PEMP- AME501

Session 08

Computer Aided Manufacturing

Session Speaker Mr. Umesh S.
M S Ramaiah School of Advanced Studies

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Session Objectives j
On completion of this Session, the delegates would have understood about The aspects of Manufacturing Process Management
Computer Aided Manufacturing Computer Aided Production Engineering Computer p Aided Production Planning g Computer Aided Quality Assurance

Numerical Control Machines Programming for Numerical Control Machines

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Manufacturing g
Manufacturing is the use of machines, tools l and d labor l b to make k things hi for f use or sale. The term may refer to a range of human activity, from handicraft to high tech, , but is most commonly y applied pp to industrial production, in which raw materials are transformed into finished goods on a large scale.
http://en.wikipedia.org/wiki/Manufacturing

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Manufacturing g Process Management g

Tools required for proper execution of various aspects of mfg. process Computer Aided Manufacturing (CAM) CNC, DNC, Robot OLP, Tooling/Fixtures Production Engineering (CAPE) Process planning planning, Work instruction Production Planning (CAPP) Mfg. concepts, Layout, Line balancing, Process and Ergonomic simulation, Resources Quality Assurance (CAQ) FMEA SPC, FMEA, SPC CMM, CMM Tolerance Stack-up Stack up Costing (ABC) Communication (ERP, MOM, HMI, PDM, SCADA ) Documentation
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Process Planning g
To establish which process and parameters are to be used, as well as the machines performing these processes, in order to manufacture the component as per the design specification Raw Material Process Planning Finished Product

Raw material to be used Sequence of machining/assembly operations Processes and machines to be used for these operations Tools, cutting speeds and feeds to be used for this purpose D l methodology Develop th d l for f quality lit assurance
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Process Planning

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Shape and Size of the raw material (stock size) Identify datum Determine setups Identify and Group part features Identify machining operations based on features and accuracy Order/sequence of operation ( production/resource planning) Select tools for each operation Set cutting parameters for each operation Select/Design fixtures for each setup Work Instructions (dimensions related, set up instructions, machining parameters etc.) Plan Quality Assurance methodology and tools
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Computer p Aided Process Planning g

Stage I - Manual classification; standardized process plans Stage II - Computer maintained process plans Stage III - Variant CAPP Stage IV - Generative CAPP Stage V - Dynamic, generative CAPP

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Computer p Aided Process Planning g

Variant Approach:
Advance Manual Approach Utilise historical data stored in computers Database b of f process plans l for f family f il of f parts Identify the family to which the part belongs R ti Retrieve process plan l for f that th t family f il Edit this plan as necessary to suit the requirement For part of a ne new famil family, develop de elop process plan manually

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Computer p Aided Process Planning g

Generative Approach:
Process p plan g generated from Engineering g g Specifications (graphical and textual) Read specification directly from CAD Identify design features Accept information about material, tolerances etc. th through h input i t Accept information about raw material stock Transform the coded data and textual data into process plans
Need g good database and logic g for f system y to make a decision Dynamic, generative CAPP
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Computer p Aided Process Planning g

Process planning effort 58% Direct labor 10% Materials 4% Scrap 10% Tooling 12% W ki Work-in-process 6% Improved cost estimating procedures and fewer calculation errors More complete and detailed process plans Improved production scheduling and capacity utilization Improved ability to introduce new manufacturing technology and d rapidly idl update d process plans to utilize the improved technology
http://www.npd-solutions.com/capp.html

Reduced process planning and production leadtime; faster response to engineering changes Greater process plan consistency; access to up-todate information in a central database

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Computer p Aided Production Planning g

Manufacturing concept planning y layout y p planning g and analysis y Factory
work flow simulation. walk-path assembly planning plant design optimization

Mixed model line balancing Workloads on multiple stations Process simulation tools e.g. die press lines, manufacturing lines g simulation and assessment of production p assembly y Ergonomic tasks Resource planning
http://en.wikipedia.org/wiki/Manufacturing_process_management

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Computer p Aided Q Quality y

Failure Mode and Effects Analysis Statistical process control Coordinate-Measuring Machine Tolerance stack-up analysis
( p (http://www.npd-solutions.com/fmea.html) p )

http://www.qualityamerica.com http://www qualityamerica com /QAProducts/images/xbar.jpg

http://www.3dcs.com/

http://www.mel.nist.gov/gallery htt // l it / ll ph/cmt/pages/herbb.htm

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Co-ordinate Measuring g Machine

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Computer Aided C Aid d Manufacturing M f i (Machining)

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Machine Tool
A powered machine for cutting or shaping or finishing metals or other materials materials
http://wordnetweb.princeton.edu/perl/webwn?s=machine%20tool

The main function of a machine tool is to remove metal from a piece of work to give it the required shape and size This is accomplished by achieving proper relative motion between the work-piece (job) and the tool
Machining equipment that cuts, shears, punches, presses, drills, rolls, grinds, sands, or forms metal, plastic, or wood stock. Not included in this definition are hand hand-held held, portable power, power or manual tools. tools
http://www-group.slac.stanford.edu/esh/hazardous_activities/machine_guarding/p_definitions.htm

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Conventional Machine Tool

Fixing of the job (raw material) Motion of the tool Manual control of the tool movement
Operator skill dependent productivity and quality Low speeds p and feeds

Product complexity Manufacturing time Machine flexibility Downstream processes

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Computer p Aided Manufacturing g

To automate the actual Production process with least amount of human intervention Software used to generate the instruction codes for a CNC machine in order for it to cut out a shape designed in a CAD

Information for machining:

Shape to be machined Accuracy to be achieved Tool/Tools to be used Sequence of machining Spindle speed Direction of rotation Feed Rate Depth of cut Coolant flow

Automation Accuracy y Flexibility

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Numerical Control ( (NC) ) Machine

Weaving Machines Self playing pianos Copying machines (not Xerox) Pantographs 1940 John Parson (punched cards for drilling of multiple holes) 1951 Parson P C Corp. (C (Control t l System S t Development, D l t MIT servo Lab) L b) 1952 3-axis Cincinnati Hydrotel Milling machine (NC) NC is a system in which actions are controlled by direct insertion of numerical data (Part Program) at some point. The system must automatically interpret at least some portion of this data
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Numerical Control ( (NC) ) Machine

Automation Op. intervention Flexibility Accuracy Consistency Cost Utilisation Skill Maintenance Pre-planning

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Numerical Control ( (NC) ) Machine

Motion Control
Rotary (Servo Motors AC (cost)/DC (speed Var.)/Fluid (speed)) Linear
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Electric Drives
To drive the main spindle (Spindle drive) To T drive d i the h saddles ddl or carriage i (A i drive) (Axis di )
Large variation in cutting speed (10 m/min to 1000 m/min) Infinitely variable speeds between the upper and the lower limits -- electric (AC or DC) or fluid motors Direct Drive Drive through gear box or through cogged belts

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LM Guides and Ball Screws

http://news.thomasnet.com/images/large/548/548044.jpg

http://www.acorn-ind.co.uk/images/ball-screws.jpg

Reduce friction and wear Smoother movement

High Efficiency Reversibility Wear and Life No Stick Slip Rigidity (pre-loading)

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Numerical Control ( (NC) ) Machine

Reading the Part Program g and p process the p program g statements Decoding Convert the decoded information into control signals Receive and transmit feedback signals g Machine Control Unit (MCU) Data Processing Unit (DPU)
Input Stream Reader Date Reading Circuit Decoding g Circuit

Control Loop Unit (CLU)

Interpolator Position Control Loop Velocity/Acc. y Control Loop p Auxiliary Function Control
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Numerical Control (NC) Programming

NC

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Vacuum Tube/1st generation Solid State Technology Punched Tape input, no storage, processing one command at a time IC and Memory Technology, Part Program input stored, Exchange information between different units, PC style Controller (RAM, ROM, Comm ports, Display, HD, KB, Editors, Graphic input devices), Canned Subroutines in ROM Communiction and Networking Technology, Central computer controlling many machines simultaneously, simultaneously Retrieval of Part Programs and distribution of instructional blocks to NC machines Communiction and Networking g Technology, gy, Central computer p for Retrieval of Part Programs and its distribution to networked CNC machines

CNC

DirNC

DisNC

N-axis m/c Number of axes along which motion can be controlled simultaneously
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Numerical Control ( (NC) ) Machine

Axis Position # of pulses A i V Axis Velocity l it Pulse P l frequency f

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Numerical Control ( (NC) ) Machine

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Numerical Control ( (NC) ) Programming g g

Point i to Point i Systems: Positioning, Drilling/Tapping, Punching Contouring Systems: Milling, Turning, Flame cutting 2 2.5 3 4

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Controls for NC machines

Open p Loop p Control
no monitoring of the actual displacement of th machine the hi slide lid No comparison of actual and required q position Motor controlled solely b the by th program input i t

Closed Loop p Control

Slide position is regulated by the diff difference between b t the th actual and programmed position Actual position is constantly monitored and fed back for comparison Very high accuracy
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Feedback devices
Position Feed Back
continuous measurement of the position iti of f the th cutting tti tool edge relative to the datum point rotary or linear measuring transducers.

Velocity y Feed Back

Normally Tachogenerator is used

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Structural Requirements q
Normal weight distribution The higher cutting speeds and feeds in CNC machines result in rapid acceleration and deceleration of the slides and the machines are subjected to fluctuating and variable forces during the machining operations The machine structure should not bend due to the heavy cutting forces All the parts of the machine structure should remain in relative e at ve relationship e at o s p regardless ega d ess o of t the e magnitude ag tude a and d direction of the stresses developed due to these forces Another source of inaccuracy in the CNC machines is the thermal distortion of the machine structure
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Cause of Inaccuracy y in Machine tools

Dynamic Loading

Static Loading

Thermal Sources
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Safety y of Operator p
Safety of operator is very important aspect, aspect which cannot be overlooked To ensure safe working g conditions the CNC machine tools are provided with Perimeter Guards Pressure mats Light barriers Interlocks

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Machining g Centers
The latest developments in the CNC machine tools are the versatile machining center. This is a single machine capable of doing a number of operations such as drilling, reaming, tapping, milling and boring. All types of f tools l are mounted d on a drum/chain d / h i or egg box type magazine, which are put into the spindle by Automatic Tool Changer (ATC) under the control of Tool Selection Instruction

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Tool Turrets

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NC Programming g g
Define Geometry of part and motion of tool with respect to the work piece

Preparatory Information: Units, Positioning method Coordinates (X,Y, Z, RX, RY, RZ) Tool/Tools to be used Spindle Speed Feed Rate Spindle On/Off Coolant On/Off Tool Control Miscellaneous
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NC Programming g g
Reference System: Right Handed Cartesian Coordinate System Y Z X Z-X plane

X Y Z Y-Z plane Z X Y
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NC Programming g g

Z-Axis:
Part Rotating Spindle Axis/Direction of Rotation Tool oo Rotating otat g Tool oo Axis/Away s/ way from o the t e workpiece wo p ece

X-Axis:
Part Rotating g Moves tool away y from the p part Tool Rotating To Right when moving along Z-axis facing the m/c
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NC Programming g g
(2,3) (-2 ( 2,1) 1) (1,-1) (-1,-3) (1,-4) (-4 ( 4,-2) 2) (2,2) (2,3)

Absolute Positioning

Relative Positioning
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NC Programming g g
Programming Syntax:
Instructions I t ti as a sequence of f Blocks Bl k containing t i i commands to set machine parameters A block is a line of words Each block is composed of several Commands Each command has an identifying Letter followed by an associated Number
N30 G01 Z-0.125 F5 N35 X3 Y2 F10
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NC Programming g g
Letter Codes
Each instruction to the machine consists of a letter followed by y a number. Each letter is associated with a specific t type of f action ti or piece i of f information i f ti needed by the machine.

Letters used in Codes N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M

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Letter Action association:

Sequence Number (N):

NC Programming g g
Block identifier (index)

Preparatory P t command d (G): (G) Cutter C tt motion/positioning ti / iti i * Dimension words (X,Y,Z,..): Location and orientation of cutter (BLU) Feed Command ( (F): ) Speed Command (S): Tool Select Command (T): Misc. Command (M): Circle Center (I,J,K): Retract/Radius (R): Dwell Command (P): % :XXXX Cutter Feed Rate ( (units) ) Spindle Speed (rpm) Tool selection from turret/tool changer Spindle On/Off, Coolant On/Off Center of a Circle Retract Distance/Radius (G dependent) Dwell Time (With G code) Program Start Flag Program Identifier
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G&M Code Sample File 41

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Block Formats:

NC Programming g g
Change Codes used to indicate changes in a block Modified Fixed block length, TAB key separates each word word, EOB character used Each word is preceded by a letter identifying the word type, followed by a number specifying content

Fixed Sequential: q Fixed block length, g contains same no. of words Block Address: Tab Sequential:

Word Address:

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Part Programming g g
Manual Part Programming:
Generate machining information in blocks based on the planned machining process using a Part Program Manuscript Tedious Involves l arithmetic ih i and d trigonometric i i calculations l l i Prone to mistakes

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Computer Assisted Part Programming:

Part Programming g g

Use high level programming languages to define part geometry and tool motions Identify part geometry, general cutter motions, feeds, speeds and d cutter parameters Code part geometry, cutter motions, and machine instructions using programming language (source) Compile the source to produce machine independent list of cutter movement and and auxiliary machine control information (Cutter Location Data File) Post-process CL Data File to generate machine control data for a particular machine (customisation)
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Automatically Programmed Tool (APT):

Part Name and specific Post-Processor Post Processor

Part Programming g g

Definition of Geometry relevant to machining Motion Statement (location) Motion Statement (surface) Additional APT Statements
Symbol = Geometry Word/Descriptive Data L1 = LINE/X1,Y1,Z1,X2,Y2,Z2 L2 = LINE/P1,P2 P1 = POINT/CENTER,C1
FROM/point_location FROM/point location TO/point_location GODLTA/x, y,z GO/{TO},Drive Surface,{TO}, Part Surface {TO}, Check Surface PAST, TANTO, ON GOLFT GORGT,GOUP, GOLFT, GORGT GOUP GODOWN, GODOWN GOFWD GOFWD, GOBACK

MACHIN/DRILL,2 COOLNT/{MIST/FLOOD/OFF} FEDRAT, SPINDL, TOOLNO, TURRET INTOL, OUTTOL MACRO CALLS

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Other Part Programming Languages:

ADAPT:

Part Programming g g
Adaptation p of APT for PCs, modular structure Single Axis Positioning & Simple Contouring in 2D and 3D Popular for positioning tasks (drilling) Combined with ADAPT Adapted APT for use in Europe Three versions P to P, turning, 3D contouring Language used is English-like and similar to machine shop terminology
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AUTOSPOT: EXPAT: COMPACT:

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Part Programming from CAD:

Part Programming g g

Utilise the part geometry data already in digital form in CAD

CAD/CAM Better Accuracy Faster Development Less prone to Errors Less chances of model discrepancy
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Approach to Part Programming from CAD:

Part Programming g g

Identify and isolate the part of the geometry requiring machining Edit/Add geometry to define boundary for tools Define Tool Geometry (library) Identify the desired sequence of machining operations and plan l the h required i d tool l path h and d cutting i parameters Calculate coordinates of the points on the path (keep it low) Graphically verify the generated path and correct if necessary Create Cutter Location data file Post-process CL data file to create Machine Code data file
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Tool Path Generation Considerations:

Part Programming g g

Rough Cut (Casting)/Rough Cut (Block) Finish Cut (contour, (contour lace, lace parallel planes) Cutter Contact (CC) Point Cutter C tt L Location ti (CL) Point P i t Gouging G i
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Tool Path Simulation and Verification:

Wood W d Models

Part Programming g g
Display cutter trajectory superimposed on geometry

Material to be removed is removed Cutter does not hit clamps or fixtures Cutter C d does not pass through h h the h fl floor, sides id or ribs ib path is efficient Cutter p
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MPM Resources
Dassault Systems (Delmia/Deneb) UGS (Tecnomatix) (T ti ) PTC IBM Surfware (SURFCAM) Autodesk Delcam (Powermill) Notixia Proplanner

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Session Summary y
The aspects p of Manufacturing g Process Management g were described and explained Application of Computer based tools in managing various aspects of MPM were described Brief history and working of Numerical Control machines were describe Methodology of programming for NC Machines was demonstrated

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