Automation Production System; Introduction to CAD/CAM

1. Automation Production System; Introduction to CAD/CAM Pringgo Widyo Laksono Industrial Engineering Dept. Sebelas Maret University

2. CAM/DNC/CNC • Definitions: • CAM: Computer Aided Manufacturing. A computer-controlled manufacturing process. A system using a computer to control a process. Systems range from three-axis NC mills to full factory automation • DNC: Direct Numerical Control • CNC: Computer Numerical Control. The use of a dedicated computer as a control system for an NC machine

3. CAD/CAM integration • The CAD model data generated during the design process can be utilized further by the Computer Aided Manufacturing process. A good CAD/CAM system eliminates the need to manually calculate tangencies or to do the trigonometry required to calculate tool paths, saving valuable programming time. It also provides a consistent finish and predictable results. http://www.engineeringzones.com/cam_nc.htm

4. Types of support that can be analyzed • Computer aided design and drafting • Computer aided engineering • Computer aided manufacturing • Computer aided process planning • Computer aided tool design • Computer aided NC part programming • Computer aided scheduling • Computer aided material requirement planning

6. Example of CAM for manufacturing support • Numerical control part programming by computers • Computer automated process planning • Computer generated work standards • Production scheduling • Material requirement planning • Shop floor control

8. The Product Cycle and CAD/CAM

9. The impact of CAD/CAM is manifest in all of the different activities in the product cycle

12. How to integrate CAD/CAM (1) CAD Program CAM Program CNC Program DXF File NC File

13. How to integrate CAD/CAM (2) Start CAM Load DXF file List NC file (Optional) Verify NC Program Plan Process Mill Part Select a layer Save NC File Planning CNC Create CAD Drawing Select a milling operation Select another layer? End Convert drawing to DXF Enter cutting Parameters Generate tool path CAD

16. Product Engineering • Product function • Product specifications • Conceptual design • Ergonomics and aesthetics • Standard • Detailed Design • Prototype development • Testing • Simulation • Analysis • Strength • Kinematics

17. Product Engineering 13. Dynamics 14. Heat 15. Flow 16. Design for manufacture 17. Design for assembly 18. Drafting

18. Manufacturing Engineering • Process planning • Process sheets • Route sheets • Tooling • Cutting tools • Jigs and fixtures • Dies and moulds • Manufacturing Information Generation • CNC part programmers • Robot programmers

19. Manufacturing Engineering 11. Inspection (CMM) programmers 12. Production organization 13. Bill of Materials 14. Material Requirement Planning 15. Production Planning 16. Shop Floor Control 17. Plant Simulation 18. Marketing and Distribution 19. Packaging 20. Distribution 21. Marketing

21. CAD technology can provide: • CAD is faster and more accurate • Developing the model and associated drafting a very easy task • CAD is possible to manipulate various dimentions, attributes and distances • Under CAD is not necessary to repeat the design or drawing • CAD can accurately calculate the various geometric properties • Modification of a model is very easy task • Use of standard components (part libraries) facilities  a very fast model development work • Several professional CAD packages provide 3D

22. CAM technology can provide: • Greater design freedom • Increased productivity • Greater operating flexibility • Shorter lead time • Improved reliability • Reduced maintenance • Reduced scrap and rework • Better management control

23. Automation and CAD/CAM • Continuous flow processes (continuous dedicated production of large amounts of bulk product  chemical plant) • Mass production of discrete products (production of large quantities of one product  automobiles) • Batch production (medium lot sizes of the same product or component  books, clothing) • Job shop production (low quantities, often kind of specialized products  prototypes)

25. Automation and CAD/CAM • Continuous flow processes • - Flow process from beginning to end • - Sensor technology  measure important variable • - Fully computer automated plan • 2. Mass production of discrete products • - Automated transfer machines • - Dial indexing machine • - Fully automated assembly lines

26. Automation and CAD/CAM 3. Batch production - Numerical Control - Direct Numerical Control - Computer Numerical Control 4. Job shop production - Numerical Control - Computer Numerical Control

27. Achievement in CAD/CAM • Interactive computer graphic systems • Color computer graphics • Animated computer graphics • Design engineering analysis • Parts classification and coding (group technology) • Design retrieval systems • Automated drafting • Design and manufacturing database • Computer assisted process planning • Computerized machinability data systems • Computer generated work standard

28. Achievement in CAD/CAM 12. Computer assisted NC part programming 13. Interactive graphics NC part programming 14. Finely tuned production scheduling 15. Materials requirement planning (MRP) 16. Shop floor control 17. Computer Numerical Control (CNC) 18. Direct Numerical Control (DNC) 19. Computer controlled robots 20. Microprocessor control applications 21. Computer aided inspection (CAI) 22. Computer aided quality testing (CAT)

29. Machining Operations • Milling • Turning • Electrical Discharge Machining (EDM)

30. CNC Machining Centers

31. CNC Lathe • http://customer.manufacture.com.tw/~likon/lnc.htm

32. Price: from 215,610 Euro Driven tools for complex drilling and milling operations as well as a complete counter spindle for machining the work pieces counter sides. CNC Lathe • http://www.gildemeister.com/gb/dreh.asp?ID=9

33. Application Examples (Turning) • http://www.gildemeister.com/gb/3_3_2_22.htm

34. EDM • The generic term EDM (Electrical Discharge Machining) can be applied to any machining process that uses an electrode to remove metal, or any other conductive material, from a work piece by generating sparks between conducting surfaces. • This is being performed in a dielectric fluid to prevent premature spark discharge. • Wire EDM uses a traveling wire electrode that passes through the work piece, the wire is, at all times, monitored by the machine’s internal computer system. This process can be seen as a very high precision band saw that can hold tolerances of +/-.0002. http://mercatech.com/

35. Absolute measuring one absolute coordinate system using (XYZ) location P (-1/1); Q (2/-1) Incremental measuring from point to point –3 left and 2 up x= -3 / y= 2 Distinction Absolute/Incremental P Q

36. Variables in Machining Process • Cutting tools: type, size, and tool material lead to different feed rates and spindle speeds • Materials: lead to different feed rates and spindle speeds

37. Variables in Machining Process

38. Milling Tools and Tool Inserts

39. M-Codes (Miscellaneous Codes) M00 Pause M02 End of Program M03 Spindle Motor on M05 Spindle Motor off M06 Tool Change G-Codes G00 Rapid traverse positioning G01 Feedrate Movement Linear G02 Feedrate Movement Circular clockwise G03 Feedrate Movement Circular counterclockwise G90 Absolute Coordinates G91 Incremental Coordinates NC Programming Codes (G/M)- A Selection-

40. Milling Operations • Most of the following operations have special G-codes: • Facing: removes material across the top surface • Contouring: removes material to a specified depth along a CAD geometry • Drilling: uses points identified on a CAD layer to drill holes to a specified depth • Pocketing: removes all material within the outline of a CAD geometry • Surface of Revolution: removes all material within a surface generated by revolving geometry about the X or Y axis

41. Leading CAM Software • Mastercam: http://www.mastercam.com/mainFrame4.htm • Unigraphics: http://www.ugsolutions.com/products/unigraphics/ • SmartCAM: http://www.sdrc.com/support/smartcam/support.shtml • EZ-CAM: http://ezcam.com/support.htm • Other Links: http://msnhomepages.talkcity.com/CerfSt/cadcamworld/navig.htm • Pro Engineer (http://www.ptc.com/)