Escolar Documentos
Profissional Documentos
Cultura Documentos
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UNIT 6
OBJECTIVES
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INPUT
6.0 INTRODUCTION
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Two important points should be made about N.C. First, the actual N.C.
machine tool can do nothing more than it was capable of doing before a control
unit was joined to it. There are now new metal removing principles involved.
N.C. machines position and drive the cutting tools, but the same milling cutters,
drills, taps, feeds, and other tools still perform the cutting operations. Cutting
speeds, feeds, and tooling principles must still be adhered to. Given this
knowledge, what is the real advantage of numerical control?
Primarily, the idle time or time to move into position for new cuts is
limited only by the machine's capacity to respond. Because the machine receives
commands from the machine control unit (MCU), it responds without hesitation.
The actual utilisation rate or chip making rate is therefore much higher than on
a manually operated machine.
The second point is that numerical control machines can initiate nothing
on their own. The machine accepts and responds to commands from the control
unit. Even the control unit cannot think, judge, or reason. Without some input
medium, e.g., punched tape or direct computer link, the machine and control
F T ra n sf o F T ra n sf o
PD rm PD rm
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unit will do nothing. The N.C. Machine will perform only when the N.C. tape is
prepared and loaded and cycle start is initiated.
6.1. NC OPERATION
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Computer:
Input command,
Processing,
Output command
Limit switches
Position feedback
Drive signal
Work table
Lead screw
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Work table
Input Dc
Comparator DAC servomotor Gear
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Pipe bending
Metal spinning
6.2.3. Finishing
Plating
Painting
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The Y axis then makes the third motion and is the shorter primary
movement.
In addition to these primary linear axes, there is provision for Rotary
axes. They are designated A, B and C, with A rotary about the X axis, B rotary
about the Y axis, and C rotary about the Z axis.
It is often required to command a motion parallel to X, Y or Z axes within
the realm of a secondary motion, or a tertiary motion within special automatic
cycles such as describing the amount of finish allowance on a turned part, or to
describe the distance of advancement of a drill during a drilling cycle etc. etc.
Linear Axes X Y Z
Rotary Axes A B C
Secondary Linear U V W
Interpolation I J K
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spindle
rotation
table
z
x
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The CNC Machine Control Unit (MCU) has to read and decode the
part programme, and to provide the decoded instructions to the control
loops of the machine axes of motion, and to control the machine tool
operations.
F T ra n sf o F T ra n sf o
PD rm PD rm
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path and radius motion because the control interpolator has the ability to
move the axis drive motors at varying velocities.
The point-to-point controls were NC controls, while the continuous
path controls could be NC or CNC controls.
NOTE: NC is a general term used for Numerical Control and is also a term
used to describe controls that run directly off tape. CNC is a
specific term for Computer Numerical Control. CNC Machines are
all NC machines, but NC controlled machines are not CNC
machines.
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certain patterns and the pattern represents a value when read by the tape
reader on the MCU.
The pattern is a code in itself, and complies to a standard, either
E.I.A. ( Electronics Industries Association ) which uses an odd number of
holes or I.S.O. ( International Standards Organization ) which uses an
even number of holes for each character. The I.S.O. code is most
commonly used in Australia. The E.I.A. code is known as an odd parity
system, and the I.S.O. code as an even parity system.
One of the tracks of each is assigned as a parity track and a hole is
sometimes punched there automatically to maintain the parity. The
purpose of parity is to check during tape reading for errors caused by
unpunched holes, dirt or oil spots etc.
6.5.2. Computers
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- by typing the program directly into the memory of the M.C.U. through
the edit function.
- programmes produced in this way can include all functions available, are
stored in the machine ready for use at any time and can be output to a
punch unit or computer for external storage.
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NOTE: Where punched tape was once the only practical way for most
programmers to transfer (or load) their programs into the controls, it is
presently being overtaken by personal computers connected directly via
interface cable. Other popular and convenient methods are simply
through the edit mode or by interactive (conversational) programming.
Companies specialising in complex die work probably use DNC more often
now. Inputting through M.D.I. mode is common providing the restrictions
noted are adhered to.
6.6. NC PROGRAMMING
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6.6.2. Incremental
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In incremental mode all moves are with respect to the last position
reached.
N10 G91
Y N15 G01 X10.Y10.F300.
N20 Y10.
N25 X20.
40 N30 X10.Y20.
30 N35 X20-Y-30.
20 N40 X-10.Y-10.
10 N45 X-50.
X N50 M02
10 20 30 40 50 60
6.6.3. Absolute
The data in the absolute system describes the next location always
in terms of its relationship to the fixed zero point. The zero point when
used as a programme datum is known as the programme origin.
The G90 code sets the control up in absolute mode. All moves are
performed with respect to the axes zero.
F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
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N10 G90
Y
N15 G01X10.Y10.F300.
N20 Y20.
N25 X30.
40
N30 X40.Y40.
30
20
N35 X60.Y10.
N40 X50.Y0.
10
N45 X0.
10 20 30 40 50 60 N50 M02
Under this command the machine tool will move in a straight line
at a defined feed rate. Combined axis motions (angled moves) will be
executed at the programming feed rate as the control will reduce the
velocity of both axes accordingly.
NOTE: If a new line with G01 is listed again somewhere below, the F250 does
not have to be written again. This is called modal.
F T ra n sf o F T ra n sf o
PD rm PD rm
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Example:
%
10 70 10
10
G90 -
G01 X100 F300
Y70
X90. Y80
90
X20.
80
80
X10. Y90.
70
XO. Y80
Y0.
100
M02
G02 - Clockwise
G03 - Counterclockwise
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The centre of the arc is defined with respect to the start point in the I and
J words as an "increment" from this point.
For G02 and G03 to function the feed rate "F." must be specified.
Example:
N5%
N10 G90
N15 G01 Y110. F200.
N20 G02 X20. I10.
N25 G03 X30. Y100. I10. 110
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b) Block.-
A block or programme line is a set of instructions to the machine
that are carried out simultaneously. A block is made up of one or more
Words and is terminated by an End of Block which is the Line Feed
Character.
c) Word.
A word is a specific instruction to the machine that will affect a
particular machine function. Every word consists of a Letter Code and a
Numerical value.
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6.7.1. Program
(Start of Program)
(Material 25.mm. dia.)
(Grip 120.m.m. from Front of Jaws)
N01 G71G90G95
N02 G50X100.Z130.
N03 S2000M03
N09 X26.
N10 G00X100.Z130.T0100
N11 M02
WORD ADDRESS The letter at the beginning of each word is called the
address character.
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CNC mills, drills and machining centers are all equipped with cycles to
perform drilling, reaming, counter boring, boring and tapping operations. Some
others have pocketing cycles, slot cutting cycles, hole pattern cycles etc, all of
which are designed to save programming time and effort.
CNC lathes usually have cycles to cover drilling, grooving/parting, screw
cutting, repetitive cut (automatic roughing) operations and others. Each cycle
has its own G code to control the sequence of motions and an accompanying set
of words to define the parameters of those motions. These words have addresses
such as: R,P,Q,D,E,I,K,H,B etc.
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machine crash. Anyone who considers their programmes to be without error and
not in need of careful and conscientious trialing has an attitude problem and is
placing expensive machinery and operators safety at risk.
There may be many ways in which a programme can be checked for
errors, but a programme can only be proved 100% by running the machine and
producing a part.
Error checking can be performed in a variety of ways:
Verification: Read through the print-out (NOT the handwritten
manuscript) carefully - sometimes mistakes can be seen
easily.
Trialing: This involves the execution of the programme without
actually cutting the part and may be carried out in several
ways depending on the type of machine, or control, or even
the philosophy of the person in charge. Adhere to the later unless
you can put up good reasons for alteration.
Trialing usually consists of running the machinewith the single
block switch active, that is, each block will only be executed by
pressing cycle start, in conjunction with the programme
being displayed on the screen.
Quite often the dry run mode is switched on to hasten
Proceedings. 'Dry Run' results in all machine motion being
executed at a preset rate, usually in the region of 50% to 80%
of the rapid traverse capability of the machine. The actual axis
velocity can be overridden from 0% to 100%. The
disadvantage of dry running a programme is that feed rates will
be masked, and attention must be paid to determining the
actual programmed feed rate for each block. This may be
displayed on the screen.
F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
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There are two basic types of control systems in numerical control: point-
to-point and contouring.
a. In a point-to-point system, also called positioning, each axis of the
machine is driven separately by lead screws and, depending on the
type of operation, at different velocities. The machine moves initially
at maximum velocity in order to reduce non-productive time, but
decelerates as the tool approaches its numerically defined position.
Thus, in an operation such as drilling (or punching a hole), the
positioning and cutting take place sequentially (Fig. 5.4).
F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
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After the hole is drilled or punched, the tool retracts upward and
moves rapidly to another position, and the operation is repeated. The
path followed from one position to another is important in only one
respect. It must be chosen to minimize the time of travel, for better
efficiency. Point-to-point systems are used mainly in drilling,
punching, and straight milling operations.
15
10 45
C.P
15
(0,0)
10
1 2
4 3 45
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Cutter Machined
radius surface
Cutter
path
Work piece
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- modal codes remain active after being entered, unless they are cancelled
by another G code; and
- non-modal codes are only active in the programme block in which they
appear.
Sample G codes
GOO Rapid movement for position
GOI Linear interpolation used for straight-line feed
G02 Circular interpolation, clockwise
G03 Circular interpolartion, counterclockwise
G04 Dwell, a programmed stop to the tool movement
G17 Circular interpolation xy plane
G18 Circular interpolation xz plane
G19 Circular interpolation yz plane
G20 Inch units
G21 Millimetre units
G28 Return to home position
G29 Return from home position
G31 Reverses programmed direction of x axis
G32 Reverses programmed direction of y axis
G41 Tool radius compensation left
G42 Tool radius compensation right
G43 Tool length compensation-positive direction
G44 Tool length compensation-negative direction
F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
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6.9.2. M codes
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i. The component programming tape and the tape reader are used
once only when the programme is copied into the computer
memory, not only this practice wills same time but it will also
reduce errors.
ii. The programming tape can be edited on the shop floor, when the
machine is placed/located. Editing, correction and optimising; such
as machine tool operations, spindle speeds and speeds; are usually
done in the test run of the tape.
iii. Computer numerical control can easily changes into metric system
if the programme is in the imperial units.
iv. It is widely used in industry. It is easily adaptable in a
computerised industry system.
v. Increased flexibility – the machine can produce a specific part,
followed by other parts with different shapes, and at reduces cost.
vi. Greater accuracy – computers have a higher sampling rate and
faster operation.
F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y
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ACTIVITY 6
6.2. You are given a drawing of a component. List down the steps you would take to
operate a NC machine in order produce the component.
6.3. Write a short paragraph on three (3) basic components of a numerical control system.
F T ra n sf o F T ra n sf o
PD rm PD rm
Y Y
Y
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FEEDBACK ON ACTIVITY 6
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6.3.(a) Machine Tool - a device designed to cut away surplus material and leave
a component of the required shape and size. It holds the work piece, cutting tool
and moves the tool and work piece relative to one another precisely enough to
achieve accuracy of size and surface finish. It can also alter the spindle speed
and feed rates, tool changing, supply of coolant etc.
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(b) The Control Unit - reads, decodes the part programme and provides the
decoded instructions to the control loops of the machine axes of motion,
and to control the machine tool operations. There are three main parts of
the control unit namely, the Control Panel, the Tape Reader and the
Processors
(c) Control system - there are two types of control systems used on NC
machines - the point-to-point system and the continuous-path system.
The point-to-point systems operates only in straight lines, which are
suitable for positioning moves on a drilling machine or limited use on a
lathe or milling machine, where at best 45% cuts are possible with two
axes running continuous path controls allow angular path and radius
motion because the control interpolator has the ability to move the axis
drive motors at varying velocities. The point-to-point controls were NC
controls, while the continuous path controls could be NC or CNC controls.
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SELF-ASSESSMENT 6
1. Numerical control machine can be done in absolute coordinate (G90) and incremental
coordinates (G91). What is the difference between the two coordinates.
2. By using G90 and G 91 coordinates write a program to cut a component in is the .below
figure.
30
J20
70
35
20
60
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FEEDBACK OF SELF-ASSESSMENT 6
1. (a) G90 Absolute mode - The data in the absolute system describes the next
location always in terms of its relationship to the fixed zero point. The
zero point when used as a programme datum is known as the programme
origin. All moves are performed with respect to the axes zero.
2.
G 90 G 91
Point
X Y X Y
Origin Point 0 0 0 0
1 30 -70 30 -70
2 30 -40 0 30
3 70 -15 40 25
4 90 -35 20 -20
5 90 -70 0 -35
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