COMPUTER AIDED

MANUFACTURING
II SEMESTER –PDD
DR Senthil Kumar
March 2016- June 2016
UNIT-V: CAM & CNC
Basics of CAM and CNC fundamentals,
applications, advantages and limitations of
CNC, Elements, Input devices, machine
tool, driving unit, CNC part programming
& codes
 CAM
• Use of computer to assist the manufacturing
process
• CAM can be applied in all types of
manufacturing scenarios
CAMA – computer aided manufacturability
analysis
– Used to get feedback about ease of manufacturing
and suggestions for redesigning the part.

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 CAM

Manufacturability
Design advisor

Knowledge
base

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 CAM
CAPP – computer aided process planning
• refers to the use of computer in complete
planning in manufacturing of
component/product
– raw material selection
– Machine selection
– Machine set-up planning
– Process sequencing
– Manufacturing time estimation
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 CAM
Computer based predictive model
• uses laws of physics to predict manufacturing
process phenomena
– Tool wear
– Solidification time – principle of heat transfer,
– Spring-back – theory of plasticity, strain hardening
– Heat affected zone

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 CAM
• Virtual manufacturing – use of computer
model and manufacturing based simulation to
evaluate manufacturing scenarios and
optimize the design of product, process, for
specified goals such as cost, quality, time, etc.

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 CAM
• Virtual manufacturing

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 CAM
Computer aided assembly planning
• used to plan optimum assembly sequence to
reduce assembly time and cost
• used to generate robot paths

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Computer Aided Inspection
• Computers are used in inspection planning
and excution
– Computer aided inspection equipment
• Coordinate Measuring Machine (CMM)
– Computer aided inspection set-up planning
– Computational metrology
– Computer aided part localization

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 CAM
Computer Controlled machines and equipment
• Computers can be used to replace manual
effort and o act as an interface between
human and machine
• EX. CNC machines, CMM, Rapid prototyping
machines, etc.

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Rapid prototyping
• used to build physical prototypes from CAD
models

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CNC Fundamentals and CNC part
programming

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 CNC Fundamentals
• Electronic Industry association (EIA) defines
CNC as:
A system in which actions are controlled by
the direct insertion of numerical data at some
point.
• Therefore a CNC system receives a numerical
data, interpret the data, then control the
action

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 Applications
• CNC is widely used for lathe, drill press, milling
machine, grinding unit, laser, sheet-metal
press working machine, tube bending machine
turning center and machining center
• welding machines (arc and resistance),
coordinate measuring machine, electronic
assembly, tape laying and filament winding

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Advantages and Limitations of CNC
• The benefits of CNC are
– high accuracy in manufacturing,
– short production time,
– reduced human error.
• The drawbacks
– high cost, maintenance, and the requirement of
skilled part programmer.

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Elements of a CNC system
• Input device
• Machine control
unit
• Machine tool
• Deriving system
• Feedback devices
• Display unit

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 Input devices
Program Loading:
• Through keyboard
• Through USB
• Through diskette drive
• Through RS 232 serial port
• Through network interface card

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 Input devices

Floppy disc derive USB flash derive

RS 232 port Ethernet port 19

Serial communication in a distributed
Numerical control system

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Ethernet network in a distributed Numerical
control system

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 Machine tool

Ball screw in a CNC machine Ball screw structure

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 Machine control unit
• Data processing unit (DPU)
– Receives part program,
– interprets and encodes the part program,
– calculates the intermediate positions of motion in
terms of basic length unit (BLU), and pass it to the
CLU.

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 Machine control unit
Control logic unit (CLU)
• Receives the calculated data, converts it into
electrical signal, and send the signal to the
driving system
• The CLU consists of:
– the circuits for position and velocity control loops,
– deceleration and backlash take up,
– function controls such as spindle on/off.

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 Driving system
– Servomotor (DC or AC)
– Stepper motor
Basic Length Unit (BLU)
• Each BLU unit corresponds to the position
resolution of the axis of motion.
• For example, 1 BLU = 0.002mm means that
the axis will move 0.002mm for every one
electrical pulse received by the motor.

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Example 3
• A stepping motor has N = 150, p = 5mm/rev; If
n = 2250 pulses, what is the distance traveled
in x-direction ? What should be the pulse
frequency for a travel speed of 400 mm/min ?
• x = (5) (2250)/150 = 75mm
• 400mm/rev= 5(RPM), from which, RPM = 80
• f = (150) (80)/60 = 200 Hz

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Zero Point of machine on a CNC lathe
Zero Point of machine on a CNC lathe
Point to point vs. contouring

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Introduction to CNC machine and
CNC part program

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 CNC part program
INFORMATION NEEDED by a CNC
1. Preparatory Information: units, incremental or absolute
positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of rotation,
stops for part movement
This information is conveyed to the machine through
a set of instructions, written in specific format
understood by MCU, - Program.
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 CNC part program
Steps to manually write CNC part program
• Study part drawing /engineering blueprint
• Choose machine tool used and Fixtures required
• Determine machining operation and their sequence
• For each operation determine:
– Cutting tools required
– Process parameter
• Calculate the tool path
• Writing part program is written.
Each line of the program, referred to as a block
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CNC part program structure

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CNC Part program address

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The preparatory function (G address/ G code)
It determines how the tool moves to the programmed target

• G00 Rapid traverse • G40 Cutter compensation –

• G01 Linear interpolation cancel
• G02 Circular interpolation, • G41 Cutter compensation –
CW left
• G03 Circular interpolation, CCW • G42 Cutter compensation-
• G08 Acceleration right
• G09 Deceleration • G70 Inch format
• G17 X-Y Plane • G71 Metric format
• G18 Z-X Plane • G80 Fixed-cycle cancel
• G19 Y-Z Plane • G81-G89 Fixed cycles
• G20 Inch Units (G70) • G90 Absolute dimensions
• G21 Metric Units (G71)
• G91 Incremental dimensions

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 Rapid positioning vs. linear interpolation

• Rapid positioning (G00) • Linear interpolation (G01)

G00 X Y Z G01 X Y Z F

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 Circular interpolation (G02/G03)
• G02 X Y I(Xc-Xs) J(Yc-Ys) • G03 X Y I J

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 Cutter compensation (G40/G41/G42)
• The cutter axis is moving • The radius of the cutter is
along the programmed path compensated

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Absolute (90) vs. Incremental (91)
dimensioning system

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Absolute (90) vs. Incremental (91) dimensioning system
 Absolute (90) vs. Incremental (91)
dimensioning system
G90 X Y G91 X Y
Absolute Increment
P0 X0 Y0 P0 X0 Y0
P0-P1 X-20 Y-20 P0-P1 X-20 Y-20
P0-P2 X12 Y-20 P1-P2 X32 Y0
P0-P3 X20 Y-12 P2-P3 X8 Y8
P0-P4 X20 Y14 P3-P4 X0 Y26
P0-P5 X12 Y20 P4-P5 X-8 Y6
P0-P6 X-20 Y20 P5-P6 X-32 Y0
Cutter compensation (G40/G41/G42)

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 Modal G-Codes
• Most G-codes set the machine in a “mode”
which stays in effect until it is changed or
cancelled by another G-code. These
commands are called “modal”.

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 Modal G-Code List
•• G00
G43 Rapid Transverse
Tool length compensation (plus)
• G01 Linear Interpolation
•• G44
G02 Tool length
Circular compensation
Interpolation, CW (minus)
• G49
G03 Tool length
Circular compensation CCW
Interpolation, cancel
• G17 XY Plane canned cycles
•
•
G80 Cancel
G18 XZ Plane
•• G81
G19 Drilling
YZ Plane cycle
•• G82
G20/G70 Counter
Inch units boring cycle
• G21/G71 Metric Units
•• G83
G40
Deep hole drilling cycle
Cutter compensation cancel
•• G90
G41 Absolute positioning
Cutter compensation left
•• G42
G91 Cutter compensation
Incremental right
positioning
• G43 Tool length compensation (plus)

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 Miscellaneous function (M Address)

• Control the machine operation other than for

coordinate system

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 Sequence/Block Number, N
• Its purpose is to identify the specific
machining operation
• It is generally good practice to increment each
block number by 5 or 10 to allow additional
blocks to be inserted if future changes are
required.

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 Dimension Words
• Distance dimension words, X,Y,Z
– Circular dimension words, I,J,K for distances to the
arc center
– Angular dimensions, A,B.C

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 X,Y, and Z Codes
• X, Y, and Z codes are used to specify the
coordinate axis.
• Number following the code defines the
coordinate at the end of the move relative to
an incremental or absolute reference point.

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 I,J, and K Codes
• I, J, and K codes are used to specify the
coordinate axis when defining the center of a
circle.

• Number following the code defines the

respective coordinate for the center of the
circle.

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 F,S, and T Codes
• F-code: used to specify the feed rate

• S-code: used to specify the spindle speed

• T-code: used to specify the tool identification

number associated with the tool to be used in
subsequent operations.

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 Three Main parts of a CNC program

Part 1- Program Setup

• N5 G90 G21 (Absolute units, metric)

• N10 M06 T2 (Stop for tool change, use

tool # 2)
• N15 M03 S1200 (Turn the spindle on CW to
1200 rpm)

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 Three Main parts of a CNC program

Part 2- Chip Removal

• N20 G00 X1 Y1 (Rapid to X1,Y1 from origin point)

• N25 Z0.125 (Rapid down to Z0.125)
• N30 G01 Z-0.125 F100 (Feed down to Z-0.125 at 100mm/min)
• N35 G01 X2 Y2 (Feed diagonally to X2,Y2)
• N40 G00 Z1 (Rapid up to Z1)
• N45 X0 Y0 (Rapid to X0,Y0)

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 Three Main parts of a CNC program

Part 3- System Shutdown

• N50 M05 (Turn the spindle off)

• N55 M00 (Program stop)

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EXAMPLE OPERATION on CNC MILLING
MACHINE

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G-CODE PROGRAM
• First pass : conventional mill to a
depth of 0.125 around edge
profile. Tool 1 is a ½ inch dia. end
mill.

%
:1002
N5 G90 G20
N10 M06 T1
N15 M03 S1200
N20 G00 X0.125 Y0.125
N30 Z0.125
N35 G01 Z-0.125 F5
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125

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• Second pass:
conventional mill to a
depth of 0.25 around
edge profile.

N35 Z-0.250
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
N60 Z0.125

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• Third pass: conventional
mill to a depth of 0.125
around pocket profile.

N65 G00 X1.25 Y1.0

N70 G01 Z-0.125 F5
N75 X1.75
N80 Y2.5
N85 X1.25
N90 Y1.0
N95 Z0.125

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• Fourth pass: climb mill
to a depth of 0.125
across remaining
material.

N100 Y2.125
N105 X2.625
N110 Z0.125
N115 G00 X-5 Y-5 Z5
N120 M05
N125 M30

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Lathe machining

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 Getting started
• Start -> Machining -> lathe Machining

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 Defining the Part Operation

– Double select the Part

Operation.1 branch in
the PPR tree. This will
display the Part
Operation window.

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• Fields that will need to be defined before you begin
machining:

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• Geometry

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• Position

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