CAD and Development 2 - Part 3

8/10/2019 CAD and Development 2 - Part 3

http://slidepdf.com/reader/full/cad-and-development-2-part-3 1/49

0esigning

artsor

Fine-blanked

arts

cost

more

han

conventionally

lanked

parts-for

the first

few.

After

hat,

he reduction

n

secondary

achining

ssociated

ith

ine

blanking

begins

o

pay

off.

An

additional

enetit

Fine.bl;ked

pans

are

stronger

han

hose

onventionally

lanked.

lvarh.r

bt.ntld

from

OtS rt..t

t.

0.230 n.

thick

and

3.9 in,

in dhncta(

lolanncaa

aru

a0.0025

n.

Ramovd

t

bul| on

wlrhar

t. th ia

tia only rcondrry

FonMs-\Dlth

losc

tolctrnca

.

. . coln ,

rtnbo3sas,

or.pedorate

.

. .

rcducas

naad for sacondaty

DlE:

chlntng

._. cutJ

untt

colt

Jt

youte

tooH;8

to

e.proce$

that

har

thcle

chanctari flc

elong

rith

tlr

e. charectcdatlcl

allociatad

eith

convanfloDal

onn|<|ng,

ake

a look

at

llm blanldnr

..

Flno

blanldng

k a r -llnenoat

oll

convrnttonal

DranKmg_

n

phlch

rnatal

psn

er

punchad

rom

ooll or

shaet

tock.

Slrnilaritta

batsecn

thala

fi9o

Focesse

i.lclude

tha

typar

ot Detadal

thlt

cln

Da lonrad;

ltr

grltlcrll

natarlrh

thrt

can ba

cold

r.orfieo

can

atlo

b. flne

blEhked,

Table t. Thror erance betsacr: fltra and convandonal

blank-

hg

li. in

thc

fldlhed

colt

ard rhechantcat

DropeF

gas

of the

part .

Utor

lkr

toart

Clrcular psrtr

up

to

16 ln,

In dt|rn,

or

lqulrr

psrtr

up

to

tB ln.

crn b€

flne

blsnked.

Tha

nin

MARIO NOSEAIZO

Pratld.nt

Modorch

Die

Corp,

Mineola, N.

Y.

Guid. t3

btant.d

rom

lO3Sst..t,

O.t8g

n,

tnick,

lol.ranc .

on

loca0on

nd

daam.t.r

of hot.

ar.

0.0004

In.

tbr

th.

lmall hol.

.nd

10.002

in. ior

th.

Ptrt lor l.tch mcchrntrm t bt.nk.d

from

1020

Bt .t

that i3 0.325 n.

ttiick.

Lcngth

's

1.35

n. lot.rrnces

on hote

diamltfi

are

+0.001,

-0.003

in.

t05.



t txt .BrAx|( tD

PAnlS

mum

natelial thtcknesss 0.030

n., and

}le max.

imum htckn€sss 0.5 n. Tlle tlrlckneGs irllmum

(no

fector

n conventionallanklng)

s need.al

o

permit

an npingementing to hold he

part

to be

blanled,

Fl8. .

llcr

Cbr lolcroncar?

'Fine-blanking

olerances

n

llneardirnensiots

t

I in.

or less can be a0.00O3n.: for dimensions

ovcr

I

in.. =0.0005-in.

oleranc* can be

held.

Tolerances

n

hole

diam€tels

epand n the ma.

terial

and

hickncls.In teel o 0.187ln.hick,

oler-

aDce

as small

as

*0.0002 n. can bc achievadi

lor lteel thicker ban 0.187n,, 10.0005n. tolel.

Ince

ate

piactlcal.

Th.re

arc no limitatlons n baxlmum

hole ize :

howcver,

practicel

mlnimum hole clianeteB

ar

summarized

elow:

?6le l -{eco;iraded mol.dol3 for

:'

' .

.

l lna

blqnking

Itilo

Bol. Dbr/stocl luct .rr

1008 hrcr8h 1024i&ft .nd

N

h .d

1030 lmuth

1095j

nly

in

lully an.

n .led, lDb.rcidlz.d cordition

{140, {140,

8630. nd

E640; l fllly

aM..l.d,

Dr.f.r.blt

|

rDlt.roidiz.d

Tr?G 302, 30,1,

305, .nd

40t

{nol

h..t-tr..t bl.); tyD.r 301,303, J00,

316,3 t?,

403,410, a2i

h lully

m-

solt,

t/.

hfd,

N

[r d,

X

h[d

Tlrh |,dnt

All

"H"

h.rdne &, (not

h.rt.

tLrt-i .rtd

"O"

l20la

.

d 2024,

''O" t.DDq onl* 60€l

r'd ?0?5Tl

d

T{)

Solt or roll h.rl.n..l, not h..t-

solt

Not

b.lt{c

Nol lln th.n 8% .oDD.r

t."l

D.dtn

Space

Batw.en

Hola*

Minlrnun

wall wldth

de.

pen&

oD

part

contiguratlon rnd 6toak thlcktar .

ln most

cales,

wall wldth shouldbe

equal

o at

,

leEst

elf

h€ naterial

hlckne ,Flg,2c.

Flattelr

.nd Edge

Enkh: Flatness l

0.001 n./

lD.

can

be expectld

l

parts

ar€ blankedron sheet

or

6ttip

materials.

Whe[

parts

are

bhnkrd trom

'l.d.d

d..l rld

br.r

.E no . €Dt .rd6d h..ru .

p|d

blllLd tro'r

t ar

do rot h.v. lnootl

.d8.r,

lPlllotyt.

rr.,tr

.hould ba

.wlu.r.d

9r'or

to tull...rl.

coil rtock. flatnc ot lbout 0,002 n./lr. csn be

obtalncd.

Fige

lurfaca tlnt,h depandron

meterlal

compG

tlon aDd 3tock tl

ckncai

The tlble

brlow lists

typtcel flnilhas lor verlour

thlckn$se

of

pa.ts

blanked fron

h.lt-he.d AISI

1008 eel.

Bhili|lo

Pdrci

t2

25

liZ

f

lflIfllflfinmll

ffidilt]lillillilllflhm

ie.

I

-Codprisn

or

conv.rdonal .rd lin..

bl,.n*ina

ie.s4.

Ac

tion of

.ih.

idpin8.oc.t

lrtc 2 d coua|.rDucn r..

idt io clot.

-

tol.Efte

p.ra

with r.liriv.lv

rdmth

c4.r

( o

die

I0 6



- f -

I

Fir. z-D.ri8I linit

iou of

finabtft.d

p.r .

Flnbh

0.030.0100

>o.t i7

l€-20

Parts

blanked

rom materlel such

aa alurninurn

and

brass

lloys rormally

have bette

edge ln.

ishcs

han Bteel

art3.

Dle

Roll .nd

Edge Squrencr :

Dle rolt,

Ft8.

2b, ls largely

a functloa

of rnaterial tblcloe$

and

6noothness

of the

part perimeter.

OD rtralght

lihes

aDdsrnootl

curves,

le

rolt

i3 $ually

llmited

to

l0% of

the matedal

hlck ess.

Hor

ever.

on

shnn

noints

(15_

or less).dl6 roll cen

be as much

as

:3oA

ot the naterial

thickn€ss.

Dcviation

rom edgesquarenes3or

parts

up to

ya-in.

hick is usually

betveer 0.0005 nd

0.001

iD.

On

parts

over

%-in,

hick, t may become

.002

' Coft€rs Sharp comeru contribute to lncreased

di€ roll

and, n

extreme ases, an even

cause

le

break.

€liminatirg

he sdvantage f

fine blanking.

Minirhum

adii

of outsidecomeri should

b€ et

least

07o

of stock hicknerEiadll

of inside

cor-

ners should

be at

least 5% of the tldckness,

Flg. 2c.

ColDh&

Fordhg, E[rbo$ln& Extrudin$

Fine.

blarking

car be used o

perforete,

oin, orm,

em-

boss,

an.l

extrude

parts

n a sinSle

press

Btroke.

In

genernl,

hete

aaeno limitations

on tlle com-

ple:'rity

f embossing

alts.

Coinirg

s subiect o

the sarne

imitations

as hole diameteE.

Formine

(bending'shouldnot exceed 0o, and tlle heighi

of

a step

should

ot

exceed

hree

stock

hicknesses,

Fig,2d.

o 2,000

4,000

5.ooo

3OO

Iun .l

ot Podr

Pi&

3-Corr <@r..iro,| of

corv.ndodt .nd

fin.

bl .t.

it:8 J9

r_

rrpiol" bLrt.d

p.ri

Toolina

(d.

fo. tinc

Dr .llnt

r.

ap4 .rEd

br u, , r.Fr.r.rrt

@li.[

cnn

Wh.l

Dc..

lf Co.t?

ToolinS osts or tiDeblanking reusuallyhlSher

than

firose

for

conventlonal

blanklhg.

Thus,

some

minimum

nunber

of

parts

must

be

produced

e-

fore

the

cost edvshtage

due

to the

ellmination

of

secondary

machining

begins

to accrue,

Fig. 3.

As

paft

c.tnplexity

incfeas€s,

he

cost ad ,antage

of

fine

blankirg

also

ilcr€ases;

the cost-vs-number

of

parts

curve

for conventional

blanking

will be

much

6teepei.

Another

cost-related

actor tiat

inlluences

the

choice

between ine blanking

and conventional

blanking

is

qrhetbe

or not

the

paft

Fill supporl

the required

o8d.

Colvendonal

blanking

tends to

weaken parts arould their perimeJerdue to the

dle

b.eak.

Equivalentine-blanked

arts

do

not

have

diebreaks, nd hus

aresttonger,

n,

Z

A.1l

at

z

a.o5/

t07



SPINNINC

&

I'LoW TlJXl,llNc

I Spinning

Metalrorking

by

spinning

is

a,versati le

process

fo 6haping

sheet

haterials.

It

is

a universal

uethod

foi producins

.t.pe"

.orro"" platr

section

ale

circular.

The

process

is general ly

usea

tor

;mpte

shapes

shere

the

quatrti t ies_do

dot

justi fy

coEpreh€neive

press

too:ing,

flared

shapes

where

press

tool ing

would

be diff icult

or

iopoisible,

,"_"i i .. i i

shapes

where

seS'ented

tool ing

can be

uti l ised

and

iarge

*oikpi.c"s

toi t,tr ictr

othet.for's

of fabrication

rould

involve.ptohibit ive

iapitat'-o"is.---Spinoiog

is ,rot

Dornally

applied

to oass groduction althougir there are so'e exceptioDs

to this

rule

(eg

kitchen

utensi ls).

spini i"g

"oiL-iJ

ci lr i"a

out

on

dachine

tools

of codv€ntional

design,

either

p""i"f iy

naiutactureltor

ttre

purpose

o

6iEply

adapted

cenrle

lathes,

uti l i ; i tr8

to;1ing

that is

siuple

and

relatively

inexpensive.

1o,

tur[ing,

whilst

at f i tst

6ithr

very

si-oi la ,

ha6

Eany

fundaeetrtal

9ift:::::":

both

ir

principle

and

application.

'rij,

i-i iru".r"t""

Ene dr.rrerent

concepts

of

spinning

end

f10v

turning.

rt

should

be

noted

that

spinninS

ie

essential ly

a fotEiDg

process

witi

no

significant

chante

in section-rhickness,

wheress,

shear

sfinning

i"

.

frogr""3i.,"

rorgirrg

operarioa

irvotvi lrg

cotrs

dersble

oetai

dispiaceoeni. '-

---

-

Th. technique

of_

spinning

is a

lanually

opeleted

plocess

where

E blank

of

r.larivety

thin

ducri. le

oetal- is

acied'up"n

"i l ;

-;1i";;_"osed

or

rolt.

tool,

sooetiEes

lever

assisted,

ia

o.aer

to'

persu"J"

-ti"

l"t". l"f

to

adouoe

the

shape

of

the

chuck-o

forDer

to

pioduce

irr" i""ii"a

corEponent.

A scheoatic

vie .

of aanual

erd

l.vei

.""i"r;;

ti;ni;;

iJ-s-io"n

iu rig.

z.

Siaple.Ehapec

can

usually

be

EadG-t

th

on€

pags,

rir i l6t

intersrage

aqr.alilg

ia ueed

or

the

loore

difficqlt

""i"ri r

s'-.i

-""ip

i *

"r,"p.r.

FolEeta

ceu

be DAnufactutad

floE

Boftwood,

hrrduood,

plastics

l€Eirretes,

aluoioir:o,

easr

iron

o 6teeLr

ttre

crroi

e'aeleiJiii'"i"i-iii

a".y

arra

ecorolrice.

spilnins

rools

ere usurlly of ,;*d:;;s;.;; ioir", typ"

""

llusrleted in Fig, 3 uounred

a lisid't;;e;;.

-

i iJ-uJi

ii 'r,,u"i..n.,

io

spiaafug

ia

essenrisl

atd

sorips

ena-taffowa-aie

*:.1'"f i-.". i . '

'

1o*

turEing

(Sheer

spinoing, powet

rol l

f,oroing,

power

spinniag,

rotary

ertlusion,

hydro

spinninS).

Itre coopotrerlts

of

a ftorr

tulning

rethe

are siuilar

to those

of

a 6tanararal

tethe,

but

are Buch

6tuldier.

Rolleti

.""

: i i i .J-

to-ti.-l iois

sliaes,

ana

these

shape

he

nork

ageitrst

a

lotetinS

,.1i4;;;";;";i:

- '"-

For irregula

shapes,

the cross.

slides-are

ttacaE

conrrolled.

lrai

slidea

nd cro6s

slides

are

senerarry

hydraulicalty

opJi.i"i-iJ"liJl

.r.n"

3;i.*irf;;:""

involved.

Marerial

lo.o

;-

.

-;;;i;;.;;;-ii=a""p

a".,' i,,s

Ploduct ralge

froD sDalt

iteEs Dade

ia

larSe

qaantities

(eg

Eetel

trlblerE)

to

lerte cottpodcBts

(aeroapace

applicationg)

iq

sEall

quantiti.r.

llar*s es large

ao 5 E in diaEeter a[d

plate

atock

up to

25

q

thick

ca be

powe spun

vithost

applyi 8

heat.

llhen heated,

blalrks

es

thick

a

14Oq

have beeo

auccessful ly

spuo.

I,lon turning ie a gevete cold working opelation aad has a Eerked effect

otr

the

Dechalical

propertie6

of the

nork

Detal.

craitr size i6 refined and alr isotropy le6ults.

Surface finiEh

is usuelly

good

alld

ao

additional f inishiag is usually

required.

StreEgth and

hardiess increase

ald ducti l i ty

decleases.



rmEncfltNcplDlE

g

,|Ut c,tt RE

h. eih re 6or

for th. s. of r.t.M ol

nlirit

t

rlt.i i. to

lleiid.

.onpon.bt. vbich virr .srcDbl. t oA.ti.t .t r.ndo .

If

thi

i

..hi.v.rl then

"fittt4"

l .]hin t.it. il th.

.tt.

@

"i

Bt€

.hdg..b1.'

.

cen.fully th. co.t o

,roducltod

i. r.dE.il n...u. th.

Gllninrtion or th. tittins

volt r.tlu.. tb.

ti .

r.quir.d to hull.l tL.

DDduct.

A cdtrllc choic. aor tb.

ldtlu ldl rili.I lllitt ot.it. u to

h. rit to

dtlov r

..don.br.

MnufacturitrB

v.ri.tio

ln

rctu.l

.ir. oa thc conpoc.t ,

but

vtlich vill nlvly. givc

q.cc.pt& .

drl... of fit h.te.. n thd d a...rlt.

Th. i.t.rchaDs.*t.

sy6te ht. ib. lollwlDg

.cororlc

.ilyut a..:-

a) corponebt. cs n. eade in

quqilty sith 1.. iLuld otr .tllt sd.do't

if .uiilhlc

gaug.. ard

t@1ina

r. u.a. nr.

qr.dity

n.t [email protected] t

be

lutftci.Di

rD.ct.l relr.s co.t..

b)

cobpon€nt. cad b.

'as .Dbl.d '

in6t.d

dr

"fiit,.it"r

i.

ti.y viU not n..a

tinlI aiUuterts

o. srirha

ch.r.ctlr

it o d.r to

proiluc.

t.ti,a..tory

.) AsE.,bIl.. .o Dde can

n. ..nic.d by . .tpl. .t.t. or EDlicdat

i.lt.

ilraq frd otock. 1ti. is [email protected]

fo th. u. dd i. .h.. Gr thu

r.conilitionira, vhicb

woufil

irrolv. tb€ Nut ct@

ol

a.s

ttrt.

to.I.ct.t

(not.

thlt for tn. clsc o . .cir1

nobc-oft"

rcltmtr

lt b6c@. o.c....rt to

@nul.ctu6 [email protected]

pong

r'to

suit{ tb..tl.tih .qclF..t

rioc. th.

co.t

of. .cld toolina 6d

soDs.

c.nDoi

t.

j@ti i.tl.

th...

ptrt.

tb.t.for.

b.cG

Prc- couIsit.

B.foE a Bylten oa intelchlngeabl. E.lDbly c.n b. oD.r.t.d ccrtrl

lundeontll conditiont luBt

b. .t:-

i) rh.

D.hirribr.

va.latiotr

(torcrsc.)

ol .ich dien.loo

lut n. fired.

ii) I1r. utirS condition

6

..ch

D.ir

oa

ptrt.

...bl.d rust b. d.ciil.il.

Procedur€

To.h6urc thot cobpo .nt. ar. uitc

rr

n.lrlr ltl.ntlcrl d

Fo..ibl.,

tb6

Mnuflctuina

lrocerr..

to b. .hpfot.il rut h. c r.f Iu cho.eo.nd clEcili.a.

T1,o

?roceitu.

involve6 l,h. follosinA:-

1. A

Pro.e6s Plshin.

noutc

1t i. i. bcbeilur.

of

th.

indiviilutl

op...tions, oil th.ir d.qucnc.

rui

.t o bc il.cid.d.

2.

Iis- -&-. e

grEci.l

Lori's &it

'quip 'nt

N't

b' d"isD'tl

ln

'ccotduc'

titb

th'

te...

pla. cboic.

of tb. i6 E

Lc.

for th. co 'cuttr'

loc'doDs

ir tt.

p".t

"ttl.

tlo lnaiYiitu.I

o .. tion.

.r.

. lon6il

I

Y'ry

ilportqt'

Fu.tio ..l iLt@

rui h. c6n.ia.r.d.

3,

r,htt 0.u..

a o.uFirF Eoui@nt

llrrt

b. d..im.tl l

oritet

to .oDlrol

tb. .ccq'cv

ol

th'

worl '

lt..ccq..rr

ol ih.

.r|a..

..d.p.cl.I

t@)lda

u.t

b' cb'ct'il

to hrgts

F.ct.io

.teil.t& .

toG D.ti :ttlo .

ro Lllli. t

rlt

(...

Bsl'oo

(r.btc

uottt))

.bs4'-

Et.

t.r . et

to dt .rt.d.l

diEnrion of

'

c@tE"nt

qd

.oi

lut

to

circd.r

b.r..

"trol.i

-

tbi. i.r

t.t€n lot

odv to

th. di@te

ol cilcDlu

hol'

but

to Ev l.t.hil

itt .nrio .

iE

.ic

8tr."

-

l. th.

.tddltn.lzo

tor tb.

. t

4tr

i. th.

o lor

botl

tl.-.r"iii

-a

tr,. uiibs,'rb; ft,.

(^r o

cdr.d

,'&4I @s,')

t -

-7-\

| |

+'J-'t- | |

\ i

l l

I

i-.

aaa

Z. IlD.

-

laalc or,o



'LIrt .

of s&q"

-3 -

the ut u ed llnlM

.Et.Ibl.

.i:.r

o th.

?.rt.

Itilta.c. b.ty€.r

tb. tvo

1tdt. of.L..

'Mlni.

a l|dlt@ Clcc&c.'

-

(o

Irt. ...ac.

yh.n

n.cc ..ry)

s

rSol ' l

"0nd6

ol Tor.r.nc.'Lltr idlcrtlob or

h. d.gi.. oa &cqGy

ot lrut ctu. f,o_

-

.ult .Il,

b ic .tr.r. ttl.

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Im1

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tr."

to

th.

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i

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i



rz r 6.4

SurI.e n'shies eatB pmdrc.d

b, odtun

ptudrcdon

p&es6,

@ti, '

RoLshn.cs

vdu,

R.tin

@j

Ebcrc

dbchsrse

rdinins

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awEse

apDtica

n

ls

L6s

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Ie r:

ssrlsi

pr2

re74

lollEplEFqe.EshrqeIijuoyEfule*.jtdfu'

*f;*."['fltrtr"l:trT'.:;fn

tFisur€1:

BS1134:

an2:

1972J

rl

12

t1



N

K

%

N

n

"if

slq

-

-T--o

-r_

l

l

_.9.

t0

ts

I8

-n

l

-q

IO

;i'

=i

-i

IA

6

l8

30

n

t0

E

30

40

l8

l0

40

50

l0

40

50

65

40

50

65

EO

m

50

65

IM

65

80

t00

120

m

I00

120

140

t00

t20

t4 0

t60

r20

l,l0

160

r8l0

t40

160

tm

2m

160

I80

\n

225

lm

2W

225

25fr

2m

D5

250 280 -t ' 225

2fi

280

3t5

zfl

280

ll 5

35 5

280

ll 5

355

400

ll 5

155

4{0

450

4m

500

400 450

450

5m

BRITTSH

STANDARD

SELECTED

SO

FITS-SHAFT

BASIS

4500B

a'



qd P

%

N

%.

%

w

@)

N

N

N .\)

';

'- "

\'',

V<

_-

6st

y-"1

cflr

.\SN

|

+

n r.

-if

l

6

-i

6

6 l0 12

t0

l8

l0

t8

t8 30

l8

4t)

30

q

()

50

40

50

50 65

50

65

65

80

65

80

80 100

80 100

lm

120

10., 120

t20 140

I20

l4t)

t40 t60

140

t60

t60 lB0

160 180

180

2m

180 2m

200 225

zm

225

225 250

225 250250

un

250

1m

280 3 t5

280

ll 5

I5 355

3 15 155

15 5

400

1 55 400

400

Afi

4m 450

500

450 500

ERITISH

STANDARD

SELECTED

SO

FITS-SHAFT

BASIS

45mB

3

\Z5.ooo

\zct.

Q6<>

l '\crr

C leAvhce

\ ls, \o6

iL\.q6o

, ' | \15

iot '

'

\ rz; .our

i I :



i c

nt

€*o

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tz

Lo.ao

\1 .cI46

D\O

r

\

Q1

_1_

S >

l - i

,)

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'13.1

:i,

tr

2o

\ . .ec;

Zc,

?o*'*1

fo \\l

zo:6

>

Y',\a

).

?r.\q\

\q,

1

q,6

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-,-\.qa

\^"\ .

I

I

l

l

\c\ ' \ 3

v\-i

-

\

v-

o^X

5

-1".r\1

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-z-.O(5

7r9.

(2o

o

I

cr-

n

Gv

^r)

'J. ,

Fctl

9

ro,.tq3

11.1"2

:o



SUn]IACE

E]ITURE

I rrgule

i i .

trhich

rould

be

4th

order

Ir cgul i ,t

ier

of

tb.

chip.

ES

tI34

-

1972

Eextute.

.,re

t{[derd

defides

2 cla86e€

of

e:<ture.

RouRhn r

the

Ndture

of Sulface

Texturg

?l:3,"i.f"""

produced

by

chip

reeoval

process

depalta

frod

the

:::.",:?

Tj.:::i:H

::,

;ii:ii.

ina.

"

pres

nr

i"iiil;;

-;;

desired

perfect

recoglise

fout

l s t Orde

I : : : : : ir i . i"f

arising

out

of

inaccuracies

in

the

Eachine

ool,

r.ck

of

lEai,gh trelr-in

lhe

l 'eys

or

guides,.or

out

of

defolDation

of

the

lrork

unde

ne

cur in8

forces dnd under lhe lrei.ghtof i rr"-r i".:- i i - i . i"r i .

2nd

Order

Irretularl ier,cEused

by vibralions

of

aDy

kild,

et chatrer-dsrk

due

o

acorrect

cuE ing

engles,

loo1 vibraEiol ls

etc.

3 d ord.

::::: -by

rhe.nachining

ts€If

end

characr.ri.rric

of

rh€ proces ,

preser

ev€n

f

the

i:chine

rre e

perfect

".a

fri"

ii"r'rifr"ii i",

arising

froE

lhe

ruptule

of

lhe

Eelerir l

drl l ing

the

lepes.tion

Centte-1i lre

.varage

height

Dethod

for

the

aEgGlssent

of

turface

IJavines

Roughnerr

(PriEaly

textule)

(secoDdary

t€*ture)

The

ir eguldti t ias

in the

lurtece

lextute

uhich

reault

fro6

thc

inhelent

ectiotr

rh. produc ion

p oces6.

rhe.e

ate

a"e.eJ-io

i;; i ;;"-;;;":;""

reed

,iarks

nd

the

irteguleri ies

lr i thin

Ehen.

Wavinca

lf. l :-"o.no""o.

of-surface

texrure

upon

Fhich

rouShness

s

3uperiDposed,

:;:i:ff:

ffi].':::i:,:::',:";:,;:ilo'",",,'*"t

in"'o.

*.t-a"ii"i.i".",

vibrarions,



Su

f

ace

topograpny

rz

trrrs wirh th.

*antcd .xcuEioE

of

thc

{vlus'

rnd

'n

oacricc

rr'c conUi.*io"

can

bc

lcc'Prcd

onlv

wh'n thc

'"i;".

"..

a*p

**et'

rnd

cldc

cnoush

rosdh'r

tor

Ji.'.".i"*

"rir'.

'li.fsi"cn

radis ro bc shau con'

orrcd

with thotc

ofthc

stylus.

Som. ryPrcrl

Profi

ca

oi rou8hnds

Iaturc'.honzon'3rr

comPrc$cd n

thc cu, l

w:Y i t '

5ho'Ln

n

R

r'

Fig. 4.

f,/Pictl

Profil.s

Mtgnification

is

3hown

thus: vert

icel

I hori2ontat

Fio. 3.

(.)

Skid

S tlidas

ov.r

crasts

of

sptciman

(i,

.cc.pt.bl.

.Pptoxim.tion

to

in't'Ptndent

'Jiti

t"t

'ieniiic."t

skid

.ttot.

n's'tiv'

ol

'i'jli,i

iii,anc

tu

whsth't

th'

skid

'nd

stvlus

dovc

in or

out

ol

Ph,sa

ld) acc.ePttbla

n;chanicat

filtrr.ian

of

wav.lengths

which

ara

iii

""^p-"a

with

s.P't'tion

of

skid

'nd

Thc di.mond

lrvlu

mav h'v'

tht

lorm

of a

90' con'

* l-,ia."

"i,".ia.

*'.t'

'tandardi 'd

'quival'nt

liP

rrdii

i "a

"p* i ' - .

ro**

"t :

rm

0.7hI

or

l0

/n

l6nN

whrlc

tha.

uD.

.rc

3h..P

cnough

or thc

gcn'r

'un

ot

."di..'ii"

i'i.r"".'.

'zrirg

do*n

ro 0

r/rn

.000r

s0

".i s. ui'o in lo.cialscd dtruhcnlr

to

grv'

b"tcr

i*.r",i"^

"t,1.

n".",*lu16

''

8

thd'

ofsaus'blo'trr'

Elccrric

iBduccr ,

follow.d

v hcir

'tr'nden(

mPr''

n.i..i..rr*.u"a.,

airplrc.mc't-5'Eitiv'

i'd'P'nd'n'

"i

lii.,

-a

rnotion'icnritivc

d'P'ndcn

on

ttllu

vclociN,. Tlc

djllincdon

i

ihPorlcni

and

thc

ut'r mult

ri"*

*uJ

ri'a

r'.

i' *l'g,

bc;au '

tb'

form'r

n'cd

h'vc

ii-'r-,i"""i

frcqucncv

rimn:rions,

rnd c"

rcProduc'

*.*ir"nn r"'c.[a

bv

thc ltvlu

r'lidvc

o lhc

datun

n.tuain""u-t

tingt.

gt*"s

and

rh' lonS'lr

w'vcl'ngtht

-iir. 'n'.

r"*'

hr'.

ficqucn*

UmiratioN

rhat

rcn'ct

thc ran . ofDrofild

ro

which rh'v

cln

b'

aPPIicd

wirhoui

scrious

misrcpr*cntation.

-r.

*.-"'r.r' Dhoto-clccrric

and

modulat.d-cldd

rranrduccB

r.

disPlaccm.nGscn'itif''

dovms

co'r

rrrnF

duccc.r . nonona.ntnv' Pi '2o-clccr f lc

dsDlrem.d-(smk

rn

hc

brntc

oi lcrx '9c^buI

(omr

-"1i".-**i,*.

*t'.'

-"."t'd

ro

rn ahPrific-

ni 6nn'

Th. cl.crncrl

5iqnJ

froh

a

disPlrccn'nrrnturc

,'"*i'*"

"ri..

".irin'"u"n

nav

Providc

thr"

kinds

;i

';;";,,;;

I)

n

a'arosu'

rc'ord

'

c

r

Pronr'

;";i;;';h"',

rcc".d<'

,ndtor

'2)

r disi'ar

rccord

li.'.:"r'-

"ir-a"

,p.-d

o.oinrtc

of

thc

Pro6l'

srrph

tal.n f.om

th. sidc

ol

thc

chai

bdng

rccord'o

on

oun.h.d

o

nden<uc

aP'

lor

" ' l_r lu ' r '

ProcA{ng

'n

:"" ; ; ; - , , ; " .

; ; ; ,

3

n*r

'n i rk ' r 'un5

o'

numci. r

ralucs ddcriprtlc

of

h.

Pro6lc-i i . , ; ; . t

dcr i 'cd

fr ;m

motion' 'nr i tnc

nnsduce^

^' . ; . ; ; ; r r '

u i tJor"

for

m'rd

no' 'auun'

ror

'h iLh

. , .* . - , r t .

f . '0, . " .1

fune/ \ r ' u ' ( d 'hb'r r rd '

NUM EFTCAL

SSESSMENT

Significanca

and

Prsparatlon

ForourDos

ofcommuDic' ioo,

aP'ci'llv

n

drlwirrgs'

r, ,i"i-'l.

.

a..;*,urf'cc

c' u(

nuhcncalY'

nd

mlnv

rDororchca

o

hit

hrvc

bc'n

cocid'rcd

A t m'nc

.;;i;";iJ;;i;-"

-p*,

"r

trr.

td(turc

i oRcn

cr'ncd

ro

s

i

p. ah. .r'. ThG

hciSh

tP:cng'

loP'

dcn

.--**.'"iii.

-0";1el'nJvrnou'

ditt'ibutiod

"d

corrcl.don

f:c@E

of th.

roushn'3

'nd

bc

cni 6cant

nd

conribu

G to

hc um

rottl

ot

rdorhruotr

ihrr-mav

bc rcq'ired:

t"t

no

3in8lc

PandclcrlrP'ndcn'

i" ,

.i""r.

*.Llt.

can

colnPkklv

dcrribc

,ti'

{rrrr

'

s...* 1,rr*'

h.vin.

qu'; difcrc'r

p'o6l'5

rrn

'"

num.nc. l lv

.qur l

Mth

raP"'

to

onc auch

Pirrm'r ' l

whil. b.inq uncqud

wilh

rcsP'a

(o

o(ncr3

rrdninrh

. . . ' 'a-" . ;*

ai .L", t ' .

tnc numb'radh{tcd t^ * ')rr '

shoD

us.

sbould

bc

dinidiscd'

"

ir."iJii

i"'"a

bv

rh.

Pic['uP

m'v

']hibit

d

"l l

r(jruvc

rc rhe,srruh.nr

darud.

(r\ gcncr.l cu^rr"'i

., i.*

**a*"*"

cls.d

d 'w.vind'

r'd

/ h'

.ho^*---.t.nrf"

cts.d

s

'oughn's

rhown

rcrrccc

i ' . r ' i " , r ' .

o."ni .

i "

r ig.

s( . '

Th'

f iFt

rwoorth6'

b ' ins

'.*r.';"i

,,i,i'"

lhird

".nd

rourth'

rcmc

Pr'Prrrtion

^f

'i.

or.nr.

i' *qu;.t

lcfo..

u3cful

cdu

r'm'n t

'rn

b'q'n

Prcrararion

ii"ot'c

rccognition

and

isolatron

t rh'

i . ;I i l ; ;;; '

; ; ; .

.* 'u' ia.

.no

rh' s'rbri5n-'d

r

. ,

' l " "u l .

' " . , . * .

rrn '

f ron

*hrch

Llcced.

Rt-oqnruon

olrhc

o t rcr 'nr

kind3of 'e\(ut

Jn ' r

or 'ha '

l ,ound.r cs 'na n orvc

omc

ocqr" ol-uds"rn"n '

I 'n

. ' " " ,1-, . " Broadtv.

oushnc$

n d"hcd

ro

it ' iud '

Jr r



Surface

opography

F2

Parameters

Erccpt lor lhc fai.ly

p.riodic

t.xiurca

3oh.tjh6 prG

dd.cd by dttihg pro.c$d, 3urfacc

rcxlure t.nd to vary

.nndomlyin h.ight .nd ipaciDg. Th€ problcm ofdecnbing

thc

diFcr.nt tin& ofr.itur. ofcF

full *oFt ior lhc

d.vic6

nf

(h.

ltttirticib. frod rhc aihplqt

fo.tu ofav.rrSing ro

ih.

<omplcxiti6 of cotrclatjon flucrioN-

Height

Th. mor

comho'lv

6.d and cdilv mc$urcd h.ight

par.mrr.r

n

'h.

av.r $ d.panur. from th. mc.r L'nc

Df thc fih.i.d pronlc. ft i tnowr i. rh. US.{ 3 rhc .{-A

rallc.

In Grcar

B.ihin

ir

wa

and

Bcndall_t

ir kno*n a

rhc ch v.lu.,

bu(

it is noq o b. knowD d rhc R.

val (

ro

lin. up

virh

ISO tfhinology

dcprh. B.a. ing r nr. rccp6 p.r

un' r

lcngth,r_J

giv.n rcvcl

har. rko br. . .oun, .d In a ncw d. thod' '

a l l thc con-

$iru.n$inusidal wrvcl.ngthr fou.d

within a

gilco w.t.-

band,

wcightcd

according to thci.

amplirudcs.

ar.

'al.

into account

in an avc.agirg

proccdurc.

Beaing

arca

A conccpt

rcqu.nd:/ cn.ount.rcd

i thar of

'b.tring

arca,

lhown in abltracr p.incipl€ in Fig.

8. th. l.vd

of

th.

intcB.cring linc bcing crprcscd cith*

a I

dcprh

bclow hc hi8h. p..l

(an

un.cftain

..icrcncc poiat)

or

a

an

ofs.r iron rh. ncah linc.

BEAFIIIG

LINE

_l

- i

-li-T_rJ

--

--t-

I INE

Fig.8.

Not tinsl bea.ing arc. of s.t

rple

3/a

a

\

100

It mulr

bc rchchb.r.d th.t thi Ec..ur. i connn.d o

a

m ll i.mDl.

of th. lurLcc

.nd do6 rot r.riacnt rhc

ov.rrll b..ring

.rc. taling

w.viD.s .rd orort or rorm

into .ccounr.

or do6 n .[ow for clrdc

deforftrtiotr

of

th. p.ak und.r load. Th6c atrd othd cotrlidcrlrjont

Crcst

curvaturesand height

distribution

Th€

.vcnsc

radiu of €u.v.r 'c

of

th. c'6t ,

tnd

thcir

hcigh dirributiotr, rr€ rcfcrcd

to in

conn€clion wnh thc

ol.lticilv ind.x in Sccdon

Fl.

whilc d. .r idic.tioru

..c

nor

gcncrally

vaihbl.,

thcr.

qu.Dridcac.t re.dil.r

bc cofrpulcd

rron

disi*cd

prc61.

cco.&-

Corelation techhiques

Thc . m.thod hav. b.cn

inilodu.cd a5

.n

.id

to dis-

tinguishing b. w.cn thc ah3pc

of

characrcrisric

profilcs.

An accourt ofthcir us i

tiv.n

in Rcfcrcncc

I L

STRAIGHTNESS,

LATNESS,

BOUNDNESS.CYLINDRICITY

AND ALIGNMENT

Alrhough

rhac

sp.cs

rE

g.ncrnllv.ons'dcr.d 3.PaF

aklv fron lurfacc t.rrur..

rhcy

can b.

highlv

iignifi.ant

'o

rhc lunclioninq of rurf.c6.

rnd mur

rh.r.forc

r.c.ive

1 lcd softc n.;don id th.

prdcrr

scction.

Th.sc sp.cls

ar.

gcncBUy

m.asurcd

wnh

a blunt nylu3

(h t

rrac.s onh

thc

crdts

oI thc roughnc$. a.d do.s

nor

appr.ci blr

.nrcr

rhc

nar.ow.r

scratch harks

Sfaiqhhc$ and fainc$ .c now b€ing ncasu..d wirh

rhc saoc basic tvpc

orappararus 6

io.

tciiure in

Fig. L

_ _-t

Fis.7. ta

-

Lf,

vtot.,-"

=

(Lrl|,^"|

Thc rtu v.lu. h bftn $cd in.pproximatc

forh,

obt.in€d by mulliplying th. AA v.lu. by l.ll

which is

thc

convcFio iacrcr

oi sincw.v6.

Thc hcight roh fi. hjghdt pcat to dccpcar l.y

lound

anyehcr. .long r

rclcckd

part of th.

pro6lc,

lnown

a

&,

i

u.d crpc.irlly

in Eu.opc, bul it

k un .d f.(or:-

bcc.ulc thc singl. crrcm. .r. loo grc.rl),d.pcnd..r on

th.

chanc.

porition

3cl.c .d.

An.v.rascd ovcrallhciFht k

morc r.prca.nt.tiv.

(han

R,.

Thc

'tcr

poirr hcishr Rr'

ir

obBincd

bv avcr.chs

thc

fivc Nghd p. b .nd frvc dc.p6r

vrllcy in th. tottl

tnver]e.

ln 1 rcccn

Gcrh.n v.n.nr, ttrown a

&.,

th.

avdagc

of fie R,

v.lu6 in fiv. coB.cutivc t.npl.3

or

cqual .ngth is tllcn.

'llhoosh

rhc rario ot on. h.jshr n.a r.

to rnothcr

,.r wirb rh. 3hrD. of th.

Drofil..

om. dcqrce

of

ron-

vcFion

is

g.ncrallv p$liblc.

lhown bclow:

l0pr

"1"

Ll8

to

l-30

t_25

5.o;

8.0

'

Wnh cLan cur .oB.ou.d-nd.

'@1.

spacing

Thc 5pi. inq

oi ih . norc sigt i f icanr

P.: i

r lonq thc

. : : r f . .c.

rd l 5.

tunct ional lv mpoi l in t

Pcrts pr '

' rn ' r

l . r { th hrvc bccn o i I .Lr '' p f r . 1r. , , ,1

htcd as o.1,

" f l \

r i

(hc

ld ja.ent

ra l lcv c\ . .cdr

r

c ' "n



'

'l-;a

r,r

-_._4_-t

:--

r ro.

Mil l ing heoret icol r oughnss.

Thc'otetical

oughness

$r{.*rr.t

.n,L.6lti.L.i

How a

wlper works

i--^;"'---

i

0.00t-0,005

l l

Fig.19

nr. l l f i r l C l l t

N

:

f r

Surfa e

(NB.

rou

9n

n ess

Ril l

2Rs

)

oi broad inish

rni l l ing

I



BS11:14:Part l : . |972

t

---g:-.-

.rtu

ro

E

du.a?|nldrn

.t rt. rk.

h

;ikr

.... rnt

t:l

SE

b.ka l:.--:+l /.

|-

-'z'g*"-

"

-L

hFiooL, L lL

tl*

ot

tr.t

.tlon .a rL rlr

h riLl

d4'-

lilUffiil*-.w

X

c.dt a I tD .lir aa{d

cl'lhrto t

Af

.aF4dlo..f

lhiLrh rr&l

.

tit

l b...d

M

C

lt .|brdr dn*

iliar.

-

L6ln

dfirn.

biL

R

A,' .d..ld,

,.3 irdn

b

t

dlr .a

t rtd k ru.l rl.

xtn l.t

aatt.-rriiat..dr..hde4.*ath.o-4.r-rr&.rr.r.E

IsrlIt,an,lYILrmalr.t r.rt,arFirIk.a.aJt

tfi

-antui

flo.r.

Swnu.latt'.t

r.cionolLy



-2

s MlcroDet169

NurnlEI_ F ln lsh Descr lp_t lon

apd Ttptc. l

Apptrcar loos

neco@ondod

lrodrod,

N6 /

v

N 4/

v

o

'/

V

or/

V

o 05/

v

Aelrrna

surfqce rh6r6 s 'oothucsr eosenr la l

rnd Turo

vtth

sqlaro

nos6

tool

e l t l r

draa

feed,

tool

bsrk. oDjoct loorbls

c.A. h lah

lpeod

ren , h&od

tl te

lnootb,

barro l 11rr ,

Bhal ts.

Jour:nr ls,

ro l l

bodles

and

o.cks

-

plano

broldcut,

co@orclo l g.t-nd.

hordetred

stacl

perts

-

runnlog aod

sl ld lDa f t tc

at b ls l vslocl ty. e-a. e€.r p lqtes

Sdooth l ln ls l r , r l thout

ccratches or oth6r

F l to

and

Potlsh,

l rp,

t lno rurr ,

roar,

d€fect lve Ddrk.. c.g.

cyl loder

r 'ored,

deol l l rat

c ls 6

cyl lndr lcr l

and

sur laco

gr lnd_

aur lacer,

Boootl

ruDnlna l r€

a. l uss ,

I l tah cldss gr lndlnA

( lntrh

-

hy.r .sul lc ron

Strst

c l rss c6ntro losr

cyt lndr lc i l ahd

.urtaco6

aho.r b l rder, hrgh

spoed lp lndl€.

-

6urtxco

gr lnd.

l rp, hotro.

bal l r rcer,

Audgoon

plos,

Iocat lns

bu her.

v l ro

dro* lng d lss. cold

str l ' ro l ls, )oc6t lon

Surntsb, pol tsh,

supor

I ln lsh, spccla l

p lnr ,

rebovrblo

burhos, very h lgh dp.od

cyl lndrtcal gr tnd,

lerres

8rrnd.

6plnd)s3. roDs,

ptsto la

cyl tnder bor€6.

EeIl

r rco tr ' rckr , cold

rtr lp

ro l r . ,

DrGclslon

ttone,

dor lee

srtbd.

AuuAe

bo.€r.

d los. l

purp

bo.ee.

O O?5/

ChroDlu

plated

Auuaoo,

. l lp

sdu8os,

opr lcsl

Dry lop brrror

r lntsh,

ret rap

'natr

t ln tr \

V

l l . ts.

d laoond tool i . spocl r l cold

' r r tp

rot l r .

scr los

art.d.



II

I I

IF

Fl9 _ t_tr- r t

Pl

n1s

h

25 /

V

Tho

rel€vao

r

Aft

t lsh

a-S.3Oa; pdrr

9 9r.1-c 1etrg q_f,r,e

t gf,4 p1lsa: e

A

vory.ouAh

E.ch

tne

dresstnr

. t ,o€ns,on6iry

;. i l ; " : '

: ' ; ; ;" . ,

" : : : . : :"

urposes

only

_

^_r6rrondbt

y

-

, .oo

th

surtrce

wt

rr ,

tro

spr

lnt6rs

or rr r r rs

--s l lg trr l ) ,

t r reautqr

n,uy

vnry

-" :r j , .

-

(or

clearanc€.

Do

loe(r

Intrn

o.o62s"

_

trut

tdr

[so

,hore

r

unl to.D

cohroct

t6

reqrttre. l ,

surface

roqul r loa

good

flotBhed

oppaorance

or

l . t t"s.durrace

rtth

tatr ly

crose

toterance

br L

o

Eovl r 'a

I la,

s.g.

traso

ptares,

Dnror (e6r.

Sur l6ce

requtr lnA

clore

dloeosr(

surrocee

rirch

,;-;;;r;;";;:::i

;;ilT,

-

i?1r",, : i ,

surfacos,rth

runDrDa

,nd

srrdrns

rrrs

.t

to,

eoloclty

_

su.tsc€6

rachrnod

to r

l ' : . , :- : : .r"": ,

Do,r€..tery

crosc (orerunce.

o,g-

bore

dnd

deAt

ot

shertE

tor

DeurrnA

l l i l l . :

.*1r""

.nd

6rrdrns

.r td

tr ,

oedrxo

v€roctry _

IntGrteronce

aDd

irey

rtrc

\ rv

\2.5/

u.s/

3

2/

v

l fdch I ue, hrn.t gr tnr t , chtt , ssw,

ier t le

ili:";.

t;t

.tlil

ll999g9 d uethods

Shqpo,

rrrn,

o l l l ,

Shape,

be. l lur

t

urn,

pr€cle

loo

cdst

.

boro,

p.tano,

drt

I

l,

rot

I,

bo_ro,

p lano,

gr

lnd,

ro6a,

rrrosch,

oore,

coonarclat

tu.tr ,

Sbap6,

Drt l ,

rouAtl

o lot,

haod

ecrape,



SI'RIACE

OR

PART

J 0-@06

N

o

{;

N-

$

-t-

sssglg,$

Pislon gs

o

packings)

*

- louslnq

f l ls no

gaskets

or se

ets &

or

a9-cut

th.reads

Clearance

su

aces

(nachined)

Datue

surfaces

\rnder

O.@1 in)

ove O.OOl- n)

ng

sulfaces

Eatln9

DecianlsDs

or

Palts-PleclsioD

sut aces

brackecs

?

faces, bases,

etc.

Pressed

fl tss

genelal

keys

&

Rofl ing

surfaces

I{orE geals

-

Worr

qears

-

hea

af

foadlnos

eraL

cans

&

fol lowers

du

general

pjvot

otat. ihg

surfaces

and

holes

etc.

p.Ins

I

chased

thleads

tith

legul.ar

cross-hatch

patteln

sEootiest

possibfe

f inish

woviness

not

consideled

\6

\D

6

o

o

o

-L

n

o

valve

stens

(autorootive)

o/I inder

bores

(?u

Pist

n

pins

CaI0 Iobes

(autolor ive)

Rod bushings (autoDotive)

cyli-.lder

boles

(O-rings

or

1-artrer

Surfaces

for soft gaskets

sr:rfaces of

fl-ura seaL -sliainS

crorind scree

rhreads

a

iorE

Sl lde ways

8

gibs

Gear leeth

(hearr ] ,

Io

cea teeth

(ordjns-ry

servlce

over

to Dp)

l-

selvlce

over

lO Dp)

i ,

.TournaL bealinos

Push f i s

MilIed

threads

<Iiding

surfaces

of

Eatlng



yl

t

Guiclo

to

'tito

Gelecilion

o-f fi,i:s

Hll-cl l

U .d t

9 l

v. r l .x lb i l l ty

.da r

lo ia,

?.3y. t . Ib l t o.

. c los. l i r t . l .v. r , .d

rort

t n9

l.npcr. tu.e5,

12Ml4

OIA

H1i-c11

l9-d l0

U3.d ror

l i id

i€. t i . loot .

psl lay

r id vary l . rqe

44

t,1r l

OrA

f l9_d

lO

iat . r ' i r i r

on

I t r n

.

89

.9

ueed lor r ldely

,cpi . r t .d

b. . r ln9s o. r .v. r r l b.r r lngs

-

So .trDlA

t19

e9

AA-17

5 i

.b l

lo . rppl l . . t ion3

r q ir in9.90od

qu. l i

t

l i

I

th . l t

e.3, to

pr0duc. .

lAMMO

HA-

l7

l7-96

Slld l^9

r ' j

r rot

nornr l ly

03ed lor

co.-

l i . out ly run. ing

b. r i^9t

u^

ers

lo iC

i3

. l iqht .

Sui

r b l .

ror

oreclslon

r l ld l ig rnd locrt ion,

6

t,1^r

DtA

l l7 h6

Su trbl .

for

n.ny

non-.unn n9

12 lM OrA

Ir t - k5

Ur.d for

locrt lon l l 3 rn. .

I

r

l lght i i . r f . ro ic. ,

ih ich

. l l r l . . l . r ov.{ .nt

of or.

D. . t . .1. lv.

lo . o th. . ,

t t

Utrd

vhg.

th. dcgr. . of

cr. . rr ica

ihrt cr.

. . ru l

t

r .on |

.N/- t6

f t

I

i3 ioL

-

-

/80

rlM

clA

rl-F _;jpr

Hz-^6

cr.r,u

. r,

r

i | ; : : : f t

'h . r

I

r i

-

; .d

3h. t t

l t -p6

F.r .our

rr r t

r r . .ot

bv.r -

3 r r r .d

d r ln . t . .b ly o.

2OO

MNI

DIA

H7-p6

au$

* . , " ' t , r "o

lor

p.r

. . . . t

-1OO

rlNl

0lA

H7_

s6

It l

i r , l r r

I i r . r

i^



Ig4 Manual

oI Bnish Standads in Engin"

ln| Dnwing and Desiln

;

q

{

I

5

a

I

^9

22

21

20

19

18

17

12

11

'10

9

7

5

t+

2

1

005

01 0.2 01

0.8

1.6

3.2

6.3

12

25.0 500

(l i ' .

7 / , , .

. .

tn, f-) 'qa

in rn icfooe'res

Exarrplr.'

Should

a

giv€n

areaof surfscsbe surface

rcund

o 3.2

rm

q akingapproximatety

minute,

then

o achi.v€

2

/,m

would

ake pproximately

.5minutss.

{Figuret1:BS1134:part2:1972)

Ytsrue

6.2 Trpbol rcIatbnship

of swt'acee utc

to

production

ine

fot

connonty-used

ooh

@d md?nats

Nor.r

This ASure s

Dot intended

for makidS @st @mpaliens b.twed difierc-ni

prc@ses

0.025



192 Manual

of British Standards n Engineefing

Drahiing and DesiSn

T;bIE 6.4

Surface

uughness

values

produced

by

common

prcduction

prccesses

and motcfinls

Roughness alue,

R.(in

pm)

Flams

utting

Snagging

Sawing

Planing,

haping

Drilling

Chemicaimi l l ing

El6ctro-dischargeachining

[4illing

Broaching

Reaming

Boring,

u.ning

BEff6lfini3hing

El€ctrolytic

rinding

Roll6rbumighing

Gdndjng

Honing

Polishing

L3pping

Sup6rfinishlng

Sand

asting

Hot rolling

Forging

Pelmanentmould

casting

Inv6etm€nt

astrng

Exlrudlng

Coldrol l ing,rawing

Discasting

I Average pplicetion

Fs\r

Lessfrequentapplication

i l

t ' " . \

( -

+J

r€1t

6

[Iablo

1: AS 1134r art

2 1972)

V,rer

Th.

reg.s shoh above .r

rypical

of lhc

pro@$cs

lhte.L Higher or lower valucs dai b. obtained un<lq special @nditiotu.

,1 i

/Ahcs

,

N.. =

"

{\ va

tla



o sng neer nges gn

General

data on.manufacluring

s

readjly

vailable

rom

books,

ournals

no

teafned apers.

Srrr.irc

daia will

be

more

ditticutt

o

_obtaio

ecause

t

witi

be

;;d;ieJ;or particlrlar

ompany

a.5

prcducl

onslrainls.

The

use of

lrends,

ndices

nA ratios

"ito*,

oaa,qn"r,

o compare

processes

l hedesigt

gtage

ut

hese

would

ormally

e

vaiidated

y making pror otype

o

owed

0f1en

y

pre-proJUCtion

nS.

Tooling

is

an

inlegral

ad

of riJanulaclufe

nd

consicieration

ust

be

given

o

looting

t the

oesrgn

lage

of the

product.

Common

ses

oi

loots

nclude

hapjng

die-s),

ouldjng;oulds),

holding

tixlures),

maniputating

0igs),

nspeclrng

tc.

GENEFAL

ESIGN

ONSIOERATIONS

s :e;

form:

matet ia l :

quant l ty:

aconomyi

accuracy:

surtacS:

3ta

da

disat lo

:

assembly;

-ac,(agingi

lnsi fuc

ons:

the

q antity

l materiaj

nvotved;

he

dimensions

ndweight

o

be

fT|lj_"*

lo

break,down

nropans,

wirh ocations

n

rypes

f

oiFls:

reiauonsnlp

o

processing

lant;

elationship

o maletjal

ize

availlole.

shape f

component;

impticity/intricary

nd elatlonship

o

pfocessin-o:

:-ll i l]

":ldjtign'

famjtiariry

irh

propedjes

nd

processino:

r€tatroFship

elweenrcp8rtjes

nd

processing;

pro0uctionaies

eq ked;

lanl

nd

systems

vailablei

nvestment

required;

quantity,

and:in9,rocessing,

nspectjon,uatity

ontroj, astaoe:

relareo

o

ptant

nd

ools

vailabjlity;

kills

availability;

t0lefances;

its;

quality

f

surface

inish;

appearance;

esjstance

0

environment;

roperty

nhancsment:

It-.j.T19?19fl

rl'

bought.our

afl

:

conrormarton;,or

a,ery;

producl

iabitityrorecrion:

educlion

n costs:

manual

r auiomaljc;

vojdance

f

€rrors;

modularisaljon;

astening

and

oining;

t0ols;

tandards;

esponsibilities;

elationshlp

jth

specilica

n;

Prgtecli:n;

andling;

ize

nd

hape

f

packst;

eed or n.transl

,

insoeclion:

c'arily

or installer,

ser,

maintaineri

anguagEs

of

export

foducts:

Further

eading:

Dieter

Engineering

esign

A

Malerials

processing

Approach ( Mccr aw-H il |)

cci l



DESIGN OT{SIDERATIONSOR

MAJOR

PFOCESSES

Der3rls

f

processes

aEbe obtainedrom

manutacturing

echnologyexts. This

section

s

only

conce.ned ilh

he desjgn c0nsideralions

elated

o

types

f

process.

a) Ma

eria l Removal

R-a?sons

or

ahoice:

malerial

prOperties

equked

or producl

icfaleormSuiledo

process:

producl orm fiay be ditiiculto achieve

sing

thef

rocesses;

accufacyet dimension

nd/or

orm

woutd

theruise

e

impractical;

surlace

oughnessequired

emands

rocess:

ayailabillty

l

plant

and

expertise

n

company;

produclion

ates ndicate

rocess:

taclllty or

computar

onuol

of

process

kectly rom

design;

Nole:

Accufacyf torm

(controlled

y

goem.trical

ol€rances)

ithln

specified

imensional

rolerance

llows

nierchanoeabiliiy

nd

pre-detgrmlned

tirs,,

Accuracy

f surface

(conrrolled

by machining

ymbor)

€duces

tresF

oncentrations

ndcofrosion

nd imponant

h€n

urface

load

nlensily

s hjgh

eg:

ams,

ears

tc)

and

closelyi

ing

surtaces

re

equrfeo.

Both

heabove epend

n

he

specific

arerial

emovarrocess

sed

Detairs

re

shown

n

he

dala

heetn he

Engineedngfawing

ourse

oles),

l l2rat lac i^^lrA6

matefal

wastage;

re lat ively

xpenslve labour;

expenslve tools to maintain

ualltyi

Considerhe tollowino:

ma h

n

abi l l ty

ol

matsr ia l ;

c la

mpabl l ly

of shapei

mosl

apprcpriate

rocess

or

accuracy

equired;

aval la l l l ty of

plant;

accessability t surfaces

o

be

processed;

tool

location

ndclearance

provlde

un.out

t necessary;

cosl ot

processing;

lase of

ptoducing

eatur€s

n mating

arts:

In

general:

machlne

only

where

necassary

or lunctjon

o specilica

ni

sp€cily east

demandingolerancendsurfaceinishorcorrectunction;sometricalorms plane,apers,

cylindrical,onical, elical,rregular)

ay

be

produced

y

surlace

eneration,

urlace

orming

and

non-cutting

orming,

b) Shapingby Sol ld i f lcat lon

Relers

o casting sing

and r melal

moulds

ncluding

njection

oulding

f non-metals.

imjlar

principles

old

or

solidiiicaiionl

slurries

ike

concrete.

conv



Thc

m{nuficturing

ysrcm

shoniisr oo

shon?

not

crouSh nformalion?

CONCEPIUAL

DESIGN

(b)

ordinary

kcftlc

(d)

clectric

G)

plastics

ug

Drffcrcit

ways

ofhcatitrg

wa .r

ETAIL

EESIGN

breakdown conccpts

inro

deiail€dobjccrivc

manuincturi.€

oues



(..s,

a ldth.)

Iodcpcndcntly

dcbu.riDs c.ll)

Fl.xiblc

c.s.

MS, IAS,

dc.)

(c.9.

ct.hi6l

plart )

Produci

quaotily

6a)

As

p€r

igur€ bove

r similer

ithbricferplanation

f key

efrects.

A classifiC3tionf

typical

p.(iuctio

sysr..ms

nd

ndustrics pf,lina

this rcchnology

b)

Typical onfiguration

s n ig

6b.CNC

mrchineyp$, cortrolsy$cms

nd

handlinc

quipment.e

flerdbility

nd

koughput onsiderations.

Machini

oirding nddegre.efdtiicrtiorl

oolingor

ixturing

pecfic

o thecell.

MachineDerationime ncreased,eductionn operatornteractiofl.

Procossdu

updareapability,

ri ine

quality

hacHngf CMMas

p.r

of ce[.

c)

Fig6c.C0pabilityfouttcr

o addrcss

hc

surft4e

t

pre

dctrrmi&d nglc

llwvs

for optimisation

fsurface

infuh nd

t€ater

ccurasy,

hisalso llows

or eatutcs

such-ar

oler o be

placcd

t rpccifc

angleo thesurfacc. rcatcr

omplodtyf

zurfacc

eometr)'

llowable

s he

cutt€r armemanipulatedo

more

locise

onemauons,

True onncuttinrcaoabilities,

Cornmcnts

ncdmpl'adty

fprogranming

n cornparisono sifiPl€r axig

olutio$,

but hiscan eovercorncyutilising ADproduccdDmodels.



'l -

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ii..nioi5



(^i

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i

Fig

2 Sinple

tiery

Dflkult to Orbnt

Easy

b Orient.



Arear ol rolerare

lor

v.rlous mod6 o,

$iembly.

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lutotnilk

lssembly

demlDd5 n.rrow

o

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r

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rlt .3seobly.qutpoE r

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.

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bor€ toleran.es ln orde lo fun.doo lcti,rilng io Eqults|Hrt

n tE

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DESTGN

OR

ASSEMELY

INOIVIDUAL

SSEMILY

VALUATION

OR

I

lFrdosdur. '1rE*r

t.srr*dsu1r'r6

3

t^mmuDbuorunY

I I I I t r

' '^ ' ,s



CNCMACHINING

Programming,Tooling,Machine,Tool

Design,Plannlng

and Control

NC Numcrical Contsol

Codcd lsEuctioDs ed o tbe rnachine ool control

slide movcmcnt,

spitdlc rotatioD

and ool

fccd. The standald

roglanming

tecbrdquewascstablishcd n this

t].?e ofmachinc.

CNC CompulerNumerical Contol

-

the nstructions rc storcdss a

proglam

n a micro-computer

attaahed

o thc

machilc. Tle comput€twill also handlcmuch olthc contol logic

ofthe machidc,makiDg

t morc adaptablc

had

carlid hard-wiredcontrollcrs.As thc cost ofDiq@-dafiorics

6 d Ecmory lsr fsllc ,

fscilitils bva

Eow

to iD.ludc:

.

Scvcml

srcr€d

progra.qa

.

S€rccn

diting

.

'Ca cd

clcles', i.c, stored

pattcf,l-

.

subprolFsls

.

Enhrnc€d

cuttar compadatio

.

Optirdiscd

nschiEing

spc.ds

Program

provitrg

.

Diaglortic EcEsagcs

DNC Direct Numerical

Control

-

a c€ntal coirputarcomJlllrlicated

with cach

CNC tool, do*r oadilg

progasra

cld

scrup

nformation or tha opaBtors.

FMS Flcxiblc MaDufacturing

Syatcm

a

gloup

ofvaricd CNC tool6, o6ot aod

convcyorsundcr

ccntEliscd coDtol,

organircd

o

produce

a ralgr ofparts,

CNC Appllcatlons

Machlnlng

2.5D3D

. , r- . -T|rEilg::Iathes, fuEdlgcenEe .

.

Milli 8

-

Machi .ing Cc$tes

FomiEg

.

Plarna .nd I$cr

Cutting

Blankllg, Dibbljl1g nd

punchbg

D

.

RapidPrototypilg

Beneflts f CNC

.

Productivity

.

Quality

.

Rcduccdlventory

.

Machil]irgcomplex bapes

ManagcmcntoDtrol



Advantages

f CNC

ProductlvW

.

Ma.hinc

utilisatio is ircrtsscd

bccauscmorc imc is spclt

eutting aDd

css imc is ts.kc

by

positio[iDg.

.

Reduccd

.t p timc il]crcascs tilisatioa

oo.

.

R.duced nubnidg

lcv€ls; machi[cs run lrupcrvi.srd?

Qua

ty

.

Prlt

nrcmorc accuntc.

.

Partsalc

morc rcpaatablc.

.

Lc$ w8tc

duc to scrap

Reduced

nventory

.

Rcduccd.tup Llc

pcnnits

mallor cotroEic

atch

uantiti.s.

.

Inw€r

lcad irncallow, owar

Etockcvcls.

.

Lowd siock avcb cduccntdlst cbargcsnd worblg crpital cquiEDcDts.

-

Machlnlng

Comprex

tapes

.

Slidc rovcdrcltsuldd

coeputcr ontol.

.

Computrr

otrtollercancdcuhtc

tcps.

.

.

FirstNC

lioNnc built 1951 t

MIT for ailcraff kinmilling,

Manegdment

Contrcl

.

CNC .rds

o CAD

r

hoocss

pla .litrg

- - -.--- ?rb-dw$drurn@--

Dnwbacks

l CNC

.

Hig capifal ost

.

Rctrahilg

8Dd cctuitlctrt of strff

.

Ncw suppofiarilitics

.

.

Maiftcnancr o rulain

bighutilisation

.

RcdurdlDcicti

peratoricsist&c

CNCPROGRAMMING

.

Odlinc

prograrDmilg

ilkcd to CAD

prcgr&E.

.

Cotrvgtsatiolsl

rograi'miDg

y thc op6a or.

.

MDI

-

Manu8lData Dput.

.

MarNal

Contol usirgjog

buttolls 'clectotrichatdwh4l',

.

Word-Addrcss

odirg sing staidard -codrs

alldM-codcs.

A

Rpical

in. ofa

pan-prograu

rlnen

r

variabtc

ioct ornat:

N020G02X88.021

3.7T0202S500F0.05M03

Thecornpact,

rimitivc

s).ntaxcflccti heorigimlwisb

o keep

apd

ape

eclsshortand aiar o

makehc bcst

seof



Pan-progamwords'

N Sequenceumb€r.

G

Prcpararory irl1ction.

X,Y,Z

Slide

motion

alongaxes.

t,J, L|rclecenEes.

T Tool code ndoffser dendfication.

S Spindlespeed.

F Feed ate speed fslide ba elj.

M Miscellaneous imction.

% Progra& start.Rewind ape.

/ Optional lock-Skip,f

switched n.

*,;

Endofblock

The numbers ollowing

thesewords may

b€ subject o format es 'ictions (e.g.

2

figures or four

figures only.

or with

assuned ocation or a decimal

point.

Modem machines

rc siightly morc

forgiving.

Preparatory unctions

Prcparatory unctiotu

change hc modeof opeEtio

prior

to a machining

action. 8S3635

(1972)

now

obsolcte,

ut

mostmachincs ollow

theseconv€ntions,

C00

Ripid rbovemrnt

G01 Linear

interpolation

G02Circular nterpolation

-

clockwise

O03Cilcular lterpolation

-

anticlockwise

G04Dwell

G33Tbrcad uning

G40 Cancelcutter compcnsation

Gr'1Cu$er ompensation,efr

G42 Cuttd

coDpensatioD,

ighi

(J/l

MeElcuruts

G80ctcBuilt-incyclcs

G90 Absolutccoordillateg

. G9l llcremcatal coordinates

O94Fecd

er

minute

G95 Fced

per

rcvolution

G96

Constanl

surfaccspeed

Many

ofthese od€s remoda.l,hcy emainn

folceuntilcaDccll€d,

hisapplieso most

ofthe otber ode

erte$ oo,

allowing mor€ compaclcodc.

Miscellaneous

unctions

Tum oDandofvarious machine

ctivities-

M00 Programstop

M02 End ofprogram

M03 Spindle

un. clockwise

M04 SpiDdle talt anti clockwise

M05

Spindl.

stop

M08 Coolant

M09 Coolant ff

M30 Rewind

Axis nomenclatue

Z-a{is

pamllel

to main spindle

(tool

or workpiece).

Positive movementn dir€ction fincreasing

islanceetw€en orkpiece

rld ool.On vertical

machiningentses,

+Z

is upwards

tom

the

worktable;

or tuming certes

+Z

is away

&orn he spindle.

X-axis

always

hor;onial,

pa al1e1

o work-bolding surface nd

orthogonal o Z-axis.

If Z-a{is is venicai,+X is to ihe right whenviewed tom ihe spindle ooking tov'ards ts supponingcoltlmn.

If Z-axis s horizontal,

+X

is to the right looking fton the spindle owards

he workpiece.



Y-axis

odhogonal o

Z

and

X, completinga rigbt handed et ofa,(es.

A lathehas

no Y-a-\is.Extraaxes

are desigdated

,

V and

W to correspondo X, Y

or

Z if th€

extsamovemen

s

parallei

o

one

ofthe

ar€s.

Extla rctary

movements

redesignated B or c.

Becauset is the wolk that mov€s,not the ool 6pi dle, the direction ofslide travel on a milling machirc canbe

confusiDg.The morc experienccdh€

operator, he more confusing

CNC axis notation€an

bel It is casier

or thc

prograob€r

io rcgard he

6iuer

as

a computer

en-plotler.

Coordinatesmay be absolute,i.c.clativ€ o

datunf or iDcrcmental,€lative

o thc cureDt

position.

Normally

selectcd

y

C90/G91,

but

FA\(JC contoller usesU.V aDdW as ncrcm€dal valu€s.

Dairm choicc and datumscttingarevital

opietations. c can dctrtify a

dlawing datnD,

component stur

pan

program

datun

and rDachine atum,Th€ ast wo mustcoilcide,

needingdocumentatioD

o commuticate

b€tween

Progammcl

and

opemlor.

Fixed datummachift

-

opcratormusl

set

work

n corcct

place.

Floatingdatum

-

opcrator csctd

datum o suit worq bul

plogarnmer

docsnot

know

preciscposition,

Datum shifi

-

O50

(sorDctimes

92) cao esctdrtum within

plogram,

or

<169>piesct

Absolute

Registcr<170>.

Zero offset- or <169>WorkShift<l7D can cpositionmachine atum.Ior a lalhe, dachinedaturn s often X=0 on

spindlccmtclide 6nd Z=0

at rear acc ofchuck.

Usc

Wolk

Shifr o resct

Z-0 at cnd facc of

finishcd

ob.

All Z values

ncgativc.

Rcfdcnc. Poinl

-

a fix€d

poinl

on thc ma.hine

o which thc slidcsmust

be

tnversed on start

up,

wh€re

preset

coordinalcvaluas

arc oaded,

CNCTOOLING

Clrbondteel. asily haped,or amateur

seonly.

HighSpccd tcel

HSS).

Solution ardening

t high cmpclaturc,

ough.Uscd

or drills.

Sint rcdCa$id.r

(Crmented

arbides). ard,

utbrittle,Highcutting arcs

with ow wcar.

Ildcxablecarbid€ 8erts.Many

gladcs

nd

shape6.ISOlassification,

- e[bi.'BordrMtrtdclcts\r); HardErdrdougfitr6an]rdbidas;-- - -

Sulface uttingSpceds

r/min)

Worl(pi.ci

Material

Tool Mild Stecl Csst on Al. alloy

Blass

Carbidc 170 100 250

180

HSS 28

18 t20 75

Spind/espeeds

Spirdles?eeds

givcn

n rcvolutioDs

er

mi u1€

pm)

by:

1000 cutting peed

m/min)

pi

*

work

or cutte diameter

fla)

e.g. o tum 30&mdiamctcr nssusing

carbideool:

S

=

1000 180 3.142 30

=

1910

-

say

1900

pln

Feed rates

or turning

Mld Steel Cast ron Al. alloy Bmss

0.25 0.25 0.3 0.3

mm/rcv

Finalchoicc ependsD

producrion

are.lool

wear

nd inisb equned.



CNC

Machino

Tool Deslgn

Fcaturcs sscntiai

o CNC

opcratior:

Slidc

positio

mcasurcnlcit

atromovcmcD

.

CoDtol slstcd

fccdba.k

-

positioD

and sp€cd.

.

Spindlcspccd

control

Automatcdwor*holding?

Fcanrrcs cquircd

o c]cploit

CNC caspsbilitics:

.

Wcar ralist

l1cc o

copc with high

utilisationsnd

mpid slida

avcl.

Rcsolutio4 r€?eatability

od

&ccuacy o foUowprograo

cofiortds

and rciicvc quali,

{.ithout

human

iDtcrvcttio "

.

Swdfcotrtol

to rBtch high

mcblicmowl

stes achicvcd

by carbidc

ools

6nd high

udlisatio ,

Safcty

ot llrlmrnncd

opentiotr rpith

rapid slid.

t'avel, 6uddc

mov.Erclt

uDda

rogra$

control

rtrd

possibly

vioirot

collisioD .

CNCMachlne

oolDeslgn

Features

Somc olutio :

DC rcrvomoton

with

positiotrl

aDdrchogelcrator

ta&aal.

Lincar

gratilgs

snd

Moitt fritrgc .

Rldi6l

gratius

or rotarycncode$,

Rigidconstuction.

Covacdslidcwsyro

cxcludc uttilgr.

Pl.stic lidaray hetcdals.

Card scDlor

itiDg.

L.sdscrcwssplsccd

y r.cilcutating

ball-agraws,

Sklt-bcd hthc with

r.ar.hou

cd hrncl

Swrrf

oolvayors Dd

butcs.

TotslcDgloEu&

Ddntcdocks.

crcpbic.l dilplsy5

or

pmgran

proviDg.

'- - -sw?EfRfib-oTel

ftod cutting rca

or wsshitrg

tltioD

slad b.d

coolaDllood

arIJ€ltl

l'scuurn

ump

iom rnachilcaDdworlGiop

coDvcyof

uDdcrfloor

hutcs

toll€)s

&lrp scparatio o rcclamatio

Illurtation of Slsnt-Bcd

athc.

Mdnufacturing

ysteEr

Tnditionalapploachcstomulti-componc.DtproductioD:



I

l

HicellDemo

Program

one

on SmartCAM

%

02222

1*

*

*

r, r,,r,* r,* *

r*

* r.i *;i

-;

*i **;i)

/+****r**r+i I . lTaETT

* i t r * r .* * **

' r

, i \

G10P02250.0

G28UO

G28V0W0

G50S3600

G144M28

G99G18

G3OUO

G30V0W0

M01

Nl

(ROUGH

ACE& TURII)

G30U0V0W0

G10Ll0PlR0,8Q3II0

T010100M41

G144G18

G97S3000M08

'

G00G99Y0.020.3M03

x64.0

20.2

G0lx-1,6f0.25

21.4

x8.8

24.6

G00x65.023.0

x6s.u3.r

x59.0

@tz-39.8

@0xs9,23,1

x53.0

G0lz-39.8

G00xs3.223.1

x47.0

G0lz-39.8

cfi0x47.223.1

x41.0

G01Z-39.8

G00x41.223.1

x35.0

G01Z-9.8

G00x7

_22-5.9

I{iccll Programtom Slrta CAM

Page:



l

Calculate he maximumand

midmum

shsft and

hole sizes or the follbwing examples.

Also oslqrlate he amountofclearance

Hole

Sh8ft Cl€araoce/iot€f,ft

,€trc€

M.rx Min

ax

Mn Mrx lvtro

90mm

hl l

Cl

I

220mn h6

N7

or interference.

l)mm no b /

Within the box

provided,

draw he

path

ofthe centre ine oftlrc cr t€r that the

following

programmewould creale.

l0

20

30

40

50

60

70

80

90

10 0

l l0

100 lfiro

GX

00 50

01

00

01

FST

01

YZ

l l0 2

M

06

03

d'

00

l0

l0

50

30

lo

0

l0

l l0

l l0

60

60

0

-5

ut

s

0

Brieflv explainwhat he tems n bold mean.

GOO

c"p,/

Cfil

Fecl

FIOO

Fe")

loo

*k

Sroo

*eJ

M06

..

c\-

+o"L

Mol

14

*

J

"

s r

s

s8

T--

t""L



?he

File Fornnat

r . r ne.- \

I L t l le tormet

Jh: asTt

,.,"r"oiit-\oeraphy) fiie

is the

de-ibcto

srandard

AD

rep.ese.talion

t)r

Rp. It

was

established

by

iD

s;/sreiuin

rhe

ate

Bos.

he

srl format

ofa

cAD mociel

s a raceted

urlbce

elresertation,i.e.

list

ofihe

triansurar

su.faces

with ao

adjaceary

nrb.matio'.

This

is the

standard

nput

fol

most

Rp

-

syslems.he.e

are wo

format for

.sfl-

files:

biaar-l

and ASCII

which

difers

as

ollow:

. Binnry.STL file

The

bi*

,

S'Il-

fi]es ornat

consists

f

an

g0

b',t?s

heade.

used

o

describe

he

solid

contained

within

the file,

then 4

b),t€s epresent

he total

number

of{bcets

n

tle

file. A

facet

s described

s

fbilow:

the fust

12

bltes

(3

x

4 blres) represent

ts rlormal,

he next

36

bltes

(3

x

j

x 4

blres)

represent

ts

(tiree)

verrices,

hen

lro unuseC

ytes are

padded

o

achieve

a block

size

oi50

bltes.

.

ASCII .STi,

ritcs

AscII iiles

usekeywords

and are

selfexDlanalorv.

he

ASCILstl

file

must

start

with the

ower

case ey'vordsolid and endwith €ndsolid.Within thesekerrords are istingsofindividual

triangles

hat defile

he aces

fthe-sorid

model.

Each ndividuar

riangle

escription

efines

single

normalvector

directed

away rom

the

sorid's

urface

ollowed

by the xyz

components

or

all

th'ee

ofthe vertices.These

values

are

all in ca.rtesiatr

oordioates

nd are

floating

point

values.

The

iargle values

shourd

an be

positive

and

contained

within

the

bu

ding vorumi

The normal

veqtor s

a unil vecror

oflength

one

based t

theorigin.

fthe

normals

re

not ncluded

henmost

software

will

generate

hem using

he right

hand ule.

Ifthe

normal

nformation

s not included

then he

three valu€s

should

be set o 0.0.

There

s a

variety

ofenors

in ASCtr

6les

hat

do not

appear fl binary

iles. For

instance,

t happens

hat

keywords

are either

skipped

ofadraneous,

hind€ring

he extraction

fdata.

Here,s

n example

fan

.STL

ASCII

file:

60ttd sot tdnahe

faceN rormat

?.33a605e-01

3.226134e_A2

.?EOO3?._C1

.urer ro.p

vertex

-1,070000e+02

0.0000r1Ce+00

.AldOiOe+02

ve*€a

-1.060000er02

0,001]O00e+00

.?6O1OO.rO2

verre:

-1.010000c+02

1,200000€+00

,3133ooe+02

endi cel

fa.et nornal

9,324258e-01

9.2Cg56ie-02

I 623.r59€_Ot

r€: tex

-1.0r0000e+02

t.20000oer00

I .Bl3eOOe+O?

verre:r

- i ,C54000e+02

0.0000C0ea00

L.?boi0Oe O?

endloop

endfa.pt

4.

The .SLC

Iile formrt

.SLC

tiles are

used

n the

tuseddeposition

modeliry

(FDM)

process

romstsgtsgy ,bg

They describe

the contours

ot\ and

he

thickless

otl each

build

layer.

.

The .SLC

fite foruat

is an

ASCtr text

file format

.

Comments

may

be llcluded.

The

begin

with

a

"#"

and

End

at tlle end

oftiat

line

.

Units arc

n

inches.

h thecase frie FDM 1600 apidproLotypingystem:

.

x,y,z should

be

positive loats

n the

ftnge

from 0 to

9 inches'

.

Layer hicknesses

aL)

range

rortr

0.005 o

0.015 nches'

The

standard

ayer hickness

s 0 010

nches.



Eaa0ple:

The

bold

characten

should

be fyped

as s. Th€

talic

charactsrs

hodd be substituted .ith

th€ir

correspoadiag alues.

911c. Y0

+

0

=

zero

lIlJl

{fi.lcnanc)

#

fi.lenarte

tnay

include

fut L

path

srrer

o *

Z

z dz

#

z

=

absolute

z of

tayei, dz

-

taye

thlck:ness

x y #

plovida

th. cooldLnatca of the cornc polnt

x

y

#

along

cach

contou .

Do not

duptlcata

the

tr

y .

. .

#

f1 st

polnt.

lhe

ls.no upper

]. iel t

oE

the.

,

x

y

*

I1u&b6r

of

poiDts

1n a

contou.r.

xv

#

C

*

Talid.nate

tbc

contou

wl.th

a

trCtr.

x

y

t

Bcgin

thc.B6cond

colrtour

otr tbj .s

].avaL...

xy

#

xy

l l

xv

*

C

*

Tcrrlll.nrle

Eh.

sccond contouE.

Z z dz

*

BGgIn

s

nclr 1ay. i

(z

-

z.o1d +

dz)

x

y

# Ba91n a n€w contou on a lard Icv.I . . .

xy

l l

xy

*

xy

l l

xy

i l

c

*

?arfiinala

th.

colrtour.

tl| t

#

AII

foLl'owing

IlDc

e .

lgnor€d.

N.QX.yzTl '1

lom

a^

Av

(,

t l

3o

oo

o O

?- Ol

06

+o

t35

t5

-Z

50

1r5

15

6o

a5

4o

-icqt'6here

Jt"



Data

preparat-,i4.l

or numerical

ontrol

-h

.{ ,

Hole

statement

Explanation

G90

G7L

G00

J

G00

G01

,

G00

G00

G00

G00

.

GO1

;

-

Se]ect

bsolute

.

Select.metric

MoS

Load

centre

drill

Above

1st hole

Centre

ddll

Retract

2nd hole

'

Centre

drill

RetIact

M06

Load

10 mm

r l i rmaicr rt r i 1i

Above

1st hole

. .

Drill

Retmct

2nd hole

Ddll

.

Retract

Program

stoP

Retum o

start

XO

x100

zL7

LZJ

x150

277

225

XO

x100

z3

22,5

'x150

L5

zz5

YO

Y100

F400

M0s

2300

225

s3000

T01

M03

F400

,M05

YO

s3000

2300

M0i

T02

225

M08

s2000

M03

_lJ

Y100

r350

M05

F350

M05.

s2000

M09

G00

GO1

IAU

\rUV

_

M00'

80

M30

M03



DRILL.AND

REAM

40

D?JLL AND

TAP

6

Ho_[S

Mlo

EqJI.SPACED

I-frES

UT'IA

POCKET

lOmm

DEEP

T-

Al

o

o

t^

POCKET

DEfP

r)

5mm

rLr_nL I

zmm

DEEP

a-



CAM

Programmihg

ystems

nd

Postprocessors

BACKGROUND

The

NC

programs

equired

y Computer

Numedcally

Controlled

CNC)

machines

were

ahvays

riten

by hand

asa series

f lines

of code G

codes

nd

Nl

codes).

This

is

still

by far

the most

common

way

to create

heseprogmms.

However

t

was

recogmsed

hat

much

of the

code s

repetitive

nd

thir

theseprograms

ould

be

generated

utomatically

.

semi-automatically.

system

or

creating

lde in

this

way

is klown

as a

CAM

programming

ystem.

^

. _ _

As

with

manual

rogramming

he

stalting oint

s

the

selection

f the

oot.

The

CAM_ rogamming ystemequiresool data. This ncludes uch hingr-ar,o. ,,""

and

shape

fthe

tool, and

he

cutting

peeds

nd

eeds

which

are o

be-used

or

the

tool.

The

p.ogramming

oftware

as

a

graphical

ser

nterface

h"r"

tt

a opar"to,

"an

raw

he

path

hat

he

or shewishes

he ooi

to follow

The

software

wi

thli

comOine

the

ool

datawith

the

geometry

ata

n order

o

ffeate

he

NC code.

-

The

style

of a

program

varies

according

he

machinery

nd

the

particular

preferences

f the machine

perator.

The

codi

itself

s

depenient

n

the'machine

controller

and he

machine

o

which

that cottroller

is

fitted.

This

means

hat

the NC

code

generated

y

the software

must

be customised,

r

,,postprocessedii

to

suit a

l1,_gir

T":lti*

operating

n a

panicular

ornp*y.

ih.'C.tM

p.grurn*ng

sotf$ralerll

have

ostprocessors

rinen

or r

to

give

t

rhe

abilhyoouipuidiff.erentstyles f progam.

HISTORY

The

earliest

CAM

systems

used the

AIT

programming

anguage.

A

computer

programmer

would

use

statements

uch

as

GOTO

andPROFILE

olefirte

the

Dath

of

the

tool.

.

In other

words

he

early

CAM

systems ad

no graphics.

Later

Apa;$erns

had

graphical

Aort

ends n

which

a line

or a curve

drawninjhe

screen

woulJginerate

APT

commands.

-,

The.system

onverted

he nputs

to a

CL

(Cutter

ocation)

ata ile. ThisCLue was thenconvertedo the ISO

code G

codes

and

M codes)

equired

y the

parlicular

machine.

The

early

postprocessors

ere

writterl

ll

the Fonrao p.ogra.^ng

language

nd

then

compiied.

In

other words

lre

only people

to'.oiiJ.*"

modifications

o the

postprocessors

ere

he

programmeis

ho had

he souice

oOe.

Udil

recedly

Unigraphics

till used his

method

or

their

CAM

system.

Approximately

0

o

12

yeaxs

go

customjsableostprocessors

ppeared

n the

scene_based

round

a macroprogramming

anguage.

mportant

work

in

this

area

was

done

by Cambridge

CAD Certre;

many

cufent

CAM

sysiems

ollow

the

structure

hat

they

d€fined.

.

The

big

advartage

of

the macro_based

rogramming

ystems

was

that

you

did

not have

to be able programmer

o

use

them.

The

b-asis

f creatrne

a

t\4E338

Chris

Beatly

Post

rccessors

Pager

l



customised

ost-processo(

as to fiIl in the

fields a a

"1ook

up table" This

information

as hen

ntery.eted

y he

postprocessing

oftware

t run ime

Curent

stMd-alone

A,V

packages

such

asSmartCA"\4,

astercL:\l,etc)use

this

principle. The user

c.eates

eomettic

ines

and

points. Data

on

eachof

these

featufes

s held

n the CAM

system.

Thisdata s corveited

on a ineby i11easis

nto

theNC codeby the

postprocessor

hich

eferences

he ook up table

or a

particular

machine.

Some CAM

systems,

articularly the CAM

modules ofi high-end CAD

systems

till use CL

data

which s then

postprocessed.his s consideredo be

an

inferior approach.

In

spite of

the structure

of

modem

postprocessors,

which allows

non-

progranrlIrerso write or

modify them,

n

reality very few

people

ry to do this

job

themselves.

They

rely on

the CAM software

supplier

o do this

ob

for them. The

suppliers

unently

chatge

300

to 400

per

day to do this

ob.

HoweYer ecause

*riting

postprocessorss

relativelyeasy

n a macro

aryuage, engineers

amiliar

with

the

metal cuttiflg

process

and with

cNC machines

n

particular,

can carry out the

ob.

This is cleady

a much

better situation

han relyingon

computer

prograDmers

SMARTCAM

TheSmartCAM

rogradming

6ftware

omprises

he ollowing

modules;

r The

ob

plan

r Themodel

atabase

r The

machine

.SMF)

lle

r The implate

.TMP)

ile

TheJob

Plan

This

s where he user

must

nput data

on the

tools which

will

be

used Associated

witha oolatel

r

The ool number.

This

s the

position

which

he ool will

haven the unet or

magazine

f the

machine.

r The ool

geometry.

The

adius fa

tool is very mportant.

n

particular

or

turldrtg

ools,

the software

will make calsulations

or "tool

nose radius

compensation"

n

order

o

generate

he

correctool

path.

r Spindle

peed

hich

will be

used or cutting

moves ssociated

ith his ool.

r

Feed

ate

which

will beused

or cutting

moves ssociated

ith this ool

TheModel

Database

The main

process

n

using CAM

software

s to &aw

the tool

patls

The opelato

selects

he tool

which hey

wish he

machineo

useand hetrdBws

the

path

which

hey

wish the tool

to follo\r.

A tool

path

s

madeup of a

series f

geometdc

elements uch

as

poirts,

linesand

arcs.

The softwale maintains

a databaseof

geometric

elements

This database

contams:

ME338

Chris

Beatty

Post

rocessors

Page:



POSTPROP

OC

'

r,Thesequenceoftheelements.i.e.rvhatordertheyshouldbeperformedin.

r Data

about

each

lement;

hat ool s

used.what s he start

point,

what s

the

end

point,

he radius fan arc,at whatdepth he

cut

s

taking

1ace,

tc

Themachine

.SMF)

i le

This

consistsf

a lisr

of

quesrions

nd

oprions

hich

ellSmanCAM ow

ro formar

code or a

particular

machine. ome fthe nformationn

this ile s:

r How many

places

f decimalshould e

output

or X,Y,

andZ

positions

r

Which emplate

.TMP)

ile o use

r

How to outputbiock

numbers

r The udts

(mm

or inches)

r The ormat o output peeds,eeds rd dwells

r How to specifya tooi change

r The format or rapid moves,inear eedmovesandcircular

arc

eed

moves.

r andmanymore

pieces

fdata o coverall he unctions fa machine.

The

emplate

.TMP)

ile

The emplateile determineshe

final format

of the code

generuted

y

SmartCAM.

SmartCAM ombines

nformationrom he modeldatabase,be

ob

plan

ad the

-

machineile

andoutputs

t rhroughhe emplateile.

Template iles are organisednto functionalsections tartingwith the "@"

symbol nd ontaininghe

ollowingasicypes

finformation:

r

Literalcode o output

asentered

for program

ead€rs,ool headers,

tc.)

r Template ords

or

output fprogram

rformation

rd controlofthat output

r Condilional

>

brackets

o make ome utput

optional

Some xamplesfthe unctional

ectionsreas ollows:

r

@TOOLCITANGE

r

@STPROF

at

startof

profile

do he ollowing)

r @LINE ata inea eedmove o he ollowing)

Themodeldatabaseednes

hether nactions a ool change, linear

eedmove,etc.

The emplate

lle

defines

what he codeshould e

ike

for this

particular

ction,alld

referenceshe machine 1eo

de6nehe omat ofthe codewhich s

cenerated.

WRITING

POSTPROCESSOR

The

process

of writing

a

postprocessor

ormally avolves he following:

CAD and Development 2 - Part 3

Documents