Numerical Control Programming. 6.1 NC PART PROGRAMMING Introduction Coordinate Systems NC Words.
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Transcript of Numerical Control Programming. 6.1 NC PART PROGRAMMING Introduction Coordinate Systems NC Words.
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Numerical Control Programming
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6.1 NC PART PROGRAMMING
Introduction• Coordinate Systems
• NC Words
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6.1.1 Coordinate System
Z AXIS workpiece-rotating machine: Z is parallel to the spindle tool-rotating machine: Z is parallel to the tool axis
Z
ZZ
Z // rotating spindle
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6.1.1 Coordinate System
X AXIS workpiece-rotating machine:
X is the direction of tool movement horizontal milling machine : X axis is parallel to the table vertical machine : +X axis points to the right when the programmer
is facing the machine.
Z
ZZ
X
X
X
X // table
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6.1.5 NC Words
N, G, X, Y Z, A, B, C, I, J, K, F, S, T, R, M
N: specify the sequence number
G: preparatory word to prepare for control functions (the motion of each axis,
coordinate system, coordinate plane, cutter radius compensation, tool length offset……)
M: miscellaneous word
to control miscellaneous functions (spindle on/off, start/stop the machine, turn on/off the coolant, change the tool, and rewind the program tape)
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6.1.5 NC Words
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6.1.5 NC Words
M00 Program stop M06 Tool change
M01 Optional stop M07 Flood coolant on
M02 End of program M08 Mist coolant on
M03 Spindle CW M09 Coolant off
M04 Spindle CCW M30 End of tape
M CODES
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6.1.5 NC Words
Modal codes and non modal codes/
• modal functions Modal functions stay active until some other command
changes it. Modal commands are arranged in sets called “modal groups”, and only one member of a modal group may be in forces at any given time.
• non-modal functions Non-modal functions have effect only on the lines on
which they occur.
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6.1.5 NC Words
modal groups
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6.1.5 NC Words
M00 Program stop M06 Tool change
M01 Optional stop M07 Flood coolant on
M02 End of program M08 Mist coolant on
M03 Spindle CW M09 Coolant off
M04 Spindle CCW M30 End of tape
M CODES modal groups
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6.1.5 NC Words
N, G, X, Y , Z, A, B, C, I, J, K, F, S, T, R, M
F: feed rate of the tool motion S: cutting-speed
T: tool number
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6.1.5 NC Words
X, Y, Z, A, B, C: provide the coordinate positions of the tool. X, Y, and Z define the three translational (Cartesian) axes of a machine. A, B and C are used for the three rotational axes about the X, Y, and Z axes.
I, J, K: specify the center for circular motion
N, G, X, Y , Z, A, B, C, I, J, K, F, S, T, R, M
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6.1.5 NC Words
R: specify the clearance height in canned-cycle
N, G, X, Y, Z, A, B, C, I, J, K, F, S, T, R, M
N0010 G81 X1.000 Y2.000 Z0.000 R1.300
Operations in drill cycle G81 :1. Rapid to location (1,2,2).2. Rapid down to the R plane:(1,2,1.3) 3. Feed to the Z point, the bottom of the hole:(1,2,0)4. Operation at the bottom of the hole .5. Rapid or feed to either the R plane or the initial height.
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NC Words
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G codes
Unit selection: • G70 (inch), G71(metric)
Coordinates selection: • G90(absolute), G91(incremental)
Working plane selection: • G17(X-Y), G18(Z-X), G19(Y-Z)
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Set up working coordinate Machine zero
• is unchangeable and usually is set up with the machine Working coordinate (is decided by the offset from the machine zero)
• G92• Be defined in program
25.2
23
Z
X
G92 X25.2 Z23.0
Machine zero
G55
G54
G56 G57 G58
G59
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Rapid traverse: G00
G00: • to make the machine move at maximum speed.
• It is used for positioning motion. G90 G00 X20.0 Y10.0
Start
EndG90:
absolute coordinate
s
(0,0)
(10,10)
(20,10)
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Linear interpolation: G01 G01:
• linear interpolation at feed speed. G91 G0l X200.0 Y100.0 F200.0
Y
100.0
XStart
End
200.0
G91: incremental coordinates
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Circular interpolation: G02, G03
G02, G03:
• For circular interpolation, the tool destination and the circle center are programmed in one block
• G02 is clockwise interpolation, G03 is counterclockwise interpolation
__;____
____03
0219
__;____
____03
0218
__;____
____03
0217
FKJ
RZY
G
GG
FKI
RZX
G
GG
FJI
RYX
G
GG
End point Circle center, radius
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Circular interpolation: G02, G03
Specify Center with I, J, K
• I, J, K are the incremental distance from the start of the arc;
• Viewing the start of arc as the origin, I, J, K have positive or negative signs.
Center
Y
Start
End
X
i
j
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Circular interpolation: G02, G03
R60R50
90 120 140 200
100
6040
O
Y
X
N0010 G92 X200.0 Y40.0 Z0; N0020 G90 G03 X140.0 Y100.0 R60.0 F300; N0030 G02 X120.0 Y60.0 R50.0;
G90: absolute
coordinates
G92:To define working
coordinate
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Circular interpolation: G02, G03
Annotation for Circular Interpolation
• I0.0, J0.0, and K0.0 can be omitted.
• If X,Y,Z are all omitted in the program, that means start and end of arc are same points.
N0020 G02 I20.0 (a full circle)
• If I, J, K, and R all appears in circular interpolation instruction, R is valid and I, J, and K are invalid
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Return to Machine Zero: G28
G28 The machine passes by the specified point, and then
move to the machine zero.
G91 G28 X_, Y_, Z_ X,Y,Z are the coordinate of specified point that is saved in
memory of machine. Usually this instruction is used in the beginning and end of
program.
A
Machine Zero
Specified point
G91: incremental coordinates
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Return to the Specified point : G29
G29 The machine passes from the machine zero by
the point that is specified in G28, and then move to the new specified point.
G29 X_, Y_, Z_ X, Y, Z are the coordinate of new specified point G28,G29 are usually used to change tool
Specified point in G28
A
Machine Zero
New specified point in G29
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M code
miscellaneous word miscellaneous functions:
• turn the spindle on/off
• start/stop the machine
• turn on/off the coolant
• change the tool
• rewind the program (tape)
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M code
M00 Program stop M06 Tool change
M01 Optional stop M07 Flood coolant on
M02 End of program M08 Mist coolant on
M03 Spindle CW M09 Coolant off
M04 Spindle CCW M30 End of tape
modal groups
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M code: M00, M01
M00 and M01 both stop the machine in the middle of a program.
M01 is effective only when the optional stop button on the control panel is depressed. The program can be resumed through the control panel.
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M code: M03, M04, M05
M03 turns on the spindle clockwise. M04 turns the spindle on counterclockwise.
(The spindle rpm must be specified in the same line or in a previous line. )
M05 turns off the spindle.
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M code: M07, M08, M09
M07 and M08 turn on different modes of coolant. • M07: flood coolant on
• M08: mist coolant on
M09 turns off the coolant.
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M code: M06
M06 signals the tool-change operation. On a machine equipped with an automatic
tool changer, it stops the spindle, retracts the spindle to the tool-change position, and then changes the tool to the one specified in the T-code.
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M code: M02, M30
M02 marks the end of the program. M30 marks the end of the tape. It stops the
spindle and rewinds the program (tape)
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Example A 2.0-in 2.0-in. square is to be milled using a 1/2-in. end
milling cutter (end mill). Write an NC part program to
make the square.
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Part program Explanation
N0010 G41 S1000 F5 M03
N0020 G00 X6.000 Y6.000 N0030 G01 Z-1.000 N0040 G01 Y8.000 N0050 G01 X8.000 M96N0060 G01 Y6.000 M96N0070 G01 X6.000 M96N0080 G01 Z1.000N0090 G40 M30
Begin compensation ( left ) , set feed and speed, spindle on ( CW)
Move to lower left cornerPlunge down the toolCut to upper left cornerCut to upper right corner with external curveCut to lower right corner with external curveCut to lower left corner with external curveLift the toolEnd the composition, stop the machine
Example
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G codes with animations
http://www.cncezpro.com/gcodes.cfm
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Manual Part Programming Example
Tool size = 0.25 inch,Feed rate = 6 inch per minute,Cutting speed = 300 rpm,Tool start position: 2.0, 2.0Programming in inches
(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
Motion of tool:p0 p1 p2 p3 p4 p5 p1 p0
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Spindle CCW
(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
1. Set up the programming parameters
N010 G70 G90 G94 G97 M04
Programming in inches
Use absolute coordinates
Spindle speed in rpm
Feed in ipm
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Flood coolant ON
(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
2. Set up the machining conditions
N020 G17 G75 F6.0 S300 T1001 M08
Machine moves in XY-plane
Feed rate
Tool no.
Spindle speed
Use full-circle interpolation
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(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
3. Move tool from p0 to p1 in straight line
N030 G01 X3.875 Y3.698
Linear interpolation
target coordinates
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(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
4. Cut profile from p1 to p2
N040 G01 X3.875 Y9.125
Linear interpolation
target coordinates
N040 G01 Y9.125
X-coordinate does not change no need to program it
or
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(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
5. Cut profile from p2 to p3
N050 G01 X5.634 Y9.125
Linear interpolation
target coordinates
1”
p3
.125
(x, y)
(6.5, 9)
y = 9 + 0.125 = 9.125(6.5 - x)2 + 0.1252 = (1 - 0.125)2
x = 5.634
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coordinates of center of circle(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
6. Cut along circle from p3 to p4
N060 G03 X7.366 Y9.125 I6.5 J9.0
circular interpolation, CCW motion
target coordinates
N060 G03 X7.366 Y9.125 I0.866 J-0.125
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(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
7. Cut from p4 to p5
N070 G01 X9.302
target coordinates (Y is unchanged)
Linear interpolation
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(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
8. Cut from p5 to p1
N080 G01 X3.875 Y3.698
target coordinates (see step 3)
Linear interpolation
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(4, 4)
(2, 2)
5”
p0
p1
p2
5”
2.5”
1”
45°
p3p4
p5
9. Return to home position, stop program
N090 G01 X2.0 Y2.0 M30
end of data
target coordinates (see step 3)
Linear interpolation
N100 M00
program stop
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10. Complete RS-274 program
N010 G70 G90 G94 G97 M04 N020 G17 G75 F6.0 S300 T1001 M08 N030 G01 X3.875 Y3.698 N040 G01 X3.875 Y9.125 N050 G01 X5.634 Y9.125 N060 G03 X7.366 Y9.125 I0.866 J-0.125 N070 G01 X9.302 N080 G01 X3.875 Y3.698 N090 G01 X2.0 Y2.0 M30
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Automatic Part Programming
Software programs can automatic generation of CNC data
Make 3D model
Define Tool
CNC data
Simulatecutting
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Automatic part programming and DNC
Very complex part shapes very large NC program
NC controller memory may not handle HUGE part program
computer feeds few blocks ofNC program to controller
When almost all blocks executed,controller requests more blocks
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Assignment (Learn this software)
CNC Simulator Download from
http://cnc-simulator.com/download/get.php?f=CncSetup453.exe
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2004 49
A system in which a central computer downloads the NC programs block by block to many NC machine tools simultaneously is called Direct Numerical Control (DNC) system.
Direct Numerical Control (DNC):
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DNC
Direct numerical control (DNC) – control of multiple machine tools by a single (mainframe) computer through direct connection and in real time 1960s technology Two way communication
Distributed numerical control (DNC) – network consisting of central computer connected to machine tool MCUs, which are CNC Present technology Two way communication
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2004 51
This system used to work with the early NC machine tools which can not read more than a block of information at a time. The central computer feed the program information one block at a time. When the machine execute the information, the next block of information would be fed.
Direct Numerical Control (DNC):
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Distributed NC is known by the same acronym as Direct Numerical Control (DNC). After the introduction of CNC, the machine tools have had the capability of storing large amount of information. Therefore, there have been no need to have drip feed information system, like, Direct Numerical Control. Instead, Distributed Numerical Control is introduced. In such a system, a host computer communicate with many CNC machine tools via networks and download or upload programs.
Distributed Numerical Control (DNC):
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With Distributed Numerical Control systems, it is possible to monitor the activities in individual CNC machine tools on host computer.
Therefore, better shop floor control can be achieved.
Distributed Numerical Control (DNC):
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TYPES of CNC CONTROL TYPES of CNC CONTROL SYSTEMSSYSTEMS
Open-loop controlOpen-loop control Closed-loop controlClosed-loop control
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OPEN-LOOP CONTROL OPEN-LOOP CONTROL SYSTEMSYSTEM
In open-loop control system step motors In open-loop control system step motors are usedare used
Step motors are driven by electric pulsesStep motors are driven by electric pulses Every pulse rotates the motor spindle Every pulse rotates the motor spindle
through a certain amountthrough a certain amount By counting the pulses, the amount of By counting the pulses, the amount of
motion can be controlledmotion can be controlled No feedback signal for error correctionNo feedback signal for error correction Lower positioning accuracy Lower positioning accuracy
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CLOSED-LOOP CONTROL CLOSED-LOOP CONTROL SYSTEMSSYSTEMS
In closed-loop control systems DC or In closed-loop control systems DC or AC motors are usedAC motors are used
Position transducers are used to Position transducers are used to generate position feedback signals generate position feedback signals for error correctionfor error correction
Better accuracy can be achievedBetter accuracy can be achieved More expensiveMore expensive Suitable for large size machine toolsSuitable for large size machine tools