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Introduction and literature survey

Introduction and literature survey. 1.1- Introduction 1.2. Computer aided design (CAD) 1.3. Computer aided manufacturing (CAM ) 1.3.1-Advantages and disadvantages of CAD and CAM 1.4. Process planning. 1.3.1-Computer-Aided Process Planning 1.3.1.1 Variant Approach.

lester-melendez
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Introduction and literature survey

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  1. Introduction and literature survey

  2. 1.1- Introduction 1.2. Computer aided design (CAD) 1.3. Computer aided manufacturing (CAM) 1.3.1-Advantages and disadvantages of CAD and CAM 1.4. Process planning

  3. 1.3.1-Computer-Aided Process Planning 1.3.1.1 Variant Approach 1.3.1.2. Generative Approach

  4. 1.5. Computer numerical control (CNC) 1.5.1 .Advantages of Computer Numerical Control 1.5.2.Disadvantages of Computer Numerical Control 1.6. Part programming 1.6.1 Manual part programming 1.6.2- Computer aided part programming

  5. 1.7. Structure previous work 1.7.1. Milling • 1.7.2. Turning • 1.8. Scope of work

  6. TURNING

  7. External Contour provide Linear Internal Contour provide Linear

  8. External Contour provide Linear or Circular interpolation Internal Contour provide Linear or Circular interpolation

  9. Threading Contour MILLTURN Key Way Feature

  10. 1. Radial holes feature (with depth ) 2. Radial holes feature (Holo depth )

  11. We will take the following Part as example to Show how software is work

  12. External Contour provide Linear or Circular interpolation & External Recess (Black continues line)

  13. Internal Contour provide Linear or Circular interpolation & Internal Recess (Red – Dashed Lines)

  14. Threading Contour provide External or Internal Contour (Blue– Dashed Lines)

  15. MILLTURN

  16. Reasons for using Mill Turn machines • Combination between milling and turning operations. • Reduce manufacturing time. • Reduce the misalignment in manufacturing • Reduce cost

  17. Keyway • Radial holes • Axial holes

  18. Features added in feature recognition module • Radial holes feature

  19. 2.KeyWay feature

  20. Radial hole part program: Fanuc21 N130 T1212 (Radial mill @5); N135 M52; N140 G96 S50G95 F0.055 M13; N145 C0 N150 G0 X41 Z-32.5; N155 G1 X16; N160 G0 X41; N165 C72 N170 G1 X16; N175 C144 N180 G1 X16; N185 C216 N190 G1 X16; N195 C288 N200 G1 X16;

  21. Sinumerik 810 T12 D12 M6 ;Radial mill @5 M52 G96 S85 G95 F0.09 M13 C0 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1 C72 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1 C144 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1 C216 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1 C288 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1

  22. Sinumerik 840 T12 D12 M6 ;Radial mill @5 M52 G96 S0 G95 F0 M13 G96 S0G95 F0 M13 C0 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C72 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C144 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C216 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C288 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C360 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0)

  23. Keyway part program Fanuc21 N130 T1212 (Radial mill @6); N135 M52; N140 G96 S50G95 F0.055 M13; N145 C0 N150 G0 X21 Z-25; N155 G1 X14; N160 G1 Z-35; N165 G0 X21; N165 C120 N170 G0 X21 Z-25; N175 G1 X14; N180 G1 Z-35; N185 G0 X21; N185 C240 N190 G0 X21 Z-25; N195 G1 X14; N200 G1 Z-35; N205 G0 X21;

  24. FUTURE WORK

  25. Turning • Calculation of Machining time. • Identifying surface finishing allowance on inclined surfaces. • Allow the software to deal with more controllers

  26. Mill Turn • Identifying the rest of mill turn features. • Introducing more controllers. Cad 3D Drafting Simulation for manufacturing process

  27. Part programming • Manual part programming • 1-Production of part programs directly in part program codes. • 2-specialist skills and knowledge are required by the part programmer. Computer aided part programming 1-to enable a computer to generate the part program code required to finish-machine the component.

  28. Part programming

  29. Part Programming • Generate the part program for Fanuc 21 controller for different advanced cycles

  30. Part programming • Generate the part program for Fanuc 21 controller • Generate some of features of the part program for sinumerik 810 controller • Adding operations parameters “feed & speeds “ data base according to material type and operation type.

  31. Part ProgrammingThreading Perform calculations • We does our calculation to get thread parameter in general case then we take the variable we need Dmin= Dmax-2P P = 0.6134*pitch Where: P … depth of teeth. Dmin… Minimum Diameter. Dmax… Maximum Diameter.

  32. Where: Q First … First Roughing Depth. Hr ... Roughing Full Depth. Ht ... Total Depth (0.613 × pitch). Hf... Finish Allowance / Finish Offset. am ... min depth of cut (0.06 – 0.08)mm.

  33. Where: n … Number of Bathes • we use these parameter in fanuc21 ,sin810 .

  34. Print out the part programming code • G78 X... Z... Q... P... F... R0

  35. CASE STUDY • External Thread: • G78 P020060 Q60 R0.04 • G78 X20.052 Z-16 Q0.311 P974 R0 F1.5 • Internal Thread: • G78 P020060 Q60 R0.04 • G78 X8.7 Z-25 Q0.256 P650 R0 F1

  36. External& Internal Thread:For Fanuc : • For External Thread • G78 P020060 Q60 R0.04 • G78 X20.052 Z-16 Q0.311 P974 R0 F1.5 • For Internal Thread • G78 P020060 Q60 R0.04 • G78 X8.7 Z-25 Q0.256 P650 R0 F1

  37. Part ProgrammingPart programming consists of planning and documenting the sequence of processing steps to be performed on an CNC machine. Part program is classified in two categories: 1- Manual part programming The term manual part programming refers to the production of part programs directly in part program codes. 2- Computer Aided Part Programming The concept of computer-aided part programming is to enable a computer to generate the part program code required to finish-machine the component.

  38. Part Programming Sequence Machining Sequence Facing External operations Drilling Internal operations Parameters form feature recognition module Machine selection • Tool selection • cutting parameters selection CNC part program

  39. Case Study (Fanuc21M)

  40. Mirror&Threaded holes

  41. Case Study (Fanuc21T)

  42. Results and Conclusion • 1-The project • Idea of project • Aim • Advantages

  43. 2- Product design considerations 3-the steps of a simulation study

  44. 3.1-Problem formulation • 3.2-Setting of objectives and overall project plan • 3.3-Model conceptualization • 3.4-Data collection • 3.5-Model translation • 3.6-Verification • 3.7-Validation • 3.8-Experimental design • 3.9-Production runs and analysis • 3.10-Repeatition • 3.11-Document and report

  45. 4-The relation between project and manufacturing in Egypt 4.1-problems of industry in Egypt 4.2-solutions of problem of industry in Egypt

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