introduction to cnc & cam engi 7928adfisher/7928-12/7928-mill_slides_2012.pdf · the cnc lab...

06-2012 C. Koenig

Introduction to Introduction to

CNC & CAMCNC & CAM

ENGI 7928ENGI 7928

Getting startedGetting started……

0606--20122012 C. KoenigC. Koenig

The CNC LabThe CNC Lab

�� Introduction to new software: Mastercam (2D milling) Introduction to new software: Mastercam (2D milling)

�� You will draw a model in SolidWorks You will draw a model in SolidWorks -- sketches must be sketches must be fully defined fully defined

�� You will use a tutorial handout to You will use a tutorial handout to ““machinemachine”” a part in a part in MastercamMastercam

�� Tutorial: Mill_1_handout available in the 7928 folder on the Tutorial: Mill_1_handout available in the 7928 folder on the S:S:\\engrengr\\coursescourses\\7928 folder7928 folder

�� When working in MastercamWhen working in Mastercam-- you must be diligent with the you must be diligent with the values you input, a typo could equal a crash.values you input, a typo could equal a crash.

�� Mastercam Labs: Thurs., July 5, Fri. July 6 with TA availableMastercam Labs: Thurs., July 5, Fri. July 6 with TA available

�� CNC DemonstrationCNC Demonstration-- in groups of 6 between July 11&12, 2in groups of 6 between July 11&12, 2--4pm4pm

�� NOTE :Mastercam is limited to 12 licenses only, therefore NOTE :Mastercam is limited to 12 licenses only, therefore you will need to find time when a station is available for you will need to find time when a station is available for you to complete the lab you to complete the lab

0606--20122012 C. KoenigC. Koenig

Memorial Engineering Memorial Engineering

Student Machine ShopStudent Machine Shop

�� Haas Super Mini CNC Mill, 15 hpHaas Super Mini CNC Mill, 15 hp

�� 10,000 rpm, 833 10,000 rpm, 833 ipmipm feed cutting ratefeed cutting rate

�� 10 Pocket umbrella tool changer10 Pocket umbrella tool changer

�� Travel: X=16Travel: X=16””, Y=12, Y=12””, Z=10, Z=10””

0606--20122012 C. KoenigC. Koenig

Memorial Engineering Memorial Engineering

Student Machine ShopStudent Machine Shop

�� MazakMazak Quick Turn Nexus 100Quick Turn Nexus 100--II CNC Lathe, 15hpII CNC Lathe, 15hp

�� 6,000 rpm, 1180 6,000 rpm, 1180 ipmipm cutting feed ratecutting feed rate

�� 12 position tool changer12 position tool changer

�� Travel: X= 11Travel: X= 11””, Z=12, Z=12””

0606--20122012 C. KoenigC. Koenig

Many types of CNC machines & Many types of CNC machines &

many outcomes!many outcomes!

�� Lathes, MillsLathes, Mills

�� 2 to 5 Axis2 to 5 Axis

�� Lathe bar feedersLathe bar feeders

�� Pallet Changer Pallet Changer CentresCentres

Photos compliments of Vincennes University Photos compliments of Vincennes University www.vuhtec.orgwww.vuhtec.org

0606--20122012 C. KoenigC. Koenig

Simple to complexSimple to complex

0606--20122012 C. KoenigC. Koenig

What is CNC?What is CNC?

�� Used to automate machine tools to perform Used to automate machine tools to perform simple to complex machining operationssimple to complex machining operations

�� Many controller languages are used Many controller languages are used

i.e. conversational & G codei.e. conversational & G code

�� Manually: code is used to build a program by Manually: code is used to build a program by manually entering commands using the key padmanually entering commands using the key pad

�� Software: for more complex or feature intense Software: for more complex or feature intense components we use CAM software to generate components we use CAM software to generate code for lengthy machining processes and /or code for lengthy machining processes and /or complex surfaces complex surfaces

0606--20122012 C. KoenigC. Koenig

Writing CodeWriting Code

�� GG--CodeCode

�� ConversationalConversational

0606--20122012 C. KoenigC. Koenig

What is CAM?What is CAM?� Computer Aided Manufacturing

� Used to assist manufacturers to generate CNCprograms

� Not a simple “click of a button”

� CAM can be parameter heavy: tools must be selected, speeds, feeds, depth of cuts, efficient tool paths selected & verified, clearances checked, reduce program times etc.

�� CAM software allows us to machine components CAM software allows us to machine components VIRTUALLY! VIRTUALLY!

0606--20122012 C. KoenigC. Koenig

79287928-- Using MastercamUsing Mastercam

�� Introduction to MastercamIntroduction to Mastercam

�� Importing SolidWorks modelsImporting SolidWorks models

�� Selecting stock sizeSelecting stock size

�� Setting up machining parametersSetting up machining parameters

�� Selecting machining operations, tool types, feeds, Selecting machining operations, tool types, feeds, speedsspeeds

�� Determine axial & radial depth cutsDetermine axial & radial depth cuts

�� Decide on rough & finish passesDecide on rough & finish passes

�� Verify Verify toolpathstoolpaths & cycle times& cycle times

�� Generate tool list, set up sheet & post operationsGenerate tool list, set up sheet & post operations

0606--20122012 C. KoenigC. Koenig

Design a solid model in SolidWorks: Design a solid model in SolidWorks:

TIP: TIP: keep it simplekeep it simple�� Note: the front plane in SolidWorks will become the top Note: the front plane in SolidWorks will become the top

plane in Mastercam.plane in Mastercam.

�� Use the recommended approach to drawing the solid Use the recommended approach to drawing the solid

model. In Mastercam we will make some minor model. In Mastercam we will make some minor

modifications to reposition the origin.modifications to reposition the origin.

�� Save the SolidWorks model Save the SolidWorks model

as an .as an .x_tx_t parasolidparasolid filefile

�� Fully define allFully define all

sketches in SWsketches in SW

-- OR potential OR potential m/cm/c

CRASH!CRASH!

0606--20122012 C. KoenigC. Koenig

We will use We will use Mill_1_ Mill_1_

2012handout2012handout in 7928 folder in 7928 folder

and follow follow the steps and follow follow the steps

to set up stock size & stock to set up stock size & stock

originorigin

Mastercam is limited to 12 licenses in this labMastercam is limited to 12 licenses in this lab

-- It is available also available in your home roomIt is available also available in your home room

0606--20122012 C. KoenigC. Koenig

The project: Pivot ClampThe project: Pivot ClampConsider: Consider:

�� How we will hold the partHow we will hold the part

�� Type of operationsType of operations

�� Facing, contours, pockets,Facing, contours, pockets,

spot drilling, drilling, spot drilling, drilling,

& type of milling& type of milling

�� Feeds, Speeds. Tool typeFeeds, Speeds. Tool type

0606--20122012 C. KoenigC. Koenig

The Mill 1 handout provides the order & type of machining The Mill 1 handout provides the order & type of machining

operations required, as well as tool selection & operations required, as well as tool selection &

recommended feeds & speeds:recommended feeds & speeds:

(note the location of the origin in Mastercam)(note the location of the origin in Mastercam)

0606--20122012 C. KoenigC. Koenig

Machining steps:Machining steps:

Tip: Tip: Think about rough cuts & finish cutsThink about rough cuts & finish cuts

In Mastercam the In Mastercam the

Operations ManagerOperations Manager

shows the machining shows the machining

operations, parameters, operations, parameters,

geometry & geometry & toolpathtoolpath-- we willwe will

create these operations.create these operations.

0606--20122012 C. KoenigC. Koenig

Select tools from the library:Select tools from the library:Tip: Filter, None, then select the tool required.Tip: Filter, None, then select the tool required.

0606--20122012 C. KoenigC. Koenig

Enter parameters as show in handout.Enter parameters as show in handout.Tip: Tip: Always enter a clear comment for each operation, this Always enter a clear comment for each operation, this

will appear in the code.will appear in the code.

0606--20122012 C. KoenigC. Koenig

Enter the parameters for each machining Enter the parameters for each machining

operation in Mastercamoperation in MastercamTip: Tip: Be sure proper clearance is given along all axis around Be sure proper clearance is given along all axis around

all work holding devices!all work holding devices!

0606--20122012 C. KoenigC. Koenig

Use Verify & Use Verify & BackplotBackplot to check to check toolpathstoolpaths, depth cuts, , depth cuts,

machining direction and moremachining direction and more……

Tip: Tip: ““Make your Make your virtual mistakesvirtual mistakes in Mastercamin Mastercam””

0606--20122012 C. KoenigC. Koenig

BackplotBackplot will show the detailed machining will show the detailed machining

steps created in each operation, tool, steps created in each operation, tool,

toolholdertoolholder, rapids moves & more., rapids moves & more.

0606--20122012 C. KoenigC. Koenig

Generate a detailed Tool ListGenerate a detailed Tool List

0606--20122012 C. KoenigC. Koenig

Generate a detailed Setup SheetGenerate a detailed Setup Sheet

0606--20122012 C. KoenigC. Koenig

Post the G Code to the post processorPost the G Code to the post processorTip: Tip: Learn how to read code and check your work!Learn how to read code and check your work!

0606--20122012 C. KoenigC. Koenig

G Codes Preparatory FunctionsG Codes Preparatory Functions

0606--20122012 C. KoenigC. Koenig

M Codes M Codes –– Misc. FunctionsMisc. Functions

0606--20122012 C. KoenigC. Koenig

Project Report RequirementsProject Report Requirements

�� Cover pageCover page

�� SolidWorks detail drawing: Pivot ClampSolidWorks detail drawing: Pivot Clamp

�� Print all Print all toolpathstoolpaths page Mastercampage Mastercam

�� Print tool list page MastercamPrint tool list page Mastercam

�� Print set up sheet page MastercamPrint set up sheet page Mastercam

�� Print the 1st page of the NC Code & Print the 1st page of the NC Code &

Annotate the major G & M code operations Annotate the major G & M code operations

on this page on this page –– see G & M Code sheets see G & M Code sheets

provided)provided)

0606--20122012 C. KoenigC. Koenig

Some parts modeled in SolidWorks (CAD) Some parts modeled in SolidWorks (CAD)

toolpathstoolpaths created using Mastercam (CAM)...&?created using Mastercam (CAM)...&?

0606--20122012 C. KoenigC. Koenig

OhOh……one last thing!one last thing!

When opening Mastercam you will need to:When opening Mastercam you will need to:

Select:Select:

�� Start Start

�� All ProgramsAll Programs

�� Mastercam X4 Mastercam X4

�� NhaspNhasp XX

�� Select Select NetHASPNetHASP buttonbutton

�� ReadRead

�� Click Activate Licenses buttonClick Activate Licenses button

�� OKOK