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Automation of machining part II – „ rise of the machines “

Technology II. Ing. Jan Tomíček. Automation of machining part II – „ rise of the machines “. Programming of machines. Machining on CNC machines is controled by a NC code .

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Automation of machining part II – „ rise of the machines “

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  1. Technology II. Ing. Jan Tomíček Automation of machiningpart II – „riseofthemachines“

  2. Programming of machines Machining on CNC machinesiscontroled by a NC code. NC codeis a list ofinstructionsforthemachineandalsofortheoperator. Instruction are executed in timeorder. NC codemusthave a specificformatsothatthecontrolsystemofmachineisable to readit.

  3. NC code form Structure and form of NC code is standardized by international standard - ISO 6983 – Numeric control programs formating Differences between different control system manufacturers and differences between versions.

  4. NC code structure Lines (blocks) Words Word has a meaning and value part S 1500

  5. ISO nc code and the others ISO is standardized code (G – code) Some manufacturers devoloped their own standard for NC code – native standard Mazak – Mazatrol Heidenhein – iTNC Siemens - Sinumeric

  6. NC code structure II. • Headinglines Definitionofrelationbetweencoordinatesystemof CNC machineand program, type ofprograming, work mode, workingconditions • Program body Cuttingand non-cutingmoves, main program andsubprograms, toolchanges • Endinglines Toolreturn to home point, change to firsttool, coordinatesreconstruction

  7. Coordinate systems Wayshow to define a movement • Absoluteprograming– positionis in all point expressed as a distance fromzero-point • Incrementalprograming– positionisexpressed as a changefrom last postion

  8. Absolut G90 X0 Y0 Z50 G0 X15 Y70 Z50 G1 X15 Y70 Z0 G1 X25 Y70 Z0 G0 X25 Y70 Z50 G0 X0 Y0 Z50 Incremental G91 G0 X15 Y70 Z0 G1 X0 Y0 Z-50 G1 X25 Y0 Z0 G1 X0 Y0 Z50 G1 X-45 Y-70 Z0 2. 3. 1. 2. 3. 1.

  9. Ways of programing • Manual programing • Shopfloor programming • Automated programing

  10. Manual programing • Editors are used. Program iswrittenmanually (by hand) line after line. • Usedforsimpleparts (butcomplextoo) • Toolpathisexactly defined • Program canbeadjusted to savetime • Can use cannedcyles • Canbeparametrized • Used in massproduction

  11. Automated programming • Work with the „sequential NC code preparation“ • Uses CAM (Computer Aided Manufacturing) software • For all parts including complex shapes • We dont need to compute the toolpath • We need correct postprocessor

  12. Sequential NC codepreparation Partprogram – workpiece, material, cuttingconditions, tools… Procesor– according to technology CL data – virtualtoolpaths on virtualmachine Postprocesor – „translator“ forthespecific CAM-control systém-machinecombination NC code– toolpathsof a realtool on a realmachine Partprogram Procesor CL-data Postprocesor NC-kód

  13. CAM software isComputerAidedManufacturing (machining) • Fromsimple 2-axis turningup to multiaxismachining • Feature ortechnologicallyoriented • Specialtypesof CAM forspecialpurpose Live presentation

  14. Shopfloor programing • Somewhere in between • Uses cycles with parameters • We have to edit these parameters manually • But the NC code is generated automatically • No postprocessing

  15. xD software 2D – just in two axis - turning 2,5D – two axis, but in layers – not simultaneously 3D – three axes simultaneously multiaxis 4D – four axis - one rotary axis (rotary table) 5D – five axis - maching (two rotary axes)

  16. Tool movement programming CAM software uses „Strategies“ Strategy – is a generalplanhow to movethetooldurignmachining Continualdevelopment Roughing – offset, raster (Zig-Zagmethod) plunging Finishingstrategies – pencilmilling, streaming, rest materialmaching

  17. CAM software developers NX (Siemens PLM software) Catia (Dassault systémes) – both 10% market share PowerMill, FeatureCAM, ArtCAM (Delcam company) ,InventorCAM (Autodesk) Wildfire – Pro/Ingineer (PTC) – 5% EdgeCAM, SurfCAM, SolidCAM, MasterCAM, OneCNC, ESPRIT, GibbsCAM

  18. Simulaton and verification • Simulation is used to control generated toolpaths for following reasons: • Colisions • Undercuts (or rest material) • Postprocesing check

  19. Verification

  20. Automatedprograming - review • Wecan do complexshapes, no need to calculatecontrolpoints • Wecan use simulationandverification • Wecanchangethetooleasily But • Weneedpostprocessor • Expensive • Program isalwayslonger (againexpensive)

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