laboratory manual and reference -...

MECH 460

Computer Aided Manufacture

Laboratory and Information Manual

This Manual was Prepared by:

Dr. G. W. Vickers

Mr. M. H. Ly

(c) University of Victoria, 1988 (c) Updated 1989 (c) Updated 1991 (c) Updated 1992 (c) Updated 1994

Reprinted December 1996 Reprinted December 1997

(c) Updated 1999 (c) Updated 2000 (c) Updated 2003 (c) Updated 2005 (c) Updated 2006 (c) Updated 2007

TABLE OF CONTENTS

Page Demonstration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 Laboratory 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Laboratory 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 Laboratory 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Laboratory 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 APPENDICES A Start up and Initialization Procedure for the Victor CNC Machines . . . . . . . . . . . A.1 B Manual Operation of the CNC TNS-3 Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1 C Automatic Operation of the Victor CNC Machines . . . . . . . . . . . . . . . . . . . . . . . . C.1 D Computer Assisted Programming for the Victor CNC Machines . . . . . . . . . . . . . D.1 E Machining the First Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.1 F Standard G-code Start and End Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.1 G Available G-codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G.1 H Postpro.c – Convert cutter location file to G-code format . . . . . . . . . . . . . . . . . . H.1 Acknowledgements

SAFETY INSTRUCTIONS

1. All work on the Victor CNC TNS-3 lathe, the Victor CNC VM-5 machining centre is

to be done under supervision. 2. Familiarize yourself with all aspects of the procedure before operating equipment. If

unsure of the correct operating procedure, request assistance from your instructor. 3. Immediately report any equipment malfunctions or unusual occurrences to your

instructor.

0.1

Demonstration OBJECTIVE

To demonstrate the basic features and operation of the Victor numerically controlled tools.

PROCEDURE A. Basic CNC machines operations

- Start-up and initialization procedure of the Victor CNC machines including

zero return and G92 (see Appendix A). - Manual operation of the CNC lathe and mill including turret indexing, tail

stock motion, table motion and tool change (see Appendix B). - Manual data input (see Appendix C). - DNC operation (see Appendix C). - Computer assisted programming for the CNC machines (see Appendix D).

B. Victor CNC machines features

• Victor CNC VM-5 Machining Center (see Figure 1) Specifications: - Maximum X axis travel 40” (1020mm) - Maximum Y axis travel 20” (510mm) - Spindle vertical travel (Z axis) 22” (560mm) - Spindle speed 35-3,500 rpm - Feed rate: tape 0.04 – 95 inch/min (1-2400 mm/min)

Jog 0 – 80 inch/min (1-2000 mm/inch) - Rapid traverse 400 inch/min (10,000mm/min) - Maximum weight on table 1,600 lbs (700 kg) - Weight, less controls 12,800 lbs (5,800kg)

0.2

Figure 1. Victor Machining Center with Fanuc System 6M-B

• Victor CNC TNS-3 Lathe (see Figure 2) Specifications: - Maximum cross travel (X-axis) 6.3” - Maximum length (Z-axis) 24.0” - Spindle speed 25-5000 rpm - Rapid feed rate X: 16.4 ft/min Z: 32.8 ft/min - Hydraulic chuck size 10” - Turret tool positions 10 - Net weight 11,000 lbs

0.3

Figure 2. Victor CNC TNS-3 lathe with Fanuc System 10-T

1.1

Laboratory 1 CNC Lathe with Symbolic FAPT Programming

OBJECTIVES

1. To demonstrate how to program (using the computer-assisted method called Symbolic FAPT) and machine a simple part on the Victor CNC TNS-3 lathe.

2. To program and machine an automobile stub shaft axle using Symbolic FAPT.

REPORT A report is not required for Lab #1. PROCEDURE (All the following operations should be done under supervision). A) Demonstration of FAPT programming.

1. Start and initialize the Victor CNC TNS-3 lathe as shown in Appendix A. 2. Operate the lathe in manual operation mode as shown in Appendix B. 3. Execute Symbolic FAPT at the lathe console as shown in Appendix D. 4. Produce a part program for the component shown in Figure 1.1 using the

instructions given in Figure 1.2. The part is to be machined from 38 mm diameter aluminum bar stock.

5. Execute NC data preparation and display the toolpath on the CRT screen.

1.2 B) Programming and machining an automobile stub-shaft axle.

1. Execute Symbolic FAPT at the lathe console as shown in Appendix D. 2. Produce the part program for the component shown in Figure 1.3 using the

following approach:

C T G R R

3. Execute NC mode at the lathe console and machine the part as shown in Appendix E. The component is to be made from 52 mm diameter aluminum bar stock.

1.3

Fig. 1.1 Demonstration Part

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2.1

Laboratory 2 2-axis CNC Mill with AutoCAD Data Input

OBJECTIVES

1. To operate a CNC milling machine and become familiar with set-up, procedures and data flow.

2. To use AutoCAD to define a series of closed 2-D polygons that form initials, or other artistic creations, within a 150 x 100 mm border. To run the output data file through the AutoLISP program called “digitize.lsp”.

3. To run the tool offset program “Offset.c” to generate a cutter location file CLfile. 4. To run the G-code file “Gcodehp.c” to generate machine code. 5. To set-up and machine the 2-D shape in plexiglass plate with a ¼ inch (6.35 mm)

diameter ball-mill on the Victor CNC Machining Center using the program “CNC.exe”.

REPORT The report should include the AutoCAD polygon drawing and the Matlab drawing with the cutter-offset path. Also it should include a flow chart of the program operation sequence and a brief assessment of the limitations of the cutter offset program. Marks for the lab will be based upon completeness of objectives and creativity of application in the lab report. The report will be due in class at a designated date that will be prior to the lab #2 session. Because of the interlocking lab schedule, late reports will not be accepted for marking. Note: While the actual machining time is not great you should use the opportunity to investigate the CNC machine set-up and controller operations. In subsequent labs part of the lab mark will be given for the amount of assistance required to set-up and machine the part. PROCEDURE (All the program for this Lab can be found in Windows NT server \\designsv1\courses\mech460\lab2) A) Demonstration of the initial ‘CP’

2.2 Step 1: Create initial using AutoCAD Start AutoCAD to create initial and then use AutoLISP program called digitize.lsp to output points data for input to program offset.c.

1. Make the initial ‘CP’ using AutoCAD. 2. Menu Format point styles select + style to display point on screen. 3. Run command DIVIDE to create points from the curve as shown in Figure 2.1. 4. Load AutoLISP program from menu Tools AutoLISP load application

Select digitize.lsp 5. Get 3 objects from AutoCAD drawing

digitize (letter C) Start new list of objects ? (Y/N) Y (start new lists of objects) Are you sure? (Y/N) Y

Pick points on the screen. when finish, press enter key Add this object to the list of objects? (Y/N) Y Save list of objects to a file? (Y/N) N (if you have another

o digitize) object tdigitize (outside letter P) Start new list of objects ? (Y/N) N Are you sure? (Y/N) Y

Pick points on the screen. when finish, press enter key Add this object to the list of objects? (Y/N) Y Save list of objects to a file? (Y/N) N (if you have another

o digitize) object tdigitize (inside letter P) Start new list of objects ? (Y/N) N Are you sure? (Y/N) Y

Pick points on the screen. when finish, press enter key Add this object to the list of objects? (Y/N) Y Save listFile name: cp.dat

of objects to a file? (Y/N) Y (When completed)

2.3

Figure 2.1 Create initial using AutoCAD

Step 2: program offset.c Study the tool offset program, which determines the position of an end mill cutter in relation to a 2-D curve defined by discrete points.

1. Understand data structure of the input (CP.DAT) and output file (CP.LOC). 2. Run program offset in DOS Window to get output file. Enter 3.175 mm for tool

radius, 1 for processing curve number 1, 1 for processing curve number 2 and 0 for processing curve number 3. Compare your output with the example output called CP.LOC.

3. Display CP.DAT and CP.LOC to make sure the tool path is correct. To get the output Figure 2.2 using command:

D:> start up matlab from window » drawtp Please Input the Design Data of the Part: cp.dat Do you want to show the cutter location?(y/n): y Please Input the offset Data of the Part: cp.loc

2.4

0 20 40 60 80 100 120 14010

20

30

40

50

60

70

80

90

x

yThe Drawing of the Design Part and Its Cutter Location

Figure 2.2 The initial CP with cutter path

Step 3: Program gcodehp.c Study the machining program, which converts a cutter location file to a G-code file.

1. Understand data structure of the input data (CP.LOC) and output file (CP.GCD). 2. Run program gcodehp in DOS Window to get gcode output file. Enter (0,0,100)

for home position, 200 for feed rate, 1200 for spindle speed, 20 for Z safety and (-3.00) for depth of cut.

3. Examine the gcode output file CP.GCD.

B) Create and machine your own series of closed 2-D polygons to form initials or other artistic creation.

2.5

List of Computer Programs for Lab #2

AutoLISP program DIGITIZE.LSP ;=============================================================== ; DIGITIZE.LSP ;This AutoLISP program saves digitized AutoCAD points to a file ;To load: From within AutoCAD, enter: (load "digitize") ;To run: From within AutoCAD, enter: digitize ; Run program for each object to be digitized ; Each digitized object will be added to list of objects ; The list of objects can be saved to a file ;================================================================ (defun c:digitize() ;================================================================== ; INITIALIZE VARIABLES ;================================================================== (setq FD nil PtList nil NewOb nil NPts 0) ;=================================================================== ; START NEW LIST OF OBJECTS? ;=================================================================== (setq New (getstring "Start new list of objects? (Y/N): ")) (if (or (= New "Y") (= New "y")) (progn (setq Sure (getstring "Are you sure? (Y/N): ")) (if (or (= Sure "Y") (= Sure "y")) (setq ObList nil) ) ) ) ;================================================================== ; GET POINTS FOR CURRENT OBJECT ;================================================================== (while (setq NewPt (getpoint "\nPick point: ")) ;================================================================ ; JUST GET X & Y COORDS FOR CURRENT POINT ;================================================================ (setq NewPt (list (car NewPt) (cadr NewPt))) ;=============================================================== ; ADD CURRENT POINT TO LIST OF POINTS FOR OBJECT ;=============================================================== (setq NewOb (reverse NewOb)) (setq NewOb (cons NewPt NewOb)) (setq NewOb (reverse NewOb)) )

2.6

;=================================================================== ; ADD OBJECT TO LIST OF OBJECTS? ;=================================================================== (setq AddOb (getstring "Add this object to the list of objects? (Y/N): ")) (if (or (= AddOb "Y") (= AddOb "y")) (prong ;============================================================== ; ADD CURRENT OBJECT TO LIST OF OBJECTS ;============================================================== (setq ObList (reverse ObList)) (setq ObList (cons NewOb ObList)) (setq ObList (reverse ObList)) ) ) ;==================================================================== ; WRITE OBJECTS TO FILE? ;==================================================================== (setq SaveOb (getstring "Save list of objects to a file? (Y/N): ")) (if (or (= SaveOb "Y") (= SaveOb "y")) (progn ;============================================================= ; GET FILE NAME FROM USER ;============================================================= (while (= FD nil) (setq FName (getstring "File name: ")) (setq FD (open FName "w")) ) ;============================================================= ; WRITE NUMBER OF OBJECTS TO FIRST LINE OF FILE ;============================================================= (setq NObs (length ObList)) (write-line (itoa NObs) FD) ;============================================================= ; WRITE DATA FOR EACH OBJECT TO FILE ;============================================================= (setq i 0) (repeat NObs (setq PtList (nth i ObList)) ;========================================================== ; WRITE NUMBER OF POINTS IN CURRENT OBJECT TO FILE ;========================================================== (setq NPts (length PtList)) (write-line (itoa NPts) FD) (setq j 0) (repeat NPts (setq Pt (nth j PtList)) ;======================================================= ; WRITE CURRENT POINT COORDINATES TO FILE ;=======================================================

2.7 (setq XCoord (car Pt)) (setq YCoord (cadr Pt)) (setq FLine (strcat (rtos XCoord)" " (rtos YCoord) " 4.0")) (write-line FLine FD) (setq j (+ j 1)) ) (setq i (+ i 1)) ) (close FD) ) ) ) Offset program /****************************************************************************/ /* Program offset.c : to calculate the tool center coordinates */ /* for a tool of radius R moving along a curve defined by discrete point. */ /* Algorithm: */ /* calculate 2 vector unit at a given point then add these vector */ /* calculate dot vector to find angle between 2 vectors */ /* calculate cross product to find direction of the normal vector */ /* Limitation: ??? */ /* Input data format ( clockwise) */ /* number lines */ /* number points of each line */ /* x y z */ /* Output data format */ /* 1 (penup) or 0 (pen down) x y z */ /* */ /****************************************************************************/ #include <stdio.h> #include <math.h> #define max 120 void loc_coord (); /* function calculate cutter location */ /****************************************************************************/ /* Main Program */ /****************************************************************************/ main() { int numpts, numobj; char inputf[80], outputf[80]; FILE *fopen(), *fp1, *fp2; float cutterR,radius; float xin[max], yin[max], z; float xout[max], yout[max]; int i, j, side; /**************************************************************************/ /* Get input and output files and tool radius */ /**************************************************************************/

2.8

printf("Program calculates cutter offset for profiling 2D POLYGON\n"); printf("Enter the name of the input file : "); scanf ("%s", inputf); fp2=fopen(inputf, "r"); if (fp2 == NULL) printf("ERROR IN OPENING INPUT FILE !!\n"); printf("Enter the name of the cutter location file : "); scanf ("%s", outputf); fp1 = fopen(outputf, "w"); if (fp1 == NULL) printf("ERROR IN OPENING OUTPUT FILE !!\n"); printf("Enter the tool radius : "); scanf ("%f", &radius); /************************************************************************/ /* Process each polygon */ /************************************************************************/ fscanf(fp2,"%d\n",&numobj); for ( j=1; j<numobj+1; ++j) { printf("Processing curve number #%3d \n", j); printf("Enter 0 = machine INSIDE the curve \n"); printf(" 1 = machine OUTSIDE the curve \n"); scanf("%d",&side); if (side == 0) cutterR = -radius; /* change sign of the cutter */ else cutterR = radius; /**********************************************************************/ /* Read input data file and store into array begining with index 1 */ /**********************************************************************/ fscanf(fp2,"%d\n", &numpts); for ( i=1; i<numpts+1; ++i) { fscanf(fp2,"%f %f %f\n",&xin[i], &yin[i], &z); } /* check to see if the date file close or open */ /* if open, close it and increased the pointer */ if (xin[1] == xin[numpts]) { xin[0] = xin[numpts-1]; yin[0] = yin[numpts-1]; } else /* curve points open. close it and add one more point */ { xin[0] = xin[numpts]; yin[0] = yin[numpts]; xin[numpts+1] = xin[1]; yin[numpts+1] = yin[1]; numpts = numpts +1; } /***********************************************************************/ /* Calculate offset by calling subroutine loc_coord */ /***********************************************************************/ loc_coord(cutterR, xin, yin, xout, yout,numpts);

2.9 /***********************************************************************/ /* Write output to the cutter location file */ /***********************************************************************/ fprintf(fp1, "1 %9.4f %9.4f %9.4f \n",xout[1],yout[1],z); for ( i =2; i< numpts; i++) fprintf(fp1, "0 %9.4f %9.4f %9.4f \n",xout[i],yout[i],z); fprintf(fp1, "0 %9.4f %9.4f %9.4f \n",xout[1],yout[1],z); } fclose(fp2); fclose(fp1); } /*==========================================================================*/ /* Subroutine calculates cutter location for each closed polygon */ /* Given tool radius (rad), xpt, ypt and numpts */ /* Return xoff and yoff */ /*==========================================================================*/ void loc_coord(rad,xpt,ypt,xoff,yoff,numpts) float rad; float xpt[], ypt[], xoff[], yoff[] ; int numpts; { #define x 0 #define y 1 int k; float vec1[2], vec2[2]; float unitvec1[2], unitvec2[2]; float plus[2], normplus[2]; float crossab,scaled, theta,temp,t1,t2; for ( k=1; k<numpts; ++k) { /* calculate vector 1 from Pk to Pk+1 */ vec1[x]=xpt[k+1]-xpt[k]; vec1[y]=ypt[k+1]-ypt[k]; /* calculate vector 2 from Pk to Pk-1 */ vec2[x]=xpt[k-1]-xpt[k]; vec2[y]=ypt[k-1]-ypt[k]; /* vector unit of vector 1 */ unitvec1[x]=vec1[x]/sqrt((vec1[x]*vec1[x])+(vec1[y]*vec1[y])); unitvec1[y]=vec1[y]/sqrt((vec1[x]*vec1[x])+(vec1[y]*vec1[y])); /* vector unit of vector 2 */ unitvec2[x]=vec2[x]/sqrt((vec2[x]*vec2[x])+(vec2[y]*vec2[y])); unitvec2[y]=vec2[y]/sqrt((vec2[x]*vec2[x])+(vec2[y]*vec2[y])); /* add two vector 1 and vector 2 */ plus[x] = unitvec1[x]+unitvec2[x]; plus[y] = unitvec1[y]+unitvec2[y]; /* cross product of vector 1 and vector 2 */ crossab = (unitvec1[x]*unitvec2[y] - unitvec2[x]*unitvec1[y]);

2.10 if (crossab < 0 ) { plus[x] = -plus[x]; plus[y] = -plus[y]; } /* vector unit of plus vector */ normplus[x]= plus[x]/sqrt((plus[x]*plus[x])+(plus[y]*plus[y])); normplus[y]= plus[y]/sqrt((plus[x]*plus[x])+(plus[y]*plus[y])); /* calculate the angle bewtween two unit vector 1 & 2 by dot */ /* product of these vector */ theta=0.5*acos(unitvec1[x]*unitvec2[x]+unitvec1[y]*unitvec2[y]); /* calculate the length of the offset point */ scaled=rad/sin(theta); /* offset point */ xoff[k]=xpt[k]+(scaled*normplus[x]); yoff[k]=ypt[k]+(scaled*normplus[y]); } }

2.11 MATLAB script file drawtp.m % This program is to draw the initial 2-D polygon and cutter offset % location file. clear all; file_name = input('Please Input the Design Data of the Part: ','s'); source_file_id = fopen( file_name, 'r'); curve_number = fscanf( source_file_id, '%d',1); hold on grid on xlabel('x'); ylabel('y'); zlabel('z'); title('The Drawing of the Design Part and Its Cutter Location'); for i = 1:curve_number point_number = fscanf(source_file_id,'%d',1); point = fscanf(source_file_id,'%f',[3,point_number]); plot3(point(1,:),point(2,:),point(3,:)); end fclose( source_file_id ); answer = input('Do you want to show the cutter location?(y/n): ','s'); if ((answer == 'y')|(answer == 'Y')) file_name = input('Please Input the offset Data of the Part: ','s'); source_file_id = fopen( file_name, 'r'); [cl_point,cl_number] = fscanf(source_file_id,'%d%f%f%f',[4,inf]); fclose( source_file_id ); cl_number = cl_number/4; i = 1; indicator = cl_point(1,i); while ((indicator == 1.0)&(i <= cl_number)) j = 1; x(j) = cl_point(2,i); y(j) = cl_point(3,i); z(j) = cl_point(4,i); if (i <= cl_number-1) i = i+1; end indicator = cl_point(1,i); while ((indicator == 0.0)&(i <= cl_number)) j = j+1; x(j) = cl_point(2,i); y(j) = cl_point(3,i); z(j) = cl_point(4,i); if (i <= cl_number-1) i = i+1; indicator = cl_point(1,i); elseif (i == cl_number) indicator = 100; end end plot3(x,y,z,'--'); clear x y z end

2.12

% Output the result of evaluation in graphics. rotate3d; hold off; end Gcode program /**************************************************************************/ /* Program gcodehp.c : to convert a cutter location file to gcode for */ /* for CNC machine */ /* Input file: cutter location with format 1 or 0 x y z */ /* Output file: G-cdoe file */ /**************************************************************************/ #include <stdio.h> int datafrmt, up_dwn, num ; float feedrate, spinspd; float zsafe, zdeep; float xx, yy, zz; float xin, yin, zin; char inputf[80], outputf[80]; FILE *fopen(), *fp1, *fp2; /***********************************************/ /* Main Program Routine */ /***********************************************/ main() { printf("Please enter the name of the input file name : \n"); scanf ("%s", inputf); fp2=fopen(inputf, "r"); if (fp2 == NULL) printf("ERROR IN OPENING INPUT FILE !!\n"); printf("Please enter the G-code output file name : \n"); scanf ("%s", outputf); fp1 = fopen(outputf, "w"); if (fp1 == NULL) printf("ERROR IN OPENING OUTPUT FILE !!\n"); printf("Enter the data format : 0 = Inches \n"); printf(" : 1 = Millimeters \n"); scanf ("%d", &datafrmt); printf("Enter the G92 home position (x y z) : \n"); scanf ("%f%f%f", &xx, &yy, &zz); printf("Enter feedrate : \n"); scanf ("%f", &feedrate); printf("Enter the spindle speed in rpm : \n"); scanf ("%f", &spinspd); printf("Enter the z safety limit coordinate : \n"); scanf ("%f", &zsafe); printf("Enter the depth of cut : \n"); scanf ("%f", &zdeep);

2.13

/***********************************************/ /* WRITE INITIAL DATA */ /***********************************************/ num = 1; fprintf(fp1,"O23; \n"); fprintf(fp1,"N%4d G92 X%8.3f Y%8.3f Z%8.3f; \n",num, xx, yy, zz); num = num + 1; if (datafrmt == 0)

fprintf(fp1,"N%4d G20; \n", num); if (datafrmt == 1) fprintf(fp1,"N%4d G21; \n", num); num = num +1; fprintf(fp1,"N%4d G90; \n", num); num = num +1; fprintf(fp1,"N%4d G00 Z%8.3f F%5.1f; \n", num, zsafe, feedrate); num = num +1; fprintf(fp1,"N%4d S%5.0f M03; \n", num, spinspd); num = num +1; /***********************************************/ /* READ TOOL PATH DATA */ /***********************************************/ while (!feof(fp2)) { fscanf (fp2,"%d %f %f %f", &up_dwn, &xin, &yin, &zin); if (up_dwn == 1) { fprintf(fp1,"N%4d G00 Z%8.3f; \n",num, zsafe); num = num +1; fprintf(fp1,"N%4d G00 X%8.3f Y%8.3f; \n",num, xin, yin); num = num +1; fprintf(fp1,"N%4d G01 Z%8.3f F%5.1f; \n",num, zdeep, feedrate); num = num +1; } if (up_dwn == 0) { fprintf(fp1,"N%4d G01 X%8.3f Y%8.3f; \n",num, xin, yin); num = num +1; } } fprintf(fp1,"N%4d G00 Z%8.3f; \n", num,zz); num = num +1; fprintf(fp1,"N%4d G00 X%8.3f Y%8.3f; \n",num, xx, yy); num = num +1; fprintf(fp1,"N%4d M05; \n",num); num = num +1; fprintf(fp1,"N%4d M30; \n",num); fprintf(fp1,"%% \n"); fclose(fp1); fclose(fp2); }

2.14 Sample data input of file CP.DAT

3 39 50.0000 20.0000 4.0 45.5000 20.0000 4.0 40.5000 21.5000 4.0 36.5000 23.0000 4.0 32.0000 25.5000 4.0 28.5000 28.5000 4.0 26.0000 32.0000 4.0 23.0000 36.5000 4.0 21.0000 40.5000 4.0 20.5000 45.0000 4.0 20.0000 49.5000 4.0 20.5000 54.5000 4.0 21.5000 59.0000 4.0 23.0000 63.5000 4.0 26.0000 67.5000 4.0 29.0000 71.0000 4.0 32.5000 74.0000 4.0 36.5000 76.0000 4.0 40.5000 78.0000 4.0 45.5000 79.0000 4.0 50.0000 79.5000 4.0 50.0000 70.0000 4.0 45.5000 69.5000 4.0 42.0000 68.5000 4.0 39.0000 66.5000 4.0 36.0000 64.0000 4.0 33.5000 61.0000 4.0 31.5000 57.5000 4.0 30.5000 54.0000 4.0 30.0000 50.0000 4.0 30.5000 46.0000 4.0 31.5000 42.5000 4.0 33.5000 39.0000 4.0 36.0000 36.0000 4.0 39.0000 33.5000 4.0 42.5000 31.5000 4.0 46.0000 30.5000 4.0 50.0000 30.0000 4.0 50.0000 20.0000 4.0 18 80.0000 20.0000 4.0 80.0000 80.0000 4.0 110.5000 80.0000 4.0 113.5000 79.5000 4.0 117.0000 78.5000 4.0 120.5000 76.0000 4.0 123.0000 73.0000 4.0 124.5000 69.5000 4.0 125.0000 65.5000 4.0 124.5000 61.5000 4.0

2.15

123.0000 58.0000 4.0 121.0000 54.5000 4.0 117.5000 52.5000 4.0 114.0000 51.0000 4.0 110.0000 50.5000 4.0 90.0000 50.5000 4.0 90.0000 20.0000 4.0 80.0000 20.0000 4.0 10 90.0000 60.0000 4.0 90.0000 70.0000 4.0 110.0000 70.0000 4.0 112.5000 69.5000 4.0 114.5000 68.0000 4.0 115.0000 65.0000 4.0 114.0000 62.5000 4.0 112.5000 60.5000 4.0 110.5000 60.0000 4.0 90.0000 60.0000 4.0

Sample data output file CP.LOC with cutter radius = 3.175mm

1 53.1750 16.8250 4.0000 0 45.0340 16.8250 4.0000 0 39.4853 18.4896 4.0000 0 35.1643 20.1100 4.0000 0 30.1775 22.8804 4.0000 0 26.1407 26.3405 4.0000 0 23.3866 30.1962 4.0000 0 20.2486 34.9033 4.0000 0 17.9070 39.5866 4.0000 0 16.8074 49.4825 4.0000 0 17.3596 55.0041 4.0000 0 18.4361 59.8486 4.0000 0 20.1509 64.9928 4.0000 0 23.5221 69.4877 4.0000 0 26.7483 73.2517 4.0000 0 30.7305 76.6650 4.0000 0 39.4604 81.0300 4.0000 0 45.0124 82.1404 4.0000 0 53.1750 83.0473 4.0000 0 53.1750 67.1582 4.0000 0 46.1157 66.3739 4.0000 0 43.3488 65.5833 4.0000 0 40.9023 63.9523 4.0000 0 38.2543 61.7457 4.0000 0 36.1180 59.1821 4.0000 0 34.4473 56.2583 4.0000 0 33.6201 53.3632 4.0000 0 33.1997 50.0000 4.0000 0 33.6201 46.6368 4.0000 0 34.4473 43.7417 4.0000 0 36.1180 40.8179 4.0000

2.16

0 38.2543 38.2543 4.0000 0 40.8179 36.1180 4.0000 0 43.7417 34.4473 4.0000 0 46.6368 33.6201 4.0000 0 53.1750 32.8028 4.0000 0 53.1750 16.8250 4.0000 1 76.8250 16.8250 4.0000 0 76.8250 83.1750 4.0000 0 110.7628 83.1750 4.0000 0 114.1993 82.6022 4.0000 0 118.3993 81.4022 4.0000 0 122.6777 78.3463 4.0000 0 125.7357 74.6766 4.0000 0 127.5949 70.3386 4.0000 0 128.1997 65.5000 4.0000 0 127.5949 60.6614 4.0000 0 125.8468 56.5824 4.0000 0 123.3271 52.1729 4.0000 0 118.9176 49.6532 4.0000 0 114.8386 47.9051 4.0000 0 110.1977 47.3250 4.0000 0 93.1750 47.3250 4.0000 0 93.1750 16.8250 4.0000 0 76.8250 16.8250 4.0000 1 93.1750 63.1750 4.0000 0 93.1750 66.8250 4.0000 0 109.6856 66.8250 4.0000 0 111.1711 66.5279 4.0000 0 111.5773 66.2233 4.0000 0 111.7222 65.3543 4.0000 0 111.2080 64.0691 4.0000 0 110.6364 63.3068 4.0000 0 110.1091 63.1750 4.0000 0 93.1750 63.1750 4.0000

Sample data output file CP.GCD

O23; N 1 G92 X 0.000 Y 0.000 Z 100.000; N 2 G21; N 3 G90; N 4 G00 Z 20.000 F200.0; N 5 S 1200 M03; N 6 G00 Z 20.000; N 7 G00 X 53.175 Y 16.825; N 8 G01 Z -3.000 F200.0; N 9 G01 X 45.034 Y 16.825; N 10 G01 X 39.485 Y 18.490; N 11 G01 X 35.164 Y 20.110; N 12 G01 X 30.177 Y 22.880; N 13 G01 X 26.141 Y 26.340; N 14 G01 X 23.387 Y 30.196; N 15 G01 X 20.249 Y 34.903;

2.17

N 16 G01 X 17.907 Y 39.587; N 17 G01 X 16.807 Y 49.482; N 18 G01 X 17.360 Y 55.004; N 19 G01 X 18.436 Y 59.849; N 20 G01 X 20.151 Y 64.993; N 21 G01 X 23.522 Y 69.488; N 22 G01 X 26.748 Y 73.252; N 23 G01 X 30.730 Y 76.665; N 24 G01 X 39.460 Y 81.030; N 25 G01 X 45.012 Y 82.140; N 26 G01 X 53.175 Y 83.047; N 27 G01 X 53.175 Y 67.158; N 28 G01 X 46.116 Y 66.374; N 29 G01 X 43.349 Y 65.583; N 30 G01 X 40.902 Y 63.952; N 31 G01 X 38.254 Y 61.746; N 32 G01 X 36.118 Y 59.182; N 33 G01 X 34.447 Y 56.258; N 34 G01 X 33.620 Y 53.363; N 35 G01 X 33.200 Y 50.000; N 36 G01 X 33.620 Y 46.637; N 37 G01 X 34.447 Y 43.742; N 38 G01 X 36.118 Y 40.818; N 39 G01 X 38.254 Y 38.254; N 40 G01 X 40.818 Y 36.118; N 41 G01 X 43.742 Y 34.447; N 42 G01 X 46.637 Y 33.620; N 43 G01 X 53.175 Y 32.803; N 44 G01 X 53.175 Y 16.825; N 45 G00 Z 20.000; N 46 G00 X 76.825 Y 16.825; N 47 G01 Z -3.000 F200.0; N 48 G01 X 76.825 Y 83.175; N 49 G01 X 110.763 Y 83.175; N 50 G01 X 114.199 Y 82.602; N 51 G01 X 118.399 Y 81.402; N 52 G01 X 122.678 Y 78.346; N 53 G01 X 125.736 Y 74.677; N 54 G01 X 127.595 Y 70.339; N 55 G01 X 128.200 Y 65.500; N 56 G01 X 127.595 Y 60.661; N 57 G01 X 125.847 Y 56.582; N 58 G01 X 123.327 Y 52.173; N 59 G01 X 118.918 Y 49.653; N 60 G01 X 114.839 Y 47.905; N 61 G01 X 110.198 Y 47.325; N 62 G01 X 93.175 Y 47.325; N 63 G01 X 93.175 Y 16.825; N 64 G01 X 76.825 Y 16.825; N 65 G00 Z 20.000; N 66 G00 X 93.175 Y 63.175; N 67 G01 Z -3.000 F200.0; N 68 G01 X 93.175 Y 66.825;

2.18

N 69 G01 X 109.686 Y 66.825; N 70 G01 X 111.171 Y 66.528; N 71 G01 X 111.577 Y 66.223; N 72 G01 X 111.722 Y 65.354; N 73 G01 X 111.208 Y 64.069; N 74 G01 X 110.636 Y 63.307; N 75 G01 X 110.109 Y 63.175; N 76 G01 X 93.175 Y 63.175; N 77 G01 X 93.175 Y 63.175; N 78 G00 Z 100.000; N 79 G00 X 0.000 Y 0.000; N 80 M05; N 81 M30; %

3.1

Laboratory 3 3-axis CNC Mill with 3 & 5-axis Pro/ENGINEER Cutter Path

Planning

OBJECTIVES

1. To operate a 3-axis CNC milling machine and become familiar with set-up, procedures and data flow.

2. To complete the Pro/ENGINEER demonstration of surface, workpiece and tool path generation for two intersecting quarter cylinders given in Procedure A).

3. To use Pro/ENGINEER to generate a similar size and shape object, fitting within a 65 x 65 x 50 mm size workpiece, with an intersecting quarter cylinder and quarter cone.

4. To use Pro/ENGINEER to produce the most efficient tool paths for 3- and 5-axis roughing and finishing operations. Use Surface Mill to create graphical tool paths for a ½ inch diameter end-mill cutter. The curved surface-machining programs should not exceed an estimated time in Pro/E of 30 minutes. The actual machining time will be significantly longer than this.

5. To output a 3-axis cutter location file for roughing and finishing operations, and generate G-code files using the postprocessor program given in Appendix H.

6. To set-up and machine the defined shape in a block of Ren 450 model making material on the 3-axis Victor CNC machining center.

REPORT The report should include Pro/E drawings of the intersecting quarter cylinder and quarter cone with at least two different tool paths for each of 3- and 5-axis finishing operations. It should also include the reasons for selecting the final 3-axis roughing and finishing operations as well as the Pro/E estimated machining time. Marks for the lab will be based primarily upon completeness of objectives in the lab report, as well as on the amount of assistance required to set-up and machine the component. The report will be due in class at a designated date that will be prior to the lab #3 session. Because of the interlocking lab schedule, late reports will not be accepted for marking.

3.2

PROCEDURE Index A) Demonstration of the tool path generation using Pro/ENGINEER p 3.2

Step 1: Produce the surface p 3.2 Step 2: Create the workpiece p 3.8 Step 3: Perform the 3-Axis machining operation setup p 3.10 Step 4: Define the 3-Axis machining operations p 3.13

4.1 Define “mill window” for first cut (rough cut) 4.2 Define the second cut (finishing Cut)

Step 5: Perform 5-axis machining operation setup p 3.20 Step 6: Create the NC code p 3.24

B) Use Pro/ENGINEER to generate an intersecting quarter cylinder and quarter cone and machine the defined shape in Ren 450 model making material on a 3-axis CNC machine.

Procedure Start A) Demonstration of the tool path generation using Pro/ENGINEER (Pro/E) Step 1: Produce the surface. The surface consists of two quarter of cylinders intersected, together form a surface (65 x 65 x 40mm) as shown in Figure 3.18.

1. Start the Pro/E program. Windows menu items, Start → Programs → PTC25

→ Pro ENGINEER→ Click on the icon Pro ENGINEER. 2. Set working directory. File → Set Working Directory, select working

directory. 3. Create the part name. Pro/E main menu, File → New, select Part in the New

window, enter part name: lab3. 4. Start of the part. The part contains some features already. The main graphics

area shows 3 datum planes and a coordinate system as shown in Figure 3.1.

3.3

Figure 3.1 Start of the Part

5. Create a quarter of cylinder with radius of 40mm and length of 65mm. • Choose INSERT → EXTRUDE from the menu. You should see a new

toolbar called dashboard appear as shown in Figure 3.2.

Figure 3.2 The Dashboard

• Click on Surface icon first and then click on the placement on the extrude dashboard (Figure 3.3) and select define. The sketch dialog window appears as shown in Figure 3.4.

Figure 3.3 The Extrude Dashboard Figure 3.4 Sketch dialog

3.4 Choose the datum place FRONT by clicking on it in the graphics window. Accept the default on the sketch dialog window and just click on the Sketch button. References sub-window pop up as shown in Figure 3.5 and click close to start sketch.

Figure 3.5 References dialog Figure 3.6 The Sketcher toolbar

• Choose Create Arc by picking its center and end points icon on Sketcher Toolbar (Figure 3.6) to sketch a quarter of circle for extrusion in plane FRONT by clicking on the center of the default origin and draw a quarter of circle the drawing windows. Click middle mouse to finish drawing the rectangle.

• Modify the dimensions to 40mm by double clicking on the dimensions on

the arc. To end sketching choose Accept icon on Sketcher Toolbar (Figure 3.6) and click OK in the Section dialog.

• Extrude the arc to form the quarter of cylinder. Enter depth value as 65mm into the depth field of the extrude dashboard (Figure 3.3) and click the Accept tick to finish (Figure 3.7).

• View the surface as shown in Figure 3.8. View → Orientation → Standard Orientation.

3.5

Figure 3.7 Dashboard controls Figure 3.8 First surface

6. Create another quarter of cylinder with radius of 30mm and length of 65mm. (using previous instruction 5) • Choose the datum place RIGHT as sketch plane. • Draw a quarter of circle as shown in Figure 3.9. • Extrude the arc to 65mm. • The intersected surface is given in Figure 3.10.

Figure 3.9 Draw 30mm arc. Figure 3.10 Two intersected surfaces

7. Trim two intersected surface to form a single surface. • Trim 1st surface. EDIT TRIM to cut out the first surface behind the

second surface. Pick 1st surface as trimmed quilt and 2nd surface as trimming object shown in Figure 3.11 and Figure 3.12 and finished surface shown in Figure 3.13.

3.6

Figure 3.11 Pick sequences Figure 3.12 Pick 1st surface as F5

Figure 3.13 Trimmed surface

• Trim 2nd surface. EDIT TRIM or pick the trim icon to cut out the surface behind 1st surface. Pick 2nd surface as trimmed quilt and edge as trimming object shown in Figure 3.14 and Figure 3.15.

Figure 3.14 Pick sequence Figure 3.15 Pick 2nd surface as F6

3.7 • The final trimmed surface as shown in Figure 3.16

Figure 3.16 Final trimmed surface

• Merge two surfaces to one surface. Select 1st surface and then hold down Ctrl key to select 2nd surface until 2 both surfaces highlighted. Select the merge tool as shown in the Figure 3.17 to merge two surfaces to form one surface as shown in Figure 3.18.

Figure 3.17 Merge tool Figure 3.18 The merged Surface

3.8

• Save the surface. File Save and Exit. Step 2: Create the workpiece. The workpiece represents the raw stock of material from which the surf will be machined. Pro/E refers to this procedure as an assembly operation.


→ Pro ENGINEER→ Click on the icon Pro ENGINEER. 2. Set working directory. File → Set Working Directory, select working

directory. 3. Create the part name. Pro/E main menu, File → New, select Manufacturing in

Type window and NC Assembly in Sub-type window, enter name: mfglab3 as shown in Figure 3.19

Figure 3.19 Creating a new file Figure 3.20 Figure 3.21

4. Load the part. From MANUFACTURE menu, select Mfg Model → Assemble →Ref. Model (Figure 3.20 and 3.21). Select Lab3.prt in the open window. The component Placement window pops up. Select to place the part at default location as shown in Figure 3.22. Click OK to close Component Placement windows as shown in Figure 3.23.

3.9

Figure 3.22 Figure 3.23 5. Create a datum plane ADTM1. Select to create a new datum plane offset

-8.00mm of NC_ASM_FRONT plane as shown in Figure 3.24.

Figure 3.24 Create new datum plane ADTM1 6. Create a workpiece 65 x 65x 50mm. From MANUFACTURE menu, select

Mfg Model → Create → workpiece. Enter a name for the workpiece: wpsurf. Select Solid Protrusion Extrude Solid Done. Select ADTM1 as sketch plane and NC_ASM_RIGHT as reference plane in Figure 3.25. Create a rectangle 65 x 65mm surrounding the surface and extrude it to 50mm as shown in Figure 3.26.

3.10

Figure 3.25 Figure 3.26

Step 3: Perform the 3-Axis machining operation setup. The setup consists of defining the type of machine to use. It also requires defining a coordinate system if one does not already exist and a retraction plane for the cutting tool. The coordinate system must match the mill orientation and the part zero.

1. MFG Setup → Operation. Operation Setup window pops up automatically as shown in Figure 3.27.

2. Define NC machine. Click NC machine icon in Figure 3.27, Machine Tool Setup windows pop up as shown in Figure 3.28. Enter the parameters as shown below

Machine name: Victor Machine type: Mill Number of Axis: 3 CNC control: FANUC 6MB Location; ELW B127

3. Define Machine Zero. Click Reference Machine Zero icon in Figure 3.27. Create MACH CSYS as Figure 3.29. Pick workpiece to create coordinate system in. Pick 3 reference planes as Figure 3.32 (click two sides and top planes while holding down Ctrl key) to place origin as shown in Figure 3.30. Orient X, Y axes as shown in Figure 3.31.

4. Define retract plane. Click Retract Surface icon in Figure 3.27. Retract Selection window pops up (Figure 3.33). Choose Along Z Axis, and in the panel of Enter Z Depth, input 10, click OK to close the window. The retract plane is shown in Figure 3.34.

3.11

Figure 3.27 Figure 3.28 5. Complete Operation setup. Click OK to close operation setup as Figure 3.35.

MFG Setup Done Return.

Figure 3.29 Figure 3.30 Figure 3.31

3.12

Figure 3.32 Defining the Coordinate System

Figure 3.33 Figure 3.34 Defining the Retract Surface

3.13

Figure 3.35 Completed Operation Setup

Step 4: Define the 3-Axis machining operations. The setup consists of defining the type of tool to use and machining parameters (tools size, cutting speed, etc.), and specify the volume of material to be removed. 4.1 Define “mill window” for first cut (rough cut)

1. Machining → NC Sequence → Machining Surface Mill → 3 Axis → Done.

2. SEQ SETUP window pops up. Ensure that name, tool, parameters, window and define cut checked and then choose DONE. (Figure 3.36).

3. Enter NC Sequence name. Type name as Rcut. 4. Tool setup table pops up. Enter the tool values as shown in Figure 3.37 and

APPLY OK. Cutter_Diam 12.7 Length 50 Corner Radius 0.0 (Flat end mill)

3.14


5. MFG PARAMS → Set. Param Tree window pops up. Input or change the

values as shown in Figure 3.38. File save parameters to file called “milprmRcut” Exit and DONE.

Figure 3.38

3.15

6. Define Mill Window. To specify the volume of material to be removed. We defined a “mill windows” on the top surface of our work piece that includes the entire work piece. Think of the work piece as being transparent and the surface as being solid. If you look down through the mill window, you will see all the volume of the material in the work piece located around the surface. • NC Sequence Define Wind Create Wind as shown in Figure 3.39

and enter a name for the window (MW1) • Machine Window pop up as shown in Figure 3.40 and choose Select as

shown in Figure 3.41

Figure 3.39 Figure 3.40 Figure 3.41

• Pick on each of the top edges of the workpiece as shown in Figure 3.42. Select Done and OK and mill windows was defined.

Figure 3.42

3.16

• Select Tool Side and change to Tool Past as shown in Figure 3.43. Make sure tool machine to outside of the surface.

Figure 3.43

7. Cut Direction windows pops up as shown in Figure 3.44. Click OK to accept

the default. 8. View tool path. Machining → NC Sequence → Play Path → NC Check. The

cutting path is shown in Figure 3.45.


3.17

9. After this completes choose DONE SEQ. If you don’t do this, you are likely to lose the definition of this NC sequence.

10. Modify cutting direction. NC Sequence Select Rcut. From SEQ SETUP, check Define Cut Done. Change Cut Angle to 90 as shown in Figure 3.46. The cutting path is shown in Figure 3.47.


11. Cut Angle 45 as shown in Figure 3.48 and the cutting path is shown in Figure 3.49.


3.18 4.2 Define the second cut (Finishing Cut)

1. Machining → NC Sequence → New Sequence →Machining → Surface Mill → 3 Axis → Done.

2. SEQ SETUP window pops up. Ensure that Name, Tool, Parameters, Surface, Define cut are checked and then close DONE.

3. Enter NC Sequence name. Type the name as FCut. 4. Tool setup table pops up. Use same tool as RCut

Cutter_Diam 12.7 Length 50 Corner Radius 0.0 (Flat end mill)

5. MFG PARAMS → Set and enter the values as shown in Figure 3.50 then File Save to file called “milprmFcut”→ Exit and DONE.

Figure 3.50

6. Create Mill Surface. NC Sequence → Seq. setup → Mill Surface → Done.

Define Surf Create Surf. Enter surface name: surf . Surf Define → Add → Copy → Done. Select the 1st cylinder and hold down Ctrl key while select 2nd cylinder. Once two cylinders have been selected click OK on Select surface window. Click OK to close Surface Copy window. Surf Define Done/Return. Direction (arrow indicates side of surface to be machine) OK. Select Srfs Select all Done/Return.

7. Cut Direction window pops up. Click OK to accept the default (Figure 3.51). 8. View tool path. Machining → NC Sequence → Play Path →NC check. The


3.19


9. After this completes choose DONE SEQ. 10. Modify cutting direction. NC Sequence Select Fcut. From SEQ SETUP,

check Define Cut Done. Change Cut Angle to 45 and the cutting path is shown in Figure 3.53. For Cut angle 90, the cutting path is given in Figure 3.54.

Figure 3.53 Cut Angle 45 Figure 3.54 Cut Angle 90 11. Modify Cut Type. Select From Surface Isolines. Highlight each surface as in

Figure 3.55 to make sure the cutting direction as in Figure 3.56. Run NC Check to display tool path as shown in Figure 3.57.

3.20


Figure 3.57

Step 5: Perform 5-axis machining operation setup.

1. MFG Setup → Operation. File New and Operation Setup window pops up automatically as shown in Figure 3.58.

2. Define NC machine. Click NC machine icon in Figure 3.27, Machine Tool Setup windows pop up as shown in Figure 3.28. Enter the parameters as shown below:

Machine name: Hass Machine type: Mill Number of Axes: 5 Axis CNC control: VMC

3.21

3. Define Machine Zero. Select NC_CSO from operation OP010. 4. Define retract plane. Select ADTM2 from operation OP010. 5. Complete Operation setup. Click OK, Done and Return.


6. Define machining operation. Machining NC Sequence Machining

Surface Mill 5 Axis Done. 7. SEQ SETUP windows pops up. Ensure that name, tool, parameters, surface

and define cut checked and then choose DONE. 8. Enter NC sequence name. Type name as Cut5X 9. Tool setup table popup. Click OK to accept the previous tool. 10. MFG PARAMS set. Param Tree window pops up. Input or change the

values as shown in Figure 3.60. File save parameters to file called “milprm5x” exit and Done.

Figure 3.60

3.22

11. Define Mill surface. Surf Pick Mill Surface Done. Select the surface as shown in Figure 3.61 and Okay. Select all and done.

Figure 3.61

12. Cut Direction window pops up. Select OK to accept the default (Figure 3.62) 13. View tool path. Machining NC Sequence Play Path NC check. The


Figure 3.62 Figure 3.63 14. After this completes, choose DONE SEQ. 15. Modify cutting direction. NC Sequence Select Cut5X. From SEQ SETUP,

check Define Cut -> Done. The cutting paths for angle 45 and 90 are given in Figure 3.64 and 3.65.

3.23

Figure 3.64 Cut angle 45 Figure 3.65 Cut angle 90 16. Modify Cut type. Select from the Surface Isolines as shown in Figure 3.66 and

cutting path is given in Figure 3.67.


17. Sequence information. NC sequence Seq. info Done Sel. Information window popup. Evaluate all information to improve cutter path.

18. Manufacturing Process. MANUFACTURE Process Mgr. Manufacturing Process Table pops up as shown in Figure 3.68.

3.24

Figure 3.68 19. Highlight two NC sequences to display cutter paths on one screen. Tools

NC check. The cutting path is given in the Figure 3.69

Figure 3.69

Step 6: Create the NC code.

1. Machining → CL Data → Output → Select Feature → NC Sequence → All Operations RCUT. PATH → FILE → Done. Enter name: rcut in the Save a Copy window. Pro/E will save the file as rcut.ncl.1. Delete the file extension “.1” to rcut.ncl for working with the postprocessor program .

3.25 2. Copy postpp.exe from \\designsv1\courses\mech460\lab3 to your current

working directory. 3. Double click to open the postpp program and enter the file name as shown in

Figure 3.70.

Figure 3.70 4. The rcut.ncl and rcut.gcd file should be open with program wordpad to edit.

The rcut.ncl file is shown below: $$* Pro/CLfile Version Wildfire 2.0 - M090 $$-> MFGNO / MFG0001 PARTNO / MFG0001 $$-> FEATNO / 34 MACHIN / UNCX01, 1 $$-> CUTCOM_GEOMETRY_TYPE / OUTPUT_ON_CENTER UNITS / INCHES LOADTL / 1 $$-> CUTTER / 12.700000 $$-> CSYS / 1.0000000000, 0.0000000000, 0.0000000000, 0.0000000000, $ 0.0000000000, 1.0000000000, 0.0000000000, 0.0000000000, $ 0.0000000000, 0.0000000000, 1.0000000000, 0.0000000000 SPINDL / RPM, 1200.000000, CLW RAPID GOTO / 71.1937467454, 66.4000000000, 10.0000000000 FEDRAT / 400.000000, IPM GOTO / 71.1937467454, 66.4000000000, 0.0000000000 GOTO / -6.1937467454, 66.4000000000, 0.0000000000 ............. GOTO / 46.1434284767, -1.4000000000, -40.0000000000 GOTO / 46.1434284767, -1.4000000000, 10.0000000000 SPINDL / OFF $$-> END / FINI

3.26 The rcut.gcd is shown below: 0111; T1; (delete this line) G00 X 71.194 Y 66.400 Z 10.000; F 400.000; G01 X 71.194 Y 66.400 Z 0.000; G01 X -6.194 Y 66.400 Z 0.000; ....... G01 X 46.143 Y -1.400 Z -40.000; G01 X 46.143 Y -1.400 Z 10.000; M30; %

Edit the beginning and the end of the gcode file so that it works on the Victor Machining Center as shown below: 0111; G90 G21; (Absolute, mm) G92 X0.0 Y0.0 Z100.0; (Set home position) S1200 M03; (Set spindle speed and switch on) G00 X 71.194 Y 66.400 Z 10.000; F 400.000; G01 X 71.194 Y 66.400 Z 0.000; G01 X -6.194 Y 66.400 Z 0.000; ....... G01 X 46.143 Y -1.400 Z -40.000; G01 X 46.143 Y -1.400 Z 10.000; G00 X0.0 Y0.0 Z100.0; (Return home) M05: (Set spindle off) M30; (End of program and rewind) %

B) Use Pro/ENGINEER to generate an intersecting quarter cylinder and quarter cone and machine the defined shape in Ren 450 model making material on a 3-axis CNC machine.

4.1

Laboratory 4 3-axis CNC Curved Surface Machining and Error

Measurement OBJECTIVES

1. To create a minimum number of 36 (6 x 6) data points from a mathematical surface model and input the data files into Pro/E to generate an analytical curved surface.

2. To superimpose a 2-D engraving shape onto the analytical curved surface. The engraving shape should be done on a fairly flat part of the surface, due to the vertical projection and geometry of the engraving tool.

3. To produce the most efficient tool paths for 3- and 5-axis roughing and finishing operations. Produce the appropriate G-code files for 3-axis roughing, finishing and surface engraving in a 4 x 4 x 2 inch size workpiece. Use the 1/2 inch diameter end-mill for roughing, the 3/8 inch diameter end-mill or ball-mill for finishing and the engraving tool. The machining operations should not exceed an estimated time in Pro/E of 45 minutes. The actual machining time will be significantly longer than this.

4. To machine the finished workpiece in Ren 450 model making material on a 3-axis CNC machine.

5. To measure the machined surface using the Coordinate Measuring Machine, CMM, with GEOPAK software. Measurements should be taken at the control points (to assess machining errors) and away from the control points (to assess machining and surface fitting errors).

REPORT The report should include the CAD drawings, with CAM drawings for at least two different tool paths for each of 3- and 5-axis finishing operations. It should also include the reasons for selecting the final 3-axis roughing and finishing operations, the estimated machining time, and the error between the analytical and machined surfaces.

4.2 Marks for the lab will be based primarily upon completeness of objectives and creativity of application as well as on the amount of assistance required to set-up and machine the component. PROCEDURE Index A) Demonstration of surface machining and engraving using Pro/ENGINEER Step 1: Plot a mathematical surface and generate control points using Matlab p 4.2 Step 2: Produce the surface using Pro/E p 4.6

Step 3: Create the workpiece p 4.8 Step 4: Perform the manufacturing setup p 4.10 Step 5: Define the machining operations p 4.11

5.1 Define “mill window” for first cut (rough cut) p 4.11 5.2 Define the second cut (Finishing Cut) p 4.13

Step 6: View tool path simulation and create the NC code p 4.14 Step 7: Engrave 2-D shape on to the surface p 4.15

B) Machine the finished workpiece in Ren 450 model making material p 4.17 C) Measure the machined surface and compare with the analytical surface using a

CMM p 4.17

Procedure Start A) Demonstration of surface machining and engraving using Pro/ENGINEER

Step 1: Plot the surface and generate control points using Matlab. ])[( 222 yyxxez +−−=

1. Start up matlab and using the following functions to plot the surface as shown in Figure 4.1.

>> [x,y]=meshgrid(-2:.1:2); >> z=x.*exp(-((x-y.^2).^2+y.^2)); >> mesh(x,y,z),xlabel('X'),ylabel('Y'),zlabel('Z')

4.3

-2

-1

0

1

2

-2

-1

0

1

2

-0.5

0

0.5

YX

Z

Figure 4.1

2. Generate 9 control points for y = -2.0 using the following functions

>> x=[-2.0, -1.5, -1, -0.5, 0.0, 0.5, 1.0, 1.5, 2.0]; >> y = -2.0; >> z=x.*exp(-((x-y.^2).^2+y.^2)) z =

Columns 1 through 6 -0.0000 -0.0000 -0.0000 -0.0000 0 0.0025 Columns 7 through 9 0.0221 0.0901 0.1980 3. Generate another 9 control points for y = -1.5, -1.0, -0.5, 0.0, 0.5, 1.0, 1.5

and 2.0.

4. Arrange 81 control points together to create a file called lab4.ibl as shown in page 4.4.

4.4

Lab4.ibl open Arclength Begin section !1 Begin curve !1 1 -2.0 -2.0 0.0 2 -1.5 -2.0 0.0 3 -1.0 -2.0 0.0 4 -0.5 -2.0 0.0 5 0.0 -2.0 0.0 6 0.5 -2.0 0.0 7 1.0 -2.0 0.0 8 1.5 -2.0 0.0 9 2.0 -2.0 0.0 Begin section !2 Begin curve !1 1 -2.0 -1.5 0.0 2 -1.5 -1.5 0.0 3 -1.0 -1.5 0.0 4 -0.5 -1.5 0.0 5 0.0 -1.5 0.0 6 0.5 -1.5 0.0025 7 1.0 -1.5 0.0221 8 1.5 -1.5 0.0901 9 2.0 -1.5 0.1980 Begin section !3 Begin curve !1 1 -2.0 -1.0 -0.0001 2 -1.5 -1.0 -0.0011 3 -1.0 -1.0 -0.0067 4 -0.5 -1.0 -0.0194 5 0.0 -1.0 0.0 6 0.5 -1.0 0.1433 7 1.0 -1.0 0.3679 8 1.5 -1.0 0.4298 9 2.0 -1.0 0.2707 Begin section !4 Begin curve !1 1 -2.0 -0.5 -0.0099 2 -1.5 -0.5 -0.0546 3 -1.0 -0.5 -0.1632 4 -0.5 -0.5 -0.2219 5 0.0 -0.5 0.0 6 0.5 -0.5 0.3658 7 1.0 -0.5 0.4437 8 1.5 -0.5 0.2449 9 2.0 -0.5 0.0728 Begin section !5 Begin curve !1 1 -2.0 0.0 -0.0366 2 -1.5 0.0 -0.1581 3 -1.0 0.0 -0.3679 4 -0.5 0.0 -0.3894

4.5 5 0.0 0.0 0.0 6 0.5 0.0 0.3894

7 1.0 0.0 0.3679 8 1.5 0.0 0.1581 9 2.0 0.0 0.0366 Begin section !6 Begin curve !1 1 -2.0 0.5 -0.0099 2 -1.5 0.5 -0.0546 3 -1.0 0.5 -0.1632 4 -0.5 0.5 -0.2219 5 0.0 0.5 0.0 6 0.5 0.5 0.3658 7 1.0 0.5 0.4437 8 1.5 0.5 0.2449 9 2.0 0.5 0.0728 Begin section !7 Begin curve !1 1 -2.0 1.0 -0.0001 2 -1.5 1.0 -0.0011 3 -1.0 1.0 -0.0067 4 -0.5 1.0 -0.0194 5 0.0 1.0 0.0 6 0.5 1.0 0.1433 7 1.0 1.0 0.3679 8 1.5 1.0 0.4298 9 2.0 1.0 0.2707 Begin section !8 Begin curve !1 1 -2.0 1.5 0.0 2 -1.5 1.5 0.0 3 -1.0 1.5 0.0 4 -0.5 1.5 0.0 5 0.0 1.5 0.0 6 0.5 1.5 0.0025 7 1.0 1.5 0.0221 8 1.5 1.5 0.0901 9 2.0 1.5 0.1980 Begin section !9 Begin curve !1 1 -2.0 2.0 0.0 2 -1.5 2.0 0.0 3 -1.0 2.0 0.0 4 -0.5 2.0 0.0 5 0.0 2.0 0.0 6 0.5 2.0 0.0 7 1.0 2.0 0.0 8 1.5 2.0 0.0 9 2.0 2.0 0.0

4.6

Step 2: Produce the surface using Pro/E. The part consists of 81 control points, together forming a surface (4” x 4” x 1”) as shown in Figure 4.4.

1. Copy lab4.ibl to your working directory. 2. Start the Pro/E program. Windows menu items, Start → Programs → PTC25

→ Pro ENGINEER Click on the icon Pro ENGINEER. 3. Set working directory. File → Set Working Directory, Select

workingdirectory. 4. Create the part name. Pro/E main menu, File → New, select Part in the New

window, enter part name: lab4srf.

5. Create a 4” x 4” x 1” surface. • Insert menu → Advanced → Blend from file → Surface. Select default

Coord system PRT_CSYS_DEF. Enter file Name: lab4.ibl. Choose default arrow for Material Side. Click ok button in figure 4.2.

• View → Model Setup → Mesh Surface → Meshing spacing. Select current surface and enter 50 for 1st direction and 2nd direction as shown in figure 4.3. The surface will display as shown in Figure 4.4.

• Save the part. File → Save and Exit.


4.7

Figure 4.4

4.8 Step 3: Create the workpiece. The workpiece represents the raw stock of material from which the part will be machined. Pro/E refers to this procedure as an assembly operation.


→ Pro ENGINEER→ Click on the icon Pro ENGINEER. 2. Set working directory. File → Set Working Directory. Select working

directory. 3. Create the part name. Pro/E main menu, File → New, select Manufacturing in

New window and NC Assembly in Sub-type window, enter name: mfglab4. 4. Load the surface. From MANUFACTURE menu, select Mfg Model →

Assemble → Ref Model. Select lab4srf in the pop up window and place the surface at default location.

5. Create a datum plane. Select to create a new datum plane offset 0.75 of NC_ASM_FRONT plane as shown in Figure 4.5.

Figure 4.5

4.9

6. Create a workpiece. From MANUFACTURE menu, select Mfg Model → Create → workpiece. Enter a name for the workpiece: wplab4. Select Solid → Protrusion → Extrude → Solid → Done. Select ADTM1 as sketch plane and NC_ASM_RIGHT as reference plane in Figure 4.6. Create a rectangle 4” x 4” x 1.5” with the surface in the center as shown in Figure 4.7.

Figure 4.6

Figure 4.7

4.10 Step 4: Perform the manufacturing setup. The setup consists of defining the type of machine to use. It also requires defining a coordinate system if one does not already exist and a retraction plane for the cutting tool. The coordinate system must match the mill orientation and the part zero.

1. MFG Setup → Operation. Operation Setup window pops up automatically.

2. Define NC machine. Click the machine icon , Machine Tool Setup windows pop up. Enter the parameters as shown below

Machine name: Victor Machine type: Mill Number of Axis: 3 CNC control: FANUC

3. Define Machine Zero. Click Reference Machine Zero icon, Menu Manager → MACH CSYS → Create. Pick workpiece and three plane of the workpiece to define coordinate system in top left corner of the workpiece (Figure 4.8).

4. Define retract plane. Click the cursor button, Choose Along Z Axis, and in the panel of Enter Z Depth, input 0.5, click OK to close the window (Figure 4.8).

Figure 4.8

4.11

Step 5: Define the machining operations. The setup consists of defining the type of tool to use and machining parameters (tools size, cutting speed, etc.), and specify the volume of material to be removed (created in the previous step). 5.1 Define “mill window” for the first cut (Rough Cut)

1. Machining → NC Sequence → Machining → Surface Mill → 3 Axis → Done.

2. SEQ SETUP window pops up. Ensure that Name, Tool, Parameters, Window, Define cut are checked and then close DONE.

3. Enter NC Sequence name. Type the name as RoughCut. 4. Tool setup table pops up. Input or change the parameter to the following

values: Cutter_Diam 0.5 (1/2” diameter end mill) Length 3 Corner Radius 0.0 (Flat end mill)

5. MFG PARAMS → Set and enter the values as shown in Figure 4.9 then File → Exit DONE.

Figure 4.9

4.12

6. Define Mill Window. NC Sequence → Define Wind → Create Wind and Enter a name for the window: mwsurf . Machine Window pop up as shown in Figure 4.10 and choose Select as shown in Figure 4.11. Pick on each of the top edge of the workpiece and select done and ok. The mill window was defined. Select Tool side and change to Tool past.


7. Cut Direction window pops up. Click OK to accept the default. 8. View tool path. Machining → NC Sequence → Play Path → NC Check. The


Figure 4.12

After this completes choose DONE SEQ. If you don’t do this, you are likely to lose the definition of this toolpath!

4.13 5.2 Define the second cut (Finishing Cut)

1. Machining → NC Sequence → New Sequence →Machining → Surface Mill → 3 Axis → Done.

2. SEQ SETUP window pops up. Ensure that Name, Tool, Parameters, Surface, Define cut are checked and then close DONE.

3. Enter NC Sequence name. Type the name as FinishCut. 4. Tool setup table pops up. Input or change the parameter to the following

values: Cutter_Diam 0.375 (3/8” diameter ball mill) Length 3 Corner Radius 0.1875 (ball mill)

5. MFG PARAMS → Set and enter the values as shown in Figure 4.13 then File → Exit DONE.

6. Create Mill Surface. NC Sequence SEQ Setup → Mill Surface → Done

(Figure 4.14). Define Surf → Create Surf. Enter surface name: surf. Surf Define Add Copy → Done. Select the lab4surf and click OK on Select surface window. Clip OK to close Surface Copy Window. Surf Deinfe Done/Return. Direction (arrow indicates side of surface to be machine) OK. Select Srfs Select all Done/Return.

7. Cut Direction window pops up. Machine in Y direction.

Figure 4.13

4.14

8. View tool path. Machining → NC Sequence → Play Path → NC check. The cutting path is shown in Figure 4.14.

Figure 4.14

Step 6: View combination tool path simulation and create the NC code.

1. Manufacturing Process. Manufacture Process Mgr. Manufacturing Process

table pops up as shown in Figure 4.15.

Figure 4.15

2. Highlight two NC sequences to display cutter paths on one screen. Tools

NC Check. The cutting path is given in the Figure 4.16.

4.15

Figure 4.16

3. Machining → CL Data → Output → Select Feature → NC Sequence →

ROUGHCUT. PATH → FILE → Done. Enter name: surf in the Save a Copy window. Pro/E will save the file as roughcut.ncl.1. Also output CL data for FINISHCUT. Save and exit Pro/E

4. Change file name from roughcut.ncl.1 to roughcut.ncl on command window for working with the postprocessor program

5. Copy postpp.exe from \\designsv1\courses\mech460\lab3 to your current working directory.

6. Convert two ncl files to gcode files using postpp program. 7. Open gcode files to edit using program wordpad.

Step7: Engrave 2-D shape on to the surface.

1. Create a 2-D shape (Groove): A groove is a projected cosmetic feature. You create a groove by making a sketch and projecting it onto a surface. However, the groove feature cannot cross surface boundaries. Open the surface file lab4surf.prt.

• Choose Insert→ Cosmetic → Groove. FEATURE REFS window pops up as shown in Figure 4.17. Select the surface onto which to project the feature.

4.16

Figure 4.17 Figure 4.18 • Set up the sketching plane and reference. • Sketch the groove section as shown in Figure 4.18. • Choose Done after the section is successfully regenerated. The groove

feature is projected onto the selected surface and has no depth. • Save and close part

2. Create an Engraving NC sequence:

• Start Pro/E and open mfglab4.mfg file. • Choose NC Sequence from the MACHINING menu. • Choose Engraving and Done from the MACH AUX menu. • Select Name, Tool, Parameters, Groove Feature from SEQ Setup

window to create new sequence call Esurf. • Create new grooving tool with Cutter diameter 0.1” and length of cut

2”. • Choose Set from MFG Params menu and enter the values as shown

in Figure 4.19. Select Advanced button to change MACHINE → CIRC_INTERPOLATION → POINTS_ONLY as shown in Figure 4.20

4.17


• Choose NC Check to simulate the machining process as shown in Figure 4.21.

• Choose Done Seq or Next Seq from the NC SEQUENCE menu when satisfied.

• Choose CL Data to output Esurf sequence and convert to Gcode.

Figure 4.21

B) Machine the finished workpiece in Ren 450 model making material. C) Measure the machined surface and compare with the analytical surface using a

CMM.

Appendix A

Start Up and Initialization Procedure

for the Victor CNC Machines

CNC TNS�� LATHE

�� Turn Power Supply ON

Main wall switch � ON

Machine switch � ON

Console power � ON

Reset EMERGENCY STOP � ON

Control ON button � ON

�� Set all OVERRIDE SWITCHES and SPIN�DLE SPEED to OFF and close lathe door�

�� Set MODE to ZRN and select NC opera�tion�

Shift jog lever to �X and �Z�

Hold jog lever until ZRN light is on�

Note� Check that turret is away from thezero return position before commencing��

CNC VM� MILLING MACHINE

�� Turn Power Supply ON

Main wall switch � ON

Machine switch � ON

Console power � ON

Reset EMERGENCY STOP � ON

READY button � ON

�� Set all OVERRIDE SWITCHES to OFF�

�� Set MODE to ZRN�

Set AXIS SELECT to ZYXA�

Hold MANUAL FEED in �� direction un�til ZRN light is on�

Note� Check that the table is away fromthe zero return position before commencing��

� Set MODE to�

MANUALMDITAPEMEMORYEDIT forNC operation or otherwise select FAPT op�eration�

� Turn Power Supply OFF

Reverse of ��

� Set MODE to�

MANUALMDITAPEMEMORYEDIT forNC operation or EDIT for CONVERSA�TIONAL programing�

� Turn Power Supply OFF�

Reverse of ��

Appendix B

Manual Operation of the CNC TNS��

Lathe

�� SADDLE AND TURRET MOVEMENT

� Fanuc Dial Control

� Set MODE SELECT to HANDLE � ��

� Select axis to X or Z�

� Rotate dial to appropriately position the saddle and turret�

� Jog level control �JOG��

� Set MODE SELECT to JOG�

� Set feedrate with FEED OVERRIDE � switch to ��

� Shift jog lever in the X or Z direction to appropriately position the saddle

and turret�

� Jog level control �RAPID�

� Set MODE SELECT to RPD�

� Set feedrate with RAPID OVERRIDE � switch to F��

� Shift jog lever in the X or Z direction to appropriately position the saddle

and turret�

�� TURRET INDEXING

� Set MODE SELECT to MANUAL�

� Select appropriate tool number with TURRET SELECT switch�

� Ensure that the turret is free to rotate�

� Press INDEX button to rotate turret�

�� SPINDLE ROTATION

� Set MODE SELECT to MANUAL�

� Turn SPINDLE SPEED dial to fully counterclockwise �o��

� Select spindle range high �GH� or low �GL� with GEAR switch�

� Select spindle direction forward �FOR� or reverse �REV� with SPINDLE

switch�

� Set rotation speed with SPINDLE SPEED dial�

�� TAILSTOCK MOVEMENT

� Set turret X axis to zero return with ZRN mode�

� Move saddle Z to align the arrows on saddle and tailstock�

� Set mode SELECT to RAPID and RAPID OVERRIDE � to ��

� Press TAILSTOCK BODY RETRACT switch and simultaneously the jog

lever to Z direction�

� Release the jog lever and select ADVANCE or RETRACT on TAILSTOCK

BODY once the location pin in the saddle has engaged with the tailstock�

Appendix CAutomatic Operation of the Victor CNC

Machines

CNC TNS�� LATHE

�� MANUAL DATA INPUT� MDI

� Zero return both axes�

� Set MODE to MDI�

� Press PROGRAM soft key to showtext�

� Key in program �max� �� charac�ters� INSERT and REWIND�

� Press PROGRAMSTART to commenceoperation�

�� MEMORY INPUT� MEM


� Set MODE to MEM�

� Select program using PROGRAM andSEARCH soft keys�

� Press REWIND soft key�


�� COMPUTER INPUT� DNC


� Set Panel Switch to TAPE�

� Set mode to EDIT with key o�

� Insert program number �same as pro�gram number to be sent using PRO�GRAM� INSERT� PROG �� EXEC�

� Set mode to MEM with key on�

� Send program from computer using DNCLATHE�


CNC VM�� MILLING MACHINE

�� MANUAL DATA INPUT� MDI

� Zero return all axes�


� Press COMMAND soft key�

� Key in program block and INPUT�

� Press CYCLE START to commenceoperation�

�� MEMORY INPUT� MEM



� Select program by input program num�ber and CURSOR DOWN ARROWkey�

� Press CURSOR UP ARROW key torewind�


�� COMPUTER INPUT� DNC


� Set MODE to TAPE�

� Send Program from Computer usingDNCMILL�


� COMPUTER INPUT� UPLOAD ANDDOWNLOAD COMPLETE PROGRAMS

�a From Computer to Lathe�


� Set MODE to EDIT with key o�

� Press PROGRAM soft key toshow text� OPERATION soft keytwice� READ soft key and PROG� soft key�

� Input program number andEXEC�

� Input program GCODE usingDNCLATHE�

�b From Lathe to Computer�



� Select program using PROGRAMand SEARCH soft keys�

� Show program text using TEXT�

� Set PC computer communica�tion directory DCOM�

� Run batch �le SRDATA�

� Choose communication modeby ALT T and �� band

rate with � �

� Name the host data �le by ALT

F and typing �lenameGCODE�

� Prepare PC computer to ac�cept data �le by ALT I �

� Press PUNCH soft key to down�load program�

� Terminate data transfer andclose host �le ALT Q �

� Return to PC directoriesALT X �

� COMPUTER INPUT� UPLOAD ANDDOWNLOAD PROGRAMS

�a From Computer to Mill�

� Option not currently available�

�b From Mill to Computer�


� Press SET soft key and set�

Input DEVICE ��

Input DEVICE ��

� Set MODE to EDIT and selectprogram�

� Set PC computer communica�tion directory DCOM�

� Run batch �le SRDATA�

� Choose communication modeby ALT T and �� band

rate with � �

� Name the host data �le by ALT

F and typing �lenameGCODE�

� Prepare PC computer to ac�cept data �le by ALT I �

� Press PUNCH soft key to down�load program�

� Terminate data transfer andclose host �le ALT Q �

� Return to PC directoriesALT X �

�� PUNCHED TAPE

�a From Computer to Punched Tape�

� Switch on the tape punch�

� Connect the tape punch to thePC serial port COM�with MODE COM��e��

� Run computer programTAPEand send �lename�GCODE�

�b From Lathe to Punched Tape�


� Connect the tape punch to theRS��C lathe serial port�

� Set MODE to MDI and changeNC parameter �� to �� for ��band rate �the system default is�� for �� band rate�


� Select program using PROGRAMand SEARCH soft keys�

� Press PUNCH soft key to punchtape�

�c From Punched Tape to Lathe

� Option not currently available�

�� PUNCHED TAPE

�a From Computer to Punched Tape�


� Connect the tape punch to thePC serial port COM�with MODE COM��e��

� Run computer program TAPEand send �lename�GCODE�

�b From Mill to Punched Tape�


� Connect the tape punch to theRS��C mill serial port�


� Press SET soft key and set�

INPUT DEVICE ��

INPUT DEVICE ��

� Set MODE to EDIT and selectprogram�

� Press PUNCH to punch tape�

�c From Punched Tape to Mill�

� Mount paper tape on the tape reader�


� Press SET soft key and set

INPUT DEVICE ��

INPUT DEVICE ��

� Set MODE to EDIT and enter pro�gram number�

� Press READ to read tape�

Appendix D

Computer Assisted Programming for theVictor CNC Machines

CNC TNS�� LATHE

�Symbolic FAPT�

�� Select Symbolic FAPT operation�

�� Select�

� DATA SET for setting FAPT parame�ters and MTF material and tool le��

� FAMILY PROGRAM for listing� re�trieval and storage of FAPT program�

� FAPT EXEC for interactive part pro�gramming�

�� To program a part select FAPT EXEC andcomplete the following ne menu selections�

� Select � BLANK and PART tochoose the material type� surface�roughness� feedrate and blank size andshape from a programmed selection�

� Select � PART FIGURE to denethe part geometry�

� Select � HOME POSITION to de�ne the tool position relative to thepart axis�

� Select DEFINITION OF MA�CHINING to dene the tool path�

� Select � NC DATA PREPARA�TION to generate G�code program�


�Conversational Programming�

�� Set MODE to EDIT with key o��

�� Press PRGRM soft key to start the pro�gram�

�� Enter program number O�� and INSRT�

EOB and INSRT�

� Press MENU key�

�� Press INITIAL SET soft key�

� Enter ��

��

EOB and INSRT�

�� Press FACING�SIDE CUTTING�POCK�

ETING�NC LANGUAGE�CONTR

�HOLE PATRN�END OF CYCLE�

��

EOB and INSRT�

�� Press END OF CYCLE and INSRT�

�� Press INITIAL SET soft key to end theprogram�

� Enter ��

EOB and INSRT�

Appendix E

Machining the First Part

CNC TNS�� LATHE



� Select program using PROGRAM andSEARCH soft keys�

� Press REWIND soft key�

� Set DRN�ON �Dry run��

� Set SBK�ON �Single block��

� Set AFL�ON �Auxilliary function MSTcodes��

� Set G�� Home Position�

� Set FEEDOVERRIDE to ��

� Press PROGRAM START�

CNC VM� MILLING MACHINE



� Select program by input program numberand CURSOR DOWN ARROW key�

� Press CURSOR UP ARROW key torewind�

� Set DRY RUN�ON�

� Set SINGLE BLOCK�ON�

� Set Z�AXIS CANCEL�ON�

� Set MST LOCK�ON�

� Set MANUAL ABSOLUTE�ON�

� Set G�� Home Position�

� Set JOG to �� i�e� slow��

� Press CYCLE START�

Appendix F

Standard G�code Start and End Programs

CNC TNS�� LATHE

N�� O�� program numberN�� G�� G� X�� X return homeN�� G�� G� Z�� Z return homeN�� G�� X Z S��

establish home positionand maximum spindlespeed

N�� G�� T�� call tool turret index �and tool o�set �

N � G� S��M��

constant surface speed�spindle speed �� rpm�spindle start CC�W

N�� G�� Xdiame�ter � �mm�

rapid traverse to part

N� G�� Z�mm� rapid traverse to part�

�

� your program�

�

N�� G�� X Z � return to intermediateposition

N�� T�� tool o�set cancelN�� M�� optional stopN�� M�� spindle o�N�� M�� end of program and

rewindN� � �� end of tape


O�� program numberN�� G�� G� Z�� Z return homeN�� G��D G� X�Y��

X and Y return home

N�� G�� X Y Z �

establish home position

N�� T�� call for tool in magazineN�� T M� � insert T� in spindle and

T on standbyN � G�� G�� G��G�� Z�� H��

absolute� mm� tool com�pensation� rapid traverseto Z��

N�� G�� X� Y�� rapid traverse to X� Y�N� S M�� set spindle speed and

� switch on�

� your program�

�

N�� G�� G� Z�M��

Z return home� spindleo�

N�� M�� end of program andrewind

N�� end of tape

Appendix G

Available G�codes

a� CNC TNS�� LATHE

G�code Table M�code Table

G code Group FunctionG�� Positioning M�� Prog stopG�� Linear interpolationG�� Circular interpolation CCW view from back M�� Optional StopG�� Circular interpolation CW Neglected when switch o�G�� DwellG� Exact stop M�� End of Tape RestartG�� ZpXp plane selectionG�� Inch input M�� Spindle Start C WG�� Metric inputG�� Safety zone check ON M�� Spindle Start CC WG�� Safety zone check OFFG�� Reference point return check M�� Spindle StopG�� Reference point returnG� Return from reference point M�� Tool ChangeG�� Return to �nd �rd �th reference pointG�� Thread cutting M�� Oil Mist OnG�� Variable lead thread cuttingG�� Circular thread cutting CW M�� Coolant Pump OnG�� Tool nose radius compensation cancelG�� Tool nose radius compensation right M� Coolant Oil Unit O�G�� Tool nose radius compensation leftG�� Local coordinate system setting M� Spindle OrientG�� Machine coordinate system selectionG�� Work coordinate system � selection M�� End of Prog� � RewindG�� Work coordinate system � selectionG�� Work coordinate system � selection M�� Low RangeG�� Work coordinate system � selectionG�� Work coordinate system � selection M�� High RangeG� Work coordinate system � selectionG�� Exact stop mode M�� Air Blow OnG�� Cutting ModeG�� Peck drilling Z axisG�� Grooving in X axisG�� Threading cycle

a� CNC�TNS�� LATHE �Cont�d�

G code Group FunctionG�� Turning cycle AG�� Thread cutting cycleG� Facing cycle BG� �� Constant surface speed controlG� Constant surface speed controlG� �� Feed per minuteG� Feed per revolutionG� �� Absolute commandG� Incremental commandG� �� Work coordinates change maximum spindle speed

setting

b� CNC VM�� MILLING MACHINE

G�code Table M�code Table

G code Group FunctionG�� Positioning �Rapid traverse� M�� Prog stopG�� Linear Interpolation �Feed�G�� Circular Interpolation CW M�� Optional StopG�� Circular interpolation CCW Neglected when switch oG� DwellG�� Imaginary axis designationG�� Exact stop check M�� End of Tape RestartG�� Oset value settingG�� XY plane selection M�� Spindle Start C�WG�� ZX Plane selectionG�� YZ plane selection M� Spindle Start CC�WG�� Input in inchG�� Input in mm M�� Spindle StopG�� Stored stroke limit ONG�� Stored stroke limit OFF M�� Tool ChangeG�� Reference point return checkG�� Return to reference point M�� Oil Mist OnG�� Return from reference pointG� Cutter compensation cancel M�� Coolant Pump OnG� �� Cutter compensation leftG� Cutter compensation right M�� Coolant Oil Unit OG� Tool length compensation � directionG �� Tool length compensation � direction M�� Spindle OrientG� Tool length compensation cancelG� Tool oset increase M�� End of Prog� � RewindG� �� Tool oset decreaseG� Tool oset double increase M� Low RangeG� Tool oset double decreaseG�� Scalling o M� High RangeG�� Scalling onG� Work coordinate system � select M�� Air Blow OnG�� Work coordinate system � selectG�� Work coordinate system � selectG�� Work coordinate system selectG�� Work coordinate system � selectG�� Work coordinate system � selectG�� Exact stop check modeG� Cutting modeG�� Custom macro simple cellG�� Custom macro modal callG�� Custom macro modal call cancellation

b� CNC VM�� MILLING MACHINE �Cont�d��

G code Group FunctionG�� Peck drilling cycleG� Counter tapping cycleG�� Fine boringG�� Canned cycle cancelG�� Drilling cycle spot boringG�� Drilling cycle counter boringG�� Peck drilling cycleG� Tapping cycleG�� Boring cycleG�� Boring cycleG�� Back boring cycleG�� Boring cycleG�� Boring cycleG�� Absolute programmingG�� Incremental programmingG�� Programming of absolute zero pointG� �� Per minute feedG�� Return to initial point in canned cycleG�� Return to R point in canned cycle

Appendix H C-Program: POSTPRO.C – Convert Cutter Location File to G-code format /**********************************************************************/ /* P O S T P R O . C */ /**********************************************************************/ #include<stdio.h> #include<math.h> /**********************************************************************/ main() /**********************************************************************/ { /*-----------------------------------------------------------------*/ /* DEFINE VARIABLES USED */ /*-----------------------------------------------------------------*/ int direct,i,j; int cir_fg,fedrate_fg,from_fg; int intol_fg,outtol_fg,spind_fg,unit_fg; float x,y,z; float x_prev,y_prev,z_prev; float xprev,yprev,zprev; float xdumc,ydumc,zdumc; float from_x,from_y,from_z; float x_cir_ctr,y_cir_ctr,z_cir_ctr; float x_cir_start,y_cir_start ; float theta_start,cir_rad; float feed_rate,spind_rpm,in_tol,out_tol,tool_no; float px,py,xprod,sx,sy; double atan(),sqrt(),fabs(); double theta1,theta2,rad1,radlow,radhigh; double xtest,ytest,ztest; char c,gcodefn[80],aptfn[80]; char pname[10]; char unit_type[6]; char spind_direct[3]; char cool_state[3]; char dum[4]; char cmd[4]; char previous_cmd[80]; char dummy[80];

FILE *fopen(),*fp1,*fp2; /*-----------------------------------------------------------------*/ /* INITIALIZE APT COMMANDS */ /*-----------------------------------------------------------------*/ static char circle[] = {"SURF"}; static char coolant[] = {"COOL"}; static char spindle[] = {"SPIN"}; static char feedrate[] = {"FEDR"}; static char fini[] = {"FINI"}; static char from[] = {"FROM"}; static char gto[] = {"GOTO"}; static char intol[] = {"INTO"}; static char outtol[] = {"OUTT"}; static char rapid[] = {"RAPI"}; static char stop[] = {"STOP"}; static char toolno[] = {"LOAD"}; static char units[] = {"UNIT"}; /*-----------------------------------------------------------------*/ /* INITIALIZE CONTROL FLAGS */ /*-----------------------------------------------------------------*/ intol_fg=outtol_fg=spind_fg=from_fg=unit_fg = 0; cir_fg = fedrate_fg = 0; direct = 4; /*=================================================================*/ /* DISPLAY THE INFORMATION ABOUT THE PROGRAM */ /*=================================================================*/ printf(" PROGRAM POSTPRO ***\n"); printf(" CONVERT AN APT-IV FILE TO G-CODE FROMAT\n"); printf("\nINPUT APT IV FILE NAME = "); scanf("%s",aptfn); fp1 = fopen(aptfn,"r"); if (fp1 == NULL) { printf("ERROR IN OPENING APT-IV FILE\n"); exit(1); } printf("\n OUTPUT G-CODE FILE NAME = "); scanf("%s",gcodefn); fp2 = fopen(gcodefn,"w"); /*=================================================================*/ /* READ PARTNO AND PARTNAME */ /*=================================================================*/ fscanf(fp1,"%6s %s",previous_cmd,pname); i = compstr(previous_cmd,"PARTNO"); if (i==4) { fprintf(fp2,"O111;\n"); } /*=================================================================*/ /* READ IN THE FIRST COMMAND */ /*=================================================================*/ fscanf(fp1,"\n%4s",cmd); /*=================================================================*/ /* CHECK IF THE COMMAND "CMD" IS "FINI" THROUGH A 'DO-WHILE' LOOP */ /*=================================================================*/

j = 0; do { /*==============================================================*/ /* CHECK IF THE COMMAND "CMD" IS "GOTO" */ /* AND READ THE FULL DATA LINE */ /*==============================================================*/ j = compstr(cmd,gto); if (j == 4) { fscanf(fp1,"%1s%f,%f,%f",&c,&x,&y,&z); /*===========================================================*/ /* IF THE COMMAND IS "GOTO", CHECK THE PREVIOUS COMMAND */ /*===========================================================*/ i = compstr(previous_cmd,"RAPI"); /*===========================================================*/ /* IF PREVIOUS COMMAND != RAPI */ /*===========================================================*/ if (i != 4) { /*===========================================================*/ /* IF PREVIOUS COMMAND = CIRCLE, */ /* CHECK IF THE POINT IS ON THE CIRCLE */ /*===========================================================*/ if(cir_fg == 1) { if(intol_fg==0) in_tol =0.2; if(outtol_fg==0) out_tol = 0.2; xtest = x_cir_ctr - x; ytest = y_cir_ctr - y; ztest = z_cir_ctr - z; rad1 = sqrt(xtest*xtest + ytest*ytest + ztest*ztest); radhigh = fabs(cir_rad) + in_tol + out_tol; radlow = fabs(cir_rad) - in_tol - out_tol; /*========================================================*/ /* IF THE POINT IS ON THE CIRCLE, */ /* CHECK IF THE CIRCLE IS CW OR CCW */ /*========================================================*/ if((rad1 >= radlow) && (rad1 <= radhigh) && ((fabs(100.0*z)) == (fabs(100.0*z_prev))) ) { /*=====================================================*/ /* AVIOD DIVIDING BY ZERO OR HAVING ONLY ONE POINT */ /*=====================================================*/ if(direct == 4 || (x == x_cir_ctr) || (xprev==x_cir_ctr)) { if(direct == 4 ) direct = 3 ; xprev = x; yprev = y; zprev = z; } /*==================================================*/ /* CALCULATE THETA1, THETA2 AND */ /* CHECK IF THE CIRCLE IS CW OR CCW */ /*==================================================*/ else

{ theta1 = atan((y-y_cir_ctr)/(x-x_cir_ctr)); theta2 = atan((yprev-y_cir_ctr)/(xprev-x_cir_ctr)); yprev = y; xprev = x; zprev = z; if(theta1>theta2 && direct == 3 ) direct = 1; if(theta1<theta2 && direct == 3 ) direct = 0; if(theta1 == theta2 && direct == 3) direct = 3; } } else /*=====================================================*/ /* OTHERWISE THE POINT IS NOT ON THE CIRCLE, */ /* THUS THE 'CIRC'IS COMPLETE */ /*=====================================================*/ { cir_fg = 0; if(direct == 0) /*==================================================*/ /* WRITE THE CW CIRCLE TO THE GCODEFN */ /*==================================================*/ { sx = x_cir_start - x_cir_ctr; sy = y_cir_start - y_cir_ctr; px = xprev - x_cir_ctr ; py = yprev - y_cir_ctr ; /*===============================================*/ /* CROSS PRODUCT OF START AND END VECTOR */ /* TO DETERMINE IF 0 < ARC < 180 */ /*===============================================*/ xprod = (py*sx - px*sy); if(xprod > 0 ) cir_rad = - cir_rad; fprintf(fp2,"G02 X%8.3f Y%8.3f Z%8.3f R%8.3f;\n", xprev,yprev,zprev,cir_rad); fprintf(fp2,"G01 X%8.3f Y%8.3f Z%8.3f;\n",x,y,z); x_prev = x; y_prev = y; z_prev = z; direct=4; } /*==================================================*/ /* WRITE THE CCW CIRCLE TO GCODEFN */ /*==================================================*/ else { sx = x_cir_start - x_cir_ctr ; sy = y_cir_start - y_cir_ctr ; px = x - x_cir_ctr ; py = y - y_cir_ctr ; xprod = py*sx - px*sy ; if(xprod < 0 ) cir_rad = - cir_rad; fprintf(fp2,"G03 X%8.3f Y%8.3f Z%8.3f R%8.3f;\n", xprev,yprev,zprev,cir_rad); fprintf(fp2,"G01 X%8.3f Y%8.3f Z%8.3f;\n",x,y,z); x_prev = x; y_prev = y; z_prev = z; direct = 4;

} } } else /*========================================================*/ /* IF PREVIOUS COMMAND IS NOT A 'CIRCLE' */ /* WRITE G01 TO GCODEFN FILE */ /*========================================================*/ { fprintf(fp2,"G01 X%8.3f Y%8.3f Z%8.3f;\n",x,y,z); x_prev = x; y_prev = y; z_prev = z; } } else /*===========================================================*/ /* IF PREVIOUS COMMAND IS A 'RAPID' */ /* WRITE G00 TO GCODEFN FILE */ /*===========================================================*/ { fprintf(fp2,"G00 X%8.3f Y%8.3f Z%8.3f;\n",x,y,z); x_prev = x; y_prev = y; z_prev = z; } } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'RAPID' */ /*==============================================================*/ j = 0; j = compstr(cmd,rapid); if ( j == 4) { fscanf(fp1,"%s",dummy); strcpy(previous_cmd,"RAPI"); } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'FEEDRATE' */ /*==============================================================*/ j = 0; j = compstr(cmd,feedrate); if ( j == 4) { fedrate_fg = 1; fscanf(fp1,"%3s%f",dummy,&feed_rate); fprintf(fp2,"F%8.3f;\n",feed_rate); strcpy(previous_cmd,"FEDR"); } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'SPINDLE SPEED' */ /*==============================================================*/ j = 0; j = compstr(cmd,spindle); if ( j == 4) { spind_fg = 1; fscanf(fp1,"%3s%f,%s",dummy,&spind_rpm,spind_direct);

i = compstr(spind_direct,"CLW"); if ( i == 4) { fprintf(fp2,"M03 S%8.3f;\n",spind_rpm); } else { if ( (compstr(spind_direct,"OFF")) != 4) { fprintf(fp2,"M04 S%8.3f;\n",spind_rpm); } } } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'CIRCLE' */ /*==============================================================*/ j = 0; j = compstr(cmd,circle); if ( j == 4) { if (cir_fg == 1) { cir_fg = 0; if (direct == 1) { sx = x_cir_start - x_cir_ctr ; sy = y_cir_start - y_cir_ctr ; px = x - x_cir_ctr ; py = y - y_cir_ctr ; xprod = py*sx - px*sy ; if(xprod < 0 ) cir_rad = - cir_rad; fprintf(fp2,"G03 X%8.3f Y%8.3f Z%8.3f R%8.3f;\n", xprev,yprev,zprev,cir_rad); x_prev = x; y_prev = y; z_prev = z; direct =4; } else { sx = x_cir_start - x_cir_ctr ; sy = y_cir_start - y_cir_ctr ; px = x - x_cir_ctr ; py = y - y_cir_ctr ; xprod = py*sx - px*sy ; if(xprod > 0 ) cir_rad = - cir_rad; fprintf(fp2,"G02 X%8.3f Y%8.3f Z%8.3f R%8.3f;\n", xprev,yprev,zprev,cir_rad); x_prev = x; y_prev = y; z_prev = z; direct =4; } } cir_fg = 1; fscanf(fp1,"%4s%f,%f,%f,%f,%f,%f,%f",dummy,&x,&y,&z, &xdumc,&ydumc,&zdumc,&cir_rad); x_cir_ctr = x; y_cir_ctr = y; z_cir_ctr = z; x_cir_start = x_prev ; y_cir_start = y_prev ;

if (x_cir_start == x_cir_ctr) theta_start = 11.0/7.0 ; else theta_start = atan((y_cir_start-y_cir_ctr)/ (x_cir_start-x_cir_ctr)); if ( (theta_start < 0.0) && (y_cir_start < y_cir_ctr) ) theta_start = theta_start ; if ( (theta_start < 0.0) && (y_cir_start > y_cir_ctr) ) theta_start = theta_start + (22.0/7.0) ; if ( (theta_start > 0.0) && (y_cir_start < y_cir_ctr) ) theta_start = theta_start + (22.0/7.0) ; } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'STOP' */ /*==============================================================*/ j = 0; j = compstr(cmd,stop); if ( j == 4) { if(spind_fg == 1) spind_fg = 0; fprintf(fp2,"M05;\n"); } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'INTOL' */ /*==============================================================*/ j = 0; j = compstr(cmd,intol); if ( j == 4) { intol_fg = 1; fscanf(fp1,"%2s%f",dummy,&in_tol); } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'OUTTOL' */ /*==============================================================*/ j = 0; j = compstr(cmd,outtol); if ( j == 4) { outtol_fg = 1; fscanf(fp1,"%3s%f",dummy,&out_tol); } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'UNITS' */ /*==============================================================*/ j = 0; j = compstr(cmd,units); if ( j == 4) { unit_fg = 1; fscanf(fp1,"%2s%s",dummy,unit_type); i = compstr(unit_type,"MM"); if (i == 4) fprintf(fp2,"G21;\n"); else fprintf(fp2,"G20;\n"); } /*==============================================================*/

/* CHECK IF THE COMMAND 'CMD' IS 'COOLANT' */ /*==============================================================*/ j = 0; j = compstr(cmd,coolant); if ( j == 4) fscanf(fp1,"%3s%3s",dummy,cool_state); /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'FROM' */ /*==============================================================*/ j = 0; j = compstr(cmd,from); if ( j == 4) { from_fg = 1; fscanf(fp1,"%1s%f,%f,%f",dummy,&from_x,&from_y,&from_z); fprintf(fp2,"G92 X%8.3f Y%8.3f Z%8.3f ;\n" ,from_x,from_y,from_z); fprintf(fp2,"G90;\n"); } /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'TOOLNO' */ /*==============================================================*/ j = 0; j = compstr(cmd,toolno); if ( j == 4) fscanf(fp1,"%3s%s",dummy,tool_no); /*==============================================================*/ /* CHECK IF THE COMMAND 'CMD' IS 'FINI' */ /*==============================================================*/ j = 0; j = compstr(cmd,fini); if ( j == 4 ) break; /*==============================================================*/ /* READ THE NEXT LINE OF THE APTFN FILE */ /*==============================================================*/ fscanf(fp1,"\n%4s",cmd); j = compstr(cmd,fini); } /*=================================================================*/ /* END OF THE DO-WHILE LOOP WHEN THE COMMAND 'CMD' IS 'FINI' */ /*=================================================================*/ while ( j != 4) ; fprintf(fp2,"M30;\n%%\n"); } /**********************************************************************/ /* FUNCTION COMPSTR ( COMPARE STRING ) */ /* RETURN '4' IF TWO STRINGS 'S' AND 'T' ARE EQUAL */ /**********************************************************************/ compstr(s,t) char s[] , t[]; { int i ; i = 0; while (s[i] == t[i])

{ if ( s[i++] == '\0') return(4); i = i+1; } return(i); }

ACKNOWLEDGEMENTS Thanks are due to previous MECH 460 and MECH 521 students for their input and suggestion in revising this manual.

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