1 IML IML 332 332E: CAM Introduction : CAM Introduction 1 COMPUTER AIDED MANUFACTURING COMPUTER AIDED MANUFACTURING IML 332E IML 332E CAD&M CAD&M LECTURE NOTES LECTURE NOTES by: H. Livatyal by: H. LivatyalSpring Spring 200 2005- 200 2006 ITU Dept. of ME ITU Dept. of ME Gümü-suyu, ISTANBUL suyu, ISTANBUL IML IML 332 332E: CAM Introduction : CAM Introduction 2 COMPUTER AIDED MANUFACTURING TOPICS • Numerical Control Systems (NC,CNC) and Machine Tools • Numerical Part Programming (Manual and Automatic/CAPP) • CAD-CAM-CNC Systems Integration • Automation in Manufacturing and Computer Integrated Manufacturing (CIM) • Flexible Manufacturing Cells (FMC) and Systems (FMS) • Sensors and Process Monitoring Systems • Rapid Prototyping Methods • Computer Aided Special and Nontraditional Manufacturing Methods
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• Numerical Control Systems (NC,CNC) and Machine Tools• Numerical Part Programming (Manual and Automatic/CAPP)• CAD-CAM-CNC Systems Integration• Automation in Manufacturing and Computer Integrated
Manufacturing (CIM)• Flexible Manufacturing Cells (FMC) and Systems (FMS) • Sensors and Process Monitoring Systems• Rapid Prototyping Methods• Computer Aided Special and Nontraditional Manufacturing
DEFINITION:DEFINITION:EffectiveEffective utilizationutilization of of computercomputer technologytechnology in in thetheMANAGEMENT, CONTROL MANAGEMENT, CONTROL andand OPERATIONS of OPERATIONS of thethemanufacturingmanufacturing facilityfacility throughthrough eithereither directdirect oror indirectindirect computercomputerinterfaceinterface withwith thethe physicalphysical andand humanhuman resourcesresources of of thethecompanycompany ((afterafter CAMI).CAMI).
DEFINITION:DEFINITION:TheThe controlcontrol of of operationoperation of of machinemachine toolstools (M/T) ((M/T) (ororotherother sheetsheet--workingworking andand weldingwelding machinesmachines)) byby aaseriesseries of of codedcoded instructionsinstructions calledcalled thethe program, program, whichwhich consistsconsists mainlymainly of of alphanumericalphanumeric characterscharacters((nembersnembers andand lettersletters).).
BigBig oppositionopposition againstagainst NC M/T in NC M/T in thethecontractorscontractors of USAFof USAFDifficultDifficult yearsyears19561956--19621962
StoringStoring thethe programsprograms on a on a computercomputer in in addadd.. toto tapestapes..11stst CNCCNC19701970
J.JackardJ.Jackard’’s method to control textile s method to control textile looms by using punched cards.looms by using punched cards.Basic ConceptBasic ConceptEarly Industrial Early Industrial
•• NC M/T NC M/T ensureensure positioningpositioning accuracyaccuracy andand repeatibilityrepeatibility withwith theirtheirDESIGN, CONSTRUCTION DESIGN, CONSTRUCTION andand CONTROLS: CONTROLS: GoodGood forfor makingmaking manymanyof of thethe samesame partpart..
•• ComplexComplex shapedshaped componentscomponents can be can be mademade automaticallyautomatically,, withwith highhighprecisionprecision andand reliabilityreliability..
•• PartsParts thatthat requirerequire aa longlong seriesseries of of operationoperation can be can be mademade withwith minimal minimal accumulatedaccumulated errorerror..
•• NC M/T can NC M/T can operateoperate in in hostilehostile andand hazardoushazardous environmentsenvironments..•• Since Since mostmost workwork is is shiftedshifted toto officesoffices fromfrom thethe shopshop--floorfloor,, productionproduction can can
be be monitoredmonitored byby thethe managementmanagement directlydirectly..•• NC M/T NC M/T mostlymostly areare capablecapable of of conductingconducting moremore thanthan oneone machiningmachining
operationoperation at a time at a time oror in a in a sequencesequence withoutwithout repeatingrepeating thethe partpart setset--upup..•• Minimum idle time Minimum idle time andand increasedincreased productivityproductivity..•• InterchangeabilityInterchangeability of of workwork betweenbetween differentdifferent productionproduction plantsplants..
PointPoint--toto--pointpoint controlcontrol systemsystem ((NumericalNumerical positioningpositioning controlcontrol, NPC), NPC)NC NC DrillDrill pressespresses usedused in in drillingdrilling preciseprecise patternspatterns of of holesholes..
StraightStraight cutcut systemsystemFeedFeed raterate at at eacheachAxisAxis is is controlledcontrolledİİndependentlyndependently,, oneone atatA time. A time. UsedUsed in in facefacemillingmilling,, PocketingPocketing etcetc..
ContouringContouring systemsystem ((continuouscontinuous pathpath systemsystem))•• EachEach servoservo motor can be motor can be controlledcontrolled in in varyingvarying speedsspeeds in in coordinationcoordination toto
produceproduce angularangular lineslines andand curvescurves..•• SomeSome simplersimpler systemssystems of of thisthis typetype useuse thethe methodmethod of of breakingbreaking downdown thethe
curvedcurved intointo smallersmaller linearlinear segmentssegments whichwhich areare connectedconnected toto eacheach otherother in a in a tiptip--toto--tailtail fashionfashion..
COMPUTERIZED NUMERICAL CONTROL (CNC) COMPUTERIZED NUMERICAL CONTROL (CNC)
CNC CNC waswas firstfirst introducedintroduced in 1970 in 1970 byby replacingreplacing thethe hardwiredhardwired MCU of a MCU of a conventionalconventional NC NC systemsystem byby aa microcomputermicrocomputer whichwhich accomplishesaccomplishes allall thethe functionsfunctions of an MCU of an MCU withwithitsits softwaresoftware..
WhatWhat is is newnew??•• FeedFeed raterate controlcontrol,, bufferingbuffering,, positionposition looploop controlcontrol ......•• AbilityAbility toto editedit andand storestore programsprograms•• AbilityAbility toto produceproduce punchedpunched ((oror magneticmagnetic)) tapestapes,, diskettesdiskettes etcetc..•• ExpandedExpanded tooltool offsetsoffsets•• ExpandedExpanded controlcontrol of of machinemachine--sequencesequence operationsoperations•• DigitizingDigitizing•• CircularCircular andand moremore advancedadvanced (NURBS (NURBS etcetc.) .) interpolationinterpolation•• ParametricParametric programmingprogramming•• Do Do loopsloops•• RoughneningRoughnening toto aa defineddefined shapeshape•• SubroutinesSubroutines•• DiagnosticDiagnostic capabilitycapability•• OnOn--screenscreen geometricgeometric programmingprogramming•• ......
CAM IN MACHINING OPERATIONSCAM IN MACHINING OPERATIONS
Basic AdvantagesBasic AdvantagesIn mass productionIn mass production•• Better geometric repeatabilityBetter geometric repeatability•• Combining many operations in one machineCombining many operations in one machine•• Flexibility: Many different parts on one machineFlexibility: Many different parts on one machine•• Flexibility: Quick and easy implementation of design Flexibility: Quick and easy implementation of design
modificationsmodificationsIn production of tools, dies and moldsIn production of tools, dies and molds•• Quick and hassleQuick and hassle--free production of complex 3free production of complex 3--DD
surfacessurfaces•• Drastic Time reduction in part programmingDrastic Time reduction in part programming•• Accurate production of the geometry developed during Accurate production of the geometry developed during
the CAD stage and verified in the CAE stagethe CAD stage and verified in the CAE stage
•• BenchingBenching• The tooling is assembled• Critical dimensions are checked: Coordinate Measuring Machine (CMM)• Hand finishing: Grinding and polishing.
•• TryoutTryout• During tryout, a limited number of parts are produced with the die or mold• Minor changes on the tooling may be necessary for required performance