Office: BN-Block, Level-3, Room-088

Office: BN-Block, Level-3, Room-088
Dr. HABEEB HATTAB HABEEB Office: BN-Block, Level-3, Room-088 Ext. No.: 7292 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

College Of Engineering Mechanical Department
University TENAGA National College Of Engineering Mechanical Department Lecture Note University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Computer Aided Manufacturing
CAM University TENAGA Nasional Lecturer: Dr. HABEEB ALANI University TENAGA Nasional Lecturer: Habeeb Al-Ani

Lecturer: Dr. HABEEB ALANI
Overview Computer Aided Manufacturing Defined Brainstorming Exercise CAM activities How It Works Summary Conclusion The segments of this program are as follows: Definition – so all participants understand what computer aided manufacturing is. Brainstorming – to stimulate all participants to think about how CAM can help their company Nuts and Bolts – the definitions of the tools used in CAM, to familiarize participants with system How It Works – A step-by-step description of how CAM is used in industry to improve efficiency A Real World Example – An example of a company using CAM, and how CAM has allowed them to be more competitive Summary of Presentation – a recap of the presentation University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

What is Computer Aided Manufacturing? It is “control of the manufacturing process by computers” involving the integration of CAD engineering data and the computerized equipment which manufactures the product. The Russell and Taylor textbook defines CAM as the “controlling of the manufacturing process” by what is essentially artificial intelligence – using programs and microprocessors to control machines so humans don’t have to. This controlling is made possible when the designs for products are created using computer software such as CAD, so the instructions for producing the product are in digital format. When the designs are created in CAD, they can then be downloaded to the computerized equipment, which in turn interprets the instructions and produces the product. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Other definitions: “Computer aided manufacturing concerns the use of algorithms for planning and controlling fabrication processes.” Computer aided manufacturing is “the use of computers for managing manufacturing processes.” The first definition is significant because it emphasizes the role that CAM plays in planning as well as controlling the process. While CAM might be more properly associated with the machinery that actually controls the production processes, its role in planning the fabrication process is central to the end-to-end process. The second definition points out the idea that CAM is the concept that computers manage the manufacturing process, in tasks that human operators previously preformed. This means that CAM can help the machinery to manage exceptions and non-conforming results, to free human operators for other tasks that require human intervention. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Using technology to produce Leveraging capital investments Increasing productivity through automation Decreasing lead time through programming and controlled machinery CAM allows companies to: Use technology to produce (utilize the gains that new technology can bring to the process) Leverage capital investments (investing in technology can financial burden, but the efficiencies gained can more than offset the costs of new technology) Increase productivity through automation (move tasks that do not require human intelligence to an automated system – only problems that machinery cannot handle could be solved by workers, decreasing labor costs) Decrease lead time through programmatically controlled machinery (decreased tool and pattern change times can lead to dramatic decreases in turn-around times) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Brainstorming Exercise
How can CAM benefit your company? Integrate design and manufacturing Make mass customization possible Reduce costs Leverage computing power Automate manufacturing processes [Stimulate participants into creatively producing ideas that can help the organization.] Several ways in which CAM can benefit a production company include: Integrating design and manufacturing (tying the two departments together results in shorter lead times and better cooperation between departments) Making mass customization possible (machinery can instantly begin producing another product [from the same product family], making mass customization of products a viable option) Reducing costs (using CAM can decrease the amount of materials waste, thus reducing overall costs) Leveraging computing power (computers are more reliable and consistent than human workers and once a process has been established, they can produce incredible productivity gains) Automating the manufacturing process (creating automated factories that do not require human intervention saves human resource costs) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Identify benefits and costs of CAM: Direct Benefits Indirect Benefits Tangible Costs Intangible Costs [Intended to allow presenters to solicit comments from audience. Participants are encouraged to think of direct benefits (readily visible), indirect benefits (hidden or long-term), tangible costs (usually tied to a dollar figure), and intangible costs (costs that are difficult to identify and quantify).] University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

What processes in your company could be more efficient through CAM? [Soliciting responses.] University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CAM activities Essentially the collection of computer technologies used in manufacturing Computer Numerical Control (CNC) Direct Numerical Control (DNC) Flexible Manufacturing System (FMS) Robots Automated material Handling Systems CAM is a collection of automated technologies that will be discussed in later slides. This is an introduction to the acronyms. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CAM activities Computer Numerically Controlled (CNC) Machine that is controlled by computer Utilizes monitor and keyboard for operator interaction Facilitates greater control over quality Allows machine to monitor the maintenance of its parts Computer Numerically Controlled machines (CNC’s) are similar to Numerically Controlled machines (NC’s) and are replacing them in manufacturing lineups. NC’s were machinery that were controlled with punch cards that were encoded with the instructions needed to produce the product. CNC’s take the automation a step further by using microprocessors to control the production process. This, in turn, enables management to have greater control over the quality and consistency of the output, and also allows machinery to monitor the condition of its parts to reduce downtime. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CAM activities Direct Numerical Control (DNC) Each machine contains own microprocessor Entire bank of machines controlled by a single central computer If used with automated material handling, considered to be a flexible manufacturing system Direct Numerical Controlled machines (DNC’s) are essentially a ‘bank’ of CNC’s controlled by a central processing point, enabling the machines to cooperatively work to finish tasks. If DNC’s are implemented with an automated material handling system (such as a conveyor belt and robot arm ‘pickers’), then the process is defined as a Flexible Manufacturing System (FMS). University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CAM activities Direct Numerical Control (DNC)
Direct Numerical Controlled machines (DNC’s) are essentially a ‘bank’ of CNC’s controlled by a central processing point, enabling the machines to cooperatively work to finish tasks. If DNC’s are implemented with an automated material handling system (such as a conveyor belt and robot arm ‘pickers’), then the process is defined as a Flexible Manufacturing System (FMS).

CAM activities Flexible Manufacturing System (FMS) Numerous computer-controlled machines fed by automated material handling system Allows for broad and deep product mix Minimal setup times enable small lot sizes Flexible Manufacturing Systems (FMS’s) utilize the gains realized by automating a large degree of the production process. A FMS uses DNC’s, which work as a unit, and feeds the raw materials into the machines using automated material handling systems. This allows the production process to rapidly complete small varied orders, as well as re-tool quickly when a different product is to be fabricated. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CAM activities Robots Mechanical manipulators that can be accessed with programming method Consistent, repetitive-motion tolerant Ideal for tasks that are hazardous to humans Robots are mechanical manipulators that are controlled using a programmatic interface. More simply, this means that the robotic appendages can be programmed to pick up and process the raw materials, with a remarkable degree of accuracy and consistency. Robots are ideal in environment that could potentially be hazardous to humans, such as contaminated waste areas or in tasks that could eventually ‘wear out’ human workers. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CAM activities Automated Materials Handling System System where raw materials are automatically fed into machines Examples: Conveyor belts Automated Guided Vehicles (AGV) Automated Storage and Retrieval Systems (ASRS) Automated Materials Handling Systems are the situation where materials are automatically loaded into process machines without human intervention. When combined with computer numerically controlled machinery, it comprises a flexible manufacturing system. Examples of automated materials handling systems are conveyor belts (or gravity-driven ramps), automated guided vehicles (AGV’s – cars that drive along predefined paths), and automated storage and retrieval systems (ASRS’s – systems in which an entire warehouse of inventory is managed and ‘pulled’ by intelligent machines). University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

How It Works Product is conceived by engineer Product is designed using CAD software CAD data is transferred to manufacturing machine’s memory Machine uses the CAD data to produce the product, with little human intervention The steps of computer aided manufacturing: The product is conceived by an engineer (or product development group) The product is designed with computer aided design software (requirements and specification are converted to digital format) The CAD data is transferred to the manufacturing machine’s memory (downloaded through the company computer network) The machine uses the CAD data to product the product (automated production process without the need of human intervention) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

How It Works Old System (without CAM) Product is designed with CAD software Each production machine is programmed individually OR – if not automated : Employees are trained on proper production of the product The ‘old’ way to producing is with numerically controlled machinery, in which punch cards are loaded into each machine and every machine works individually. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

How It Works New System (using CAM) Product is designed with CAD software Product specifications are sent over the plant network to each machine Machines have ‘intelligence’ to produce the products without human intervention With the new system of producing (using CAM) the product is designed and the production plans are transmitted in a digital format, enabling performance and efficiency gains. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CAM solution: Enables faster turnaround of new products Reduces waste by using raw materials more efficiently Generates costs based on design specifications With CAM, C D Ward and Associates has realized the following benefits: Faster turnaround of new products (getting new fashions to market faster makes the company an industry leader) Reduces waste by using raw materials more efficiently (the computers calculate and most efficient use of the fabric to ensure that waste is minimized) Generates costs based on design specifications (allows for a more accurate representation of costs of manufacturing each product) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Summary Here’s what we’ve looked at so far…. Definition Brainstormed CAM activities How It Works CAM solution [Summary of the presentation] University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Conclusion CAM enables companies to leverage capital investment CAM allows for cost savings that can be passed on to the final consumer CAM utilizes human resources more efficiently to minimize labor costs Three areas to consider as you finish: CAM enables companies to leverage capital investments (invest in fixed costs that reduce variable costs) CAM allows for cost savings that can be passed on to the final consumer (lowered product cost allows company to compete at an advantage over competitors) CAM utilizes human resources more efficiently to minimize labor costs (using labor more efficiently allows company to reduce costs, with employees working more productively.) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Remember & remember X 1000 If you want to be part of a profession dedicated to quality and continuous improvement, consider CAM as your career of choice… References for materials used in this presentation. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI 25

THANK YOU References for materials used in this presentation. HABEEB University TENAGA Nasional Lecturer: Dr. HABEEB ALANI 26

CAM Systems & CNC Machine
University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

History John Parsons and US Air Force define a need to develop a machine tool capable of machining complex and close tolerance aircraft parts with the same quality time after time. MIT is the subcontractor and builds the machine for the project. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

History: Continued MIT announces Automatic Programmed Tools (APT) programming language Direct Numerical Control (DNC). This eliminates paper tape punch programs and allows programmers to send files directly to machine tools University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

History: Continued Kearney & Trecker machine tool builders market first machining center 1970’s - CNC machine tools & Distributed Numerical Control 1980’s - Graphics based CAM systems introduced. Unix and PC based systems available University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

History: Continued 1990’s - Price drop in CNC technology PC- Windows/NT based “Open Modular Architecture Control (OMAC)” systems introduced to replace “firmware” controllers. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Control Systems Open-Loop Control Stepper motor system
Current pulses sent from control unit to motor Each pulse results in a finite amount of revolution of the motor001” is possible

Control Systems Open-Loop Limitations Control unit “assumes” desired position is achieved No positioning compensation Typically, a lower torque motor Open-Loop Advantages Less complex, Less costly, and lower maintenance costs University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Control Systems Closed-Loop Control Variable DC motors - Servos
Positioning sensors -Resolvers Feedback to control unit Position information compared to target location Location errors corrected

Control Systems Closed-Loop Advantages DC motors have the ability to reverse instantly to adjust for position error Error compensation allows for greater positional accuracy (.0001”) DC motors have higher torque ranges.. stepper motors University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Control Systems Closed-loop limitations Cost University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Three Basic Categories of Motion Systems
Point to Point - No contouring capability Straight cut control - one axis motion at a time is controlled for machining Contouring - multiple axis’s controlled simultaneously University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Three Basic Categories of Motion Systems

CNC - NC Machine Tools Computer Numerical Control (CNC) - A numerical control system in which the data handling, control sequences, and response to input is determined by an on-board computer system at the machine tool. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CNC Advantages Increased Program storage capability at the machine tool Program editing at the machine tool Control systems upgrades possible Option -resident CAM system at machine tool Tool path verification University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Machining Centers Machine motion is programmable Servo motors drive feed mechanisms for tool axis’s Positioning feedback is provided by resolvers to the control system University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

NC Numerical Control (NC) - A control system which primarily processes numeric input. Limited programming capability at the machine tool. Limited logic beyond direct input. These types of systems are referred to as “hardwire controls” and were popular from the 1950’s to 1970’s. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Machining Centers A machining center can be defined as a machine tool capable of: Multiple operation and processes in a single set-up utilizing multiple axis Typically has an automatic mechanism to change tools University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Machining Centers Example - A turning center capable of OD turning, external treading, cross-hole drilling, engraving, and milling. All in machining is accomplished in one “set-up.” Machine may have multiple spindles. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Programming Methods-APT
Developed as a joint effort between the aerospace industry, MIT, and the US Airforce Still used today and accounts for about 5 -10% of all programming in the defense and aerospace industries University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Machining Centers University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Programming Methods Automatically Programmed Tools (APT) A text based system in which a programmer defines a series of lines, arcs, and points which define the overall part geometry locations. These features are then used to generate a cutter location (CL) file. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Requires excellent 3D visualization skills Capable of generating machine code for complicated part programs 5 axis machine tools University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Part definition P1=Point/12,20,0 C1=Circle/Center,P1,Radius,3 LN1=Line/C1. ATANGL,90 Cutter Commands TLRT,GORT/LN1.TANTO,C1 GOFWD/C1,TANTO,L5 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Programming Methods-CAM
Computer Aided Machining (CAM) Systems Graphic representation of the part PC based Integrated CAD/CAM functionality “Some” built-in expertise Speed & feed data based on material and tool specifications University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Tool & material libraries Tool path simulation Tool path editing Tool path optimization Cut time calculations for cost estimating University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Import / export capabilities to other systems Examples: Drawing Exchange Format (DXF) Initial Graphics Exchange Standard (IGES) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

The Process CAD to NC File
Start with graphic representation of part Direct input Import from external system Example DXF / IGES 2D or 3D scan Model (At this point you have a graphics file of your geometry) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Define cutter path by selecting geometry Contours Pockets Hole patterns Surfaces Volume to be removed (At this point the system knows what you want to cut) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Define cut parameters Tool information Type, Rpm, Feed Cut method Example - Pocket mill zig-zag, spiral, inside-out Rough and finish parameters (At this point the system knows how you want to cut the part) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Execute cutter simulation Visual representation of cutter motion Modify / delete cutter sequences (At this point the system has a “generic” cutter location (CL) file of the cut paths) University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Post Processing CL file to machine specific NC code Filters CL information and formats it into NC code based on machine specific parameters Work envelope Limits - feed rates, tool changer, rpm’s, etc. G & M function capabilities University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Output: NC Code Numerical Control (NC) Language A series of commands which “direct” the cutter motion and support systems of the machine tool. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Output: NC Code G-Codes (G00, G1, G02, G81) Coordinate data (X,Y,Z) Feed Function (F) Miscellaneous functions (M13) N - Program sequence number T - Tool call S - Spindle command University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Output: NC Code NC Program Example N01G90 G80 N03 GOO T12 M06 N05 GOO X0 Y0 Z.1 F10 S2500 M13 N07 G1Z-.5 N09 G02 X-10. I0J0F20 N13 X0Y10 N17 X10Y0 N19 X0Y-10 N21 X-10Y0 N23 M2 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Example of CNC Programming
What What Must Be Done To Drill A Hole On A CNC Vertical Milling Machine An example of creating a CNC program using a simple hole drilled on a computer numerical controlled (CNC) vertical milling machine. University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

1.) X & Y Rapid To Hole Position
Tool Home Top View 1.) X & Y Rapid To Hole Position In this case, we are using a simple analogy to stress how a programmer must be able to visualize a CNC program’s execution. We first look at how a machinist would machine a hole in a work piece held in a vise on a milling machine. Then we’ll show how the same operation will be performed with a CNC program. The machinist standing in front of the milling machine has everything they need right in front of them. They wouldn’t forget something as simple as turning the spindle on before trying to drill the hole. On the other hand, a CNC programmer must typically work with nothing more than a blueprint, a pencil, a calculator, and a blank piece of paper. They must be able to visualize every motion and function of the program’s execution in their minds. Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Top View 2.) Z Axis Rapid Move Just Above Hole 3.) Turn On Coolant 4.) Turn On Spindle .100” Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Top View 5.) Z Axis Feed Move to Drill Hole Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Top View 6.) Rapid Z Axis Move Out Of Hole Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Top View 7.) Turn Off Spindle 8.) Turn Off Coolant 9.) X&Y Axis Rapid Move Home Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Here’s The CNC Program! Tool At Home O0001 Top View N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09 Here is the same operation (drilling a hole) performed by a CNC program. Each step will be explained. N030 G91 G28 X0 Y0 Z0 Front View N035 M30 University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Tool At Home Top View O0001 O0001 Number Assigned to this program Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Tool At Home O0001 Top View N005 G54 G90 S600 M03 N005 Sequence Number G54 Fixture Offset G90 Absolute Programming Mode S600 Spindle Speed set to 600 RPM M03 Spindle on in a Clockwise Direction Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

O0001 Top View N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 G00 Rapid Motion X1.0 X Coordinate 1.0 in. from Zero Y1.0 Y Coordinate 1.0 in. from Zero Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

O0001 Top View N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 G43 Tool Length Compensation H01 Specifies Tool length compensation Z.1 Z Coordinate .1 in. from Zero M08 Flood Coolant On Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

O0001 Top View N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 G01 Straight Line Cutting Motion Z-.75 Z Coordinate -.75 in. from Zero F3.5 Feed Rate set to 3.5 in./min. Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

O0001 Top View N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09 Front View G00 Rapid Motion Z.1 Z Coordinate .1 in. from Zero M09 Coolant Off University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

O0001 N005 G54 G90 S600 M03 Top View N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09 N030 G91 G28 X0 Y0 Z0 G91 Incremental Programming Mode G28 Zero Return Command X0, Y0, Z0 X,Y,& Z Coordinates at Zero Front View University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

O0001 Top View N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N025 G00 Z.1 M09 N030 G91 G28 X0 Y0 Z0 Front View N035 M30 M30 End of Program University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Output: NC Code - Canned Cycles

CAD to NC Code University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Advantages of CNC Machine Tools
Ease of part duplication Flexibility Repeatability Quality control through process control University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Accommodates simple to complex parts geometry Improved part aesthetics Increased productivity Technology costs are decreasing University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

Reduced set-up time Reduced lead times Reduced inventory Better machine utilization Job advancement opportunities University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

CNC machine tools are more rigid than conventional machine tools $$$- Climb milling requires about % less horsepower vs. conventional cutting, but requires a ridged machine tool with no backlash Increased Rpm’s and feeds University TENAGA Nasional Lecturer: Dr. HABEEB ALANI

THANK YOU References for materials used in this presentation. HABEEB University TENAGA Nasional Lecturer: Dr. HABEEB ALANI 82

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