Winter term 00/01 Industrial Applications of Computers Computer Aided Manufacturing (CAM) Computer Numerical Control (CNC)

Winter term 00/01 CAM/DNC/CNC  Definitions:  CAM: Computer Aided Manufacturing. A computer- controlled manufacturing process. A system using a computer to control a process. Systems range from three-axis NC mills to full factory automation  DNC: Direct Numerical Control  CNC: Computer Numerical Control. The use of a dedicated computer as a control system for an NC machine

Winter term 00/01 CAD/CAM integration  The CAD model data generated during the design process can be utilized further by the Computer Aided Manufacturing process. A good CAD/CAM system eliminates the need to manually calculate tangencies or to do the trigonometry required to calculate tool paths, saving valuable programming time. It also provides a consistent finish and predictable results.

Winter term 00/01 How to integrate CAD/CAM (1) CAD ProgramCAM ProgramCNC Program DXF File NC File Computer Aided Design  Geometry of part is created (3D or 2D; surface or solid) Computer Aided Manufacturing  Program the part with G/M-codes Computer Numerical Control  Produce the part Milling Lathe Electric Discharge

Winter term 00/01 CAM How to integrate CAD/CAM (2) Plan Process Create CAD Drawing Select a layer Convert drawing to DXF Load DXF file Select a milling operation Generate tool path Enter cutting Parameters Start Select another layer? Save NC File List NC file (Optional) Verify NC Program Mill Part End CNC Planning CAD

Winter term 00/01 Machining Operations  Milling  Turning  Electrical Discharge Machining (EDM)

Winter term 00/01 CNC Machining Centers

Winter term 00/01 CNC Lathe 

Winter term 00/01 CNC Lathe  Price: from 215,610 Euro Driven tools for complex drilling and milling operations as well as a complete counter spindle for machining the work pieces counter sides.

Winter term 00/01 Application Examples (Turning) 

Winter term 00/01 EDM  The generic term EDM (Electrical Discharge Machining) can be applied to any machining process that uses an electrode to remove metal, or any other conductive material, from a work piece by generating sparks between conducting surfaces.  This is being performed in a dielectric fluid to prevent premature spark discharge.  Wire EDM uses a traveling wire electrode that passes through the work piece, the wire is, at all times, monitored by the machine’s internal computer system. This process can be seen as a very high precision band saw that can hold tolerances of +/

Winter term 00/01 Distinction Absolute/Incremental  Absolute measuring  one absolute coordinate system using (XYZ) location  P (-1/1); Q (2/-1)  Incremental measuring  from point to point  –3 left and 2 up  x= -3 / y= 2 P Q

Winter term 00/01 Variables in Machining Process  Cutting tools: type, size, and tool material lead to different feed rates and spindle speeds  Materials: lead to different feed rates and spindle speeds

Winter term 00/01 Variables in Machining Process Work Material Cutting Speeds in SFPM End MillsFly cuttersDrillsReamers HSSCarbideHSSCarbideHSSCarbideHSSCarbide Aluminum Cast iron Soft Hard Stainless Steel

Winter term 00/01 Milling Tools and Tool Inserts

Winter term 00/01 NC Programming Codes (G/M) - A Selection-  M-Codes (Miscellaneous Codes)  M00 Pause  M02 End of Program  M03 Spindle Motor on  M05 Spindle Motor off  M06 Tool Change  G-Codes  G00 Rapid traverse positioning  G01 Feedrate Movement Linear  G02 Feedrate Movement Circular clockwise  G03 Feedrate Movement Circular counterclockwise  G90 Absolute Coordinates  G91 Incremental Coordinates

Winter term 00/01 Milling Operations  Most of the following operations have special G-codes:  Facing: removes material across the top surface  Contouring: removes material to a specified depth along a CAD geometry  Drilling: uses points identified on a CAD layer to drill holes to a specified depth  Pocketing: removes all material within the outline of a CAD geometry  Surface of Revolution: removes all material within a surface generated by revolving geometry about the X or Y axis

Winter term 00/01 Leading CAM Software  Mastercam:  Unigraphics:  SmartCAM:  EZ-CAM:  Other Links:  Pro Engineer (