CAD/CAM
Lectures for 4th grade students
Department of Engineering Materials
College of Engineering / University of Al_Qadisiyah
Dr. Layth Fadhil Shakir
PHD. of production engineering
E-mail:
[email protected]Numerical Control
Introduction
Numerical control may be defined as a method of programmable automation in which various
functions of machine tools are controlled by numbers, letters and symbols. In NC, the numbers form
a program of instructions. The instructions may be:
a) To start or stop the machine tool spindle
b) To control the spindle speed
c) To change the tool
d) To change the feed rate
e) To switch the coolant on/off
f) To position the tool at a desired position.
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Advantages of NC machine tools
1. The manufacturing lead time in NC machines is less. This is owing to fewer set-ups, reduced work
handling time, automatic tool changes, etc.
2. Close tolerance can be maintained on the products, parts can be produced more accurately.
3. NC fixtures are simple and less costly. Since the part program can take care of the geometry generated,
the need for expensive fixtures is minimized.
4. Floor space requirements are reduced because one NC machine center can accomplish the production of
several conventional machines.
5. The quality of the products is improved because of automation and the absence of inter- related human
factors.
6. Cutting tools can be used at optimum speeds and feeds.
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NC motion modes
represents tool positioning type in NC machines which can be classified into the following three
categories:
1. Point-to-Point mode.
PTP can be used to perform drilling, bending and spot welding. Point coordinate in PTP mode always
incremental. PTP mode can be either Sequential [parallel to one of the axes] or Simultaneous [x=y (45°)
then parallel to one of the axes]. See the following example.
Ex1: Show all possible PTP movements and give the coordinates for the drills in Fig
Programed Tool-path Motion: Point
(Incremental) Simultaneous Sequential from-to coordinates.
(Absolute)
X25 Y30 P1-a-P2 P1-c-P2 P1 to P2 P1 (0,0)
Or P2 (25,35)
P1-d-P2 P3 (75,15)
X50 Y-20 P2-b-P3 P2-f-P3 P2 to P3 a (25,25)
Or b (45,15)
P2-e-P3 c (25,0)
d (0,35)
e (25,15)
f (75,35)
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2. Straight Cut Mode.
In this type of positioning, the feed control is shared by all programable axes of the machine which allows
the system to perform milling in addition to drilling.
The problem is the x and y movement either parallel to the axes or in 45°, and the resulting error depends
on the programed increment.
Ex2: An NC straight cut performed from point P1 (0,0) to point P2 (120,60). Calculate the tool-path error
and make the suitable adjustment to minimize it.
Solution:
the given dimension would make the tool moves from P1 to a to P2 with
error = ab̅.
Error= ab̅ = P1 a Sinα = √𝑥 2 + 𝑦 2 𝑆𝑖𝑛𝛼 = √2𝑦 𝑆𝑖𝑛𝛼
𝛼 + 𝛽 = 45
𝑦
𝛽 = tan−1 = 26.656° ⇒ 𝛼 = 18.435°
𝑥
⇒ Error = 26.832mm
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This error is too large, by reducing the programed increments to x= 40, y=20.
Error= 8.94mm ⇒still large
By using programed increments x=0.5, y=0.25 error= 0.11 [ this value is acceptable in rough milling and
some other operations].
3. Contouring cut mode.
Each axis moves continuously at different speed (velocity). It can perform angular surface, two dimensional
curves and three-dimensional contours. The error occurs when the velocity drops down in one of the axes.
Ex3: An NC milling machine has to cut a slot located between two points (5,5) and (50,50) in X-Y plane.
Recommended feed rate along the slot is 120 mm/min. find the approximate cutting time and axes velocity.
If the speed in Y-axis dropped by 20%, what is the error in Y-position?
Solution:
𝑳 √𝟒𝟓𝟐 + 𝟒𝟓𝟐 Y-axis speed dropped by 20%
𝑻𝒎 = = = 𝟎. 𝟓𝟑𝒎𝒊𝒏 𝐕𝐲 = (𝟎. 𝟖) ∗ (𝐕𝐲˳) = 𝟔𝟕. 𝟖𝟔 𝐦𝐦/𝐦𝐢𝐧
𝒇𝒓 𝟏𝟐𝟎
𝑽𝒙 = 𝑽𝒚 = 𝒇 ∗ 𝒄𝒐𝒔𝟒𝟓 = 𝟖𝟒. 𝟖𝟐𝟓𝒎𝒎/𝒎𝒊𝒏 𝐘 𝐧𝐞𝐰 𝐩𝐨𝐬𝐢𝐭𝐢𝐨𝐧 = (𝟔𝟕. 𝟖𝟔 ∗ 𝟎. 𝟓𝟑) = 𝟑𝟓. 𝟗𝟔
𝐄𝐫𝐫𝐨𝐫 = 𝟓𝟎 − 𝟑𝟗. 𝟗𝟔 = 𝟏𝟒. 𝟎𝟑
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NC control systems
Two main types of NC control systems: open loop and closed loop. Fig 1.
Open loop Closed loop
➢ No feed-back. ➢ With feed-back.
➢ Not accurate. ➢ High accuracy.
➢ Easy to build. ➢ Difficult to build.
➢ Use stepper-motors. ➢ Use servo-motors.
Figure 1
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A. Open loop system.
Stepper-motor in open loop system receives specific number of pulses (np) to rotate to angular position
(Am) depending on the number of step angles of the motor (ns). The motor then drives the lead screw
through a gear box by ratio (rg) to move to an angular position (As). This rotation makes the table of the
machine to move a linear distance (X) according to lead screw pitch (p). The rotational speed of the motor
(Nm) and (Ns) of the lead screw, the latter gives the linear speed (V) of the table. The pulses train came out
in a frequency (f).
𝟑𝟔𝟎 𝑨𝒎 = 𝜶. 𝒏𝒑
𝜶=
𝒏𝒔 Am= motor angular position (degree)
α= angular step/pulse
ns= number of step angle of motor
(integer)
𝟔𝟎. 𝒇 𝑵𝒎 𝑨𝒎
𝑵𝒎 = 𝒓𝒈 = =
𝒏𝒔 𝑵𝒔 𝑨𝒔
Nm= motor rotational speed (rpm) Ns= lead screw rotational speed (rpm)
f= pulse frequency (Hz) As= lead screw angular positin
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𝑷. 𝑨𝒔 𝑽 = 𝑵𝒔. 𝑷
𝑿=
𝟑𝟔𝟎 V= feed rate or linear velocity of table
X= table movement distance (mm) (mm/min)
P= lead screw pitch (mm/rev)
Ex4: A steeping motor has 48 step angles. The motor out put coupled with a lead screw by gear ratio 4:1,
lead screw pitch =5mm/rev. the work table most move a distance 75mm from its current position by a linear
speed of 400mm/min. Determine a- How many pulses needed to move the table to the specified distance. b-
Motor rotary speed and c- pulse frequency.
a- b-
𝟑𝟔𝟎 𝒅𝒆𝒈𝒓𝒆𝒆 𝟒𝟎𝟎
𝜶= = 𝟕. 𝟓 𝑽 = 𝑵𝒔. 𝑷 ⇒ 𝑵𝒔 = = 𝟖𝟎 𝒓𝒑𝒎
𝟒𝟖 𝒑𝒖𝒍𝒔𝒆 𝟓
𝑷. 𝑨𝒔 (𝟓)𝒙𝑨𝒔 𝑵𝒎 = 𝑵𝒔. 𝒓𝒈 = 𝟖𝟎𝒙𝟒 = 𝟑𝟐𝟎 𝒓𝒑𝒎
𝑿= ⇒ 𝟕𝟓 = ⇒ 𝑨𝒔 = 𝟓𝟒𝟎𝟎°
𝟑𝟔𝟎 𝟑𝟔𝟎
𝑨𝒎
𝒓𝒈 = ⇒ 𝑨𝒎 = 𝟒𝒙𝟓𝟒𝟎𝟎 = 𝟐𝟏𝟔𝟎𝟎°
𝑨𝒔
𝟐𝟏𝟔𝟎𝟎
𝑨𝒎 = 𝜶. 𝒏𝒑 ⇒ 𝒏𝒑 = = 𝟐𝟖𝟖𝟎 𝒑𝒖𝒍𝒔𝒆𝒔
𝟕. 𝟓
c-
𝟔𝟎. 𝒇 𝟑𝟐𝟎𝒙𝟒𝟖
𝑵𝒎 = ⇒𝒇= = 𝟐𝟓𝟔 𝑯𝒛
𝒏𝒔 𝟔𝟎
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HW1: The work table of positioning system is driven by lead screw whose pitch =6mm/rev. the lead screw
is connected to stepper-motor shaft with gear ration 5:1. Stepper-motor has 48 step angels. The table must
move a distance of 250mm in a linear velocity of 500mm/min. calculate the number of pulses, motor rotation
speed and the pulse rate.
B. Closed loop system
There are differences in calculations of closed loop should be considered:
1. The feedback system usually contain an optical encoder. (ns) here is the number of pulses generated by
the encoder disk per revolution.
2. The angular step (α) is the angle between encoder slots.
3. Gear ratio (rg) 1:1 so the angular position and rotation speed of the motor and lead screw will be the
same. Or used to estimate motor rotation speed only.
𝑿. 𝒏𝒔
𝒏𝒑 = 𝟔𝟎. 𝒇
𝑷
np= total number of pulses for a distance. 𝑵𝒔 =
𝒏𝒔
ns= number of encoder pulses/rev Ns= lead screw rotational speed (rpm)
X= table movement (mm) f= pulse frequency (Hz)
P=lead screw pitch
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𝑽 = 𝑵𝒔. 𝑷 𝑽. 𝒏𝒔
𝒇=
V= feed rate or linear velocity of table 𝟔𝟎. 𝑷
(mm/min) f= pulse frequency (Hz)
EX5: The worktable of a numerical control machine tool is driven by a closed-loop positioning system
which consists of a servomotor, leadscrew, and optical encoder. The leadscrew has 4 threads/in and is
coupled directly to the motor shaft (gear ratio = 1:1). The optical encoder generates 200 pulses per motor
revolution. The table has been programmed to move a distance of 7.5 in at a feed rate = 20.0 in/min. (a)
How many pulses are received by the control system to verify that the table has moved the programmed
distance? What are (b) the pulse rate and (c) motor speed that correspond to the specified feed rate?
𝑿. 𝒏𝒔 𝟕. 𝟓𝒙𝟐𝟎𝟎
𝒏𝒑 = = = 𝟔𝟎𝟎𝟎 𝒑𝒖𝒍𝒔𝒆𝒔
𝑷 𝟎. 𝟐𝟓
𝑽. 𝒏𝒔 𝟐𝟎𝒙𝟐𝟎𝟎
𝒇= = = 𝟐𝟔𝟔. 𝟔𝟕𝑯𝒛
𝟔𝟎. 𝑷 𝟔𝟎𝒙𝟎. 𝟐𝟓
𝑽 𝟐𝟎
𝑵𝒎 = 𝑵𝒔 = = = 𝟖𝟎 𝒓𝒑𝒎
𝑷 𝟎. 𝟐𝟓
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HW2: An NC machine tool table is powered by a servomotor, leadscrew, and optical encoder. The
leadscrew has a pitch = 5.0 mm and is connected to the motor shaft with a gear ratio of 16:1. The optical
encoder is connected directly to the leadscrew and generates 200 pulses/rev of the leadscrew. The table must
move a distance = 100 mm at a feed rate = 500 mm/min. Determine (a) the pulse count received by the
control system to verify that the table has moved exactly 100 mm; and (b) the pulse rate and (c) motor speed
that correspond to the feed rate of 500 mm/min.
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