1
Chapter
PRINCIPLES OF CAD/CAM SYSTEMS
AND CNC MACHINES
Objectives:
To understand the basics of CAD/CAM systems and its output, CL files and their different formats.
To see the basics of the APT Language and its instructions.
To have an overview of different types and possibilities of CNC Controllers available on the market.
To understand the difference between machine configurations provided by machine manufacturers.
To understand common terminology used during CAD/CAM/PP/CNC applications.
To realize the need for a generic solution, to adjust, adapt CAM outputs into specific machine inputs.
Confronting the Real World
What bridges CAD/CAM Systems to CNC Machines?
CAD/CAM Post NC
System Processing Machining
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CAM System ~ World
- ANVIL-5000
- CADAM
- CADDS-5
- CAMAX
- CATIA
- CIMPLEX
- EUCLID
- GNC
- ICEM/DDN
- I-DEAS Master Series
- INTERGRAPH
- MASTERCAM
- PATHTRACE
- POWERMILL
- Pro/ENGINEER
- SURFCAM
- TOPSOLID CAM
- UNIGRAPHICS
- WORK NC
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CAM System - Functionalities
- Can Generate CL Files (APT Files)
- Customize APT Commands
- CAM-POST integration
CLAMP/AAXIS,ON
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APT Instructions
- APT : Automatically Programmed Tools
- APT File is a set of manufacturing instructions
- Each APT line represent one manufacturing instruction
- APT contains tool path (or cutter location)
- First CAM system generation was APT systems based
Example 1.1 – Samples of APT Instructions
LOADTL / 5
COOLNT / FLOOD
FEDRAT / 11.8110, IPM
GOTO / 1,2,3
GOTO / 3.45500, 3.05000, -1.33800, 0.70710, 0.70710, 0.00000
PPRINT / ‘This is an APT command’
CLAMP / BAXIS, ON
SPINDL / 70.0000, RPM, CLW
MODE / CONTUR, ON Common Error
GOTO instructions are referenced to part
origin, not the machine origin!
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APT Instructions
MAJOR word : Main instruction subject (Only one per line)
MINOR word : Arguments of the main instruction subject
/ : Separation between the MAJOR word and arguments
, : Separation between arguments
Example 1.2 – Translation of APT instruction in machine instruction (G Code)
Numeric
MAJOR value Major or
Word Minor
word
SPINDL / 70.0000 , RPM , CLW
Slash
Comma
In ISO, this APT command turns on the spindle clockwise at 70.0000 RPM. On most ISO
controllers, a post-processor would translate :
SPINDL / 70.0000 , RPM , CLW S70 M3
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CL File Types
- CL: Cutter Location or Center-Line file
- ASCII based or Binary file containing a set of APT instructions
- Can be opened with a text editor (Notepad, Wordpad, Vi etc.)
Common CL File Extensions
* .aptsource CATIA
* .clf UGS_NX
* .cls UGS_NX
* .ncl ProNC
* .NCI Mastercam
* .CAM TopSolid’CAM
* .cut PowerMill
* and more (SurfCam, Cimatron, …)
CL Files are also commonly called
APT Files or Input Files
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CL File Types
- CATIA V5
- Extension: *.aptsource files
- Approx. 90-95% ISO APT
- Using .pptable to modify syntax
http://www.3ds.com
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CL File Types
- Pro/Engineer
- Extension: *.ncl files
- Approx. 85-90% ISO APT
http://www.PTC.com
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CL File Types
- NX PLM solution
- Extension: *.cls files
- Approx. 80-85% ISO APT
- Using .tcl to modify syntax
http://www.plm.automation.siemens.com
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CL File Types
- Mastercam
- Extension: *.NCI files
- Approx. 10-15% ISO APT
http//:www.Mastercam.com
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G Codes
G & M codes are machining instructions directed to controllers to drive manufacturing
CNC machines.
G codes are controller based functions while M code calls are mostly addressed to the
machine.
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Tape File Types
- Each line is called a «block » Remember…
Tape Files are also commonly called
- One block can contain one or many instructions MCD Files (Machine Control Data), Output
Files, G Code Files or ISO Code Files
- Machining instructions can be modal
- Machine coordinates are referenced from the machine origin
Example 1.3 – ISO machine instruction block sample
Controller Functions
Machine Functions
G90: Absolute mode
M3: Spindle clockwise
G02: Circular interpolation Coordinates of control point to be reached
M8: Coolant flood
Block number N10 G90 G02 X25 Y15 I75 J54 S100 F150 M3 M8
Center coordinates of arc Feedrate
Rotation speed of spindle
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NC Tape File Types
- Fanuc Controller
- Easy readability
- 90-95% ISO
http://www.GEFanuc.com
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NC Tape File Types
- Heidenhain Controller
- ISO or Conversational
- Ease of use
http://www.heidenhain.com/
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NC Tape File Types
- Siemens Controller
- Flexibility
- TRAORI modes
- Cycles
- 60-65% ISO
http://www.Siemens.com
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Machine Configuration
Axis configurations using ISO standards : Z
- Linear axis: X, Y, Z Y
W
- Secondary axis: U, V, W
B
- Rotation axis: A, B, C (A’ or a for table) C V
A
X
U
Example 1.4 – Machine configuration samples
XYZ (VMC 3-Axis) XYZB’(HMC 4-Axis) XYZCA(Gantry 5-Axis)
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Machine Configuration
Example 1.5 – Machine configuration samples ~ Milling
XYZac (5-Axis) XYZbc (5-Axis) XYZABCc (7-Axis)
XYZBC (5-Axis) XYZNC (5-Axis) XYZnc (5-Axis)
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Machine Configuration
Example 1.6 – Machine configuration samples ~ Turning or Mill/Turning
ZX_C (2-axis Turn or Mill/Turn) ZXUWC (4-Axis Turn)
ZXYCB_WC’
(7-Axis Multi-task)
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Machine Configuration ~ Multi-Axis
Multi-axis with Pivot Distance (or Joint):
- Signed distance from the spindle face to the center of a rotary axis. (head-head)
- Some controllers (newest breed) have distance inside in their kinematics processor
- Tool-tip programming (RTCP)
Example 1.7 – Pivot distance from a C-A head configuration (Gantry type)
Pivot
distance
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CAM-POST Features
A single post can also
link several CAD/CAM
systems to the same
interface kits machine tool
CAM system
CAM-POST®
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CAM-POST Features
A single post can also link
several CAD/CAM systems
to the same machine tool
UI
with error
messages and
debug tools MCD
G&M code
ISO code
CAM-POST CAM-POST
interface kit Post-processor Tape file
Listing file
trace of the
process for
PLM
Graphic Post-processing offers Machine
Simulation WHILE Post-processing
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CAM-POST kinematics
15 axis Motion Processor and more
- 3 Primary Linear axes (X Y Z)
- 3 Secondary or co-linear axes (U V W)
- 3 Rotary Tables (A’ B’ C’)
- 3 Rotary Heads (A B C)
- 1 Quill or Extending axes (E)
- 2 Removable Rotary Head Attachments,
such as a Nutating Axis (N) or any
Fixed/Variable angle head
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CAM-POST Features
Virtual Machine® for Graphical NC Post-Processing
Solution
ICAM's advanced machine tool simulation product, when
integrated with CAM-POST allows NC programmers to
graphically simulate and test programs for collisions and
over-travel easily and automatically during post-processing,
before the machine code is implemented within the
production environment.
Rotating Tool Center Point (RTCP - G43.4 or Siemens
TRAORI modes) Some controllers offer linearization
capabilities during 5 axis movements for a better control
and numerous advantages like tool compensation and,
most important of all, simplified 5 axis programming.
NURBS Capabilities
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Exercises
Exercise 1.1 - Find the configuration for each of the following CNC machines using the ISO standard.
……… ……… ………
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Answers
XYZWB’
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Answers
XYZWC’A
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Answers
XYZA’B’
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