3 m/s
surface grinding.
2. Grinding carbide and steel at the same time without
wheel loading.
3. Grinding thin sections where abrasive wheel pressures
Page 13 of 45
12
10/30/2011
UltrasonicMachining
UltrasonicMachining
BySKMondal
UltrasonicMachining
UltrasonicMachining
UltrasonicMachining
ProcessParameters
2
( w db )3/2 nf
3
Page 14 of 45
13
10/30/2011
EffectofmachiningparametersonMRR
UltrasonicMachine
UltrasonicMachine
UltrasonicMachine
to a drill press.
y It has additional features to carry out USM of brittle
work material.
y The
is
which
Th workpiece
k i
i mounted
t d on a vice,
i
hi h can be
b
located at the desired position under the tool using a 2
axis table.
y The table can further be lowered or raised to
accommodate work of different thickness.
y Slurry delivery and return system
the
th vibration
ib ti to
t the
th required
i d amplitude
lit d off 15 50 m and
d
accommodates the tool at its tip.
Transducer
SubsystemsofUSM
Subsystemsof
USM
y The
Page 15 of 45
14
10/30/2011
ToolholderorHorn
Tool
materials.
y The harder the tool material, the faster its wear rate will
be.
Limitations
Applications
y LowMRR
y Ratherhightoolwear
y Lowdepthofhole
dies.
Note
ChemicalMachining
(i)
Glass
(ii)
Silicon
(iii)
Germanium
y Tool in USM is generally made of Steel
printing.
y Cutting speed of 0.00250.1 mm/minute very slow
Page 16 of 45
15
10/30/2011
ChemicalMachining
PhotoChemicalMachining
y PCM is a material removal process using chemicals
PhotoChemicalMachining
LaserBeamMachining
94
LaserBeamMachining
LaserBeamMachining
y Produceslargeremelt zone
laser welding
y Canproduceholesassmallas0.0005mmdiameter
y Canproducedeepholes
workpiece
k i
y Usedtoproducecoolingholesinblades/vanesforjet
engines
Page 17 of 45
96
16
10/30/2011
ElectronBeamMachining
ElectronBeamMachining
electron
beam
directed
toward
workpiece
y Energy of electron beam melts/ vaporizes selected
region of workpiece
y Electron beam moved by deflection coils
y Similar process to EB welding
97
98
PlasmaArcCutting
WaterJetMachining
y Narrowjetofwaterdirected,athighpressureand
velocity,againstsurfaceofworkpiece
y Jetofwatererodessurfaceofworkpiece,thereby
cuttingworkpiece
y Computercontroltoachieveshape
99
100
WaterJetMachining
AbrasiveJetMachining(Dry)
y Similar to sand blasting, except that a very narrow jet
101
Page 18 of 45
102
17
10/30/2011
AbrasiveWJCutting
AbrasiveJetMachining
AbrasiveWJCutting
y Evolution of
technology
mixing
tube
Ch10:NonConventionalMachiningOperation
Q.No
1
2
3
4
5
6
7
Option
D
B
B
D
D
B
A
Q.No
8
9
10
11
12
13
14
Option
D
A
B
D
A
A
B
Page 19 of 45
18
10/30/2011
NC,CNC&Robotics
WhatisNC/CNC?
y NC is an acronym for Numerical Control and CNC is an
BySKMondal
WhatisthedifferencebetweenNCandCNC?
WhatisthedifferencebetweenNCandCNC?
capability.
y The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
cards
y As the technology evolved, the machines were equiped
with increasingly powerful microprocessors (computers)
with the addition of these computers, NC machines
become CNC machines.
y CNC machines have far more capability than their
predecessor.
contd..
DoallmachinesspeakthesameCNC
language
WheredidCNCgetstarted?
cards.
Page 20 of 45
10/30/2011
WhatisaConversationalControl
AreCNCmachinesfasterthan
conventionalmachines?
operator/programmer
use
simple
descriptive
AreCNCmachinesmoreaccurate
thanconventionalmachines?
NC/CNCMachinesAdvantages
y High Repeatability and Precision e.g. Aircraft parts
y Volume of production is very high
who
h is
i running
i the
th machine,
hi
how
h
well
ll the
th machines
hi
has
h
been maintained, quality of setup and so on.
Turbines
y Flexibility in job change, automatic tool settings, less
scrap
y More safe, higher productivity, better quality
y Less paper work, faster prototype production, reduction
in lead times
NC/CNCMachinesDisadvantages
y Costlysetup,skilledoperators
y Computers,programmingknowledgerequired
y Maintenanceisdifficult
NC/CNC/DNC
y Direct Numerical Control is a system that uses a
Page 21 of 45
10/30/2011
Directnumericalcontrol
DNC
13
14
BasicCNCPrinciples
StepperMotor
y The stepper motor is special type of synchronous motor
BasicLengthUnit(BLU)
y In NC machine, the displacement length per one pulse
Page 22 of 45
10/30/2011
Example
IES2011Conventional
2.
3.
StatementforLinkedAnswersquestions:S1
In the feed drive of a PointtoPoint open loop CNC
drive, a stepper motor rotating at 200 steps/rev drives a
table through a gear box and lead screwnut mechanism
(pitch = 4 mm, number of starts = 1).
Output rotational speed
The gear ratio = Input rotational speed is given by U = 14
The stepper motor (driven by voltage pulses from a pulse
generator) executes 1 step/pulse of the pulse generator.
The frequency of the pulse train from the pulse
generator is f = 10,000 pulses per minute.
ControlSystemspossibleinCNCMachine
y Point to point mode:
Page 23 of 45
10/30/2011
Pointtopointstraightlinemode
Coordinatesystem
y All the machine tool use Cartesian Coordinate system.
y The first axis to be identified is the Z axis, This is
Righthandcoordinatesystems
Page 24 of 45
10/30/2011
5axesCNCverticalaxismachiningcentreconfiguration
Thefollowingarethestepstobefollowed
whiledevelopingtheCNCpartprograms.
y Processplanning
y Axesselection
y Toolselection
y Cuttingprocessparametersplanning
y Jobandtoolsetupplanning
y Machiningpathplanning
y Partprogramwriting
y Partprogramproving
Page 25 of 45
10/30/2011
CNCprogramming
PartProgramming
Importantthingstoknow:
y FANUCCONTROLL
CoordinateSystem
y SIEMENSCONTROLL
Units,incrementalorabsolutepositioning
Coordinates:X,Y,Z,RX,RY,RZ
Feedrateandspindlespeed
CoolantControl:On/Off,Flood,Mist
ToolControl:Toolandtoolparameters
TableofImportantGcodes
ProgrammingKeyLetters
y O Programnumber(Usedforprogramidentification)
Code
Meaning
Format
G00
RapidTransverse
N__G00X___Y___Z___
y N Sequencenumber(Usedforlineidentification)
G01
LinearInterpolation
N__G01X___Y___Z___F___
y G Preparatoryfunction
G02
CircularInterpolation,
CW
N__G02X__Y__Z___R___F___
G
G03
CircularInterpolation,
C
l
l
CCW
N G X___Y___Z__R__F___
N__G03
X
Y
Z R F
G04
Dwell
y D Toolradiusoffsetdesignation
G17
G18
XY Plane
XZPlane
y T ToolDesignation
G19
YZPlane
y X Xaxisdesignation
y Y Yaxisdesignation
g
y Z Zaxisdesignation
y R Radiusdesignation
y F Feedratedesignation
y S Spindlespeeddesignation
y H Toollengthoffsetdesignation
y M Miscellaneousfunction
TableofImportantGcodes
Code
Meaning
Format
G20/G70 InchUnit
G21/G71
MetricUnit
G28
AutomaticReturntoReference
Point
Cuttercompensationcancel
N__G02X___Y__Z__I___J__K__F__
N__G03 X__Y__Z__I__J__K__F__
N__G04P___
TableofImportantGcodes
Code Meaning
Format
G44
Toollengthcompensation N__G44H__
(minus)
G49
Toollengthcompensation
cancel
C
y
Cancelcannedcycles
Cuttercompensationleft
N__G41D__
G
G80
G81
G42
Cuttercompensationright
N__G42D__
G90
Absolutepositioning
G91
Incrementalpositioning
G43
Toollengthcompensation
(plus)
N__G43H__
G92
Absolutepreset,changethe N__G92X__Y__Z__
datumposition
G40
G41
Drillingcycle
N__G81Z__R__F__
Page 26 of 45
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Rapidtraverse:G00
Linearinterpolation:G01
y G01:
y G00:
y linearinterpolationatfeedspeed.
y tomakethemachinemoveatmaximumspeed.
G91G0lX200.0Y100.0F200.0
y Itisusedforpositioningmotion.
G90G00X20.0Y10.0
G90G00X20 0Y10 0
End
G90:
absolute
coordinates
G91:
incremental
coordinates
(20,10)
End
100.0
(10,10)
(0,0)
Start
200.0
Start
Circularinterpolation:G02,G03
Circularinterpolation:G02,G03
y G02,G03:
y Forcircularinterpolation,thetooldestinationandthecircle
centerareprogrammedinoneblock
y G02isclockwiseinterpolation,G03iscounterclockwise
interpolation
G 02
R
G17
X __ Y __
G 03
I __
G 02
R
G18
X __ Z __
G 03
I __
F __;
J __
F __;
K __
G 02
R
G19
Y __ Z __
G 03
J __
F __;
K __
End
point
Start
Center
Circularinterpolation:G02,G03
G92:
Todefineworking
coordinate
Or
distancefromthestartof
thearc;
h
Start
>180 R
R=50mm
N0010G92X200.0Y40.0Z0;
N0020G90G03X140.0Y100.0I60.0F300
N0030G02X120.0Y60.0I 50.0
y I,J,Karetheincremental
SpecifyRwith
signbeforeit:
G91G02X60.0Y20.0R50.0 F300.0
G91G02X60.0Y20.0R50.0 F300.0
Circlecenter,radius
y SpecifyCenterwithI,J,K
End
End
180 +R
Circularinterpolation:G02,G03
Y
R=-50mm
N0010G92X200.0Y40.0Z0
N0010G92X200
0Y40 0Z0
N0020G90G03X140.0Y100.0R60.0F300
N0030G02X120.0Y60.0R50.0
y Viewingthestartofarcas
theorigin,I,J,Khave
positiveornegativesigns.
G90:
absolute
coordinates
Y
100
60
40
R50
R60
X
90 120 140
200
Page 27 of 45
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Circularinterpolation:G02,G03
ToolCompensation
AnnotationforCircularInterpolation
y ToolRadiusCompensation
y I0.0,J0.0,andK0.0canbeomitted.
y LefthandG41
y IfX,Y,Zareallomittedintheprogram,thatmeans
y RighthandG42
startandendofarcaresamepoints.
startandendofarcaresamepoints
y CanceltoolradiuscompensationG40
C
l l di
i G
N0020G02I20.0(afullcircle)
y ToolHeightCompensation
y IfI,J,K,andRallappearsincircularinterpolation
y PositiveG43
instruction,RisvalidandI,J,andKareinvalid
y NegativeG44
y CanceltoolheightcompensationG49
ToolRadiusCompensation
CancelToolCompensation:G40
y Toolradiuscompensationsmakeitpossibleto
programdirectlyfromthedrawing,andthuseliminate
thetooloffsetcalculation
y Notethedifferencebetweentwoways
G41(G42)D
N0060G01 X2.000Y1.700
N0070G40
7
4 M02
N0060G40G01 X2.000Y1.700M02
y D:theradiusoftooltocompensateissavedinamemoryunitthat
D th di ft lt
t i
di
itth t
isnamedD
y G41/G42isdirectlyrelatedwithdirectionoftoolmovementand
whichsideofpartiscut.
rampoffblock
ToolHeightCompensation
effectivetotheendpoint
ToolHeightCompensation
y Example:
G43(G44)H
y N0010G91G00X12.0Y80.0
y H:specifiedmemoryunitusedtosaveheight
y N0020G44Z32.0H02
compensationoftool.
y Positivecompensation(G43):
G91:
incremental
coordinates
y Ifweput0.5mmintoH02,
realposition=specifiedposition+valuesavedinH
y realposition=32.0 0.5=32.5
y Negativecompensation(G44):
realposition=specifiedposition valuesavedinH
y Canceltoolheightcompensation:G49
Page 28 of 45
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TableofImportantMcodes
y M00Programstop
Rulesforprogramming
Block Format
y M01Optionalprogramstop
y M03Spindleonclockwise
y M04Spindleoncounterclockwise
Sample Block
Restrictions on CNC blocks
Each may contain only one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feed rate
Each may contain only one specified tool or spindle speed
The block numbers should be sequential
Both the program start flag and the program number must be
independent of all other commands (on separate lines)
The data within a block should follow the sequence shown
in the above sample block
y M05Spindlestop
y M06Toolchange
y M08Coolanton
y M09Coolantoff
y M10Clampson
y M11Clampsoff
y M02orM30Programstop,resettostart
ToolHome
ExampleofCNCProgramming
Top
View
y WhatMustBeDoneToDrillAHoleOnACNC
VerticalMillingMachine
g
1.)X&YRapidToHolePosition
Front
View
Top
View
2.)ZAxisRapidMove
JustAboveHole
3.)TurnOnCoolant
Top
View
5
5.)ZAxisFeedMoveto
DrillHole
4.)TurnOnSpindle
)
O
i dl
Front
View
.100
Front
View
Page 29 of 45
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10/30/2011
Top
View
6.)RapidZAxisMove
OutOfHole
Front
View
Front
View
7.)TurnOffSpindle
8.)TurnOffCoolant
9.)X&YAxisRapid
MoveHome
Front
View
HeresTheCNCProgram!
Top
View
Top
View
ToolAtHome
ToolAtHome
O0001
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N025G00Z.1M09
N030G91G28X0Y0Z0
N035M30
Top
View
O0001
O0001
NumberAssignedtothisprogram
Front
View
ToolAtHome
Top
View
O0001
N005G54G90S600M03
N005
G54
G90
S600
M03
Front
View
Top
View
SequenceNumber
FixtureOffset
AbsoluteProgrammingMode
SpindleSpeedsetto600RPM
SpindleoninaClockwiseDirection
O0001
N005G54G90S600M03
N010G00X1.0Y1.0
G00
G
X1.0
Y1.0
R idM i
RapidMotion
XCoordinate1.0in.fromZero
YCoordinate1.0in.fromZero
Front
View
Page 30 of 45
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Top
View
Front
View
Top
View
Front
View
Top
View
Front
View
O0001
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
G43
H01
Z.1
M08
Top
View
ToolLengthCompensation
SpecifiesToollengthcompensation
ZCoordinate.1in.fromZero
FloodCoolantOn
O0001
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
N025G00Z.1M09
G00
Z.1
M09
Top
View
Front
View
RapidMotion
ZCoordinate.1in.fromZero
CoolantOff
O0001
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z
.75F3.5
N020G01Z.75F3.5
N025G00Z.1M09
N030G91G28X0Y0Z0
N035M30
M30
EndofProgram
Front
View
O0001
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
G01
Z.75
F3.5
StraightLineCuttingMotion
ZCoordinate.75 in.fromZero
FeedRatesetto3.5in/min.
O0001
N005G54G90S600M03
N010G00X1.0Y1.0
N015G43H01Z.1M08
N020G01Z.75F3.5
75 3 5
N025G00Z.1M09
N030G91G28X0Y0Z0
G91
IncrementalProgrammingMode
G28
ZeroReturnCommand
X0,Y0,Z0
X,Y,&ZCoordinatesatZero
APTLanguage
y APT (Automatically Programmed Tools)
y The APT language consists of many different types of
Page 31 of 45
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Words
y The words to be used in the statements are built up from
ThecompleteAPTpartprogramconsistsof
thefollowingfourtypesofstatements
y Geometry
y Motion
y Postprocessor
y Compilationcontrol
OtherPartProgrammingLanguages
APTLanguage
y
y
y
Additionalstatements:
MACHIN/DRILL, 2
COOLNT/
Forexample:
p
COOLNT/MIST COOLNT/FLOOD COOLNT/OF
FEDRAT/
SPINDL/
Forexample: SPINDL/ON SPINDL/1250, CCLW
TOOLNO/
TURRET/
END
76
Point (POINT)
APTLanguage
OthercapabilitiesofAPT,themacrofacility,withusevariableargumentasina
FORTRANsubroutine,forexample:
y
(3, 4, 5)
whenthedefinitionofthemacroDRILLis:
PTA
77
Page 32 of 45
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Point (POINT)
Point (POINT)
PTC
LIN2
LIN3
PTB
C1
LIN1
PTD
Point (POINT)
PTE = POINT/ YLARGE, INTOF, C1, C2
PTE = POINT/ XLARGE, INTOF, C1, C2
PTF = POINT/ YSMALL, INTOF, C1, C2
PTF = POINT/ XSMALL, INTOF, C1, C2
Point (POINT)
PT7 = POINT/ CENTER, C6
y
y
C1
C6
PTE
PT7
PTF
C2
Line (LINE)
Line (LINE)
LIN4 = LINE/ PT6, 15, -30, 3
y
y
PT6
P2
P1
L4
(15,30,3)
LIN1
x
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Line (LINE)
Line (LINE)
y
PT3
L14
L
P1
40
L12
PT1
L16
LINE1
30
PT4
LINE2=LINE/P1,ATANGL,30,LINE1
20
40
L15
15
(32,3,2)
Line (LINE)
Line (LINE)
LINE1
LINE1
LINE1=LINE/SLOPE,1,INTERC,XAXIS,6
LINE1=LINE/ATANGL,30,INTERC,d
=30
(6,0)PointofXIntercept
Line (LINE)
Line (LINE)
The LEFT & RIGHT modifier indicates whether the line
is at the left or right tangent point, depending on how
one looks at the circle from the point.
Right
PT40
L1
L1
Left
Left
C11
L4
PT51
PT51
Right
L2
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Line (LINE)
Line (LINE)
Left
C3
L6
Right
Right
L8
C4
L9
C3
L7
Left
L8
L9
L7
Line (LINE)
Line
LN5 = LINE/ INTOF, PLAN1, PLAN2
LN5
y
PNT6
PNT5
LN3
LN4
LN15
PLAN1
LN13
PLAN2
x
Plane (PLANE)
Plane (PLANE)
PLAN10
PT15
PT15
PT6
PT12
PT6
3.0
PT12
3.0
PT4
PT4
z
PLAN14
PLAN14
x
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Circle (CIRCLE)
Circle (CIRCLE)
C3 = CIRCLE/ CENTER, PT6, TANTO, LN4
C7 = CIRCLE/ CENTER, PT8, PT5
C1 = CIRCLE/ 3, 6, 5, 4.3
C1 = CIRCLE/ CENTER, PT3, RADIUS, 4.3
y
C1
LN4
PT5
4.3
PT3
(3,6,5)
PT6
PT8
C7
C3
Contouring:
Checksurface
Drivesurface
y
tool is riding.
y Drive surface: the surface against which the edge of
cutter
Directionof
cuttermotion
motion is to stop.
Partsurface
CS
CS
DS
GOLFT/
CS
DS
DS
GORGT/
GOUP/
TO
ON
PAST
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GOUP
GOLFT
GOFWD
FROM/PTARG
GO/TO,L1,TO,PL2,TOL3
GORGT/L3,PAST,L4
PL4
PL3
Present tool
position
GOBACK
GORGT
GODOWN
PL1
Previous
tool position
PL2
PTARG
(starting location of cutter)
Machining Specifications
Machining Specifications
FEDRAT/ : specifies the feed rate for moving the tool along the
part surface in inches per minute:
FEDRAT/ 4.5
SPINDL/ : gives the spindle rotation speed in revolutions per
minute:
SPINDL/ 850
COOLNT/ FLOOD
COOLNT/ OFF
TURRET/ 11
Machining Specifications
Machining Specifications
TOLERANCE SETTING: Nonlinear motion is accomplished in
straight-line segments, and INTOL/ and OUTTOL/ statements
dictate the number of straight-line segments to be generated.
INTOL/ 0.0015
CUTTER: specifies
p
a cutter diameter for offset ((rough
g versus finish
cutting). If a milling cutter is 0.5 in. in diameter and we have
OUTTOL/ 0.001
CUTTER/ 0.6
then the tool will be offset from the finish cut by 0.05 in.
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Machining Specifications
APTLanguage
OtherMotionstatements:
GO/{TO}, Drive surface, {TO} Part surface, {TO},
Check surface
Or
GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
Check surface
AndthesamewithPASTorONinsteadofTO
GOLFT/
GORGT/
GOUP/
GODOWN/
GOFWD/
GOBACK/
Forexample:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST, L1, TO, PS, TANTO, C1
110
IES2008
IES2007
40
30
110
20
L2
L3
135
20
C1
110
120
80
L1
20
100
P1
+ 40
P2
20
40
C2
L5
E
R40
L4
P
Material : M S.
8 mm
IES2006
R20
IES2011Conventional
State the method of defining line segment of
cutter motion using APT program format.
[5 Marks]
100 mm
80
50
60
200 mm
Material: MS
Thickness: 8.0 mm
Page 38 of 45
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Whatisanindustrialrobot?
Robotics
AdvantagesofRobots
DisadvantagesofRobots
WhatCanRobotsDo?
Asimov'sthreelawsofrobotics
IndustrialRobots
Material handling
Material transfer
Machine loading and/or unloading
Spot welding
Continuous arc welding
Spray coating
Assembly
Inspection
MaterialHandling
Manipulator
Assembly
Manipulator
SpotWelding
Manipulator
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Allrobotshavethefollowingbasiccomponents:
WristConfigurations
2.
3.
4.
5.
y Wristassemblyisattachedtoendofarm
y Endeffector isattachedtowristassembly
y Functionofwristassemblyistoorientendeffector
y Bodyandarmdeterminesglobalpositionofend
effector
y Twoorthreedegreesoffreedom:
y Roll
y Pitch
y Yaw
EndEffectors
GrippersandTools
y Thespecialtoolingforarobotthatenablesitto
performaspecifictask
y Twotypes:
y Grippers tograspandmanipulateobjects(e.g.,
parts)duringworkcycle
y Tools toperformaprocess,e.g.,spotwelding,spray
painting
DegreesofFreedom
DegreesofFreedom(contd.)
configuration.
y Each of the five basic motion configurations utilizes three
Page 40 of 45
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DegreesofFreedom(contd.)
The radial traverse: is the extension and retraction
RobotControlSystems
JointDriveSystems
y Limitedsequencecontrol pickandplace
operationsusingmechanicalstopstosetpositions
y Electric
y Useselectricmotorstoactuateindividualjoints
y Preferreddrivesystemintoday'srobots
y Hydraulic
y Useshydraulicpistonsandrotaryvaneactuators
y Notedfortheirhighpowerandliftcapacity
y Pneumatic
y Typicallylimitedtosmallerrobotsandsimplematerial
transferapplications
y Playbackwithpointtopointcontrol records
workcycleasasequenceofpoints,thenplaysback
thesequenceduringprogramexecution
y Playbackwithcontinuouspathcontrol
greatermemorycapacityand/orinterpolation
capabilitytoexecutepaths(inadditiontopoints)
y Intelligentcontrol exhibitsbehaviorthatmakes
itseemintelligent,e.g.,respondstosensorinputs,
makesdecisions,communicateswithhumans
WorkingEnvelope
RobotControlSystem
Joint1
Joint2
Cell
Supervisor
Level2
Controller
&Program
Level1
Joint3
Joint4
Joint5
Joint6
Sensors
Level0
Page 41 of 45
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RobotProgramming
RoboticArcWeldingCell
y Leadthrough programming
y Work cycle is taught to robot by moving the
y Robotperforms
fluxcoredarc
welding(FCAW)
operationatone
workstation
k
i
whilefitter
changespartsat
theother
workstation
Leadthrough ProgrammingAdvantages
Leadthrough Programming
y Advantages:
1. Poweredleadthrough
y Commonforpointto
pointrobots
y Usesteachpendant
2. Manualleadthrough
y Convenientfor
continuouspath
controlrobots
y Humanprogrammer
physicalmoves
manipulator
y Easilylearnedbyshoppersonnel
y Logicalwaytoteacharobot
y Nocomputerprogramming
y Disadvantages:
y Downtimeduringprogramming
y Limitedprogramminglogiccapability
y Notcompatiblewithsupervisorycontrol
CAD
CAM
Geometric Modeling
g
Engineering Analysis
Automated Drafting
ComputerAidedManufacturing(CAM):
y ComputerAidedProcessPlanning(CAPP)
y ComputerizedmaterialResourcePlanning(MRP)
y NCpartprogramming
y RobotProgramming
R b P
i
y ComputerizedScheduling
y Computerizedprocesscontrol
y ComputerizedManufacturingControlbyFMS
y Shopfloorcontrol
y ComputerAidedQualityControl(CAQC)
y ComputerAidedInspection
Page 42 of 45
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WhatisanFMS?
FMSComponents
FMSGoals
AdvantagesofFMS
y Faster, lower cost changes from one part to another
of workers
y Reduced
inventory,
y, due to the p
planning
g and
programming precision
y Consistent and better quality, due to the automated
control
y Lower cost/unit of output, due to the greater
productivity using the same number of workers
y Savings from the indirect labor, from reduced errors,
rework, repairs and rejects
DisadvantagesofFMS
y Limited ability to adapt to changes in product or product
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APT Program
MACHIN/ MILL
CLPRNT
UNITS/MM
P0 = POINT/ 0, 0, 3
P1 = POINT/ 1, 0
L1 = LINE/ P1, SLOPE, 0
L2 = LINE/ P1, SLOPE, 90
L3 = LINE/ PARLEL, L1, YLARGE, 2
L4 = LINE/ (POINT/ 4, 2), SLOPE, 1, L3
P3
L5 = LINE/ (POINT/ 6,
6 4),
4) ATANGL,
ATANGL 270,
270 L4
L4
L3
L5
P2
P4
L3
L2
P1
L6
L1
CUTTER/ 60
TOLER/ 0.1
SPINDL/ 200
COOLNT/ ON
P0
FEDRAT/ 20
APT Program
APTLanguage
Example:
FROM/ P0
GO/TO, L1, TO, PL, TO, L2
GOFWD/ P1, PAST, L3
GORGT/ L3, TO, P2
GOLFT/ P2, ON, P3
P3
L4
L3
L5
P2
P4
L2
COOLNT/ OFF
P1
L3
L6
L1
SPINDL/OFF
END
FINI
P0
148
APTLanguage
Answer:
APTLanguage
Example1:
FROM/SP
GO/TO, L1, TO, PS, ON, L6
GORGT/L1, PAST, L2
GORGT/L2, TANTO, C1
GOFWD/C1, TANTO, L3
GOFWD/L3, PAST, L4
GOLFT/L4, PAST, L5
GOLFT/L5, PAST, L6
GOLFT/L6, PAST, L1
GOTO/SP
149
150
Page 44 of 45
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APTLanguage
Answer:
APTLanguage
Example2:
APTLanguage
Answer:
152
ReferenceBook
y CAD/CAM:ComputerAidedDesignand
ManufacturingByGroover
FROM/SP
GO/TO, L1, TO, PS, ON, L4
GORGT/L1, PAST, L2
GOLFT/L2,
GOLFT/L2 PAST,
PAST L3
GOLFT/L3, PAST, C1
GOLFT/C1, PAST, L3
GOLFT/L3, PAST, L4
GOLFT/L4, PAST, L1
GOTO/SP
y CNCMachines ByB.S.Pabla,M.Adithan
y Machinetooldesignandnumericalcontrol By
Mehta
y ComputerControlOfManu.Systems ByKoren
153
Page 45 of 45
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