Ch-11 NC; CNC; DNC; FMS; Automation and Robotics_2.pdf

Production

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NC, CNC & Robotics What is NC/CNC?
 NC is an acronym for Numerical Control and CNC is an
acronym for Computer Numerical Control.
What is the difference between NC and CNC ?
 The difference between NC and CNC is one of age and
capability.
 The earliest NC machines performed limited functions
and movements controlled by punched tape or punch
cards.
 As the technology evolved, the machines were equiped
with increasingly powerful microprocessors (computers)
with the addition of these computers, NC machines
become CNC machines.
 CNC machines have far more capability than their
predecessor. contd…..
What is the difference between NC and CNC ?
 Some of the enhancements that came along with CNC
include: Canned Cycles, Sub Programming, Cutter
Compensation, Work coordinates, Coordinate system
rotation, automatic corner rounding, chamfering, and B-
spline interpolation.
Where did CNC get started?
 1940 Jhon Parson developed first machine able to drill
holes at specific coordinates programmed on punch
cards.
 1951 MIT developed servo-mechanism
 1952 MIT developed first NC machines for milling.
 1970 First CNC machinescame into picture
Now-a-day’s modified 1970’s machines are used.
Do all machines speak the same CNC
language
 No, while there is fairly standard set of G and M codes,
there is some variation in their application. For example
a G0 or G00 command is universally regarded as the
command for rapid travel. Some older machines do not
have a G00 command. On these machines, rapid travel is
commanded by using the F (feed) word address.
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What is a “Conversational Control”
 CNC machine tool builders offer an option what is
known as the conversational control. This control lets
the operator/programmer use simple descriptive
language to program the part. The control then
displayed a graphical representation of the instructions
so the operator/programmercan verify the tool path.
Are CNC machines faster than
conventional machines?
 Yes, No, Sometimes. When it comes to making a single,
simple part it is hard to beat a conventional mill or lathe.
CNC machines move faster in rapid travel than
conventional machines.
Are CNC machines more accurate
than conventional machines?
 Yes, they can be. But like anything else it depends on
who is running the machine, how well the machines has
been maintained, quality of setup and so on.
GATE - 1994
CNC machines are more accurate than conventional
machines because they have a high resolution
encoderand digital read-outs for positioning.
Trueor false?
NC/CNC Machines-Advantages
 High Repeatability and Precision e.g. Aircraftparts
 Volumeof production is very high
 Complex contours/surfaces need to be machined. E.g.
Turbines
 Flexibility in job change, automatic tool settings, less
scrap
 More safe, higher productivity, better quality
 Less paper work, faster prototype production, reduction
in lead times
NC/CNC Machines-Disadvantages
 Costlysetup, skilled operators
 Computers,programming knowledge required
 Maintenance is difficult
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NC/CNC/DNC
 Direct Numerical Control is a system that uses a
central computer to control several machines at the same
time
 Distributed Numerical Control (DNC): the central
computer downloads complete programs to the CNC
machines, which can be workstations or PCs, and can get
the informationfor the machine operations.
 The speed of the system is increased, large files can be
handled and the number of machine tools used is
expanded.
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Direct numerical control
14
DNC
15
GATE - 1993
With reference to NC machine, which of the
followingstatement is wrong?
(a) Both closed-loop and open-loop control systems are
used
(b) Paper tapes, floppy tapes and cassettes are used for
data storage
(c) Digitizersmay be used as interactive input devices
(d) Post processor is an item of hardware
Stepper Motor
 The stepper motor is special type of synchronous motor
which is designed to rotate through a specific angle
(Called step) for each electrical pulse received from the
control unit.
Basic CNC Principles
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GATE - 2007
Which type of motoris NOT used in axis or spindle
drivesof CNC machine tools?
(a) Inductionmotor (b) DC servo motor
(c) Stepper motor (d) Linearservo motor
Basic Length Unit (BLU)
 In NC machine, the displacement length per one pulse
output from machine is defined as a Basic Length Unit
(BLU).
 In the CNC computer each bit (binary digit) represents 1
BLU.
Bit = BLU
 Example: If one pulse makes a servo motor rotate by one
degree and the servo motor moves the table by 0.0001
mm, one BLU will be 0.0001 mm.
 The lead of a ball screw is related to the displacement
unitof the machine tool table.
Statement for Linked Answers questions: S-1
In the feed drive of a Point-to-Point open loop CNC
drive, a stepper motor rotating at 200 steps/rev drives a
table through a gear box and lead screw-nut mechanism
(pitch = 4 mm, number of starts = 1).
The gear ratio = is given by U =
The stepper motor (driven by voltage pulses from a pulse
generator) executes 1 step/pulse of the pulse generator.
The frequency of the pulse train from the pulse
generator is f = 10,000 pulses per minute.
speed
rotational
Input
speed
rotational
Output
4
1
GATE – 2008 Q-1 (Statement in S-1)
The Basic Length Unit (BLU), i.e., the table
movement corresponding to 1 pulse of the pulse
generator, is
(a) 0.5 microns (b) 5 microns
(c) 50 microns (d) 500 microns
GATE – 2008 Q-2 (Statement in S-1)
A customer insists on a modification to change the BLU
of the CNC drive to 10 microns without changing the
table speed. The modificationcan be accomplished by
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Control Systems possible in CNC Machine
 Pointto point mode:
Point-to-point straight line mode
Co-ordinate system
 All the machine tool use Cartesian Co-ordinatesystem.
 The first axis to be identified is the Z – axis, This is
followed by X and Y axes respectively.
Right-hand coordinate systems
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IES - 2000
Assertion (A): The axis of an NC drilling machine
spindleis denoted as z-axis.
Reason (R): In NC machine tool, the axis
perpendicular to both x- and y-axis is designated as
z-axis
(a) Both A and R are individually true and R is the
correctexplanation of A
(b) Both A and R are individually true but R is not the
correctexplanation of A
(c) A is true but R is false
(d) A is false but R is true
5 axes CNC vertical axis machining centre configuration
The following are the steps to be followed
while developing the CNC part programs.
 Process planning
 Axes selection
 Toolselection
 Cutting process parameters planning
 Job and tool setup planning
 Machining path planning
 Part programwriting
 Part program proving
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 For a CNC machine control unit (MCU) decides cutting
speed, feed, depth of cut, tool selection , coolant on off
and tool paths. The MCU issues commands in form of
numeric data to motors that position slides and tool
accordingly.
Part Programming
 FANUC CONTROLL
 SIEMENS CONTROLL
CNC programming
Important things to know:
• Coordinate System
• Units, incremental or absolute positioning
• Coordinates: X,Y,Z, RX,RY,RZ
• Feed rate and spindle speed
• Coolant Control: On/Off, Flood, Mist
• Tool Control: Tool and tool parameters
Programming Key Letters
 O - Program number (Used for program identification)
 N - Sequence number (Used for line identification)
 G - Preparatory function
 X - X axis designation
 Y - Y axis designation
 Z - Z axis designation
 R - Radius designation
 F – Feed rate designation
 S - Spindle speed designation
 H - Tool length offset designation
 D - Tool radius offset designation
 T - Tool Designation
 M - Miscellaneous function
Table of Important G codes
Code Meaning Format
G00 Rapid Transverse N__G00 X___ Y___ Z___
G01 Linear Interpolation N__G01 X___ Y___ Z___ F___
G02 Circular Interpolation,
CW
N__G02X__ Y__ Z___ R___ F___
N__G02X___ Y__Z__I___J __K __ F __
G03 Circular Interpolation,
CCW
N__G03X___ Y___ Z__R__F___
N__G03X__ Y__Z__I__J __K __ F __
G04 Dwell N__G04P___
G17 XY Plane
G18 XZ Plane
G19 YZ Plane
Table of Important G codes
Code Meaning Format
G20/G70 Inch Unit
G21/G71 Metric Unit
G28 Automatic Return to Reference
Point
G40 Cutter compensation cancel
G41 Cutter compensation left N__G41D__
G42 Cutter compensation right N__G42D__
G43 Tool length compensation
(plus)
N__G43H__
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Table of Important G codes
Code Meaning Format
G44 Tool length compensation
(minus)
N__G44H__
G49 Tool length compensation
cancel
G80 Cancel canned cycles
G81 Drilling cycle N__G81 Z__R__F__
G90 Absolute positioning
G91 Incremental positioning
G92 Absolute preset, change the
datum position
N__G92X__Y__Z__
Rapid traverse: G00
 G00:
 to make the machine move at maximum speed.
 It is used for positioning motion.
G90 G00 X20.0 Y10.0
Start
End
G90:
absolute
coordinates
(0,0)
(10,10)
(20,10)
Linear interpolation: G01
 G01:
 linear interpolation at feed speed.
G91 G0l X200.0 Y100.0 F200.0
Y
100.0
X
Start
End
200.0
G91:
incremental
coordinates
Circular interpolation: G02, G03
 G02, G03:
 For circular interpolation, thetool destination and the circle
center are programmed in one block
 G02 is clockwise interpolation, G03 is counterclockwise
interpolation
__;
__
__
__
__
03
02
19
__;
__
__
__
__
03
02
18
__;
__
__
__
__
03
02
17
F
K
J
R
Z
Y
G
G
G
F
K
I
R
Z
X
G
G
G
F
J
I
R
Y
X
G
G
G




































End
point
Circlecenter, radius
Circular interpolation: G02, G03
G91 G02 X60.0 Y20.0 R50.0 F300.0
G91 G02 X60.0 Y20.0 R-50.0 F300.0
Start
End
R=-50mm
Y
X
R=50mm
Specify R with
sign before it:
180° +R
>180° -R
Circular interpolation: G02, G03
 Specify Center with I, J, K
 I, J, K are the incremental
distance from the start of
thearc;
 Viewing the start of arc as
theorigin, I, J, K have
positiveor negative signs.
Center
Y
Start
End
X
i
j
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Circular interpolation: G02, G03
N0010 G92 X200.0 Y40.0 Z0 ;
N0020 G90 G03 X140.0 Y100.0 I -60.0 F300;
N0030 G02 X120. 0 Y60.0 I- 50.0;
Or
N0010 G92 X200.0 Y40.0 Z0;
N0020 G90 G03 X140.0 Y100.0 R60.0 F300;
N0030 G02 X120.0 Y60.0 R50.0;
R60
R50
90 120 140 200
100
60
40
O
Y
X
G90:
absolute
coordinates
G92:
To define working
coordinate
Circular interpolation: G02, G03
Annotation for Circular Interpolation
 I0.0, J0.0, and K0.0 can be omitted.
 If X,Y,Z are all omitted in the program, that means
start and end of arc are same points.
N0020 G02 I20.0 (a full circle)
 If I, J, K, and R all appears in circular interpolation
instruction, R is valid and I, J, and K are invalid
Tool Compensation
 Tool-RadiusCompensation
 Left hand G41
 Right hand G42
 Cancel tool-radius compensation G40
 Tool-HeightCompensation
 Positive G43
 Negative G44
 Cancel tool-height compensation G49
Tool-Radius Compensation
 Tool-radius compensations make it possibleto
program directlyfrom the drawing, and thus eliminate
the tool-offsetcalculation
G41 (G42) D
 D: the radius of tool tocompensate is saved in a memory unit that
is named D
 G41/G42 is directly related with direction of tool movement and
which side of part is cut.
Cancel Tool Compensation: G40
 Note the difference between two ways
N0060 G40 G01 X2.000 Y1.700 M02
N0060 G01 X2.000 Y1.700
N0070 G40 M02
ramp off block effective to the end point
Tool-Height Compensation
G43 (G44) H
 H: specified memory unit used to save height
compensation of tool.
 Positive compensation (G43):
real position = specified position + value saved in H
 Negative compensation (G44):
real position = specified position - value saved in H
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Tool-Height Compensation
 Example:
 N0010 G91 G00 X12.0 Y80.0
 N0020 G44 Z-32.0 H02;
 If we put 0.5mm into H02,
 real position = -32.0 - 0.5 = -32.5
 Cancel tool-height compensation: G49
G91:
incremental
coordinates
Table of Important M codes
 M00 Program stop
 M01 Optional program stop
 M03 Spindle on clockwise
 M04 Spindle on counterclockwise
 M05 Spindle stop
 M06 Tool change
 M08 Coolant on
 M09 Coolant off
 M10 Clamps on
 M11 Clamps off
 M02 or M30 Program stop, reset to start
Rules for programming
Block Format
N135 G01 X1.0 Y1.0 Z0.125 F5
Sample Block
• Restrictions on CNC blocks
• Each may contain only one tool move
• Each may contain any number of non-tool move G-codes
• Each may contain only one feed rate
• Each may contain only one specified tool or spindle speed
• The block numbers should be sequential
• Both the program start flag and the program number must be
independent of all other commands (on separate lines)
• The data within a block should follow the sequence shown
in the above sample block
Example of CNC Programming
 What Must Be Done To Drill A Hole On A CNC
Vertical Milling Machine
Top
View
Front
View
Tool Home
1.) X & Y Rapid To Hole Position
Top
View
Front
View
2.) Z Axis Rapid Move
Just Above Hole
3.) Turn On Coolant
4.) Turn On Spindle
.100”
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Top
View
Front
View
5.) Z Axis Feed Move to
Drill Hole
Top
View
Front
View
6.) Rapid Z Axis Move
Out Of Hole
Top
View
Front
View
9.) X&Y Axis Rapid
Move Home
7.) Turn Off Spindle
8.) Turn Off Coolant
Top
View
Front
View
Tool At Home
O0001
N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N030 G91 G28 X0 Y0 Z0
N035 M30
N025 G00 Z.1 M09
Here’s The CNC Program!
Top
View
Front
View
Tool At Home
O0001
O0001
Number Assigned to this program
Top
View
Front
View
Tool At Home
O0001
N005 G54 G90 S600 M03
N005 SequenceNumber
G54 Fixture Offset
G90 Absolute Programming Mode
S600 Spindle Speed set to 600 RPM
M03 Spindle on in a Clockwise Direction
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Top
View
Front
View
O0001
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
Top
View
Front
View
O0001
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
Top
View
Front
View
O0001
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.
Top
View
Front
View
O0001
N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
G00 Rapid Motion
Z.1 Z Coordinate .1 in. from Zero
M09 Coolant Off
N025 G00 Z.1 M09
Top
View
Front
View
O0001
N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N030 G91 G28 X0 Y0 Z0
G91 Incremental Programming Mode
G28 Zero Return Command
X0, Y0, Z0
X,Y,& Z Coordinates at Zero
N025 G00 Z.1 M09
Top
View
Front
View
O0001
N005 G54 G90 S600 M03
N010 G00 X1.0 Y1.0
N015 G43 H01 Z.1 M08
N020 G01 Z-.75 F3.5
N035 M30
N030 G91 G28 X0 Y0 Z0
N025 G00 Z.1 M09
M30 End of Program
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APT Language
 APT (Automatically Programmed Tools)
 The APT language consists of many different types of
statements made up of the following valid letters, numerals
and punctuation marks.
 Letters: ABCDEFGHIJKLMNOPQRSTUVWXYZ
 Numerals: 0 1 2 3 4 5 6 7 8 9
/ A slash divides a statement into two sections. eg.,
GO/PAST,
, A comma is used as a separator between the elements in
a statement generally to the right of the slash.
= An equals is used for assigning an entity to a symbolic
name, e.g., P1 = POINT/25,50,30.
Words
 The words to be used in the statements are built up from
one to six letters or numerals with the first one being a
letter. No special character is allowed in the words.
The complete APT part program consists of
the following four types of statements
 Geometry
 Motion
 Post processor
 Compilationcontrol
Other Part Programming Languages
 ADAPT (ADaptation APT) was the first attempt to adapt APT
programming system for smaller computers
 AUTOSPOT (AUTOmatic Sytem for POsitioning Tools) was
developed by IBM and first introduced in 1962
 EXAPT (EXtended subset of APT) was developed jointly in
German in about 1964 by several universities to adapt APT for
European use. It is compatible with APT and thus can use the
same processor as APT
 COMPACT was developed by Manufacturing Data Systems, Inc.
(MDSI)
 SPLIT (Sundstrand Processing Language Internally Translated)
was developed by Sundstrand Corporation, intended for its own
machine tools
 MAPT (Micro-APT) is a subset of APT, to be run on the
microcomputers 77
APT Language
Additional statements:
 MACHIN/DRILL, 2
 COOLNT/
Forexample: COOLNT/MIST COOLNT/FLOOD COOLNT/OFF
 FEDRAT/
 SPINDL/
Forexample: SPINDL/ON SPINDL/1250, CCLW
 TOOLNO/
 TURRET/
 END
78
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APT Language
Othercapabilitiesof APT, the macro facility,with usevariableargumentas ina
FORTRAN subroutine, forexample:
P0 = POINT/0.0, 0.3, 0.1
FROM/P0
CALL/DRILL, X=1.0, Y=1.0, Z=0.1, DEPTH=0.7
CALL/DRILL, X=2.0, Y=1.0, Z=0.1, DEPTH=0.7
GOTO/P0
when thedefinitionof the macroDRILL is:
DRILL = MACRO/X, Y, Z, DEPTH
GOTO/X,Y,Z
GODLTA/0,0, -DEPTH
GODLTA/0,0, DEPTH
TARMAC
79
Point (POINT)
PTA = POINT/ 3,4,5
PTA
y
x
z
(3, 4, 5)
Point (POINT)
PTB = POINT/ INTOF, LIN1, LIN2
LIN2
LIN1
PTB
Point (POINT)
PTD = POINT/ YSMALL, INTOF, LIN3, C1
PTD = POINT/ XSMALL, INTOF, LIN3, C1
PTC = POINT/ YLARGE, INTOF, LIN3, C1
PTC = POINT/ XLARGE, INTOF, LIN3, C1 PTC
PTD
LIN3
C1
x
y
Point (POINT)
PTE = POINT/ YLARGE, INTOF, C1, C2
PTE = POINT/ XLARGE, INTOF, C1, C2
PTF = POINT/ YSMALL, INTOF, C1, C2
PTF = POINT/ XSMALL, INTOF, C1, C2
y
x
C1
C2
PTE
PTF
Point (POINT)
PT7 = POINT/ CENTER, C6
C6
PT7
y
x
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Line (LINE)
LIN1 = LINE/ P1, P2
LIN1
P1
P2
y
x
Line (LINE)
LIN4 = LINE/ PT6, 15, -30, 3
PT6
L4 (15, -30, 3)
y
x
Line (LINE)
L12 = LINE/ PT4, ATANGL, 20, XAXIS
L14 = LINE/ PT1, ATANGL, 40
L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS
L16 = LINE/ PT3, ATANGL, 40, YAXIS
y
x
L16
PT3
PT1
L14
L12
PT4
(32, -3, 2)
L15
40°
40° 20°
15°
Line (LINE)
LIN = LINE/ POINT, ATANGL, ANGLE (in degrees), LINE
P1
LINE1
LINE2
x
y
LINE2 = LINE/ P1, ATANGL, 30, LINE1
30°
Line (LINE)
LIN = LINE/ SLOPE, SLOPE VALUE, INTERC, MODIFIER, d
where the slope value is y/x. The modifier options are [XAXIS,
YAXIS], and d is the corresponding intercept value on the selected
axis (i.e., modifier).
x
y
(6,0) Pointof X-Intercept
LINE1
LINE1 = LINE/ SLOPE, 1, INTERC, XAXIS, 6
Line (LINE)
LIN = LINE/ ATANGL, DEGREES, INTERC, MODIFIER, d
The modifier options are [XAXIS, YAXIS], and d is the
corresponding intercept value on the selected axis (i.e., modifier).
x
y
d
LINE1
 = 30°
LINE1 = LINE/ ATANGL, 30, INTERC, d
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Line (LINE)
The LEFT & RIGHT modifier indicates whether the line
is at the left or right tangent point, depending on how
one looks at the circle from the point.
L1 = LINE/ PT51, LEFT, TANTO, C11
L1
C11
PT51
Line (LINE)
L2 = LINE/ PT51, RIGHT, TANTO, C11
L3 = LINE/ PT40, RIGHT, TANTO, C11
L4 = LINE/ PT40, LEFT, TANTO, C11
Left
Right
PT51
L1
L3
L4
L2
Right
Left
PT40
Line (LINE)
L6 = LINE/ LEFT, TANTO, C3, LEFT, TANTO, C4
C3
L6
L9
C4
L8
L7
Left
Right
The descriptive words LEFT and RIGHT are used by
looking from the first circle written towards the
second circle.
Line (LINE)
L6 = LINE/ RIGHT, TANTO, C4, RIGHT, TANTO, C3
C3
L6
L9
C4
L8
L7
Right
Left
Line (LINE)
LN3 = LINE/ PNT6, PARLEL, LN15
LN4 = LINE/ PNT5, PERPTO, LN13
y
x
PNT6 LN3
LN15
LN13
PNT5
LN4
Line
LN5 = LINE/ INTOF, PLAN1, PLAN2
PLAN2
PLAN1
LN5
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Plane (PLANE)
PLAN10 = PLANE/ PT6, PT12, PT15
PT15
PT12
PT6
PT4
y
x
z
PLAN10
PLAN14
3.0
Plane (PLANE)
PLAN14 = PLANE/ PT4, PARLEL, PLAN10
PLAN14 = PLANE/ PARLEL, PLAN10, YSMALL, 3.0
PT15
PT12
PT6
PT4
y
x
z
PLAN10
PLAN14
3.0
Circle (CIRCLE)
C1 = CIRCLE/ 3, 6, 5, 4.3
C1 = CIRCLE/ CENTER, PT3, RADIUS, 4.3
PT3
(3,6,5)
C1
y
x
4.3
Circle (CIRCLE)
C3 = CIRCLE/ CENTER, PT6, TANTO, LN4
C7 = CIRCLE/ CENTER, PT8, PT5
C3
y
x
LN4
PT6
C7
y
x
PT8
PT5
The Machining Plan
Contouring:
 Part surface: the surface on which the end of the
tool is riding.
 Drive surface: the surface against which the edge of
the tool rides.
 Check surface: a surface at which the current tool
motion is to stop.
The Machining Plan
cutter
z
x
y
Directionof
cuttermotion
Drive surface Check surface
Partsurface
2/24/2015
18
The Machining Plan
CS
DS
TO
CS
DS
ON
CS
DS
PAST
The Machining Plan
Motion commands:
GOLFT/ : Move left along the drive surface
GORGT/ : Move right along the drive surface
GOUP/ : Move up along the drive surface
GODOWN/ : Move down along the drive surface
GOFWD/ : Move forward from a tangent position
GOBACK/ : Move backward from a tangent position
Previous
tool position
GODOWN
GORGT
Present tool
position
GOFWD
GOUP
GOLFT
GOBACK
FROM/PTARG
GO/TO, L1, TO, PL2, TO L3
GORGT/L3, PAST, L4
Machining Specifications
Postprocessor commands for a particular machine tool are:
MACHIN/ : used to specify the machine tool and call the
postprocessor for that tool:
MACHIN/ DRILL, 3
COOLNT/ : allows the coolant fluid to be turned on or off:
COOLNT/ MIST
COOLNT/ FLOOD
COOLNT/ OFF
Machining Specifications
FEDRAT/ : specifies the feed rate for moving the tool along the
part surface in inches per minute:
FEDRAT/ 4.5
SPINDL/ : gives the spindle rotation speed in revolutions per
minute:
SPINDL/ 850
TURRET/ : can be used to call a specific tool from an automatic
tool changer:
TURRET/ 11
2/24/2015
19
Machining Specifications
TOLERANCE SETTING: Nonlinear motion is accomplished in
straight-line segments, and INTOL/ and OUTTOL/ statements
dictate the number of straight-line segments to be generated.
INTOL/ 0.0015
OUTTOL/ 0.001
Machining Specifications
PARTNO: identifies the part program and is inserted at the start of
the program.
CLPRNT: indicates that a cutter location printout is desired.
CUTTER: specifies a cutter diameter for offset (rough versus finish
cutting). If a milling cutter is 0.5 in. in diameter and we have
CUTTER/ 0.6
then the tool will be offset from the finish cut by 0.05 in.
Machining Specifications
FINI: specifies the end of the program.
APT Language
OtherMotion statements:
 GO/{TO}, Drive surface, {TO} Part surface, {TO},
Check surface
Or
 GO/{TO}, Drive surface, {TO} Part surface, {TANTO},
Check surface
…And the same with PAST or ON instead of TO
 GOLFT/
 GORGT/
 GOUP/
 GODOWN/
 GOFWD/
 GOBACK/
For example:
GO/TO, L1, TO, PS, TANTO, C1
GO/PAST, L1, TO, PS, TANTO, C1
112
IES-2008
Name the four types of statements in a complete APT
part program. Prepare part program for geometry
description of the contour shown in the figure below:
[15-Marks]
R
20
R
20
135°
L3
L2
20
20
30 40
L1
80
L5
L4
C2
P1
P2
Y
X
C1
Answer:
PARTNO CONTOUR
MACHIN/MILL, 1
CLPRNT
UNITS/MM
P0 = POINT/0.0, 0.0, 0.0
P1 = POINT/110.0, 20.0, 0.0
P2 = POINT/20.0, 20.0, 0.0
P3 = POINT/90.0, 110.0, 0.0
P4 = POINT/20.0, 100.0, 0.0
P5 = POINT/50.0, 130.0, 0.0
L1 = LINE/P2, ATANGL, 90, XAXIS
L2 = LINE/P4, ANTNGL, 45, XAXIS
L3 = LINE/P5, ATANGL, 135, L2
L4 = LINE/P1, PERPTO, L3
L5 = LINE/P1, PERPTO, L4
C1=CIRCLE/CENTER, P3, RADIUS, 20.0
C2=CIRCLE/CENTER, P1, RADIUS, 20.0
PL1=PLANE/P1, P2, P3
2/24/2015
20
CUTTER/25.0
TOLER/0.1
INTOL/0.05
OUTTOL/0.05
FEDRAT/200
SPINDL/500, CLW
COOLNT/ON
FROM/P0
GO/TO, L1, TO, PL1, TO, L5
GOLFT/L1, PAST, L2
GORGT/L2, PAST, L3
GORGT/L3, TANTO, C1
GOFWD/C1, PAST, L4
GOFWD/L4, PAST, C2
GORGT/C2, PAST, L5
GORGT/L5, PAST, L1
Contd….
RAPID
GOTO/P0
COOLNT/OFF
SPINDL/OFF
END
FINI
Contd….
GATE -2008 (PI)
Suppose point P1 in APT programming is coded by statement
P1 = POINT/XSMALL, INTOF, LN1, CR1
The coded geometric situation without causing error is
Robotics
What is an industrial robot?
A robot is a reprogrammable, multifunctional
manipulator designed to handle material, parts, tools or
specialized devices through variable programmed
motionsfor the performanceof a variety of tasks.
Advantages of Robots
 Robotics and automation can, in many situation, increase
productivity, safety, efficiency, quality, and consistency of
products
 Robots can work in hazardous environments
 Robots need no environmental comfort
 Robots work continuously without any humanity needs and
illnesses
 Robots have repetable precision at all times
 Robots can be much more accurate than humans, they may have
mili or micro inch accuracy.
 Robots and their sensors can have capabilities beyond that of
humans
 Robots can process multiple stimuli or tasks simultaneously,
humans can only one.
 Robots replace human workers who can create economic
problems
2/24/2015
21
Disadvantages of Robots
 Robotslack capabilityto respond in emergencies, this can cause:
– Inappropriate and wrong responses
– A lack of decision-making power
– A loss of power
– Damage to the robot and otherdevices
– Human injuries
 Robotsmay have limited capabilitiesin
– Degrees of Freedom
– Dexterity
– Sensors
– Vision systems
– Real-time Response
 Robotsare costly, due to
– Initial cost of equipment
– Installation Costs
– Need for peripherals
– Need for training
– Need for Programming
What Can Robots Do?
Industrial Robots
Material Handling
Manipulator
Assembly
Manipulator
SpotWelding
Manipulator
•Material handling
•Material transfer
•Machine loading and/or unloading
•Spot welding
•Continuous arc welding
•Spraycoating
•Assembly
•Inspection

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Ch-11 NC; CNC; DNC; FMS; Automation and Robotics_2.pdf

  • 1. 2/24/2015 1 NC, CNC & Robotics What is NC/CNC?  NC is an acronym for Numerical Control and CNC is an acronym for Computer Numerical Control. What is the difference between NC and CNC ?  The difference between NC and CNC is one of age and capability.  The earliest NC machines performed limited functions and movements controlled by punched tape or punch cards.  As the technology evolved, the machines were equiped with increasingly powerful microprocessors (computers) with the addition of these computers, NC machines become CNC machines.  CNC machines have far more capability than their predecessor. contd….. What is the difference between NC and CNC ?  Some of the enhancements that came along with CNC include: Canned Cycles, Sub Programming, Cutter Compensation, Work coordinates, Coordinate system rotation, automatic corner rounding, chamfering, and B- spline interpolation. Where did CNC get started?  1940 Jhon Parson developed first machine able to drill holes at specific coordinates programmed on punch cards.  1951 MIT developed servo-mechanism  1952 MIT developed first NC machines for milling.  1970 First CNC machinescame into picture Now-a-day’s modified 1970’s machines are used. Do all machines speak the same CNC language  No, while there is fairly standard set of G and M codes, there is some variation in their application. For example a G0 or G00 command is universally regarded as the command for rapid travel. Some older machines do not have a G00 command. On these machines, rapid travel is commanded by using the F (feed) word address.
  • 2. 2/24/2015 2 What is a “Conversational Control”  CNC machine tool builders offer an option what is known as the conversational control. This control lets the operator/programmer use simple descriptive language to program the part. The control then displayed a graphical representation of the instructions so the operator/programmercan verify the tool path. Are CNC machines faster than conventional machines?  Yes, No, Sometimes. When it comes to making a single, simple part it is hard to beat a conventional mill or lathe. CNC machines move faster in rapid travel than conventional machines. Are CNC machines more accurate than conventional machines?  Yes, they can be. But like anything else it depends on who is running the machine, how well the machines has been maintained, quality of setup and so on. GATE - 1994 CNC machines are more accurate than conventional machines because they have a high resolution encoderand digital read-outs for positioning. Trueor false? NC/CNC Machines-Advantages  High Repeatability and Precision e.g. Aircraftparts  Volumeof production is very high  Complex contours/surfaces need to be machined. E.g. Turbines  Flexibility in job change, automatic tool settings, less scrap  More safe, higher productivity, better quality  Less paper work, faster prototype production, reduction in lead times NC/CNC Machines-Disadvantages  Costlysetup, skilled operators  Computers,programming knowledge required  Maintenance is difficult
  • 3. 2/24/2015 3 NC/CNC/DNC  Direct Numerical Control is a system that uses a central computer to control several machines at the same time  Distributed Numerical Control (DNC): the central computer downloads complete programs to the CNC machines, which can be workstations or PCs, and can get the informationfor the machine operations.  The speed of the system is increased, large files can be handled and the number of machine tools used is expanded. 13 Direct numerical control 14 DNC 15 GATE - 1993 With reference to NC machine, which of the followingstatement is wrong? (a) Both closed-loop and open-loop control systems are used (b) Paper tapes, floppy tapes and cassettes are used for data storage (c) Digitizersmay be used as interactive input devices (d) Post processor is an item of hardware Stepper Motor  The stepper motor is special type of synchronous motor which is designed to rotate through a specific angle (Called step) for each electrical pulse received from the control unit. Basic CNC Principles
  • 4. 2/24/2015 4 GATE - 2007 Which type of motoris NOT used in axis or spindle drivesof CNC machine tools? (a) Inductionmotor (b) DC servo motor (c) Stepper motor (d) Linearservo motor Basic Length Unit (BLU)  In NC machine, the displacement length per one pulse output from machine is defined as a Basic Length Unit (BLU).  In the CNC computer each bit (binary digit) represents 1 BLU. Bit = BLU  Example: If one pulse makes a servo motor rotate by one degree and the servo motor moves the table by 0.0001 mm, one BLU will be 0.0001 mm.  The lead of a ball screw is related to the displacement unitof the machine tool table. Statement for Linked Answers questions: S-1 In the feed drive of a Point-to-Point open loop CNC drive, a stepper motor rotating at 200 steps/rev drives a table through a gear box and lead screw-nut mechanism (pitch = 4 mm, number of starts = 1). The gear ratio = is given by U = The stepper motor (driven by voltage pulses from a pulse generator) executes 1 step/pulse of the pulse generator. The frequency of the pulse train from the pulse generator is f = 10,000 pulses per minute. speed rotational Input speed rotational Output 4 1 GATE – 2008 Q-1 (Statement in S-1) The Basic Length Unit (BLU), i.e., the table movement corresponding to 1 pulse of the pulse generator, is (a) 0.5 microns (b) 5 microns (c) 50 microns (d) 500 microns GATE – 2008 Q-2 (Statement in S-1) A customer insists on a modification to change the BLU of the CNC drive to 10 microns without changing the table speed. The modificationcan be accomplished by
  • 5. 2/24/2015 5 Control Systems possible in CNC Machine  Pointto point mode: Point-to-point straight line mode Co-ordinate system  All the machine tool use Cartesian Co-ordinatesystem.  The first axis to be identified is the Z – axis, This is followed by X and Y axes respectively. Right-hand coordinate systems
  • 6. 2/24/2015 6 IES - 2000 Assertion (A): The axis of an NC drilling machine spindleis denoted as z-axis. Reason (R): In NC machine tool, the axis perpendicular to both x- and y-axis is designated as z-axis (a) Both A and R are individually true and R is the correctexplanation of A (b) Both A and R are individually true but R is not the correctexplanation of A (c) A is true but R is false (d) A is false but R is true 5 axes CNC vertical axis machining centre configuration The following are the steps to be followed while developing the CNC part programs.  Process planning  Axes selection  Toolselection  Cutting process parameters planning  Job and tool setup planning  Machining path planning  Part programwriting  Part program proving
  • 7. 2/24/2015 7  For a CNC machine control unit (MCU) decides cutting speed, feed, depth of cut, tool selection , coolant on off and tool paths. The MCU issues commands in form of numeric data to motors that position slides and tool accordingly. Part Programming  FANUC CONTROLL  SIEMENS CONTROLL CNC programming Important things to know: • Coordinate System • Units, incremental or absolute positioning • Coordinates: X,Y,Z, RX,RY,RZ • Feed rate and spindle speed • Coolant Control: On/Off, Flood, Mist • Tool Control: Tool and tool parameters Programming Key Letters  O - Program number (Used for program identification)  N - Sequence number (Used for line identification)  G - Preparatory function  X - X axis designation  Y - Y axis designation  Z - Z axis designation  R - Radius designation  F – Feed rate designation  S - Spindle speed designation  H - Tool length offset designation  D - Tool radius offset designation  T - Tool Designation  M - Miscellaneous function Table of Important G codes Code Meaning Format G00 Rapid Transverse N__G00 X___ Y___ Z___ G01 Linear Interpolation N__G01 X___ Y___ Z___ F___ G02 Circular Interpolation, CW N__G02X__ Y__ Z___ R___ F___ N__G02X___ Y__Z__I___J __K __ F __ G03 Circular Interpolation, CCW N__G03X___ Y___ Z__R__F___ N__G03X__ Y__Z__I__J __K __ F __ G04 Dwell N__G04P___ G17 XY Plane G18 XZ Plane G19 YZ Plane Table of Important G codes Code Meaning Format G20/G70 Inch Unit G21/G71 Metric Unit G28 Automatic Return to Reference Point G40 Cutter compensation cancel G41 Cutter compensation left N__G41D__ G42 Cutter compensation right N__G42D__ G43 Tool length compensation (plus) N__G43H__
  • 8. 2/24/2015 8 Table of Important G codes Code Meaning Format G44 Tool length compensation (minus) N__G44H__ G49 Tool length compensation cancel G80 Cancel canned cycles G81 Drilling cycle N__G81 Z__R__F__ G90 Absolute positioning G91 Incremental positioning G92 Absolute preset, change the datum position N__G92X__Y__Z__ Rapid traverse: G00  G00:  to make the machine move at maximum speed.  It is used for positioning motion. G90 G00 X20.0 Y10.0 Start End G90: absolute coordinates (0,0) (10,10) (20,10) Linear interpolation: G01  G01:  linear interpolation at feed speed. G91 G0l X200.0 Y100.0 F200.0 Y 100.0 X Start End 200.0 G91: incremental coordinates Circular interpolation: G02, G03  G02, G03:  For circular interpolation, thetool destination and the circle center are programmed in one block  G02 is clockwise interpolation, G03 is counterclockwise interpolation __; __ __ __ __ 03 02 19 __; __ __ __ __ 03 02 18 __; __ __ __ __ 03 02 17 F K J R Z Y G G G F K I R Z X G G G F J I R Y X G G G                                     End point Circlecenter, radius Circular interpolation: G02, G03 G91 G02 X60.0 Y20.0 R50.0 F300.0 G91 G02 X60.0 Y20.0 R-50.0 F300.0 Start End R=-50mm Y X R=50mm Specify R with sign before it: 180° +R >180° -R Circular interpolation: G02, G03  Specify Center with I, J, K  I, J, K are the incremental distance from the start of thearc;  Viewing the start of arc as theorigin, I, J, K have positiveor negative signs. Center Y Start End X i j
  • 9. 2/24/2015 9 Circular interpolation: G02, G03 N0010 G92 X200.0 Y40.0 Z0 ; N0020 G90 G03 X140.0 Y100.0 I -60.0 F300; N0030 G02 X120. 0 Y60.0 I- 50.0; Or N0010 G92 X200.0 Y40.0 Z0; N0020 G90 G03 X140.0 Y100.0 R60.0 F300; N0030 G02 X120.0 Y60.0 R50.0; R60 R50 90 120 140 200 100 60 40 O Y X G90: absolute coordinates G92: To define working coordinate Circular interpolation: G02, G03 Annotation for Circular Interpolation  I0.0, J0.0, and K0.0 can be omitted.  If X,Y,Z are all omitted in the program, that means start and end of arc are same points. N0020 G02 I20.0 (a full circle)  If I, J, K, and R all appears in circular interpolation instruction, R is valid and I, J, and K are invalid Tool Compensation  Tool-RadiusCompensation  Left hand G41  Right hand G42  Cancel tool-radius compensation G40  Tool-HeightCompensation  Positive G43  Negative G44  Cancel tool-height compensation G49 Tool-Radius Compensation  Tool-radius compensations make it possibleto program directlyfrom the drawing, and thus eliminate the tool-offsetcalculation G41 (G42) D  D: the radius of tool tocompensate is saved in a memory unit that is named D  G41/G42 is directly related with direction of tool movement and which side of part is cut. Cancel Tool Compensation: G40  Note the difference between two ways N0060 G40 G01 X2.000 Y1.700 M02 N0060 G01 X2.000 Y1.700 N0070 G40 M02 ramp off block effective to the end point Tool-Height Compensation G43 (G44) H  H: specified memory unit used to save height compensation of tool.  Positive compensation (G43): real position = specified position + value saved in H  Negative compensation (G44): real position = specified position - value saved in H
  • 10. 2/24/2015 10 Tool-Height Compensation  Example:  N0010 G91 G00 X12.0 Y80.0  N0020 G44 Z-32.0 H02;  If we put 0.5mm into H02,  real position = -32.0 - 0.5 = -32.5  Cancel tool-height compensation: G49 G91: incremental coordinates Table of Important M codes  M00 Program stop  M01 Optional program stop  M03 Spindle on clockwise  M04 Spindle on counterclockwise  M05 Spindle stop  M06 Tool change  M08 Coolant on  M09 Coolant off  M10 Clamps on  M11 Clamps off  M02 or M30 Program stop, reset to start Rules for programming Block Format N135 G01 X1.0 Y1.0 Z0.125 F5 Sample Block • Restrictions on CNC blocks • Each may contain only one tool move • Each may contain any number of non-tool move G-codes • Each may contain only one feed rate • Each may contain only one specified tool or spindle speed • The block numbers should be sequential • Both the program start flag and the program number must be independent of all other commands (on separate lines) • The data within a block should follow the sequence shown in the above sample block Example of CNC Programming  What Must Be Done To Drill A Hole On A CNC Vertical Milling Machine Top View Front View Tool Home 1.) X & Y Rapid To Hole Position Top View Front View 2.) Z Axis Rapid Move Just Above Hole 3.) Turn On Coolant 4.) Turn On Spindle .100”
  • 11. 2/24/2015 11 Top View Front View 5.) Z Axis Feed Move to Drill Hole Top View Front View 6.) Rapid Z Axis Move Out Of Hole Top View Front View 9.) X&Y Axis Rapid Move Home 7.) Turn Off Spindle 8.) Turn Off Coolant Top View Front View Tool At Home O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N030 G91 G28 X0 Y0 Z0 N035 M30 N025 G00 Z.1 M09 Here’s The CNC Program! Top View Front View Tool At Home O0001 O0001 Number Assigned to this program Top View Front View Tool At Home O0001 N005 G54 G90 S600 M03 N005 SequenceNumber G54 Fixture Offset G90 Absolute Programming Mode S600 Spindle Speed set to 600 RPM M03 Spindle on in a Clockwise Direction
  • 12. 2/24/2015 12 Top View Front View O0001 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 Top View Front View O0001 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 Top View Front View O0001 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. Top View Front View O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 G00 Rapid Motion Z.1 Z Coordinate .1 in. from Zero M09 Coolant Off N025 G00 Z.1 M09 Top View Front View O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N030 G91 G28 X0 Y0 Z0 G91 Incremental Programming Mode G28 Zero Return Command X0, Y0, Z0 X,Y,& Z Coordinates at Zero N025 G00 Z.1 M09 Top View Front View O0001 N005 G54 G90 S600 M03 N010 G00 X1.0 Y1.0 N015 G43 H01 Z.1 M08 N020 G01 Z-.75 F3.5 N035 M30 N030 G91 G28 X0 Y0 Z0 N025 G00 Z.1 M09 M30 End of Program
  • 13. 2/24/2015 13 APT Language  APT (Automatically Programmed Tools)  The APT language consists of many different types of statements made up of the following valid letters, numerals and punctuation marks.  Letters: ABCDEFGHIJKLMNOPQRSTUVWXYZ  Numerals: 0 1 2 3 4 5 6 7 8 9 / A slash divides a statement into two sections. eg., GO/PAST, , A comma is used as a separator between the elements in a statement generally to the right of the slash. = An equals is used for assigning an entity to a symbolic name, e.g., P1 = POINT/25,50,30. Words  The words to be used in the statements are built up from one to six letters or numerals with the first one being a letter. No special character is allowed in the words. The complete APT part program consists of the following four types of statements  Geometry  Motion  Post processor  Compilationcontrol Other Part Programming Languages  ADAPT (ADaptation APT) was the first attempt to adapt APT programming system for smaller computers  AUTOSPOT (AUTOmatic Sytem for POsitioning Tools) was developed by IBM and first introduced in 1962  EXAPT (EXtended subset of APT) was developed jointly in German in about 1964 by several universities to adapt APT for European use. It is compatible with APT and thus can use the same processor as APT  COMPACT was developed by Manufacturing Data Systems, Inc. (MDSI)  SPLIT (Sundstrand Processing Language Internally Translated) was developed by Sundstrand Corporation, intended for its own machine tools  MAPT (Micro-APT) is a subset of APT, to be run on the microcomputers 77 APT Language Additional statements:  MACHIN/DRILL, 2  COOLNT/ Forexample: COOLNT/MIST COOLNT/FLOOD COOLNT/OFF  FEDRAT/  SPINDL/ Forexample: SPINDL/ON SPINDL/1250, CCLW  TOOLNO/  TURRET/  END 78
  • 14. 2/24/2015 14 APT Language Othercapabilitiesof APT, the macro facility,with usevariableargumentas ina FORTRAN subroutine, forexample: P0 = POINT/0.0, 0.3, 0.1 FROM/P0 CALL/DRILL, X=1.0, Y=1.0, Z=0.1, DEPTH=0.7 CALL/DRILL, X=2.0, Y=1.0, Z=0.1, DEPTH=0.7 GOTO/P0 when thedefinitionof the macroDRILL is: DRILL = MACRO/X, Y, Z, DEPTH GOTO/X,Y,Z GODLTA/0,0, -DEPTH GODLTA/0,0, DEPTH TARMAC 79 Point (POINT) PTA = POINT/ 3,4,5 PTA y x z (3, 4, 5) Point (POINT) PTB = POINT/ INTOF, LIN1, LIN2 LIN2 LIN1 PTB Point (POINT) PTD = POINT/ YSMALL, INTOF, LIN3, C1 PTD = POINT/ XSMALL, INTOF, LIN3, C1 PTC = POINT/ YLARGE, INTOF, LIN3, C1 PTC = POINT/ XLARGE, INTOF, LIN3, C1 PTC PTD LIN3 C1 x y Point (POINT) PTE = POINT/ YLARGE, INTOF, C1, C2 PTE = POINT/ XLARGE, INTOF, C1, C2 PTF = POINT/ YSMALL, INTOF, C1, C2 PTF = POINT/ XSMALL, INTOF, C1, C2 y x C1 C2 PTE PTF Point (POINT) PT7 = POINT/ CENTER, C6 C6 PT7 y x
  • 15. 2/24/2015 15 Line (LINE) LIN1 = LINE/ P1, P2 LIN1 P1 P2 y x Line (LINE) LIN4 = LINE/ PT6, 15, -30, 3 PT6 L4 (15, -30, 3) y x Line (LINE) L12 = LINE/ PT4, ATANGL, 20, XAXIS L14 = LINE/ PT1, ATANGL, 40 L15 = LINE/ 32, -3, 2, ATANGL, -15, XAXIS L16 = LINE/ PT3, ATANGL, 40, YAXIS y x L16 PT3 PT1 L14 L12 PT4 (32, -3, 2) L15 40° 40° 20° 15° Line (LINE) LIN = LINE/ POINT, ATANGL, ANGLE (in degrees), LINE P1 LINE1 LINE2 x y LINE2 = LINE/ P1, ATANGL, 30, LINE1 30° Line (LINE) LIN = LINE/ SLOPE, SLOPE VALUE, INTERC, MODIFIER, d where the slope value is y/x. The modifier options are [XAXIS, YAXIS], and d is the corresponding intercept value on the selected axis (i.e., modifier). x y (6,0) Pointof X-Intercept LINE1 LINE1 = LINE/ SLOPE, 1, INTERC, XAXIS, 6 Line (LINE) LIN = LINE/ ATANGL, DEGREES, INTERC, MODIFIER, d The modifier options are [XAXIS, YAXIS], and d is the corresponding intercept value on the selected axis (i.e., modifier). x y d LINE1  = 30° LINE1 = LINE/ ATANGL, 30, INTERC, d
  • 16. 2/24/2015 16 Line (LINE) The LEFT & RIGHT modifier indicates whether the line is at the left or right tangent point, depending on how one looks at the circle from the point. L1 = LINE/ PT51, LEFT, TANTO, C11 L1 C11 PT51 Line (LINE) L2 = LINE/ PT51, RIGHT, TANTO, C11 L3 = LINE/ PT40, RIGHT, TANTO, C11 L4 = LINE/ PT40, LEFT, TANTO, C11 Left Right PT51 L1 L3 L4 L2 Right Left PT40 Line (LINE) L6 = LINE/ LEFT, TANTO, C3, LEFT, TANTO, C4 C3 L6 L9 C4 L8 L7 Left Right The descriptive words LEFT and RIGHT are used by looking from the first circle written towards the second circle. Line (LINE) L6 = LINE/ RIGHT, TANTO, C4, RIGHT, TANTO, C3 C3 L6 L9 C4 L8 L7 Right Left Line (LINE) LN3 = LINE/ PNT6, PARLEL, LN15 LN4 = LINE/ PNT5, PERPTO, LN13 y x PNT6 LN3 LN15 LN13 PNT5 LN4 Line LN5 = LINE/ INTOF, PLAN1, PLAN2 PLAN2 PLAN1 LN5
  • 17. 2/24/2015 17 Plane (PLANE) PLAN10 = PLANE/ PT6, PT12, PT15 PT15 PT12 PT6 PT4 y x z PLAN10 PLAN14 3.0 Plane (PLANE) PLAN14 = PLANE/ PT4, PARLEL, PLAN10 PLAN14 = PLANE/ PARLEL, PLAN10, YSMALL, 3.0 PT15 PT12 PT6 PT4 y x z PLAN10 PLAN14 3.0 Circle (CIRCLE) C1 = CIRCLE/ 3, 6, 5, 4.3 C1 = CIRCLE/ CENTER, PT3, RADIUS, 4.3 PT3 (3,6,5) C1 y x 4.3 Circle (CIRCLE) C3 = CIRCLE/ CENTER, PT6, TANTO, LN4 C7 = CIRCLE/ CENTER, PT8, PT5 C3 y x LN4 PT6 C7 y x PT8 PT5 The Machining Plan Contouring:  Part surface: the surface on which the end of the tool is riding.  Drive surface: the surface against which the edge of the tool rides.  Check surface: a surface at which the current tool motion is to stop. The Machining Plan cutter z x y Directionof cuttermotion Drive surface Check surface Partsurface
  • 18. 2/24/2015 18 The Machining Plan CS DS TO CS DS ON CS DS PAST The Machining Plan Motion commands: GOLFT/ : Move left along the drive surface GORGT/ : Move right along the drive surface GOUP/ : Move up along the drive surface GODOWN/ : Move down along the drive surface GOFWD/ : Move forward from a tangent position GOBACK/ : Move backward from a tangent position Previous tool position GODOWN GORGT Present tool position GOFWD GOUP GOLFT GOBACK FROM/PTARG GO/TO, L1, TO, PL2, TO L3 GORGT/L3, PAST, L4 Machining Specifications Postprocessor commands for a particular machine tool are: MACHIN/ : used to specify the machine tool and call the postprocessor for that tool: MACHIN/ DRILL, 3 COOLNT/ : allows the coolant fluid to be turned on or off: COOLNT/ MIST COOLNT/ FLOOD COOLNT/ OFF Machining Specifications FEDRAT/ : specifies the feed rate for moving the tool along the part surface in inches per minute: FEDRAT/ 4.5 SPINDL/ : gives the spindle rotation speed in revolutions per minute: SPINDL/ 850 TURRET/ : can be used to call a specific tool from an automatic tool changer: TURRET/ 11
  • 19. 2/24/2015 19 Machining Specifications TOLERANCE SETTING: Nonlinear motion is accomplished in straight-line segments, and INTOL/ and OUTTOL/ statements dictate the number of straight-line segments to be generated. INTOL/ 0.0015 OUTTOL/ 0.001 Machining Specifications PARTNO: identifies the part program and is inserted at the start of the program. CLPRNT: indicates that a cutter location printout is desired. CUTTER: specifies a cutter diameter for offset (rough versus finish cutting). If a milling cutter is 0.5 in. in diameter and we have CUTTER/ 0.6 then the tool will be offset from the finish cut by 0.05 in. Machining Specifications FINI: specifies the end of the program. APT Language OtherMotion statements:  GO/{TO}, Drive surface, {TO} Part surface, {TO}, Check surface Or  GO/{TO}, Drive surface, {TO} Part surface, {TANTO}, Check surface …And the same with PAST or ON instead of TO  GOLFT/  GORGT/  GOUP/  GODOWN/  GOFWD/  GOBACK/ For example: GO/TO, L1, TO, PS, TANTO, C1 GO/PAST, L1, TO, PS, TANTO, C1 112 IES-2008 Name the four types of statements in a complete APT part program. Prepare part program for geometry description of the contour shown in the figure below: [15-Marks] R 20 R 20 135° L3 L2 20 20 30 40 L1 80 L5 L4 C2 P1 P2 Y X C1 Answer: PARTNO CONTOUR MACHIN/MILL, 1 CLPRNT UNITS/MM P0 = POINT/0.0, 0.0, 0.0 P1 = POINT/110.0, 20.0, 0.0 P2 = POINT/20.0, 20.0, 0.0 P3 = POINT/90.0, 110.0, 0.0 P4 = POINT/20.0, 100.0, 0.0 P5 = POINT/50.0, 130.0, 0.0 L1 = LINE/P2, ATANGL, 90, XAXIS L2 = LINE/P4, ANTNGL, 45, XAXIS L3 = LINE/P5, ATANGL, 135, L2 L4 = LINE/P1, PERPTO, L3 L5 = LINE/P1, PERPTO, L4 C1=CIRCLE/CENTER, P3, RADIUS, 20.0 C2=CIRCLE/CENTER, P1, RADIUS, 20.0 PL1=PLANE/P1, P2, P3
  • 20. 2/24/2015 20 CUTTER/25.0 TOLER/0.1 INTOL/0.05 OUTTOL/0.05 FEDRAT/200 SPINDL/500, CLW COOLNT/ON FROM/P0 GO/TO, L1, TO, PL1, TO, L5 GOLFT/L1, PAST, L2 GORGT/L2, PAST, L3 GORGT/L3, TANTO, C1 GOFWD/C1, PAST, L4 GOFWD/L4, PAST, C2 GORGT/C2, PAST, L5 GORGT/L5, PAST, L1 Contd…. RAPID GOTO/P0 COOLNT/OFF SPINDL/OFF END FINI Contd…. GATE -2008 (PI) Suppose point P1 in APT programming is coded by statement P1 = POINT/XSMALL, INTOF, LN1, CR1 The coded geometric situation without causing error is Robotics What is an industrial robot? A robot is a reprogrammable, multifunctional manipulator designed to handle material, parts, tools or specialized devices through variable programmed motionsfor the performanceof a variety of tasks. Advantages of Robots  Robotics and automation can, in many situation, increase productivity, safety, efficiency, quality, and consistency of products  Robots can work in hazardous environments  Robots need no environmental comfort  Robots work continuously without any humanity needs and illnesses  Robots have repetable precision at all times  Robots can be much more accurate than humans, they may have mili or micro inch accuracy.  Robots and their sensors can have capabilities beyond that of humans  Robots can process multiple stimuli or tasks simultaneously, humans can only one.  Robots replace human workers who can create economic problems
  • 21. 2/24/2015 21 Disadvantages of Robots  Robotslack capabilityto respond in emergencies, this can cause: – Inappropriate and wrong responses – A lack of decision-making power – A loss of power – Damage to the robot and otherdevices – Human injuries  Robotsmay have limited capabilitiesin – Degrees of Freedom – Dexterity – Sensors – Vision systems – Real-time Response  Robotsare costly, due to – Initial cost of equipment – Installation Costs – Need for peripherals – Need for training – Need for Programming What Can Robots Do? Industrial Robots Material Handling Manipulator Assembly Manipulator SpotWelding Manipulator •Material handling •Material transfer •Machine loading and/or unloading •Spot welding •Continuous arc welding •Spraycoating •Assembly •Inspection