cnc training (sahil gupta 9068557926)
DESCRIPTION
Training PPT on CNC MACHINESTRANSCRIPT
1INDUSTRIAL TRAINING
ON
CNC MACHINES
UNDER THE GUIDANCE OF
Er. Sanjay Jindal (DGM Maintenance)
Submitted By: Er. Sahil Gupta Roll NO: 2110003
2CNC Machines
Computer Numerical control (CNC) is the Automation of Machine Tools that are operated by abstractly programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone.
Modern CNC systems, end-to-end component design is highly automated using Computer-aided Design (CAD) and Computer-aided Manufacturing (CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a postprocessor, and then loaded into the CNC machines for production.
Basic CNC Principle
All computer controlled machines are able to accurately and repeatedly control motion in various directions. Each of these directions of motion is called an axis. Depending on the machine type there are commonly TWO to FIVE axes.
X,Y,Z – Axis Cartesian Coordinate System
X,Y,Z,A,B – Axis CNC Coordinate System
A: Rotary axis along X - Axis B: Rotary axis along Y - Axis
4Key
ConceptNumber
OneCYCLESTART
FEEDHOLD
EDIT
AUTO
MDI JOG
HANDLE
ZERORETURNMODE
0%
100%
200%
FEEDRATEOVERRIDE
10%
25% 50%
100%
RAPIDOVERRIDE
1
12
TURRET INDEX2
345
67
8 9 10 11
SLOW FAST
EMERGENCYSTOP
FANUC 10T
POWERON
OFF
O N G P AX Y Z Q BI J K R C
F D H L #M S T /EOB
U V W
Sp
E ? @ @,
[ ] ( ) *
PAGE CURSOR
SHIFT
7 8 94 5 61 2 3- 0+ = CAN
RESET
START
CALC
INPUT
NC/PC
AUX
X00.0000Z00.0000
X ZX1
X10X100
0
ON
OFFDRYRUN
SINGLEBLOCK
MACHINELOCK
OPTIONALSTOP
BLOCKDELETE
X+
X-
Z-
JOYSTICK
Z+
ON OFF
SPINDLE
ORIGIN
X Z
0%100%
130%
SPINDLE LOAD
0%100%
130%
AXIS LOAD
X Z
OD ID
CLAMPDIRECTION
OFF ON
MEMORYPROTECT
CHUCK TAILSTOCKKey concept #2From programmer’s viewpoint
You must understand the machine you’ll be working with!
From operator’s viewpointKey concept #1
In key concept #2 we look at the machine from a programmer’s viewpoint
In key concept #1 we look at the machine from an operator’s viewpoint
5
Machine Configurations(2-axis Only)
Front view of machine
Headstock & Spindle Work-holding
Device
JobTailstock
BodyCenter
Turret
8
N0020: Instruction Number G00: Tool Not at Home position G57: Rotation of axis after tool base position S500: Speed of Rotation 500Rpm M04: Bypass Flag OR alarm
Operator’s Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
10
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
11
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
12
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
13
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
14
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
15
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
16
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
17
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
18
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
19
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
20
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
21
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
22
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
23
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
24
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
25
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
26
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
27
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
28
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
29
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
30
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
31
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
32
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
33
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
34
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
35
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
36
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
37
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
38
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
39
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
40
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
41
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
42
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
43
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
44
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
45
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
46
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
47
Z Axis- +
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
48
Z Axis- +
Z is the length controlling axis
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
50
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
51
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
52
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
53
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
54
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
55
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
56
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
57
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
58
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
59
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
60
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
61
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
62
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
63
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
64
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
65
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
66
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
67
X A
xis
-
+
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
68
X A
xis
-
+X is the diameter controlling axis
Instruction : N0020 G57 G00 X3.0 Z3.5 S500 M04
X A
xis
-
+
3.000
X3.0
If you want to turn a 3.0 inch diameter…X3.0 will be the commanding word
3.500
If you want to turn a 3.5 inch Length… will be the commanding word
Z3.5
Programmer’s View
First motive of the programmer is to get the machine ready for production by changing the current program and then analyse the problem in the machine due to which the breakdown occurs.
71 ATC NOT WORKING
STAGE – 1 : Check the Problem using CNC Ladder Logic
Input of “Tool arrived” is not coming.a)Check the tool positionb)Fix tool in pocketc)Check other conflictsd)Bypass the input X067e)Look over the process for one cyclef)Handover the machine to Operator.
Result : Machine is ready for production
STAGE – 2 :Find Actual Cause of Problem
STAGE -3 : STAGE – 4 :KAIZEN POKA YOKE
STAGE – 5 : STAGE - 6WHY – WHY ? FAULT TREE
72INITIAL: X067 is NOCause : Limit Switch input is missing
ACTION : Bypass X067 (say with M054 NC)Result : Tool Clamped
73STAGE – 2 : Actual Cause of Problem a) Limit Switch input missing
b) PDB Not Working c) Strobe Length Increased d) Nut Opened.
STAGE – 3 : KAI ZEN - Change For Better
Limit Switch Proximity SwitchREPLACED
a) Increased Performanceb) Reliabilityc) Life about 15yearsd) Delay Decreasede) Easy to replace
74STAGE – 4 : POKA-YOKE Mistake-Proofing
BEFORE AFTER
This mechanism in a manufacturing process is that which helps an equipment operator to avoid (YOKE) mistakes (POKA). The purpose is to eliminate product defects by preventing , correcting , or drawing attention to human errors as they occur.
Using one NUT make the length of strobe increased on prolong use. Bt using two NUTs, one after other make it fix for long use which reduces human as well as mechanical errors. This helps in reducing required maintenance.
75STAGE – 5 WHY –WHY ?
76STAGE –6 FAULT TREE
78
Name :- Sahil Gupta
Roll No. :- 2110003
Branch :- E.C.E.