CAD/CAM

Introduction
Introduction to CAM
Here we will define the basic concepts and applications of conventional
numerical control. Modern NC systems rely heavily on computer technology.
.
What is Numerical Control
Numerical control is defined as a form of programmable automation in which
the process is controlled by numbers, letters, and symbols. In NC, the
numbers form a program of instructions designed for a particular work part or
job. It is much easier to write new programs than to make major changes in
the production equipment.
Usage of NC Technology
There is a wide variety of operations that can be done with the help of
NC technology. Examples include:
Milling, turning, sheet metal, inspection, Electrical discharge
machining, grinding, laser cutting, rapid prototyping, welding etc.

However, NC finds its principal applications in metal machining

processes. The machined workparts are designed in various sizes and
shapes, and most machined parts produced in industry today are made in
small to medium size batches. The suitability of NC for these kinds of
jobs is the reason for the tremendous growth of NC in metal working
industry.

Historical Background
Pioneering work of John T. Parsons in late 1940s: He conceived a method
of using punched cards containing coordinate positions data to
control the machine tool. The machine was directed to move in small
increments, thus generating the desire surface of an airfoil. Parsons
demonstrated his concept to U.S. Air Force, which subsequently
sponsored a series of research projects at the Servomechanisms Lab. of
the MIT.
The initial work at MIT involved the development of a prototype NC milling
machine, by retrofitting a conventional tracer mill with position
servomechanisms for the three machine tool axes.

Shortly after that the machine tool builders began initiating their own
development projects to introduce commercial NC units.

There was an additional research at MIT to design a part programming

language that could be used for controlling the NC machines. This work
resulted in APT language, which stands for Automatically Programmed
Tools. The objective of the APT research was to provide a means by which the
part programmer could communicate the machining instructions to the machine
tool in simple English like statements.

Basic Components of An NC System

1- Program of instructions
2- Controller unit, also called a machine control unit (MCU)
3- Machine tool or other controlled process
General relationship of the three components ?

1- Program of Instructions
It is the step by step set of instructions which tell the machine tool what to do.
Punched cards
Magnetic tape
Manual data input (MDI): used for relatively simple jobs
Direct numerical control (DNC)
Who prepares this program of instructions?

2- Control Unit
This consists of the electronics and hardware that read and interpret the
program of instructions and convert it into mechanical actions of the machine
tool. Typical elements include:
Tape reader
A data buffer
Signal output channels to the machine tool
Feedback channels for the machine tool
Sequence controls to coordinate the overall operation of the foregoing elements.

It should be noted that nearly all modern NC systems today are sold with a
microcomputer as the controller unit. This type of NC is called computer
numerical control CNC.

The tape reader is an electromechanical device for winding and reading the
punched tape containing the program of instructions. The data contained on the
tape are read into the data buffer.
The purpose of this device to store the input instructions in logical blocks of
information. A block of information usually represents one complete step in
the sequence of processing elements. For example one block may be the
data required to move the machine table to a certain position and drill a hole at
that location.
The signal output channels are connected to the servomotors and other
controls in the machine tool. Through these channels, the instructions are sent
to the machine tool from the controller unit. To make certain that the
instructions have been properly executed by the machine, feedback data are
sent back to the controller via the feedback channels. The most important
function of this return loop is to assure that the table and workpeiece have been
properly located with respect to the tool.
Sequence controls coordinate the activities of the other elements of the
controller unit. The tape reader is actuated to read data into the buffer from the
tape, signals are sent to and from the machine tool, and so on. These types of
operations must be synchronized and this is the function of the sequence
controls.

Control panel/Control console

This contains the dials and switches by which the machine operator runs the
NC system. It may also contain data displays to provide information to the
operator. Although NC system is an automatic system to load and unload the
machine, and to perform various other duties. To be able to discharge these
duties, the operator must be able to control the system, and this is done
through the control panel.
Direct programming

3- Machine Tool
The third basic component of an NC system is the machine tool or other
controlled process. It is the part of the NC system which performs useful work.
Machining operations
This consists of spindle, worktable, motors, controls necessary to drive the
Cutting tools, fixtures and other auxiliary equipment (tool changer, chillers,
coolant, hydraulic system, pneumatic system, touch probe, tool measurement
system)

NC Procedure
To utilize numerical control in manufacturing, the following steps must be
accomplished.
1- Process planning
2- Part programming
- Manual part programming
- Computer assisted part programming
3- Tape preparation
4- Tape verification
5- Production