INTRODUCTION TO COMPUTER AIDED

MANUFACTURING - CAM

 Computer Aided Manufacturing involves the use

of computer programs specifically designed to
create the geometry and tool paths needed for
parts to be machined. These tool paths can then
be automatically processed into a program
specific for the CNC machine to be used.
 CAM reduces waste and energy for enhanced
manufacturing and production efficiency via
increased production speeds, raw material
consistency and more precise tooling accuracy.
NUMERICAL CONTROL (NC) DEFINED

 Programmable automation in which the mechanical

actions of a ‘machine tool’ are controlled by a
program containing coded alphanumeric data that
represents relative positions between a work head
and a work part.
Program Machine
Instructions Control Unit

Transformati
on
Process
Power
COMPUTER NUMERICAL CONTROL
 Conventionally, an operator decides and adjusts
various machines parameters like feed, depth
depending on type of job, and control the slide
movements by hand. In a CNC machine function
and slide movements are controlled by motors
using Computer Programs.
DIFFERENCE BETWEEN NC AND CNC
MACHINE TOOLS
NC CNC
 NC machine tool does not  CNC machine tool require
require computer.
computer.
 Modify the program is  Modify the program is EASY.
DIFFICULT.
 The part program is entered  The part program is entered
on the and
program TAPE. stored in COMPUTER.
 Each part program requires  Large number of part
separate program tape. program can be
stored in computer.
DIRECT NUMERICAL CONTROL (DNC)
• “A system connecting a set of numerically controlled machines to
a common memory for part program or machine program storage
with provision for on-demand distribution of data to machines.”
ADVANTAGES OF CNC
1. CNC machines can be used continuously 24 hours a day,
365 days a year and only need to be switched off for
occasional maintenance.

2. CNC machines are programmed with a design which can

then be manufactured hundreds or even thousands of times.
Each manufactured product will be exactly the same.

3. Less skilled/trained people can operate CNCs unlike

manual lathes / milling machines etc.. which need skilled
engineers.

4. CNC machines can be updated by improving the software

used to drive the machines
LIMITATION OF CNC
1.Higher Investment cost
2.Higher maintenance
3.Requirment of Specialized operators
4.Planned Support facility
SELECTION CRITERIA FOR CNC
MACHINES
1.The tool or Material moves Automatically.
2.Tool can operate in 1-5 axes.
3.Larger machines have a machine control
unit(MCU) which manages operations.
4.Movements is control by motors.
5.Feedback is provided by sensor.
TYPES OF CNC MACHINES
 Based on Motion Type:
 Point-to-Point
 Continuous path

 Based on Control Loops:

 Open loop
 Closed loop

 Based on Power Supply:

 Electric
 Hydraulic
 Pneumatic

 Based on Positioning System

 Incremental
 Absolute
BASIC CNC PRINCIPLES
 All computer controlled machines are able to
accurately and repeatedly control motion in various
directions. Each of these directions of motion is
called an axis. Depending on the machine type
there are commonly two to five axes.
 Additionally, a CNC axis may be either a linear axis
in which movement is in a straight line, or a rotary
axis with motion following a circular path.
FEATURES OF CNC MACHINERY
 The tool or material moves.
 Tools can operate in 1-5 axes.

 Larger machines have a machine control unit

(MCU) which manages operations.
 Movement is controlled by a motors (actuators).

 Feedback is provided by sensors (transducers)

 Tool magazines are used to change tools

automatically.
SPINDLE DRIVES

 The spindle drives are used to provide angular motion to the

workpiece or a cutting tool. Figure shows the components of
a spindle drive. These drives are essentially required to
maintain the speed accurately within a power band which
will enable machining of a variety of materials with
variations in material hardness. The speed ranges can be
from 10 to 20,000 rpm. The machine tools mostly employ DC
spindle drives. But as of late, the AC drives are preferred to
DC drives due to the advent of microprocessorbased AC
frequency inverter. High overload capacity is also needed for
unintended overloads on the spindle due to an inappropriate
feed. It is desirous to have a compact drive with highly
smooth operation.
MACHINE STRUCTURE

 Higher Precision and Repeatability

 Reliability
 Efficiency
ELEMENTS OF CNC MACHINES :
 Types :-

 Chip Collection Arrangement

 Continuous Rotary Table

 Tool Pallet Changes

 Foundation Bolt Kits

 Leaf Exchange for Electricals

 Machine Light

 Electrical Equipment Suitable

 Hand Tools
ELEMENTS OF CNC MACHINES :
 Applications :-

 Table :
1. Pallet Table Surface 320 X 320 mm
2. Max. Permissible Load 250 kg
3. Table T- slots (no. X width X pitch) 3 X 12 X 100

 Axes Travel and Rages :

1. Longitudinal 420 mm
2. Cross 350 mm
3. Vertical 350 mm
4. Distance for Spindle Face to 100 mm (min.)
Center Line of Table 450 mm (max.)
ELEMENTS OF CNC MACHINES :
 Applications :-

 Spindle :
1. Spindle Taper BT – 40/ISO 40
2. Spindle Diameter 70 mm
3. Spindle Speed 40-4000 (60-6000)rpm
4. Spindle Power 5.5 to 75 kw

 Feed Rates :
1. Rapid Traverse Rate 20,000 mm/min
2. Feed Rate 6000 mm/min
AXIS AND MOTION NOMENCLATURE :-
CNC LATHE

 On most CNC lathes the Z Axis is parallel to

the spindle and longer than the X Axis.
AXIS AND MOTION NOMENCLATURE :-
CNC MILL

 On this gantry mill the spindle travels along

the X Axis. The travel direction of the table
designates the Y Axis. The Z Axis is designated by
the stationary vertical column.
CNC TOOLING :-

 Types of CNC tooling :

1. Drilling : Drill Press, Mills, etc.

Tooling : Drill Bits
2. Milling : Mill, Horizontal Mill
Tooling : End Mills, Ball Mills
3. Cutting : Hand Saw, Band Saw, Cold Saw
Tooling : Circular Blades, Band Type Blades
4. Turning : Metal Lathe, Wood Lathe
Tooling : Turning Tools, Parting Tools, Boring
Tools
CNC TOOLING :-

 Application of CNC tooling :

1. Reduced set-up time

2. Flexibility
3. Repeatability
4. To give High accuracy
5. Increased Rpm’s and feeds
CNC TURNING MACHINES

• In the area of turning systems, two basic types are available:

 Vertical CNC Lathe
 Horizontal CNC Lathe

Vertical Horizontal
MACHINING CENTERS :-

 Multiple operation and processes in a single set-up

utilizing multiple axis
 Typically has an automatic mechanism to change tools
 Machine motion is programmable
 Servo motors drive feed mechanisms for tool axis’s
 Positioning feedback is provided by resolvers to the
control system
WORK HOLDING DEVICE:-

 Machine Vice
 Clamping Elements
 Chucks
 Collects
 Turning Fixtures
 Fixtures
TOOL HOLDING DEVICE :-

 Drill socket
 Drill sleeves
 Drill chucks
APPLICATIONS:-
TOOL & WORK HOLDING DEVICE :-

1. Industries for removing metal

2. Industries for Fabricating Metals
3. Electrical Discharge Machining (EDM) Industry
4. Woodworking- routing and drilling
5. Number of lettering and engraving systems
CNC PART PROGRAMMING
IMPORTANCE OF VARIOUS POSITION :-

Machine Home
REFERENCE POINT
SET POSITION
RUN
CNC PROGRAMMING
 Important things to know:

• Coordinate System

• Units, incremental or absolute positioning

• Coordinates: X,Y,Z, RX,RY,RZ

• Feed rate and spindle speed

• Coolant Control: On/Off, Flood, Mist

 IMPORTANT G CODES
 G00 Rapid Transverse
 G01 Linear Interpolation
 G02 Circular Interpolation, CW
 G03 Circular Interpolation, CCW
 G17 XY Plane,G18 XZ Plane,G19 YZ Plane
 G20/G70 Inch units
 G21/G71 Metric Units
 G40 Cutter compensation cancel
 G41 Cutter compensation left
 G42 Cutter compensation right
 G43 Tool length compensation (plus)
 G43 Tool length compensation (plus)
 G44 Tool length compensation (minus)
 G49 Tool length compensation cancel
 G80 Cancel canned cycles
 G81 Drilling cycle
 G82 Counter boring cycle
 G83 Deep hole drilling cycle
 G90 Absolute positioning
 G91 Incremental positioning
 IMPORTANT M CODES
 M00 Program stop
 M01 Optional program stop
 M02 Program end
 M03 Spindle on clockwise
 M04 Spindle on counterclockwise
 M05 Spindle stop
 M06 Tool change
 M08 Coolant on
 M09 Coolant off
 M10 Clamps on
 M11 Clamps off
 M30 Program stop, reset to start
SIMPLE PART PROGRAMMING FOR
TURNING
 O0013
 N0005 G53
N0010 T0303
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X22.50 Z2.0 S500
N0080 G01 Z-30.0 F100
N0090 G00 X23.0 Z2.0 S500
N0100 G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
N0110 G00 Z2.0
N0120 X50.0 Z50.0
N0130 M30
SIMPLE PART PROGRAMMING FOR
MILLING
 O0013
 N0005 G53
N0010 T0303
N0020 G57 G00 X26.00 Z0.0 S500 M04
N0030 G01 X-0.20 F100
N0040 G00 Z2.0
N0050 X50.0 Z50.0
N0060 T0404
N0070 G57 G00 X22.50 Z2.0 S500
N0080 G01 Z-30.0 F100
N0090 G00 X23.0 Z2.0 S500
N0100 G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
N0110 G00 Z2.0
N0120 X50.0 Z50.0
N0130 M30
FLEXIBLE MANUFACTURING SYSTEM (FMS) :-

 A flexible manufacturing system has four or more

processing workstations connected mechanically
by a common part handling system and
electronically by a distributed computer system.
THREE CAPABILITIES THAT A MANUFACTURING
SYSTEM MUST POSSESS TO BE A FLEXIBLE.

1. The ability to identify and distinguish among the

different part styles processed by the system.
2. Quick changeover of operating instructions, and
3. Quick changeover of physical setup.
oCOMPONENTS OF FMS
1. Workstations.
2. Material handling and storage systems.
3. Computer control system.

o TYPES OF WORKSTATIONS
1. Load/Unload Stations.
2. Machining Stations.
3. Other processing Stations. (punching, shearing,
welding, etc.)
4. Assembly Station.
5. Other Stations and Equipment. (Inspection, Vision,
etc)
o FUNCTIONS OF THE HANDLING SYSTEM
1. Independent movement of workparts between stations.
2. Handle a variety of workpart configurations.
3. Temporary storage.
4. Convenient access for loading and unloading
workparts.
5. Compatible with computer control.
COMPUTER INTEGRATED MANUFACTURING
(CIM):-
 Computer-integrated manufacturing (CIM) is the
manufacturing approach of using computers to
control the entire production process
 This integration allows individual processes to
exchange info with each other and initiate
actions
 Through the computers integration,
manufacturing can be faster and less error-prone,
although the main advantage is the ability to
create automated manufacturing processes
BENEFIT FROM CIM
1. Creation of a truly interactive system that enables
manufacturing functions to communicate easily with other
relevant functional units
2. Accurate data transferability among manufacturing plant
or subcontracting facilities at implant or diverse locations
3. Faster responses to data-changes for manufacturing
flexibility
4. Increased flexibility towards introduction of new products
5. Improved accuracy and quality in the manufacturing
process (continued)
6. Improved quality of the products.
7. Reduction of lead times which generates a competitive
advantage.
CIM & PRODUCTION CONTROL SYSTEM
ROLE OF THE ELEMENTS OF CIM SYSTEM

 Marketing
 Product Design
 Planning & Purchase
 Manufacturing Engineering
 Factory Automation Hardware
 Warehousing
 Logistics and Supply Chain Management
 Finance
 Information Management
SUBSYSTEMS IN COMPUTER-INTEGRATED
MANUFACTURING

Major Elements of a CIM System

SUBSYSTEMS IN COMPUTER-INTEGRATED
MANUFACTURING

Various Activities in CIM

ROBOTICS :-

 An industrial robot is reprogrammable,

multifunctional manipulator designed to move
materials, parts, tools or special devices through
variable programmed motions for the
performance of a variety of tasks.

Various Activities in CIM

ROBOTICS :-

 An industrial robot is reprogrammable,

multifunctional manipulator designed to move
materials, parts, tools or special devices through
variable programmed motions for the
performance of a variety of tasks.

 Elements of Robot :-
 Body - Links + Joints
 Effectors - Hands, Torch, Tool, etc.
 Actuators - Electric Motor, Hydraulic
Systems, Pneumatic Systems etc.
ELEMENTS OF ROBOT :-

 Body - Links + Joints

 Effectors - Hands, Torch, Tool, etc.
 Actuators -Electric Motor, Hydraulic
Systems, Pneumatic Systems
etc.
 Sensors - Active or Passive
 Controllers -Open Loop or Closed Loop
 Software -Deliberative or Reactive
Methods
TYPES OF ROBOT :-

 Industrial Robot
 Mobile Robot
 Space Robot
 Military Robot
 Spy Robot
 Remote Operated Vehicle
APPLICATION OF ROBOT :-

 Processing Operations
 Assembly
 Inspection
 Machine Loading and Unloading
 Material Handling
RAPID PROTOTYPING:-

 Rapid prototyping is the name given to a host of

related technologies that are used to fabricate
physical objects directly from Computer-
Aided Design (CAD) data sources. These
methods are generally similar to each other in
that they add and bond materials in layer wise-
fashion to form objects .
ADVANTAGES OF RAPID PROTOTYPING :-

• Increase effective communication;

• Decrease development time;
• Decrease costly mistakes