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PEMP- AME501
Session Speaker
Mr. Umesh S.
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Session Ob ectivesOn completion of this Session, the delegates would have
understood about The aspects of Manufacturing Process Management
Computer Aided Manufacturing
Computer Aided Production Engineering
Com uter Aided Production Plannin
Computer Aided Quality Assurance
Numerical Control Machines
Programming for Numerical Control Machines
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ManufacturinManufacturing is the use of machines,
too s an a or to ma e t ngs or use or sale. The term may refer to a range of
human activity, from handicraft to high
tech but is most commonl a lied to
industrial production, in which raw
goods on a large scale.
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http://en.wikipedia.org/wiki/Manufacturing
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Manufacturin Process Mana ementTools required for proper execution of various aspects of mfg. process
Computer Aided Manufacturing (CAM)
Production Engineering (CAPE)CNC, DNC, Robot OLP, Tooling/Fixtures
Production Planning (CAPP)
Mfg. concepts, Layout, Line balancing,
,
Quality Assurance (CAQ)Process and Ergonomic simulation, Resources
, , , - Costing (ABC)
Communication (ERP, MOM, HMI, PDM, SCADA )
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Documentation
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Process PlanninTo establish which process and parameters are
to be used, as well as the machines performing
these processes, in order to manufacture the
component as per the design specification
Raw Material Finished ProductProcess
Planning
Raw material to be used
Sequence of machining/assembly operations
Processes and machines to be used for these operations
Tools, cutting speeds and feeds to be used for this purpose
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eve op me o o ogy or qua y assurance
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Process PlanningShape and Size of the raw material (stock size)Identify datum
Identify and Group part featuresIdentify machining operations based on features and accuracy
Order/sequence of operation ( production/resource planning)
Select tools for each operation
Select/Design fixtures for each setup
machining parameters etc.)
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Com uter Aided Process Plannin
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process plans
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Stage III - Variant CAPP
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Stage V - Dynamic, generative CAPP
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Com uter Aided Process Plannin Variant Approach:
Advance Manual Approach Utilise historical data stored in computers
Database of process plans for family of parts
Identify the family to which the part belongs e r eve process p an or a am y
Edit this plan as necessary to suit the requirement
or par o a new am y, eve op process p anmanually
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Com uter Aided Process Plannin Generative Approach: Process lan enerated from En ineerin
Specifications (graphical and textual) Read specification directly from CAD
Identify design features
Accept information about material, tolerances etc.roug npu
Accept information about raw material stock
process plans
Need ood database and lo ic or s stem to make a decision
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Dynamic, generative CAPP
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Com uter Aided Process Plannin Process planning effort 58% Direct labor 10%
Improved cost estimatingprocedures and fewercalculation errors
Scrap 10% Tooling 12%
More complete and detailedprocess plans
or - n-process
Reduced process planning and
Improved production
scheduling and capacity
response to engineeringchanges Improved ability to introduce
new manufacturing technology
Greater process planconsistency; access to up-to-date information in a central
an rap y up ate processplans to utilize the improvedtechnology
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http://www.npd-solutions.com/capp.html
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Com uter Aided Production Plannin Manufacturing concept planning
Factor la out lannin and anal sis
work flow simulation. walk-path assembly planning
lant desi n o timization
Mixed model line balancing
Workloads on multiple stations Process simulation tools e.g. die press lines, manufacturing
lines
Er onomic simulation and assessment of roduction assembl
tasks
Resource planning
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http://en.wikipedia.org/wiki/Manufacturing_process_management
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Com uter Aided ualit Failure Mode and Effects Analysis
htt ://www.n d-solutions.com/fmea.html
Statistical process control -
Tolerance stack-up analysis
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. .
/QAProducts/images/xbar.jpgp: www.me .n s .gov ga ery
ph/cmt/pages/herbb.htmhttp://www.3dcs.com/
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Co-ordinate Measurin Machine
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omputer e anu actur ng
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Machine ToolA powered machine for cutting or shaping or finishing
http://wordnetweb.princeton.edu/perl/webwn?s=machine%20tool
The main function of a machine tool is to remove metal
from a piece of work to give it the required shape and size
between the work-piece (job) and the tool
Machining equipment that cuts, shears, punches, presses, drills, rolls,grinds, sands, or forms metal, plastic, or wood stock. Not included in
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, , .http://www-group.slac.stanford.edu/esh/hazardous_activities/machine_guarding/p_definitions.htm
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Conventional Machine Tool Fixing of the job (raw material)
Motion of the tool Manual control of the tool movement
Operator skill dependent productivity and quality
Low s eeds and feeds
Product complexity
Machine flexibility
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Com uter Aided ManufacturinTo automate the actual
Production process with least
Software used to generate the
instruction codes for a CNC
Information for machining:
amount of human intervention machine in order for it to cut out
a shape designed in a CAD
Shape to be machined
Accuracy to be achieved Automation
Sequence of machining
Spindle speed ccuracy Direction of rotationFeed Rate
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Coolant flow
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Numerical Control NC MachineWeaving MachinesSelf playing pianos
Copying machines (not Xerox)
1940 John Parson (punched cards for drilling of multiple holes)
arson orp. on ro ys em eve opmen , servo a
1952 3-axis Cincinnati Hydrotel Milling machine (NC)
NC is a system in which actions are controlled by direct insertion
of numerical data (Part Program) at some point. The system must
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automatically interpret at least some portion of this data
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Numerical Control NC Machine Automation Op. intervention
Flexibility
Accuracy
Cost Utilisation Skill Pre-planning
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Numerical Control NC Machine
Motion Control
Rotary (Servo Motors AC (cost)/DC (speed Var.)/Fluid(speed))
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Electric Drives To drive the main spindle (Spindle drive)
o r ve t e sa es or carr age x s r ve
Large variation in cutting speed (10 m/min to 1000 m/min)
Infinitely variable speeds between the upper and the lower
--
Direct Drive
Drive through gear box or through cogged belts
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LM Guides and Ball Screws
http://news.thomasnet.com/images/large/548/548044.jpg http://www.acorn-ind.co.uk/images/ball-screws.jpg
High Efficiency
Reduce friction and
wear
Reversibility Wear and Life
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Smoother movement
Rigidity (pre-loading)
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Numerical Control NC Machine Reading the Part Program Decodin and rocess the ro ram statements
Convert the decoded information into control signals Receive and transmit feedback signals
Machine Control Unit (MCU)
Data Processing Unit
(DPU)
Control Loop Unit
(CLU)
Input Stream ReaderDate Reading Circuit
Decodin Circuit
InterpolatorPosition Control Loop
Velocit /Acc. Control Loo
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Auxiliary Function Control
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Numerical Control (NC) Programming
NCVacuum Tube/1st generation Solid State Technology
Punched Tape input, no storage, processing one command at a time
CNC
IC and Memory Technology, Part Program input stored, Exchange
information between different units, PC style Controller (RAM, ROM,
Comm ports, Display, HD, KB, Editors, Graphic input devices), Canned
Subroutines in ROM
Communiction and Networking Technology, Central computer
,
and distribution of instructional blocks to NC machines
Communiction and Networkin Technolo , Central com uter for
DisNC Retrieval of Part Programs and its distribution to networked CNCmachines
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N-axis m/c Number of axes along which motion can be controlled simultaneously
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Numerical Control NC MachineAxis Position # of pulses
x s e oc y u se requency
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Numerical Control NC Machine
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Numerical Control NC Pro rammin
Po nt to Po nt Systems:
Positioning, Drilling/Tapping, Punching
Contouring Systems:
Milling, Turning, Flame cutting
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Controls for NC machines O en Loo Control Closed Loo Control
no monitoring of theactual displacement of
Slide position isregulated by the
e mac ne s e
No comparison of
actual and re uired
erence e ween e
actual and programmed
positionposition
Motor controlled solely
Actual position is
constantly monitored
y e program npu
comparison
Very high accuracy
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Feedback devices Position Feed Back Velocit Feed Back
continuousmeasurement of the
Normally Tacho-generator is used
pos on o e cu ng
tool edge relative to the
datum point rotary or linear
measuring transducers.
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Structural Re uirements Normal weight distribution
result in rapid acceleration and deceleration of the slidesand the machines are subjected to fluctuating and variableforces during the machining operations
The machine structure should not bend due to the heavy
All the parts of the machine structure should remain inrelative relationshi re ardless of the ma nitude and
direction of the stresses developed due to these forces Another source of inaccuracy in the CNC machines is the
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thermal distortion of the machine structure
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Cause of Inaccurac in Machine tools
Dynamic
Loading
Static Loading
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Thermal Sources
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Safet of O erator
,
cannot be overlooked To ensure safe workin conditions the CNC
machine tools are provided with
Perimeter Guards Pressure mats
Light barriers
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Machinin Centers The latest developments in the CNC machine tools
are the versatile machining center.
This is a single machine capable of doing a
number of operations such as drilling, reaming,
tapping, milling and boring.
types o too s are mounte on a rum c a n or
egg box type magazine, which are put into the
the control of Tool Selection Instruction
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Tool Turrets
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NC Pro ramminDefine Geometry of part and motion of tool with respect to the work piece
Preparatory Information: Units, Positioning method Coordinates (X,Y, Z, RX, RY, RZ)
Tool/Tools to be used
Spindle Speed
Spindle On/Off
Coolant On/Off
Tool Control
Miscellaneous
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NC Pro ramminReference System:
Right Handed Cartesian Coordinate System
ZYX
Z-X plane
YXZ
Y-Z plane
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XZY
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NC Pro rammin
Z-Axis:Part Rotating Spindle Axis/Direction of RotationTool Rotatin Tool Axis/Awa from the work iece
X-Axis:Part Rotating Moves tool away from the part
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Tool Rotating To Right when moving along Z-axis facing the m/c
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NC Pro rammin
(2,3)
-
(2,3)
- -,
(1,-1)
,
(2,2)
(-1,-3) (1,-4)
Absolute Positioning Relative Positioning
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NC Pro ramminProgramming Syntax:ns ruc ons as a sequence o oc s con a n ng
commands to set machine parameters
A block is a line of words
Each block is composed of several Commands
an associatedNumber
N30 G01 Z-0.125 F5
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N35 X3 Y2 F10
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NC Pro ramminLetter Codes
Each instruction to the machine consistsof a letter followed b a number.
Each letter is associated with a specific
ype o ac on or p ece o n orma on
needed by the machine.
Letters used in Codes
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N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
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NC Pro ramminLetter Action association: Sequence Number (N): Block identifier (index)
* repara ory comman : u er mo on pos on ng
Dimension words (X,Y,Z,..): Location and orientation of cutter (BLU)
Feed Command F : Cutter Feed Rate units
Speed Command (S): Spindle Speed (rpm)
Tool Select Command (T): Tool selection from turret/tool changer Misc. Command (M): Spindle On/Off, Coolant On/Off
Circle Center (I,J,K): Center of a Circle
Dwell Command (P): Dwell Time (With G code)
% Program Start Flag G&M Code
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:XXXX Program IdentifierSample File
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NC Pro ramminBlock Formats: Fixed Sequential: Fixed block length, contains same no. of words
Block Address: Change Codes used to indicate changes in a block
Tab Sequential: Modified Fixed block length, TAB key
,
Word Address: Each word is preceded by a letter identifying
the word type, followed by a number specifyingcontent
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Part Pro ramminManual Part Programming:
Generate machining information in blocks based on the plannedmachining process using a Part Program Manuscript
Tedious
Invo ves ar t met c an tr gonometr c ca cu at ons
Prone to mistakes
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Part Pro ramminComputer Assisted Part Programming:Use hi h level ro rammin lan ua es to define art eometr
and tool motions
Identify part geometry, general cutter motions, feeds, speeds
an cutter parameters
Code part geometry, cutter motions, and machine instructions
Compile the source to produce machine independent list of
cutter movement and and auxiliar machine control information
(Cutter Location Data File)
Post-process CL Data File to generate machine control data
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for a particular machine (customisation)
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Part Pro ramminAutomatically Programmed Tool (APT):
-
Definition of Geometry relevant to machining=
L1 = LINE/X1,Y1,Z1,X2,Y2,Z2
L2 = LINE/P1,P2
P1 = POINT/CENTER,C1
Motion Statement (location)
FROM/ oint location_
TO/point_location
GODLTA/x, y,z
GO/{TO},Drive Surface,{TO}, Part Surface {TO}, Check Surface
PAST, TANTO, ON Additional APT Statements, , , , ,
MACHIN/DRILL,2COOLNT/{MIST/FLOOD/OFF}
FEDRAT, SPINDL, TOOLNO, TURRET
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,
MACRO CALLS
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Part Pro ramminOther Part Programming Languages: ADAPT: Adaptation of APT for PCs, modular structure
Single Axis Positioning & Simple Contouring
in 2D and 3D
AUTOSPOT: Popular for positioning tasks (drilling)
Combined with ADAPT
EXPAT: Adapted APT for use in Europe
Three versions P to P, turning, 3D contouring
COMPACT: Language used is English-like and similar to
machine shop terminology
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Part Pro ramminPart Programming from CAD:Utilise the art eometr data alread in di ital form in CAD
Part Programming from CAD:
CAD/CAM
Better Accuracy
Faster Development
Less prone to Errors
Less chances of model discrepancy
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Part Pro ramminApproach to Part Programming from CAD:
Edit/Add geometry to define boundary for tools
Define Tool Geometry (library)
Identify the desired sequence of machining operations andp an t e requ re too pat an cutt ng parameters
Calculate coordinates of the points on the path (keep it low)
Graphically verify the generated path and correct if necessary
Create Cutter Location data file
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Post-process CL data file to create Machine Code data file
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Part Pro ramminTool Path Generation Considerations: Rou h Cut Castin /Rou h Cut Block
, ,
u er oca on o n
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oug ng
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Part Pro ramminTool Path Simulation and Verification:
oo
Models
superimposed on geometry
Material to be removed is removed
Cutter does not hit clamps or fixtures
utter oes not pass t roug t e oor, s es or r s
Cutter ath is efficient
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MPM Resources Dassault Systems (Delmia/Deneb)
PTC
ecnoma x
Surfware (SURFCAM)
Delcam (Powermill)
Proplanner
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Session Summar
The as ects of Manufacturin Process Mana ement
were described and explained
Application of Computer based tools in managing
various aspects of MPM were described
Brief history and working of Numerical Controlmachines were describe
Methodology of programming for NC Machines was
demonstrated
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