Computer Aided Manufacturing (CAM)

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 At the end of these lecture series on “CAM”,
you must be able to understand following
concepts:
1. Introduction
2. Economic aspects of NC Machines
3. Rapid Manufacturing
4. NC Part Programming

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 When capturing the machining steps of a
particular part in a programme, we call that
programme as the Part Programme.
 The control system reading and executing
the part programme is called the Controller.
 Both part programme and controller within
the machine tool give rise to automation
without the need of human operators.
 Part programming uses the NC (Numerical
Control) technology.
 What is NC? (A quick question)

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NC
computer numerical control is the automation
of machine tools by means of computer
executed pre-programmed sequences of
machine control commands.

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 Numerical Control may be defined as a form
of programmable automation from which a
manufacturing process is controlled by
numbers, letters, and symbols i.e.
alphanumeric data.
 Why do we need part programming,
controller, and NC technology?
 Part programming is control to be the turning
point in the material processing in terms of
its removal, addition, design intricacy, tight
tolerances which may not be achieved by
manual approach.

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 NC technology is based on controlling the
motion of the drives of machine tools and
the motion of cutting tool via part
programme.
 An NC part programme is a set of statements
or instructions which may be interpreted and
executed by machine controller that are
further converted into signals which move
the spindles and drives.

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NC has applications in metal cutting
,automatic drafting,
high removal is required
workpart require 100% inspection
NC technology is suitable to series of
machining process.

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Applications of NC Technology
 NC has found its ample applications in wide variety of
operations including;
1. Drafting (The process of
Providing drafts e.g. in dies Material
Addition/Non-
And molds) removal
1. Assembly i.e. Welding
2. Sheet metal press-working
3. Milling
4. Turning
Material
5. Drilling Removal
6. Grinding
7. Sawing
8. Boring
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 NC softwares are based on two modes;
1. Integrated
2. Standalone
 In case of integrated mode,

 Standalone NC software is considered to be

independent of a CAD/CAM system. These softwares
require pre-processing in terms of generating IGES or
STEP.
 Examples of standalone NC Softwares are as follows;
1. MASTERCAM
2. SURFCAM

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 Now, what is CNC?
 CNC stands for “Computer Numerical Control”
 Some CNC machines are as follows;
1. EDM Wire-Cut Machine
2. Turret punching press
3. Milling
4. Turning
5. Coordinate measuring machine
6. Rapid Manufacturing Equipment
7. Drilling
8. Boring
9. Grinding
10. Sawing
11. Welding (i.e. Material Addition Process)

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 What is the different between NC and CNC machines? [1]
 The main difference between NC and CNC is nothing but
the controller unit. In other words, the machine control
unit (MCU) for NC is simply a digital electronic circuit (not
the central processing unit) or hardwired NC machine
tools.

 CNC machines involves using minicomputers as MCU.

 With the advances in electronics and computers, high
performance microprocessors and programmable logic
controllers (PLCs) are also serving the purpose of
automating conventional manufacturing processes.
[1] http://www.prototypetoday.com/cnc machining/concept-
of-nc-and-cnc

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 In modern CNC Technology, the machine
control unit MCU consists of a microcomputer
and control hardware that stores the
program of commands and executes it by
converting each instruction into mechanical
actions of machine tool i.e. one command at
a time.
 The MCU also takes account of system
software, calculation algorithm, and
transition software to covert the NC parts
program into a usable format for the MCU.

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NC is superior to conventional manufacturing
processes in a number of ways;
 Parts can be produced in less time, so are
less expensive. The non productive time in
NC machine tools may be reduced in
following ways;
a) By reducing the no. of set ups
b) By reducing the set up time
c) By reducing work piece handling time
d) By reducing the tool changing time

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 Parts can be produced very accurately using NC
machines even for small batch production. In
conventional machining, the precision of parts is
largely determined by human skills.
 Operator involvement in the part manufacture is
reduced to minimum as a result. Operator is only
required to set up the tool and work.
 Since part programme takes care of the
geometry generated, the requirements for the
jigs and fixtures are greatly reduced depending
upon the part geometry.

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 Inspection time is reduced to a great extent,
since all the parts in the batch are similar
except few cares are taken in order to
compensate for tool wears in the part
programme preparation.
 The need for certain types of form tools are
completely eliminated in NC machine tools
because of generating the required geometry
via a part programme.
 Lead times are reduced to a greater extent
depending upon the part intricacy which
sometimes requires the fixtures.

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 CNC machining centres may perform a
number of machining operations which are
usually performed on various machine tools
(drilling, milling, grinding etc.). This results
ultimately in reduction in floor space and
production cost.
 Part processing times are highly reduced due
to significant reduction in the set up times
which is hard to achieve in case of
conventional machine tools.

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 Operator fatigue is totally vanished in the
part manufacture.
 Tools may be used at optimal feeds and
speeds which may be programmed.
 The modifications in the part programme can
easily be translated into the manufacturing
instruction with the help of part programme
without the need of changing requirement
for jigs, fixtures and tooling. This adds the
manufacturing flexibility in NC and CNC
machine tools.

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 The capability of NC machine tools (metal
removal) is comparatively high due to the
fair design of NC machine tool.

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 Economics of an NC machine tools address
various facets of NC machines when parts are
actually and continuously manufactured in
the NC machine shop.
 Although NC machine tools guarantee many
advantages, these machines may not be
prevented from having some disadvantages.
 Economics of NC machines deal with their
advantages and disadvantages as compared
to their counterparts such as conventional
machine tools.

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1. Higher Investment Cost
 Demanding high machine utilization (two or three
shifts per day) in order to get considerable monetary
returns
 NC machine tools are highly sophisticated and use
complex technology.
2. Higher Maintenance Cost
 Since NC machines are extensively used as compared
to ordinary machines, maintenance problem for these
kind of machines usually arise which must be planned
over certain period of time.
 Maintenance cost has been experienced to be higher
as compared to conventional machine tools.

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 It has been reported by the companies that
average percentage increase in NC maintenance
cost ranges from 48% for non-NC milling
machines to 63% for non-NC machining centres.
3. Training required for NC personnel
 Operations performed at NC machine requires
higher level of skills than that of traditional
operations.
 Part programming and NC maintenance staff are
two fields where availability of skilled personnel
has been found to be short.
 The problem finding, hiring, and imparting
training to the NC staff may be deemed to be a
disadvantage of NC machine tools.

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1. Non-productive time reduced
 NC machines ensure an increase in time for
which these machines are actually engaged to
perform a particular operation.
 NC machine achieves this by considering fewer
setups, less time required in setting up,
reduction in handling time for part, availability
of ATC (automatic tool change) on some
machines, so on.
 A comparison of the cycle time of machining a
part between NC and traditional machines,
reports that NC cycle time turns to be 65% of
the traditional presswork punching.

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2. Reduction in fixturing
 NC machines require simple fixtures
 These simple fixtures cost less than those of
intricate fixtures
 Positioning requirement is usually controlled by
the NC programme rather than a jig/fixture.
3. Reduction in manufacturing lead time
 Part to be processed are set up in a faster way
with NC and fewer setups are usually needed
resulting in a sharp reduction in lead time to
deliver a product to the consumers.
 According to a report, reduction in average lead
time range from 26% to 44% depending on the
type of machine tool.

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4. Manufacturing flexibility enhanced
 It seems to be easy to adapt to changes in the
engineering design, production schedule,
changeovers in the job for orders to be rushed,
and so on.
5. Quality control improved
 Human errors are expected to be higher when
intricate parts are machines. This problem is
fixed greatly when NC machines are utilized.
 With NC machines, part are produced with
greater accuracy, reduction in scrap, and lower
inspection needs.
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 As per a report, average reduction in scrap
from NC ranges from 31 to 44% depending on the
type of machine tool. Likewise, annual cost
savings in terms of decreasing the inspection
needs turn to be about 38%.
6. Inventory reduced
 A substantial reduction in inventory is achieved
with NC due to fewer setups and shorter lead
times.
 Floor space needs reduced
 As the production requirement from several
conventional machines is usually covered by NC
machine, the amount of floor space needed is
less as compared to conventional machine shop.

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 This is the extensions of Rapid Prototyping.
 What is a prototype?A prototype is an early sample,
model, or release of a product built to test a
concept or process.

 What is a model?
 A representation of a system that allows for
investigation of the properties of the system and,
in some cases, prediction of future outcomes.
Models are often used in quantitative analysis and
technical analysis, and sometimes also used in
fundamental analysis.
 What is the difference between prototype and
model?
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 Why do we prototype?
 The roles that prototypes play in the product
development process are several. They
include the following:
(1) Experimentation and learning
(2) Testing and proofing
(3) Communication and interaction
(4) Integration
(5) Scheduling

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 Rapid Prototyping (RP) Wheel

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 RP Systems

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Pre-Processing
 This is the essential working stage on geometric
model in .stl format accomplished on a
dedicated computer with software compatible to
RP system.
Processing
 This involves printing a geometric model at the
RP system e.g. 3D printer or FDM.
Post-Processing
 This step consists of removing useless material
from the prototype or model after getting the
model printed e.g. extra supporting material in
case of FDM and extra powder in case of 3D
Printer.

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 Powder Based::Binder Jetting::Z-510

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 Internal Components

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 Software Interface

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 Z-Edit

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 Powder is a substance named as Z-Powder.
 It is a mixture with following compositions;

 Our as IME students should be “Safety First”

 The potential hazards of this powder are as
follows;
 P.T.N.S (Please Turn to Next Slide)

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1. Eye Irritation
2. Intestinal Irritation i.e. Stomach
disturbances
3. Inhalation (it may result in chronic health
issues)
4. Skin (it may also result in chronic health
issues)
Emergency First Aid
Inhalation:
 Remove from area to fresh air. Seek medical
attention if respiratory irritation develops or
if breathing becomes difficult.
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Eye Contact:
 Immediately flush eyes with copious amounts
of water for at least 15 minutes. Call
physician if irritation continues.
Skin Contact:
 Immediately wash skin with soap and rinse
with large amounts of water. Remove and
wash contaminated clothing promptly.
 If skin has become cracked, take appropriate
action to prevent infection and promote
healing.
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 Minimum Ignition Energy (ASTM E 2019): 5kJ <MIE
<10kJ
 Dust Cloud Minimum Explosibile Concentration
(ASTM E 1515): N/A
 While working in the lab, you are required to
minimize unsafe manners or activities e.g.
smoking, eating, driking, staying in the lab when
there are fumes of powder in the air etc.
 So what should we do more to above for
minimizing unsafe activities?
 Ans:: Wear respirator, chemical safety goggles,
and chemical gloves.
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 Z-Binder is used to bind the powder in an
effort to develop a prototype or model.
 Z-binder is also a mixture with following
compositions;

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Emergency First Aid Measures
Eye Contact Exposure:
 Immediately flush eyes with copious amounts of
water for at least 15 minutes. Call a
 physician.
Skin Contact Exposure:
 Remove contaminated clothing, shoes, and
leather goods. Immediately wash with soap and
rinse with copious amounts of water.
Oral Exposure (Ingestion):
 Wash out mouth with water provided the person
is conscious and seek medical attention.

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 Potential Hazards are associated with Z-
Binders in terms of their prolonged exposure;
1. Skin
2. Respiration
3. Harmful if swallowed (It may affect crucial
human organs e.g. kidneys, liver, etc.)
 Prolonged exposure can cause: Nausea,
headache, and vomiting.

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 Z-Binders don’t catch fire due to significant
portion of water in the mixture of binders.

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 Solid
Based::Material Extrusions::Einstart-
C::FDM

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 What is a polymer?
 Polymeric materials may be divided to three broad
classes;
1. Thermoplastics
2. Thermosets
3. Elastomers

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 THERMOPLASTICS

AMORPHOUS SEMICRYSTALLINE

Polycarbonate Polyethylene

Polyphenylene Oxide Polypropylene

ABS Thermoplastic Polyester

Polystyrene Nylon

Polyetherimide Polyphenylene Sulphide

Acrylic Acetal

Polysulfone Poly-ether-ether-ketone

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 Poly(lactic acid) or polylactide (PLA) is a biodegradable thermoplastic
aliphatic polyester derived from renewable resources, such as corn
starch, tapioca roots, chips or starch, or sugarcane.
 Biodegradeable thermoplastics (of a substance or object) is capable of
being decomposed by bacteria or other living organisms and thereby
avoiding pollution
 Starch is an odourless, tasteless white substance occurring widely in
plant tissue and obtained chiefly from cereals and potatoes.
 It is a polysaccharide which functions as a carbohydrate store and is an
important constituent of the human diet.

PLA Filament Advantages:

 No contamination, tilt, easy to remove supporting parts.
 Suitable for high precision 3D models printing, you can get more model
details.
 The filament extrudes precisely for fast printing and consistent layering.
 Filament comes with a light spool in a sealed package with a bag of
desiccant.
 Appropriate stickiness, no first-layer problem.
 Colourful filaments can help you realize your ideal printing models.

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Emergency First Aid
Inhalation
 Heating PLA may produce vapours which can
cause irritation. Victim should be moved to fresh
air as an emergency first aid.
Skin Irritation
 No first aid is required in case of no irritation.
Otherwise, rinse the hands with plenty water in
case of irritation.
Eye Irritation
 No first aid is required in case of no irritation.
Vapours may cause eye irritation. Hence rinse
the eyes with plenty water in case of irritation.
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 Molten PLA may cause burns.
 Avoid generating PLA dust; fine dust
dispersed in air in sufficient concentrations,
and in the presence of an ignition source is a
potential dust explosion hazard.
 Oxides of carbon, aldehydes. May decompose
upon heating to produce corrosive and/or
toxic fumes.
 Avoid inhalation of material or combustion
by-products (e.g. oxides of carbon and
aldehydes).
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 Crucial Properties of PLA
1. Appearance Spool,string,strand
2. Physical State solid
3. Odor odorless,sweet,plastic
4. Color clear,translucent,opaque
5. Melting Point 150 - 180 °C
6. Autoignition 388 °C
7. Decomposition >250 °C
8. Density 1.25 g/cc

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