COMPUTER AIDED MANUFACTURING

By R.C.Saini

Definitions
CAD-Computer Aided Design CADD-Computer Aided Design and Drafting

CAM-Computer Aided Manufacturing CAPP-Computer Aided Process planning CATD-Computer Aided Tool Design

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AUTOMATION IN INDUSTRY
What is automation? Type of automation system

Fixed automation (e.g. automated

assembly line)

Programmable automation (e.g. robots) Flexible automation (FMS)

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Types of Production systems

Mass production system (Large lots,(1000-100000), nut bolts etc.) Batch production system (Medium lots 100-1000)

Job Shop production system (small lots, aircrafts, ship etc.)

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Mass production
Mass production (also called flow production, repetitive flow production or serial production) is the production of large amounts of standardized products, including and especially on assembly lines. The concepts of mass production are applied to various kinds of products, from fluids and particulates handled in bulk (such as food, fuel, chemicals, and mined minerals) to discrete solid parts (such as fasteners) to assemblies of such parts (such as household appliances and automobiles).

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Batch production

Batch production is the manufacturing technique of creating a component at a workstation before moving to the next step in production.

Batch production is common in bakeries and in the manufacture of sports shoes, pharmaceutical ingredients, inks, paints and adhesives.

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Batch production
There are several advantages of batch production; it can reduce initial capital outlay because a single production line can be used to produce several products There are inefficiencies associated with batch production as equipment must be stopped, re-configured, and its output tested before the next batch can be produced. Time between batches is known as downtime.

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Job production

Job production involves producing a one-off product for a specific customer. Job production is most often associated with small firms (making railings for a specific house, building/repairing a computer for a specific customer, making flower arrangements for a specific wedding etc.) but large firms use job production too. Examples include:

Designing and implementing an advertising campaign Auditing the accounts of a large public limited company Building a new factory Rakesh 8 Installing machinery in a factory Chander Saini

Job production
Benefits Work is generally of a high quality A high level of customization is possible to meet the customer's exact requirements Significant flexibility is possible, especially when compared to mass production Workers can be easily motivated due to the skilled nature of the work they are performing Disadvantages include: Higher cost of production Requires the use of specialist labor (compare with the repetitive, low-skilled jobs in mass production) Slow compared to other methods (batch production and mass production) Essential features There are a number of features that should be implemented in a job production environment, they include: Clear definitions of objectives should be set. Clearly outlined decision making process.
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A Computer Aided Process Planning (CAPP)Rakesh Chander Saini frame-work

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PRODUCT CYCLE

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CLASSIFICATION OF MODERN M/C TOOL

N C M/C TOOLS (Numeric control) DNC M/C TOOLS (Direct numeric

control)

CNC M/C TOOLS (Computer Numeric

control)

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N C M/C TOOLS
NUMERICAL CONTROL or Control by Numbers started in late 1960 N C m/c tools are controlled by letters, no. & symbols . N C m/c runs on a program fed to it. All the functions of a NC m/c tool are controlled electronically, hydraulically or pneumatically.

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PRINCIPLE OF OPERATION OF NC M/C TOOL

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DNC
In a Direct Numerical Control system (DNC), a mainframe computer is used to coordinate the simultaneous operations of a number NC machines . The main tasks performed by the computer are to program and edit part programs as well as download part programs to NC machines. Machine tool controllers have limited memory and a part program may contain few thousands of blocks. The program is stored in a separate computer and sent directly to the machine, one block at a time. Rakesh Chander Saini

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DNC

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DNC

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CLOSED LOOP CONTROL IN A CNC M/C TOOL

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Automatic functions of NC m/c tool

Starting and stopping of m/c tool spindle Controlling the spindle speed Positioning the tool tip & guiding along desired path Feed rate controlling Changing of tool in the spindle

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Mode of operation of NC/CNC m/c tool

1.

Point to point (drilling ,punching operation )

Capability to operate all three axes but not simultaneously It is possible to move the tool to any point (in X & Y axes) in the fastest speed & carry out the m/cing

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Mode of operation of NC/CNC m/c tool

2. Point to point in straight line (milling st.

line)

Tool has the capability to carryout a continuous motion in each of the axis direction

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TYPE OF CONTROL SYSTEM IN CNC M/C SYSTEM

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Mode of operation of NC/CNC m/c tool

3. 2 axis contouring with switch-able plane
(2-axis contour milling) -simultaneous motion capability in any two

axes.

4. 3-axis contouring continuous path

-capability of simultaneous three or more axes motion - useful for m/cing most of the complex 3D profiles such as aerospace components, moulds & dies
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TYPE OF CONTROL SYSTEM IN CNC M/C SYSTEM

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Elements of NC M/C tools

1. Machine control unit (MCU) -MCU controls the motion of the cutting tool, spindle speeds, feed rate, tool changes, cutting fluid application & several other functions of m/c tool

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M/C TOOL CONTROL UNIT

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Elements of NC M/C tools

2. Part program (software element)
-detailed plan of manufacturing instructions - format is standardized by ISO Example of part program : N30 N40 N50 N60 G00 X120.0 Y45.0 Z-85.0 * G90 * G03 X200.0 Y200.0 I-100.0 J0F200 * G01 X120.0 Y110.0 *

Where N30 Block no.30(minimum of three digit e.g.N009) G00 geometrical function (two digit information G00 to G99) G03 circulation interpolation, anticlockwise G90 - specific absolute input dimensions G91 specific incremental input dimensions I distance to arc centre or thread lead parallel to X J - distance to arc centre or thread lead parallel to Y F feed function * - end of block
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Reference points and axis on a Milling Machine

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Illustrative Example for mirroring

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Elements of NC M/C tools

contd.

Part program can also be developed directly using CAD/CAM systems such as Uni-graphics, Pro-engineer, I-deas or CAM system such as master CAM ,smart CAM, surf CAM ,Duct etc.

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Elements of NC M/C tools

NC tooling
-each tool is set in a different adapter - program instructions pick the tool from respective pocket for m/cing

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Elements of NC M/C tools

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Elements of NC M/C tools

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Applications of NC/CNC machine tools

CNC was initially applied to metal working machinery: Mills, Drills, boring machines, punch presses etc and now expanded to robotics, grinders, welding machinery, EDM's, flame cutters and also for inspection equipment etc. The machines controlled by CNC can be classified into the following categories: CNC mills and machining centers. CNC lathes and turning centers CNC EDM CNC grinding machines CNC cutting machines (laser, plasma, electron, or flame) CNC fabrication machines (sheet metal punch press, bending machine, or press brake) CNC welding machines Rakesh Chander CNC coordinate measuring machines Saini

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CLOSED LOOP CONTROL IN A CNC M/C TOOL

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Reference Points

(1.1) Reference Points Part programming requires establishment of some reference points. Three reference points are either set by manufacturer or user. a) Machine Origin The machine origin is a fixed point set by the machine tool builder. Usually it cannot be changed. Any tool movement is measured from this point. The controller always remembers tool distance from the machine origin. b) Program Origin It is also called home position of the tool. Program origin is point from where the tool starts for its motion while executing a program and returns back at the end of the cycle. This can be any point within the workspace of the tool which is sufficiently away from the part. In case of CNC lathe it is a point where tool change is carried out. c) Part Origin The part origin can be set at any point inside the machine's electronic grid system. Establishing the part origin is also known as zero shift, work shift, floating zero or datum. Usually part origin needs to be defined for each new setup. Zero shifting Rakesh Chander part allows the relocation of the part. Sometimes the Saini accuracy is41

CNC milling machine

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4 axis CNC TIG welding machine

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Applications of NC/CNC machine tools

CNC was initially applied to metal working machinery: Mills, Drills, boring machines, punch presses etc and now expanded to robotics, grinders, welding machinery, EDM's, flame cutters and also for inspection equipment etc.

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The machines controlled by CNC can be classified into the following categories: CNC mills and machining centers. CNC lathes and turning centers CNC EDM CNC grinding machines CNC cutting machines (laser, plasma, electron, or flame) CNC fabrication machines (sheet metal punch press, bending machine, or press brake) CNC welding machines CNC coordinate measuring machines
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Advantages of CNC
Some of the dominant advantages of the CNC machines are: CNC machines can be used continuously and only need to be switched off for occasional maintenance. These machines require less skilled people to operate unlike manual lathes / milling machines etc. CNC machines can be updated by improving the software used to drive the machines. Training for the use of CNC machines can be done through the use of 'virtual software'. The manufacturing process can be simulated virtually and no need to make a prototype or a model. This saves time and money. Once programmed, these machines can be left and do not require any human intervention, except for work loading and unloading. These machines can manufacture several components to the required accuracy without any fatigue as in the case of manually operated machines. Savings in time that could be achieved with the CNC machines Rakesh Chander Saini are quite significant.

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Disadvantages of CNC
CNC machines are generally more expensive than manually operated machines. The CNC machine operator only needs basic training and skills, enough to supervise several machines. Increase in electrical maintenance, high initial investment and high per hour operating costs than the traditional systems. Fewer workers are required to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment.
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CNC

Coordinate

Measuring

Machines:

A coordinate measuring machine is a dimensional measuring device, designed to move the measuring probe to determine the coordinates along the surface of the work piece. Apart from dimensional measurement, these machines are also used for profile measurement, angularity, digitizing or imaging. A CMM consists of four main components: the machine, measuring probe, control system and the measuring software. The control system in a CMM performs the function of a live interaction between various machine drives, displacement transducers, probing systems and the peripheral devices Rakesh Chander Saini 48

Control systems can be classified according to the following groups of CMMs. 1. Manually driven CMMs 2. Motorized CMMs with automatic probing systems 3. Direct computer controlled (DCC) CMMs 4. CMMs linked with CAD, CAM and FMS etc.
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Cantilever type CMM

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Gantry type CMM

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Coordinate Measuring Machine (CMM)

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Ram EDM

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Wire cut EDM

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ACTUATORS

TRANSDUCERS AND FEEDBACK ELEMENTS

 A hardware device Changes one type of physical quantity into

another type
Converts a controller command signal to a change in

physical parameter (usually mechanical, such as position or velocity change) Example includes electric current to the rotational speed of electric motor.

Categories Of ACTUATOR
1.

ELECTRIC
Most commonly used Output can be linear or rotational

2.

HYDRAULIC
Hydraulic fluid used to amplify the signal Used when large forces are required

3. PNEUMATIC
Uses compressed air as driving power Limited to low force applications

ELECTRIC MOTOR
Consists of a stator and a rotor Converts electrical power into mechanical power In automation and industrial control there are three types:1) 2)

DC Motors AC Motors

DC MOTORS
Powered by constant current and voltage Rotor turned by continuously producing torque, produced by relative polarity change between the rotor and the stator Disadvantage of worn brushes is present

Using brushless DC motor, above disadvantage is overcome, also allows higher speed operations

DC Servomotors

Servomotor means a feedback loop, to achieve speed control Normally used in mechanized and automated systems Used as prime movers numerically controlled machinery, or other applications, requiring quick and sudden starts and stops

Motor is connected either directly or through a gear reduction to machinery, fan, pump, etc.

Apparatus represents load driven by motor

Load requires certain torque to operate, related to rotational speed

Torque increases with speed, relationship is represented as, T= Kw, T=Torque, w=angular velocity
K=Constant of proportionality b/w torque and angular velocity

Torque-Speed Curve:-

Starting Torque

Torque
T

Operating Point No-load Speed

Speed

CHARACTERISTICS AND LIMITATIONS

DC Servomotor possess ability to deliver very high torque at starting velocity of zero 2) It is a variable-speed motor, and its direction of rotation can be reversed
1)

DC Servomotor operation neglects brush contact losses at commutator, armature losses, windage and mechanical friction losses at bearings

AC MOTORS
Operate by generating a rotating magnetic field in stator, speed of rotation depends on frequency of input electrical power Categorized into two types:Induction Motors widely used, simple construction and low manufacturing cost. Synchronous Motors Complex in construction and require a device exciter to initiate rotation of

INDUCTION & SYNCHRONOUS MOTORS

Both

operate at constant speed depending on frequency of internal power.

Includes

applications requiring running at fixed speed, acting as a drawback, as speed changes are required oftenly.
Motor

speed is proportional to frequency, so changing frequency changes motor

STEPPER MOTOR
Also known as step motors or stepping motors Provides rotation in the form of angular displacements, called step angles. Every step is actuated by a discrete electrical pulse. Relation between step angle and number of steps:-

Typical Torque-Speed Curve :Torque T Locked-step mode Slewing mode

Speed

Two operating modes are shown :LOCKED-STEP MODE each pulse received by motor causes a discrete angular step to be taken, the motor starts and stops with each pulse, direction can also be reversed. SLEWING MODE usually for higher speeds, rotation is continuous and does not allow stopping and reversing at each step. The relationship between rotating speed and pulse frequency is retained in slewing mode.

TRANSDUCERS
An electronic device converting energy from one form to another. Example includes microphones, loudspeakers, etc. Types:1. A SENSOR
2.

An ACTUATOR

3.

The THIRD includes both functions

1.

A SENSOR - used to detect parameter in one form and convert it in another form of energy (electrical or digital), such as a tachometer.

2.

An ACTUATOR - one which gets stands responsible for the output action, converting electrical signal into generally nonelectrical energy. Example includes a loudspeaker which converts an electrical signal into a variable magnetic field and, subsequently, into acoustic waves.
The THIRD includes both functions - for example, a typical ultrasonic transducer switches back and forth many times a second between acting as an actuator to produce ultrasonic waves, and acting as a sensor to detect ultrasonic waves.

3.

RESOLVER
A type of rotary electrical transformer used for measuring degrees of rotation.
Types:a. Two-pole resolvers for absolute angle position b. Multi-pole resolvers for accurate angle position Other types include:

Receiver Resolvers

INDUCTOSYN
A Resolver whose output phase is proportional to the shaft angle. Its an Inductive transformer sensor. transducers used for accurate measurement of angular or linear position displacements.
Types:Rotary Inductosyn Transducer Incremental & Absolute Linear Inductosyn Transducer Flexible tapes & Rigid bar.

OPTICAL ENCODER
Digital

device to measure position and /or

speed.
Consists

of a disk separating the light source from the photo cell.

Disk

rotates, photocell senses the light through slots as series of pulses.

Number

or frequency of pulses are proportional to speed and position of shaft connected to disk.