NC-3e-S 11-14, 14/06, 06/04/07

Chapter 7 NUMERICAL CONTROL

REVIEW QUESTIONS
7.1 What is numerical control? Answer: As e!ine in the te"t, numerical control #NC$ is a !orm o! %ro&ramma'le automation in (hich the mechanical actions o! a machine tool or other e)ui%ment are controlle '* a %ro&ram containin& co e al%hanumeric ata. 7.+ What are the three 'asic com%onents o! an NC s*stem? Answer: ,he three com%onents are #1$ the %art %ro&ram o! instructions, #+$ the machine control unit, an #3$ the %rocessin& e)ui%ment #e.&., machine tool$ that accom%lishes the o%eration. 7.3 What is the ri&ht-han rule in NC an (here is it use ? Answer: ,he ri&ht-han rule is use to istin&uish %ositi-e an ne&ati-e irections !or the rotational a"es in NC. .sin& the ri&ht han (ith the thum' %ointin& in the %ositi-e linear a"is irection # +x, +y, or +z$, the !in&ers o! the han are curle in the %ositi-e rotational irection !or the a, b, an c a"es. 7.4 What is the i!!erence 'et(een %oint-to-%oint an continuous %ath control in a motion control s*stem? Answer: /oint-to-%oint s*stems mo-e the (or0ta'le to a %ro&ramme location (ithout re&ar !or the %ath ta0en to &et to that location. 1* contrast, continuous %ath s*stems are ca%a'le o! continuous simultaneous control o! t(o or more a"es, thus %ro-i in& control o! the tool tra2ector* relati-e to the (or0%art. 7.3 What is linear inter%olation, an (h* is it im%ortant in NC? Answer: 4inear inter%olation is the ca%a'ilit* to machine alon& a strai&ht-line tra2ector* that ma* not 'e %arallel to one o! the (or0ta'le a"es. 5t is im%ortant in NC 'ecause man* (or0%iece &eometries re)uire cuts to 'e ma e alon& strai&ht lines to !orm strai&ht e &es an !lat sur!aces, an the an&les o! the lines are not 'e %arallel to one o! the a"es in the coor inate s*stem. 7.6 What is the i!!erence 'et(een a'solute %ositionin& an incremental %ositionin&? Answer: 5n a'solute %ositionin&, the (or0hea locations are al(a*s e!ine (ith res%ect to the ori&in o! the NC a"is s*stem. 5n incremental %ositionin&, the ne"t (or0hea %osition is e!ine relati-e to the %resent location. 7.7 6o( is com%uter numerical control #CNC$ istin&uishe !rom con-entional NC? Answer: CNC is an NC s*stem (hose machine control unit is a e icate microcom%uter rather than a har (ire controller, as in con-entional NC. 7.7 Name !i-e o! the ten !eatures an ca%a'ilities o! a mo ern CNC machine control unit liste in the te"t. Answer: ,he ten !eatures an ca%a'ilities i enti!ie in the te"t are #1$ stora&e o! more than one %art %ro&ram, #+$ -arious !orms o! %ro&ram in%ut, such as %unche ta%e, ma&netic ta%e, !lo%%* is0ette, 8S-+3+ communications (ith e"ternal com%uters, an manual ata in%ut, #3$ %ro&ram e itin& at the machine tool, #4$ !i"e c*cles an %ro&rammin& su'routines #macros$, #3$ linear an circular inter%olation, #6$ (or0%iece %ositionin& !eatures !or setu%, #7$ cutter len&th an si9e com%ensation, #7$ acceleration an eceleration calculations (hen the cutter %ath chan&es a'ru%tl*, #:$ communications inter!ace, an #10$ ia&nostics to etect mal!unctions an ia&nose s*stem 'rea0 o(ns. 7.: What is istri'ute numerical control #;NC$? Answer: ;istri'ute numerical control is a istri'ute com%uter s*stem in (hich a central com%uter communicates (ith multi%le CNC machine control units. 5t e-ol-e !rom irect numerical control in (hich the central com%uter %la*e the role o! the ta%e rea er, o(nloa in& %art %ro&rams one 'loc0 at a time. 5n a mo ern istri'ute NC s*stem, entire %art %ro&rams are o(nloa e to the <C.s. Also sho% !loor ata is collecte '* the central com%uter to measure sho% %er!ormance. 7.10 What are some o! the machine tool t*%es to (hich numerical control has 'een a%%lie ? Answer: NC has 'een a%%lie to nearl* all machine tools t*%es, inclu in& lathes, 'orin& mills, rill %resses, millin& machines, an c*lin rical &rin ers.

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NC-3e-S 11-14, 14/06, 06/04/07 7.11 What is a machinin& center? Answer: As e!ine in the te"t, a machinin& center is a machine tool ca%a'le o! %er!ormin& multi%le machinin& o%erations on a sin&le (or0%iece in one setu%. ,he o%erations in-ol-e rotatin& cutters, such as millin& an rillin&, an the !eature that ena'les more than one o%eration to 'e %er!orme in one setu% is automatic tool-chan&in&. 7.1+ Name !our o! the si" %art characteristics that are most suite to the a%%lication o! numerical control liste in the te"t. Answer: ,he si" %art characteristics i enti!ie in the te"t are the !ollo(in&: #1$ 'atch %ro uction, #+$ re%eat or ers, #3$ com%le" %art &eometr*, #4$ much metal nee s to 'e remo-e , #3$ man* se%arate machinin& o%erations on the %art, an #6$ the %art is e"%ensi-e. 7.13 Althou&h NC technolo&* is most closel* associate (ith machine tool a%%lications, it has 'een a%%lie to other %rocesses also. Name three o! the si" e"am%les liste in the te"t. Answer: ,he si" non-machine tool a%%lications liste in the te"t are #1$ electrical (ire-(ra% machines, #+$ com%onent insertion machines, #3$ ra!tin& machines #x-y %lotters$, #4$ coor inate measurin& machines, #3$ ta%e la*in& machines !or %ol*mer com%osites, an #6$ !ilament (in in& machines !or %ol*mer com%osites. 7.14 What are !our a -anta&es o! numerical control (hen %ro%erl* a%%lie in machine tool o%erations? Answer: ,he te"t lists the !ollo(in& 11 a -anta&es: #1$ non%ro ucti-e time is re uce , #+$ &reater accurac* an re%eata'ilit*, #3$ lo(er scra% rates, #4$ ins%ection re)uirements are re uce , #3$ more-com%le" %art &eometries are %ossi'le, #6$ en&ineerin& chan&es can 'e accommo ate more &race!ull*, #7$ sim%ler !i"tures are nee e , #7$ shorter manu!acturin& lea times, #:$ re uce %arts in-entor*, #10$ less !loor s%ace re)uire ue to !e(er machines, an #11$ o%erator s0ill re)uirements are re uce . 7.13 What are three isa -anta&es o! im%lementin& NC technolo&*? Answer: =our isa -anta&es are i enti!ie in the te"t: #1$ hi&her in-estment cost 'ecause NC machines are more e"%ensi-e than con-entional machine tools, #+$ hi&her maintenance e!!ort ue to &reater technolo&ical so%histication o! NC, #3$ %art %ro&rammin& is re)uire , an #4$ e)ui%ment utili9ation must 'e hi&h to 2usti!* the hi&her in-estment, an this mi&ht mean a itional (or0 shi!ts are re)uire in the machine sho%. 7.16 1rie!l* escri'e the i!!erences 'et(een the t(o 'asic t*%es o! %ositionin& control s*stems use in NC? Answer: ,he t(o t*%es o! %ositionin& control s*stems use in NC s*stems are o%en loo% an close loo%. An o%en-loo% s*stem o%erates (ithout -eri!*in& that the actual %osition achie-e in the mo-e is the same as the %ro&ramme %osition. A close -loo% s*stem uses !ee 'ac0 measurements to con!irm that the !inal %osition o! the (or0ta'le is the location s%eci!ie in the %ro&ram. 7.17 What is an o%tical enco er, an ho( oes it (or0? Answer: An o%tical enco er is a e-ice !or measurin& rotational s%ee that consists o! a li&ht source an a %hoto etector on either si e o! a is0. ,he is0 contains slots uni!orml* s%ace aroun the outsi e o! its !ace. ,hese slots allo( the li&ht source to shine throu&h an ener&i9e the %hoto etector. ,he is0 is connecte to a rotatin& sha!t (hose an&ular %osition an -elocit* are to 'e measure . As the sha!t rotates, the slots cause the li&ht source to 'e seen '* the %hotocell as a series o! !lashes. ,he !lashes are con-erte into an e)ual num'er o! electrical %ulses. 7.17 With re!erence to %recision in an NC %ositionin& s*stem, (hat is control resolution? Answer: Control resolution is e!ine as the istance se%aratin& t(o a 2acent a ressa'le %oints in the a"is mo-ement. A ressa'le %oints are locations alon& the a"is to (hich the (or0ta'le can 'e s%eci!icall* irecte to &o. 5t is esira'le !or control resolution to 'e as small as %ossi'le. 7.1: What is the i!!erence 'et(een manual %art %ro&rammin& an com%uter-assiste %art %ro&rammin&? Answer: 5n manual %art %ro&rammin&, the %ro&rammer %re%ares the NC co e usin& a lo(-le-el machine lan&ua&e. 5n com%uter-assiste %art %ro&rammin&, the %art %ro&ram is (ritten usin& >n&lish-li0e statements that are su'se)uentl* con-erte into the lo(-le-el machine lan&ua&e. 7.+0 What is %ost%rocessin& in com%uter-assiste %art %ro&rammin&? Answer: /ost%rocessin& con-erts the cutter location ata an machinin& comman s in the C4;A,A !ile into lo(-le-el co e that can 'e inter%rete '* the NC controller !or a s%eci!ic machine tool. ,he out%ut o! %ost%rocessin& is a %art %ro&ram consistin& o! ?-co es, x-, y-, an z-coor inates, S, =, <, an other +4

NC-3e-S 11-14, 14/06, 06/04/07 !unctions in (or a 7.+1 ress !ormat. A uni)ue %ost%rocessor must 'e (ritten !or each machine tool s*stem.

What are some o! the a -anta&es o! CA;/CA<-'ase NC %art %ro&rammin& com%are to com%uter-assiste %art %ro&rammin&? Answer: ,he te"t lists the !ollo(in& a -anta&es o! CA;/CA< NC %art %ro&rammin&: #1$ the %art %ro&ram can 'e simulate o!!-line to -eri!* its accurac*@ #+$ the time an cost o! the machinin& o%eration can 'e etermine @ #3$ the most a%%ro%riate toolin& can 'e automaticall* selecte !or the o%eration@ #4$ the CA;/CA< s*stem can automaticall* insert the o%timum -alues !or s%ee s an !ee s@ #3$ in constructin& the &eometr* or the tool %ath, the %ro&rammer recei-es imme iate -isual !ee 'ac0 on the CA;/CA< monitor@ #6$ the CA; ata'ase containin& the %art esi&n can 'e use to construct the tool %ath rather than re e!inin& the %art &eometr*@ an #7$ some o! the ste%s in the tool %ath construction can 'e automate .

7.++

What is manual ata in%ut o! the NC %art %ro&ram? Answer: <anual ata in%ut is (hen the machine o%erator manuall* enters the %art %ro&ram ata an motion comman s irectl* into the <C. %rior to runnin& the 2o'.

PROBLEMS NC Applications
7.1 A machina'le &ra e o! aluminum is to 'e mille on an NC machine (ith a +0 mm iameter !our-tooth en millin& cutter. Cuttin& s%ee A 1+0 m/min an !ee A 0.007 mm/tooth. Con-ert these -alues to re-/min an mm/re-, res%ecti-el*. Solution: N A

1+0m / min A 1909 9 re!"#in +0#103 $ m / re-

=ee in mm/re- A #4 teeth/re-$#0.07 mm/tooth$ A 0 $% ##"re! 7.+ A cast iron (or0%iece is to 'e !ace mille on an NC machine usin& cemente car'i e inserts. ,he cutter has 16 teeth an is 1+0 mm in iameter. Cuttin& s%ee A +00 m/min an !ee A 0.003 mm/tooth. Con-ert these -alues to re-/min an mm/re-, res%ecti-el*. Solution: N A

+00m / min. A &$0 & re!"#in 1+0#103 $ m / re-

=ee in mm/re- A #16 teeth/re-$#0.03 mm/tooth$ A 0 '0 ##"re! 7.3 An en millin& o%eration is %er!orme on an NC machinin& center. ,he total len&th o! tra-el is 6+3 mm alon& a strai&ht line %ath to cut a %articular (or0%iece. Cuttin& s%ee A +.0 m/s an chi% loa #!ee /tooth$ A 0.073 mm. ,he en millin& cutter has t(o teeth an its iameter A 13.0 mm. ;etermine the !ee rate an time to com%lete the cut. Solution: N A

+.0# 60$ m / min. A +346.3 re-/min 13#103 $ m / reA 1 (7& #in

fr A +346.3 re-/min#+ teeth/re-$#0.073 mm/tooth$ A $'% 0 ##"#in Tm A

B o-ertra-el allo(ance A 1.0 tool iameter A 13 mm. 7.4 A turnin& o%eration is to 'e %er!orme on an NC lathe. Cuttin& s%ee A +.3 m/s, !ee A 0.+ mm/re-, an e%th A 4.0 mm. Wor0%iece iameter A 100 mm an its len&th A 400 mm. ;etermine #a$ rotational s%ee o! the (or0'ar, #'$ !ee rate, #c$ metal remo-al rate, an # $ time to tra-el !rom one en o! the %art to the other. Solution: #a$ N A

6+3 + 13 B 37+.0

+.3# 60$ m / min. A )77 & re!"#in 100#103 $ m / re-.

#'$ fr A 477.3 re-/min#0.+ mm/re-$ A 9& & ##"#in #c$ RMR A -! A +.3 m/s#103$#.+ mm$#4.0 mm$ A %000 ##$"s # $ Tm A 400/:3.3 A ) 1'' #in 7.3 A numerical control rill %ress rills !our 10.0 mm iameter holes at !our locations on a !lat aluminum %late in +3

NC-3e-S 11-14, 14/06, 06/04/07 a %ro uction (or0 c*cle. Althou&h the %late is onl* 1+ mm thic0, the rill must tra-el a !ull +0 mm -erticall* at each hole location to allo( !or clearance a'o-e the %late an 'rea0throu&h o! the rill on the un ersi e o! the %late. Cuttin& con itions: s%ee A 0.4 m/s an !ee A 0.10 mm/re-. 6ole locations are in icate in the !ollo(in& ta'le: 6ole num'er 1 + 3 4 "-coor inate #mm$ +3.0 +3.0 100.0 100.0 *-coor inate #mm$ +3.0 100.0 100.0 +3.0

,he rill starts out at %oint #0,0$ an returns to the same %osition a!ter the (or0 c*cle is com%lete . ,ra-el rate o! the ta'le in mo-in& !rom one coor inate %osition to another is 300 mm/min. C(in& to e!!ects o! acceleration an eceleration, an time re)uire !or the control s*stem to achie-e !inal %ositionin&, a time loss o! 3 s is e"%erience at each sto%%in& %osition o! the ta'le. Assume that all mo-es are ma e so as to minimi9e the total c*cle time. 5! loa in& an unloa in& the %late ta0e +0 s #total han lin& time$, etermine the time re)uire !or the (or0 c*cle. Solution: ;rillin& o%erations: N A

0.4# 60$ A 763.: re-/min 10#103 $

fr A Nf A 763.:#0.10$ A 76.3: mm/min =or each hole, Tm A +0/76.3: A 0.+6+ min Assume retraction o! ril at each hole ta0es an e)ual time. ,otal time/hole A 0.3+4 min =or !our holes, Tm A 4#0.3+4$ A +.0:6 min Wor0%art an a"is s*stem (ith assume tool %ath sho(n in accom%an*in& ra(in&: * #+3,100$ #100,100$

#+3,+3$ #0,0$

#100,+3$ " #100,0$

+3+ + +3+ D 73 D 73 D 73 D +3+ + 100+ A 363.43 mm

,otal istance tra-ele 'et(een %ositions A ,ime to mo-e 'et(een %ositions A

363.43 3# 3$ A 0.:77 min + 300 60

C*cle time A Th D Tm D mo-e time A +0/60 D +.0:6 D 0.:77 A $ )0( #in

Anal*sis o+ Open Loop ,ositionin- S*ste#s

7.6 ,(o ste%%in& motors are use in an o%en loo% s*stem to ri-e the lea scre(s !or "-* %ositionin&. ,he ran&e o! each a"is is +30 mm. ,he sha!t o! the motors are connecte irectl* to the lea scre(s. ,he %itch o! each lea scre( is 3.0 mm, an the num'er o! ste% an&les on the ste%%in& motor is 1+3. #a$ 6o( closel* can the %osition o! the ta'le 'e controlle , assumin& there are no mechanical errors in the %ositionin& s*stem? #'$ What are the re)uire %ulse train !re)uencies an corres%on in& rotational s%ee s o! each ste%%in& motor in or er to ri-e the ta'le at +73 mm/min in a strai&ht line !rom %oint #" A 0, * A 0$ to %oint #" A 130 mm, * A ++0 mm$? Solution: #a$ ta'le %osition can 'e controlle to

3mm A 0 0%) ##. 1+3

#'$ ,ra-el rate o! the ta'le vt A +73 mm/min !rom #x A 0, y A 0$ to #x A 130 mm, y A ++0 mm$. An&le A tan -1#++0/130$ A 3:.4+ ,ra-el rate !or x-a"is A +73 cos 3:.4+ A 13:.: mm/min

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NC-3e-S 11-14, 14/06, 06/04/07 x-a"is motor s%ee N A /ulse rate fp A

13:.:mm / min. A 46.63 re-/min 3mm / re-.

1+3%ulse / re-# 46.63re- / min$ A 97 1& ./ 60s / min.

+36.7mm / min. A 77.:+ re-/min 3mm / re-.

,ra-el rate !or y-a"is A +73 sin 3:.4+ A +36.7 mm/min y-a"is motor s%ee N A /ulse rate fp A 7.7

1+3%ulse / re-# 77.:+re- / min$ A 1() )1 ./ 60s / min.

Cne a"is o! an NC %ositionin& s*stem is ri-en '* a ste%%in& motor. ,he motor is connecte to a lea scre( (hose %itch is 4.0 mm, an the lea scre( ri-es the ta'le. Control resolution !or the ta'le is s%eci!ie as 0.013 mm. ;etermine #a$ the num'er o! ste% an&les re)uire to achie-e the s%eci!ie control resolution, #'$ si9e o! each ste% an&le in the motor, an #c$ linear tra-el rate o! the motor at a %ulse !re)uenc* o! +00 %ulses %er secon . Solution: #a$ Num'er o! ste% an&les n s A #'$ Ste% an&le A

4.0mm / reA +66.67 %(7 pulses"re! 0.013mm / %ulse

360 A 1 $)' +67

60s / min# +00%ulses / s$ A )) 9) re!"#in +67%ulses / re-. 4inear tra-el rate o! machine ta'le A 44.:4 re-/min#4.0 mm/re-$ A 179 ' ##"#in
#c$ <otor s%ee N A 7.7 ,he (or0ta'le in an NC %ositionin& s*stem is ri-en '* a lea scre( (ith a 4 mm %itch. ,he lea scre( is %o(ere '* a ste%%in& motor (hich has +30 ste% an&les. ,he (or0ta'le is %ro&ramme to mo-e a istance o! 100 mm !rom its %resent %osition at a tra-el s%ee o! 300 mm/min. #a$ 6o( man* %ulses are re)uire to mo-e the ta'le the s%eci!ie istance? #'$ What is the re)uire motor s%ee an #c$ %ulse rate to achie-e the esire ta'le s%ee ? Solution: #a$ >). #6.14$: x A pA . 8earran&in&, A A 360x/p A 360#100 mm$/#4.0 mm/re-.$ A :000 360

A 360/+30 A 1.44 Since rg A 1.0, A A Am A np. 8earran&in&, np A Am/ A :000/1.44 A (%&0 pulses.
#'$ Nm A

300mm / min. A 7& re!"#in 4.0mm / re-.

60 f p ns rg A 73 re-/min

#c$ Since rg A 1.0, N A Nm. >). #6.16$: N A 8earran&in&, fp A A $1% & ./ 7.:

A ste%%in& motor (ith +00 ste% an&les is cou%le to a lea scre( throu&h a &ear re uction o! 3:1 #3 rotations o! the motor !or each rotation o! the lea scre($. ,he lea scre( has +.4 threa s/cm. ,he (or0ta'le ri-en '* the lea scre( must mo-e a istance A +3.0 cm at a !ee rate A 73 cm/min. ;etermine #a$ the num'er o! %ulses re)uire to mo-e the ta'le, #'$ re)uire motor s%ee , an #c$ %ulse rate to achie-e the esire ta'le s%ee . Solution: #a$ /itch p A np A 360 xrg p

1 A 4.1667 mm/re-. an A 360/+00 A 1.7 +.4thr s / cm

A A (00000 pulses

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NC-3e-S 11-14, 14/06, 06/04/07 #'$ 4ea scre( N A

730mm / min. A 170 re-/min 4.1667 mm / re-.

<otor s%ee Nm A 3#170$ A 900 re!"#in #c$ fp A 7.10

+00# :00$ ns N m A A $000 pulses"s 60 60

A com%onent insertion machine ta0es +.0 sec to %ut a com%onent into a %rinte circuit #/C$ 'oar , once the 'oar has 'een %ositione un er the insertion hea . ,he x-y ta'le that %ositions the /C 'oar uses a ste%%er motor irectl* lin0e to a lea scre( !or each a"is. ,he lea scre( has a %itch A 3.0 mm. ,he motor ste% an&le A 7.+ e&rees an the %ulse train !re)uenc* A 400 69. ,(o com%onents are %lace on the /C 'oar , one each at %ositions #+3, +3$ an #30, 130$, (here coor inates A mm. ,he se)uence o! %ositions is #0,0$, #+3, +3$, #30, 130$, #0,0$. ,ime re)uire to unloa the com%lete 'oar an loa the ne"t 'lan0 onto the machine ta'le A 3.0 sec. Assume that 0.+3 sec. is lost ue to acceleration an eceleration on each mo-e. What is the hourl* %ro uction rate !or this /C 'oar ? Solution: ns A fp A vt ns rg 60 p

360 A 30 ste%s/re7.+
fp p ns =

. ?i-en rg A 1.0 an rearran&in& the e)uation, vt A

# 400 %uls / s$#3.0mm / re-$ A 40 30 %uls / re-.

mm/s

+3mm A 0.6+3 s 40mm / s 130 +3 ,ime !or mo-e !rom #+3, +3$ to #30, 130$ A A 3.1+3 s 40 130 ,ime !or mo-e !rom #30, 130$ to #0, 0$ A A 3.73 s 40
,ime !or mo-e !rom #0, 0$ to #+3, +3$ A C*cle time Tc A 3.0 D #0.6+3 D 0.+3 D +.0$ D #3.1+3 D 0.+3 D +.0$ D #3.73 D 0.+3$ A 17.+3 s C*cle rate #assume e)ual to %ro uction rate$ Rc A 7.11

60"60 A %0' 7 units"hr. 17.+3

,he t(o a"es o! an x-y %ositionin& ta'le are each ri-en '* a ste%%in& motor connecte to a lea scre( (ith a 4:1 &ear re uction. ,he num'er o! ste% an&les on each ste%%in& motor is +00. >ach lea scre( has a %itch A 3.0 mm an %ro-i es an a"is ran&e A 400.0 mm. ,here are 16 'its in each 'inar* re&ister use '* the controller to store %osition ata !or the t(o a"es. #a$ What is the control resolution o! each a"is? #'$ What are the re)uire the rotational s%ee s an corres%on in& %ulse train !re)uencies o! each ste%%in& motor in or er to ri-e the ta'le at 600 mm/min in a strai&ht line !rom %oint #+3,+3$ to %oint #300,130$? 5&nore acceleration. Solution: #a$ CR1 A p/rgns A 3.0/#4 " +00$ A 0.006+3 mm CR+ A L/#+B E 1$A 400/#+16 E 1$ A 400/63,333 A 0.00610 mm CR A <a"F0.006+3, 0.00610G A 0 00(%& ## #'$ vt A 600 mm/min !rom #+3, +3$ to #300, 130$ x A 300 - +3 A +73 mm, y A 130 - +3 A 1+3 mm An&le A A tan -1#1+3/+73$ A +4.44 vtx A 600 cos +4.44 A 346.++ mm/min Nx A rgvtx/p A 4#346.++$/3.0 A )$( 9' re!"#in fpx A Nxns/60 A 436.:7#+00$/60 A 1)&( ( ' ./ vty A 600 sin +4.44 A +47.+7 mm/min Ny A rgvty/p A 4#+47.+7$/3.0 A 19' ($ re!"#in fpx A Nyns/60 A 1:7.63#+00$/60 A ((% 1 ./

Anal*sis o+ Close1 Loop ,ositionin- S*ste#s

7.1+ A c ser-omotor is use to ri-e one o! the ta'le a"es o! an NC millin& machine. ,he motor is cou%le irectl* to the lea scre( !or the a"is, an the lea scre( %itch A 3 mm. ,he o%tical enco er attache to the lea scre( emits 300 %ulses %er re-olution o! the lea scre(. ,he motor rotates at a normal s%ee o! 300 re-/min. ;etermine #a$ control resolution o! the s*stem, e"%resse in linear tra-el istance o! the ta'le a"is, #'$

+7

NC-3e-S 11-14, 14/06, 06/04/07 !re)uenc* o! the %ulse train emitte '* the o%tical enco er (hen the ser-omotor o%erates at !ull s%ee , an #c$ tra-el rate o! the ta'le at normal r%m o! the motor. Solution: #a$ CR A #'$ fp A nsNm A

3mm / reA 0 01 ## 300%ulse / re-

300%ulse / re- # 300re- / min$ A +300 %ulse/s A %&00 ./ 60s / min.

3mm / re- # +300%ulse / s$#60s / min$ A 1&00 ##"#in 300%ulse / re-

#c$ vt A 60pfp/ns A 7.13

5n /ro'lem 7.3, the a"is corres%on in& to the !ee rate uses a c ser-omotor as the ri-e unit an an o%tical enco er as the !ee 'ac0 sensin& e-ice. ,he motor is &eare to the lea scre( (ith a 10:1 re uction #10 turns o! the motor !or each turn o! the lea scre($. 5! the lea scre( %itch A 3 mm, an the o%tical enco er emits 400 %ulses %er re-olution, etermine the rotational s%ee o! the motor an the %ulse rate o! the enco er in or er to achie-e the !ee rate in icate . Solution: =rom /ro'lem 7.3, fr A 37+ mm/min

10#37+mm / min$ A 7() re!"#in 3mm / re-. #37+mm / min$#400%ulse / re- $ f r ns = fp A A &09 $$ ./ 60 p #60s / min$#3mm / re- $
Nm A rgfr/p A 7.14 ,he (or0ta'le o! an NC machine is ri-en '* a close -loo% %ositionin& s*stem (hich consists o! a ser-omotor, lea scre(, an o%tical enco er. ,he lea scre( %itch A 4 mm an is cou%le irectl* to the motor sha!t #&ear ratio A 1:1$. ,he o%tical enco er &enerates ++3 %ulses %er lea scre( re-olution. ,he ta'le has 'een %ro&ramme to mo-e a istance o! +00 mm at a !ee rate A 430 mm/min. #a$ 6o( man* %ulses are recei-e '* the control s*stem to -eri!* that the ta'le has mo-e the %ro&ramme istance? What are #'$ the %ulse rate an #c$ motor s%ee that corres%on to the s%eci!ie !ee rate? Solution: #a$ x A pn p ns rge . 8earran&in&, np A xns +00mm#++3%ulse / re- $ = A 110%&0 pulses p 4 mm / re-

#'$ fr A

#430mm / min$# ++3%ulse / re- $ A 4+1.773 %ulse/s A )%1 '7& ./ #60s / min$#4 mm / re- $ 430mm / min A 11% & re!"#in 4 mm / re-

#c$ N A fr/p A 7.13

A NC machine tool ta'le is %o(ere '* a ser-omotor, lea scre(, an o%tical enco er. ,he lea scre( has a %itch A 3.0 mm an is connecte to the motor sha!t (ith a &ear ratio o! 16:1 #16 turns o! the motor !or each turn o! the lea scre($. ,he o%tical enco er is connecte irectl* to the lea scre( an &enerates +00 %ulses/re- o! the lea scre(. ,he ta'le must mo-e a istance A 100 mm at a !ee rate A 300 mm/min. ;etermine #a$ the %ulse count recei-e '* the control s*stem to -eri!* that the ta'le has mo-e e"actl* 100 mm@ an #'$ the %ulse rate an #c$ motor s%ee that corres%on to the !ee rate o! 300 mm/min. Solution: #a$ x A p np/ns 8earran&in&, np A xns/p A 100#+00$/3 A )000 pulses #'$ fp A fr ns /60p A 300#+00$/60#3$ A $$$ $ ./ #c$ N A rg fr /p A 16 " 300/3 A 1(00 re!"#in

7.16

Sol-e the %re-ious %ro'lem assumin& the o%tical enco er is irectl* cou%le to the motor sha!t rather than to the lea scre(. Solution:#a$ x A p np/rg ns 8earran&in&, np A rg x ns/p A 16#100$#+00$/3 A ()0000 pulses #'$ fp A rg fr ns /60p A 16#300$#+00$/60#3$ A &$$$ $ ./ #c$ N A rg fr /p A 16 " 300/3 A 1(00 re!"#in

7.17

A lea scre( cou%le

irectl* to a c ser-omotor is use to ri-e one o! the ta'le a"es o! an NC millin& +:

NC-3e-S 11-14, 14/06, 06/04/07 machine. ,he lea scre( has +.3 threa s/cm. ,he o%tical enco er attache to the lea scre( emits 100 %ulses/re- o! the lea scre(. ,he motor rotates at a ma"imum s%ee o! 700 re-/min. ;etermine #a$ the control resolution o! the s*stem, e"%resse in linear tra-el istance o! the ta'le a"is, #'$ !re)uenc* o! the %ulse train emitte '* the o%tical enco er (hen the ser-omotor o%erates at ma"imum s%ee @ an #c$ tra-el s%ee o! the ta'le at ma"imum motor s%ee . Solution: #a$ p A

1 A 0.4 cm A 4.0 mm, +.3threa s / cm

CR A p/ns A 4.0/100 A 0 0) ##

#'$ fp A Nns/60 A 700 re-/min#100 %ulse/re-$$/#60 s/min$ A 1$$$ $ ./ #c$ vt A Np A 700 re-/min#4.0 mm/re-.$ A $%00 ##"#in 7.17 Sol-e the %re-ious %ro'lem onl* the ser-omotor is connecte to the lea scre( throu&h a &ear 'o" (hose re uction ratio A 10:1 #10 re-olutions o! the motor !or each re-olution o! the lea scre($. Solution: #a$ p A

1 A 0.4 cm A 4.0 mm, +.3threa s / cm

CR A p/ns A 4.0/100 A 0 0) ##

#'$ fp A Nns/60rg A 700 re-/min#100 %ulse/re-$$/#10#60 s/min$$ A 1$$ $$ ./ #c$ vt A Np/rg A 700 re-/min#4.0 mm/re-.$/10 A $%0 ##"#in 7.1: A millin& o%eration is %er!orme on a NC machinin& center. ,otal tra-el istance A 300 mm in a irection %arallel to one o! the a"es o! the (or0ta'le. Cuttin& s%ee A 1.+3 m/s an chi% loa A 0.03 mm. ,he en millin& cutter has !our teeth an its iameter A +0.0 mm. ,he a"is uses a c ser-omotor (hose out%ut sha!t is cou%le to a lea scre( (ith %itch A 6.0 mm. ,he !ee 'ac0 sensin& e-ice is an o%tical enco er (hich emits +30 %ulses %er re-olution. ;etermine #a$ !ee rate an time to com%lete the cut, #'$ rotational s%ee o! the motor an #c$ %ulse rate o! the enco er at the !ee rate in icate . Solution: #a$ N A #1.+3 " 103 mm/s$/#+0 mm/re-$ A 1:.7: re-/s. fr A N f nt A 1:.7:#0.03$#4$ A $ 97' ##"s #'$ N A fr /p A #3.:77 mm/s$/#6 mm/re-$ 2 0 (($ re!"s 7.+0 Tm A 300/3.:77 A 7& ) s 2 1 %( #in fp A ns N A +30#0.663$ A 1(& 7& ./

A c ser-omotor ri-es the "-a"is o! a NC millin& machine ta'le. ,he motor is cou%le irectl* to the ta'le lea scre(, (hose %itch A 6.+3 mm. An o%tical enco er is connecte to the lea scre(. ,he o%tical enco er emits 1+3 %ulses %er re-olution. ,o e"ecute a certain %ro&ramme instruction, the ta'le must mo-e !rom %oint #" A 77.3 mm, * A 33.0$ to %oint #" A +3.0 mm, * A 170.0 mm$ in a strai&ht-line tra2ector* at a !ee rate A +00 mm/min. ;etermine #a$ the control resolution o! the s*stem !or the "-a"is, #'$ rotational s%ee o! the motor, an #c$ !re)uenc* o! the %ulse train emitte '* the o%tical enco er at the esire !ee rate. Solution: #a$ CR A p/ns A #6.+3 mm/re-$/#1+3 %ulse/re-$ A 0 0& ## #'$ <o-e !rom #77.3, 33.0$ to #+3.0, 170.0$ at fr A +00 mm/min x A +3.0 - 77.3 A -6+.3, y A 170.0 - 33.0 A 143.0, An&le A A tan -1#143/-6+.3$ A 113.3+ fr A +00 cos 113.3+ A +00#-0.3:37$ A -7:.1: mm/min N A frx/p A #-7:.17 mm/min$/#6.+3 mm/re-$ A 31% (7 re!"#in #c$ fp A nsN/60 A

(1+.67 )(1+3)
60

A %( ) ./

Resolution an1 Accurac* o+ ,ositionin- S*ste#s

7.+1 A t(o-a"is NC s*stem use to control a machine tool ta'le uses a 'it stora&e ca%acit* o! 16 'its in its control memor* !or each a"is. ,he ran&e o! the "-a"is is 600 mm an the ran&e o! the *-a"is is 300 mm. ,he mechanical accurac* o! the machine ta'le can 'e re%resente '* a Normal istri'ution (ith stan ar e-iation A 0.00+ mm !or 'oth a"es. =or each a"is o! the NC s*stem, etermine #a$ the control resolution, #'$ accurac*, an #c$ re%eata'ilit*. Solution: #a$ "-a"is: CR+ A

600 +
16

y-a"is: CR+ A A 0 007( ##

600 A 0 0091 ## 63,336 1

30

NC-3e-S 11-14, 14/06, 06/04/07 #'$ x-a"is: Accurac* A y-a"is: Accurac* A

0.00:1 CR D 3#0.00+$ A 0 010( ## + 3 A + +

0.0076 D 3#0.00+$ A 0 009' ## +

#c$ 8e%eata'ilit* A 3 A 3#0.00+$ A 0 00( ## 7.++ Ste%%in& motors are use to ri-e the t(o a"es o! an insertion machine use !or electronic assem'l*. A %rinte circuit 'oar is mounte on the ta'le (hich must 'e %ositione accuratel* !or relia'le insertion o! com%onents into the 'oar . 8an&e o! each a"is A 700 mm. ,he lea scre( use to ri-e each o! the t(o a"es has a %itch o! 3.0 mm. ,he inherent mechanical errors in the ta'le %ositionin& can 'e characteri9e '* a Normal istri'ution (ith stan ar e-iation A 0.003 mm. 5! the re)uire accurac* !or the ta'le is 0.04 mm, etermine #a$ the num'er o! ste% an&les that the ste%%in& motor must ha-e, an #'$ ho( man* 'its are re)uire in the control memor* !or each a"is to uni)uel* i enti!* each control %osition. CR + 3 A 0.3CR D 3#0.003$ A 0.04 #as s%eci!ie $ + Assume CR A CR1. 0.3CR1 A 0.04 - 0.013 A 0.0+3 mm, CR1 A 0.03 mm p p CR1 A . 8earran&in&, ns A , since rg A 1. ns rg CR1 ns A A (0 steps"re!. Solution: #a$ Accurac* A #'$ 4et CR+ CR1 .CR+ A +B A 14,001 B ln+ A ln 14001 0.6:31 B A :.346:, 7.+3

700mm L L = . 8earran&in&, +B - 1 A A 14,000 %ositions CR+ 0.03mm / ste% + 1

B

A 13.77 1) 4its

8e!errin& 'ac0 to /ro'lem 7.7, the mechanical inaccuracies in the o%en loo% %ositionin& s*stem can 'e escri'e '* a normal istri'ution (hose stan ar e-iation A 0.003 mm. ,he ran&e o! the (or0ta'le a"is is 300 mm, an there are 1+ 'its in the 'inar* re&ister use '* the i&ital controller to store the %ro&ramme %osition. =or the %ositionin& s*stem, etermine #a$ control resolution, #'$ accurac*, an #c$ re%eata'ilit*. # $ What is the minimum num'er o! 'its that the 'inar* re&ister shoul ha-e so that the mechanical ri-e s*stem 'ecomes the limitin& com%onent on control resolution? Solution: #a$ CR1 A p/ns A 4 mm/+30 A 0.016 mm. 300 300 L CR+ A B A 1+ A A 0.1++ mm. + 1 40:3 + 1 CR A <a"FCR1, CR+G A <a"F0.016, 0.1++G A 0 1%% ##. #'$ Accurac* A 0.3 CR D 3 A 0.3#0.1++$ D 3#0.003$ A 0 07( ##. #c$ 8e%eata'ilit* A 3 A 3#0.003$ A 0 01& ## # $ =or mechanical errors to 'e the limitin& !actor in control resolution in this %ro'lem, C81 must A C8+. 300 ,hus, 0.016 A B . 8earran&in&, +B -1 A 300/0.016 A 31,+30 + 1 B ln + A ln 31,+31 0.6:313 B A 10.34:7 B A 14.:3 .se B 2 1& 4its

7.+4

,he %ositionin& ta'le !or a com%onent insertion machine uses a ste%%in& motor an lea scre( mechanism. ,he esi&n s%eci!ications re)uire a ta'le s%ee o! 0.4 m/s an an accurac* A 0.0+ mm. ,he %itch o! the lea scre( A 3.0 mm, an the &ear ratio A +:1 #+ turns o! the motor !or each turn o! the lea scre($. ,he mechanical errors in the motor, &ear 'o", lea scre(, an ta'le connection are characteri9e '* a normal istri'ution (ith stan ar e-iation A 0.00+3 mm. ;etermine #a$ the minimum num'er o! ste% an&les in the ste%%in& motor an #'$ !re)uenc* o! the %ulse train re)uire to ri-e the ta'le at the esire ma"imum s%ee . Solution: #a$ Accurac* A 0.3 CR D 3 : 0.0+ A 0.3 CR D 3#0.00+3$ A 0.3 CR D 0.073 0.0+ - 0.0073 A 0.01+3 A 0.3 CR, CR A 0.0+3 mm Assume CR A CR1 31

NC-3e-S 11-14, 14/06, 06/04/07 CR1 A 0.0+3 A p/#rg ns$ A 3.0/+ns. 8earran&in&, ns A 3/#+ " 0.0+3$ A 100 step an-les #'$ fp A 7.+3 rg vt ns p A +#0.4$#100$/#3.0$

+ #0.4m / s$#100%ulse / re-$ 3#103 $ m / re-

A 1(0000 ./

,he t(o a"es o! an x-y %ositionin& ta'le are each ri-en '* a ste%%in& motor connecte to a lea scre( (ith a 10:1 &ear re uction. ,he num'er o! ste% an&les on each ste%%in& motor is +0. >ach lea scre( has a %itch A 4.3 mm an %ro-i es an a"is ran&e A 300 mm. ,here are 16 'its in each 'inar* re&ister use '* the controller to store %osition ata !or the t(o a"es. #a$ What is the control resolution o! each a"is? #'$ What are the re)uire rotational s%ee s an corres%on in& %ulse train !re)uencies o! each ste%%in& motor in or er to ri-e the ta'le at 300 mm/min in a strai&ht line !rom %oint #30,30$ to %oint #100,+00$? 5&nore acceleration an eceleration. Solution: #a$ CR1 A p/rgns A 4.3/#10 " +0$ A 0.0++3 mm 300 300 L CR+ A B A 16 A A 0.00437 mm 63,333 + 1 + 1 CR A <a"F0.0++3, 0.00437G A 0 0%%& ## #'$ vt A 300 mm/min !rom #30, 30$ to #100, +00$ x A 100 - 30 A 70 mm, y A +00 - 30 A 170 mm, An&le A A tan -1#170/70$ A 67.6+ vtx A 300 cos 67.6+ A 1:0.37 mm/min, Nx A rgvtx/p A 10#1:0.37$/4.3 A )%$ 0( re!"#in fpx A Nx ns/60 A 4+3.06#+0$/60 A 1)1 0% ./ vty A 300 sin 67.6+ A 46+.34 mm/min, Ny A rgvty/p A 10#46+.34$/4.3 A 10%7 )% re!"#in fpx A Ny ns /60 A 10+7.4+#+0$/60 A $)% )7 ./

NC Manual ,art ,ro-ra##inNote: A%%en i" A7 (ill 'e re)uire to sol-e the %ro'lems in this &rou%. 7.+6 Write the %art %ro&ram to rill the holes in the %art sho(n in =i&ure /7.+6. ,he %art is 1+.0 mm thic0. Cuttin& s%ee A 100 m/min an !ee A 0.06 mm/re-. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. Write the %art %ro&ram in the (or a ress !ormat usin& a'solute %ositionin&. ,he %ro&ram st*le shoul 'e similar to >"am%le A7.1. Solution: At the 'e&innin& o! the 2o', the rill %oint (ill 'e %ositione at a tar&et %oint locate at x A 0, y A 0, an z A D 10. ,he %ro&ram 'e&ins (ith the tool %ositione at this tar&et %oint. =ee is &i-en as 0.06 mm/re-. 8otational s%ee o! rill is calculate as !ollo(s: NA

100 A 3173 re-/min 10#103 $

Comments ;e!ine ori&in o! a"es. 8a%i mo-e to !irst hole location. ;rill !irst hole. 8etract rill !rom hole. 8a%i mo-e to secon hole location. ;rill secon hole. 8etract rill !rom hole. 8a%i mo-e to thir hole location. ;rill thir hole. 8etract rill !rom hole. 8a%i mo-e to !ourth hole location. ;rill !ourth hole. 8etract rill !rom hole. 8a%i mo-e to !i!th hole location. ;rill !i!th hole. 8etract rill !rom hole. 8a%i mo-e to si"th hole location. ;rill si"th hole. 8etract rill !rom hole. 8a%i mo-e to tar&et %oint, sto% s%in le rotation. 3+

NC %art %ro&ram co e N001 ?+1 ?:0 ?:+ H0 I0 J010.0@ N00+ ?00 H040.0 I0+3.0@ N003 ?01 ?:3 J-+0.0 =0.06 S3173 <03@ N004 ?01 J010.0@ N003 ?00 I100.0@ N006 ?01 ?:3 J-+0.0 =0.06@ N007 ?01 J010.0@ N007 ?00 H100.0@ N00: ?01 ?:3 J-+0.0 =0.06@ N010 ?01 J010.0@ N011 ?00 H160.0@ N01+ ?01 ?:3 J-+0.0 =0.06@ N013 ?01 J010.0@ N014 ?00 H1+3.0 I060.0@ N013 ?01 ?:3 J-+0.0 =0.06@ N016 ?01 J010.0@ N017 ?00 H+00.0 I040.0@ N017 ?01 ?:3 J-+0.0 =0.06@ N01: ?01 J010.0@ N0+0 ?00 H0 I0 <03@

NC-3e-S 11-14, 14/06, 06/04/07 N0+1 <30@ 7.+7 >n o! %ro&ram, sto% machine.

,he %art in =i&ure /7.+7 is to 'e rille on a turret-t*%e rill %ress. ,he %art is 13.0 mm thic0. ,here are three rill si9es to 'e use : 7 mm, 10 mm, an 1+ mm. ,hese rills are to 'e s%eci!ie in the %art %ro&ram '* tool turret %ositions ,01, ,0+, an ,03. All toolin& is hi&h s%ee steel. Cuttin& s%ee A 73 mm/min an !ee A 0.07 mm/re-. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. Write the %art %ro&ram in the (or a ress !ormat usin& a'solute %ositionin&. ,he %ro&ram st*le shoul 'e similar to >"am%le A7.1. Solution: At the 'e&innin& o! the 2o', the rill %oint (ill 'e %ositione at a tar&et %oint locate at x A 0, y A 0, an z A D 10. ,he %ro&ram 'e&ins (ith the tool %ositione at this tar&et %oint. =ee is &i-en as 0.07 mm/re-. 8otational s%ee s !or the three rill iameters are calculate as !ollo(s: =or the 7 mm rill, N A 73/#7 " 10-3$ A +:74 re-/min =or the 10 mm rill, N A 73/#10 " 10-3$ A +377 re-/min =or the1+ mm rill, N A 73/#1+ " 10-3$ A 1:7: re-/min NC %art %ro&ram co e N001 ?+1 ?:0 ?:+ H0 I0 J010.0@ N00+ ?00 H0+3.0 I0+3.0 ,01@ N003 ?01 ?:3 J-+0.0 =0.07 S+:74 <03@ N004 ?01 J010.0@ N003 ?00 H130.0@ N006 ?01 ?:3 J-+0.0 =0.07@ N007 ?01 J010.0@ N007 ?00 H173.0@ N00: ?01 ?:3 J-+0.0 =0.07@ N010 ?01 J010.0@ N011 ?00 H100.0 I073.0 ,0+@ N01+ ?01 ?:3 J-+0.0 =0.07@ N013 ?01 J010.0@ N014 ?00 H030.0@ N013 ?01 ?:3 J-+0.0 =0.07@ N016 ?01 J010.0@ N017 ?00 H030.0 I073.0 ,03@ N017 ?01 ?:3 J-++.0 =0.07@ N01: ?01 J010.0@ N0+0 ?00 H0 I0 <03@ N0+1 <30@ Comments ;e!ine ori&in o! a"es. 8a%i mo-e to !irst hole location, select 7 mm rill. ;rill !irst hole. 8etract rill !rom hole. 8a%i mo-e to secon hole location. ;rill secon hole. 8etract rill !rom hole. 8a%i mo-e to thir hole location. ;rill thir hole. 8etract rill !rom hole. 8a%i mo-e to !ourth hole location, select 10 mm rill. ;rill !ourth hole. 8etract rill !rom hole. 8a%i mo-e to !i!th hole location. ;rill !i!th hole. 8etract rill !rom hole. 8a%i mo-e to si"th hole location, select 1+ mm rill. ;rill si"th hole. 8etract rill !rom hole. 8a%i mo-e to tar&et %oint, sto% s%in le rotation. >n o! %ro&ram, sto% machine.

7.+7

,he outline o! the %art in the %re-ious %ro'lem is to 'e %ro!ile mille usin& a 30 mm iameter en mill (ith !our teeth. ,he %art is 13 mm thic0. Cuttin& s%ee A 130 mm/min an !ee A 0.073 mm/tooth. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. ,(o o! the holes in the %art ha-e alrea * 'een rille an (ill 'e use !or clam%in& the %art urin& %ro!ile millin&. Write the %art %ro&ram in the (or a ress !ormat (ith ,A1 se%aration an -aria'le (or or er. .se a'solute %ositionin&. ,he %ro&ram st*le shoul 'e similar to >"am%le A7.+. Solution: As state , t(o o! the holes rille in /ro'lem 7.+7 (ill 'e use to clam% the (or0%art !or millin& the outsi e e &es. ,he %art (ill 'e !i"ture so that its to% sur!ace is 40 mm a'o-e the sur!ace o! the machine tool ta'le, an the "-* %lane o! the a"is s*stem (ill 'e e!ine 40 mm a'o-e the ta'le sur!ace. As &i-en, a 30 mm iameter en mill (ith !our teeth (ill 'e use . ,he cutter is assume to ha-e a si e tooth en&a&ement len&th o! 40 mm. ,hrou&hout the machinin& se)uence the 'ottom ti% o! the cutter (ill 'e %ositione +3 mm 'elo( the %art to% sur!ace, (hich corres%on s to z A -+3 mm. Since the %art is 13 mm thic0, this 9 %osition (ill allo( the si e cuttin& e &es o! the millin& cutter to cut the !ull thic0ness o! the %art urin& %ro!ile millin&. Cuttin& s%ee is s%eci!ie as 130 m/min. 8otational s%ee o! the cutter is calculate as N A 130/#30 " 10-3$ A 13:+ re-/min. ?i-en a !ee A 0.073 mm/tooth, !ee rate is calculate as 13:+#4$#0.073$ A 341 mm/min. Cutter iameter ata has 'een manuall* entere into o!!set re&ister 03. At the 'e&innin& o! the 2o', the cutter (ill 'e %ositione so that its center ti% is at a tar&et %oint locate at x A -30, y A -30, an z A D 10. ,he %ro&ram 'e&ins (ith the tool %ositione at this location. NC %art %ro&ram co e N001 ?+1 ?:0 ?:+ H-030.0 I-030.0 J010.0@ Comments ;e!ine ori&in o! a"es. 33

NC-3e-S 11-14, 14/06, 06/04/07 N00+ ?00 J-0+3.0 S13:+ <03@ N003 ?01 ?:4 ?4+ I0 ;03 =341@ N004 ?01 H+00.0@ N003 ?01 I030.0@ N006 ?01 H130.0@ N007 ?17 ?0+ H1+3.0 I073.0 80+3.0@ N007 ?01 H1+3.0 I100.0@ N00: ?01 I0+3.0@ N010 ?01 H0 I030.0@ N011 ?01 I0@ N01+ ?40 ?00 H-030.0 I-030.0 J010.0 <03@ N013 <30@ 7.+: 8a%i to cutter e%th, turn s%in le on. 1rin& tool to startin& *--alue, start cutter o!!set. <ill lo(er %art e &e. <ill ri&ht strai&ht e &e. <ill hori9ontal ste% a'o-e t(o 7 mm holes Circular inter%olation aroun arc. <ill -ertical ste% a'o-e arc. <ill to% %art e &e. <ill an&le e &e at le!t o! %art. <ill -ertical e &e at le!t o! %art. 8a%i mo-e to tar&et %oint, cancel o!!set, s%in le sto%. >n o! %ro&ram, sto% machine.

,he outline o! the %art in =i&ure /7.+: is to 'e %ro!ile mille , usin& a +0 mm iameter en mill (ith t(o teeth. ,he %art is 10 mm thic0. Cuttin& s%ee A 1+3 mm/min an !ee A 0.10 mm/tooth. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. ,he t(o holes in the %art ha-e alrea * 'een rille an (ill 'e use !or clam%in& the %art urin& millin&. Write the %art %ro&ram in the (or a ress !ormat (ith ,A1 se%aration an -aria'le (or or er. .se a'solute %ositionin&. ,he %ro&ram st*le shoul 'e similar to >"am%le A7.+. Solution: As state , the t(o holes (ill 'e use to clam% the (or0%art urin& millin&. ,he %art (ill 'e !i"ture so that its to% sur!ace is 40 mm a'o-e the sur!ace o! the machine tool ta'le, an the "-* %lane o! the a"is s*stem (ill 'e e!ine 40 mm a'o-e the ta'le sur!ace. As &i-en, a +0 mm iameter en mill (ith t(o teeth (ill 'e use . ,he cutter is assume to ha-e a si e tooth en&a&ement len&th o! 30 mm. ,hrou&hout the machinin& se)uence the 'ottom ti% o! the cutter (ill 'e %ositione +0 mm 'elo( the %art to% sur!ace, (hich corres%on s to z A -+0 mm. Since the %art is 10 mm thic0, this 9 %osition (ill allo( the si e cuttin& e &es o! the millin& cutter to cut the !ull thic0ness o! the %art urin& %ro!ile millin&. Cuttin& s%ee is s%eci!ie as 1+3 m/min. 8otational s%ee o! the cutter is calculate as N A 1+3/#+0 " 10-3$ A 1:7: re-/min. ?i-en a !ee A 0.10 mm/tooth, !ee rate is calculate as 1:7:#+$#0.10$ A 3:7 mm/min. Cutter iameter ata has 'een manuall* entere into o!!set re&ister 03. At the 'e&innin& o! the 2o', the cutter (ill 'e %ositione so that its center ti% is at a tar&et %oint locate at x A -30, y A -30, an z A D 10. ,he %ro&ram 'e&ins (ith the tool %ositione at this location. NC %art %ro&ram co e N001 ?+1 ?:0 ?:+ H-030.0 I-030.0 J010.0@ N00+ ?00 J-0+0.0 S1:7: <03@ N003 ?01 ?:4 ?4+ I0 ;03 =3:7@ N004 ?01 H073.0@ N003 ?01 H130.0 I043.0+@ N006 ?01 I070.0@ N007 ?01 H070.0@ N007 ?17 ?0+ H030.0 I100.0 8030.0@ N00: ?01 I1+3.0@ N010 ?01 H0@ N011 ?01 I0 N01+ ?40 ?00 H-030.0 I-030.0 J010.0 <03@ N013 <30@ Comments ;e!ine ori&in o! a"es. 8a%i to cutter e%th, turn s%in le on. 1rin& tool to startin& *--alue, start cutter o!!set. <ill lo(er hori9ontal e &e o! %art. <ill an&le e &e at 33 e&rees. <ill -ertical e &e at ri&ht o! %art. <ill hori9ontal e &e lea in& to arc. Circular inter%olation aroun arc. <ill -ertical ste% a'o-e arc. <ill to% %art e &e. <ill -ertical e &e at le!t o! %art. 8a%i mo-e to tar&et %oint, cancel o!!set, s%in le sto%. >n o! %ro&ram, sto% machine.

NC ,art ,ro-ra##in- in A,T

Note: A%%en i" 17 (ill 'e re)uire to sol-e the %ro'lems in this &rou%. 7.30 Write the A/, &eometr* statements to e!ine the hole %ositions o! the %art in =i&ure /7.+6. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. Solution: /oints are e!ine 10 mm a'o-e %art sur!ace !or con-enience in su'se)uent rillin&.

34

NC-3e-S 11-14, 14/06, 06/04/07

10 dia., 6 holes

P2
100 125 60 40 25

P3

P4

P6 P1 P0
40 100 125 160 200 225

P5

/0 A /C5N,/0, 0, 10.0 /1 A /C5N,/40.0, +3.0, 10.0 /+ A /C5N,/40.0, 100.0, 10.0 /3 A /C5N,/100.0, 100.0, 10.0 /4 A /C5N,/160.0, 100.0, 10.0 /3 A /C5N,/+00.0, 40.0, 10.0 /6 A /C5N,/1+3.0, 60.0, 10.0 7.31 Write the com%lete A/, %art %ro&ram to %er!orm the rillin& o%erations !or the %art ra(in& in =i&ure /7.+6. Cuttin& s%ee A 0.4 m/s, !ee A 0.10 mm/re-., an ta'le tra-el s%ee 'et(een holes A 300 mm/min. /ost%rocessor call statement is <AC65N/;8544, 04. Solution: S%in le s%ee N A 0.4#60$/#10 " 10-3$ A 764 re-/min. See ra(in& in %re-ious solution. /A8,NC /A8, /6.6 ;85445N? <AC65N/ <AC65N/;8544, 04 C4/8N, .N5,S/<< 8><A8K /art &eometr*. /oints are e!ine 10 mm a'o-e %art sur!ace. /0 A /C5N,/0, 0, 10.0 /1 A /C5N,/40.0, +3.0, 10.0 /+ A /C5N,/40.0, 100.0, 10.0 /3 A /C5N,/100.0, 100.0, 10.0 /4 A /C5N,/160.0, 100.0, 10.0 /3 A /C5N,/+00.0, 40.0, 10.0 /6 A /C5N,/1+3.0, 60.0, 10.0 8><A8K ;rill 'it motion statements. 8a%i tra-erse s%ee #8A/5;$ set at 300 mm/min =8C<//0 8A/5; ?C,C//1 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//+ S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//3 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 33

NC-3e-S 11-14, 14/06, 06/04/07 ?C;4,A/0, 0, 30 8A/5; ?C,C//4 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//3 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//6 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//0 S/5N;4/C== =5N5 7.3+ Write the A/, &eometr* statements to e!ine the hole %ositions o! the %art in =i&ure /7.+7. .se the lo(er le!t corner o! the %art as the ori&in in the x-y a"is s*stem. Solution: /oints are e!ine 10 mm a'o-e %art sur!ace !or con-enience in su'se)uent rillin&. See ra(in& 'elo(. /0 A /C5N,/0, 0, 10.0 /1 A /C5N,/+3.0, +3.0, 10.0 /+ A /C5N,/130.0, +3.0, 10.0 /3 A /C5N,/173.0, +3.0, 10.0 /4 A /C5N,/100.0, 73.0, 10.0 /3 A /C5N,/30.0, 73.0, 10.0 /6 A /C5N,/30.0, 30.0, 10.0

125 25

10 dia., 2 holes 12 dia., 1 hole

P5
100 75 50 25

P4

25 rad. 8 dia., 3 holes

P1 P0
25 50 75 100

P6

P2

P3

150

175

200

7.33

Write the A/, %art %ro&ram to %er!orm the rillin& o%erations !or the %art ra(in& in =i&ure /7.+7. .se the ,.88>, comman to call the i!!erent rills re)uire . Cuttin& s%ee A 0.4 m/s, !ee A 0.10 mm/re-., an ta'le tra-el s%ee 'et(een holes A 300 mm/min. /ost%rocessor call statement is <AC65N/,.8;84,0+. Solution: S%in le s%ee N A 0.4#60$/#10 " 10-3$ A 764 re-/min. See ra(in& in %re-ious solution. /A8,NC /A8, /6.6 ;85445N?

36

NC-3e-S 11-14, 14/06, 06/04/07 <AC65N/ <AC65N/,.8;84, 0+ C4/8N, .N5,S/<< 8><A8K /art &eometr*. /oints are e!ine 10 mm a'o-e %art sur!ace. /0 A /C5N,/0, 0, 10.0 /1 A /C5N,/+3.0, +3.0, 10.0 /+ A /C5N,/130.0, +3.0, 10.0 /3 A /C5N,/173.0, +3.0, 10.0 /4 A /C5N,/100.0, 73.0, 10.0 /3 A /C5N,/30.0, 73.0, 10.0 /6 A /C5N,/30.0, 30.0, 10.0 8><A8K ;rill 'it motion statements. 8a%i tra-erse s%ee #8A/5;$ set at 300 mm/min =8C<//0 8A/5; ,.88>,/,01 ?C,C//1 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//+ S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//3 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ,.88>,/,0+ ?C,C//4 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//3 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ,.88>,/,03 ?C,C//6 S/5N;4/764, C4W =>;8A,/0.10, 5/8 ?C;4,A/0, 0, -30 ?C;4,A/0, 0, 30 8A/5; ?C,C//0 S/5N;4/C== =5N5 7.34 Write the A/, &eometr* statements to e!ine the outline o! the %art in =i&ure /7.+7. .se the lo(er le!t corner o! the %art as the ori&in in the x-y a"is s*stem.

37

NC-3e-S 11-14, 14/06, 06/04/07 Solution: . /oints are e!ine +3 mm 'elo( %art u%%er sur!ace to %ro-i e !ull en&a&ement o! cutter.
125 25 10 dia., 2 holes

L5 P4 P9 P10

P3 L4

12 dia., 1 hole 25 rad.

L6
100 75 50 25

P5 L7 P0
25 50 75

C1 P11 L1

L3 P7 P8

P2 L2 P1

8 dia., 3 holes

P6

100

150

175

200

/0 A /C5N,/0, 0, -+3.0 /1 A /C5N,/+00.0, 0, -+3.0 /+ A /C5N,/+00.0, 30.0, -+3.0 /3 A /C5N,/1+3.0, 100.0, -+3.0 /4 A /C5N,/+3.0, 100.0, -+3.0 /3 A /C5N,/0, 30.0, -+3.0 41 A 45N>//0, /1 4+ A 45N>//1, /+ 43 A 45N>//+, /A84>4, 41 44 A 45N>//3, />8/,C, 43 43 A 45N>//3, /4 46 A 45N>//4, /3 47 A 45N>//0, /3 C1 A C58C4>/H4A8?>, 44, I4A8?>, 43, 8A;5.S, +3.0 /41 A /4AN>//0, /1, /3 7.33 Write the com%lete A/, %art %ro&ram to %ro!ile mill the outsi e e &es o! the %art in =i&ure /7.+7. ,he %art is 13 mm thic0. ,oolin& A 30 mm iameter en mill (ith !our teeth, cuttin& s%ee A 130 mm/min, an !ee A 0.073 mm/tooth. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. ,(o o! the holes in the %art ha-e alrea * 'een rille an (ill 'e use !or clam%in& the %art urin& %ro!ile millin&. /ost%rocessor call statement is <AC65N/<544, 06. Solution: S%in le s%ee N A 130/#30 " 10-3$ A 13:+ re-/min. =ee rate fr A 13:+#4$#0.073$ A 341 mm/min. See ra(in& in %re-ious solution. /A8,NC /A8, /6.7 /8C=54> <5445N? <AC65N/ <AC65N/<544, 06 C4/8N, .N5,S/<< 5N,C4/0.01 C.,,>8/30.0 8><A8K /oints are e!ine +3 mm 'elo( %art u%%er sur!ace to %ro-i e !ull en&a&ement o! cutter. /,A8? A /C5N,/-+0.0, -30.0, -+3.0 /0 A /C5N,/0, 0, -+3.0 /1 A /C5N,/+00.0, 0, -+3.0 /+ A /C5N,/+00.0, 30.0, -+3.0 /3 A /C5N,/1+3.0, 100.0, -+3.0 /4 A /C5N,/+3.0, 100.0, -+3.0 /3 A /C5N,/0, 30.0, -+3.0

37

NC-3e-S 11-14, 14/06, 06/04/07 41 A 45N>//0, /1 4+ A 45N>//1, /+ 43 A 45N>//+, /A84>4, 41 44 A 45N>//3, />8/,C, 43 43 A 45N>//3, /4 46 A 45N>//4, /3 47 A 45N>//0, /3 C1 A C58C4>/H4A8?>, 44, I4A8?>, 43, 8A;5.S, +3.0 /41 A /4AN>//0, /1, /3 =8C<//,A8? S/5N;4/13:+, C4W =>;8A,/341, 5/< ?C/,C, 41, ,C, /41, ,C, 47 ?C8?,/41, /AS,, 4+ ?C4=,/4+, /AS,, 43 ?C4=,/43, ,AN,C, C1 ?C=W;/C1, ,C, 44 ?C=W;/44, /AS,, 43 ?C4=,/43, /AS,, 46 ?C4=,/46, /AS,, 47 ?C=W;, 47, /AS,, 41 ?C,C//,A8? S/5N;4/C== =5N5 7.36 Write the A/, &eometr* statements to e!ine the %art &eometr* sho(n in =i&ure /7.+:. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. Solution: /oints are e!ine +0 mm 'elo( %art u%%er sur!ace to %ro-i e !ull en&a&ement o! cutter.

P4

50

L6

P3 L5
30 rad.

125 75

L7

C1

L4

P2 L3

10 dia., 2 holes

25

P0
25 75

L1 P1
150

35 deg.

/0 A /C5N,/0, 0, -+0.0 /1 A /C5N,/73.0, 0, -+0.0 /+ A /C5N,/130.0, 70.0, -+0.0 /3 A /C5N,/30.0, 1+3.0, -+0.0 /4 A /C5N,/0, 1+3.0, -+0.0 41 A 45N>//0, /1 4+ A 45N>//1, A,AN?4, 33 43 A 45N>//+, />8/,C, 41 44 A 45N>//+, /A84>4, 41 43 A 45N>//3, />8/,C, 41 46 A 45N>//4, /3 47 A 45N>//0, /4 C1 A C58C4>/H4A8?>, 43, I4A8?>, 44, 8A;5.S, 30.0 3:

NC-3e-S 11-14, 14/06, 06/04/07 /41 A /4AN>//0, /+, /4 7.37 Write the com%lete A/, %art %ro&ram to %er!orm the %ro!ile millin& o%eration !or the %art ra(in& in =i&ure /7.+:. ,oolin& A +0 mm iameter en mill (ith t(o teeth, cuttin& s%ee A 1+3 mm/min, an !ee A 0.10 mm/tooth. ,he %art is 10 mm thic0. .se the lo(er le!t corner o! the %art as the ori&in in the "-* a"is s*stem. ,he t(o holes in the %art ha-e alrea * 'een rille an (ill 'e use !or clam%in& the %art urin& millin&. /ost%rocessor call statement is <AC65N/<544, 01. Solution: S%in le s%ee N A 1+3/#+0 " 10-3$ A 1:7: re-/min. =ee rate fr A 1:7:#+$#0.10$ A 3:7 mm/min. See ra(in& in %re-ious solution. /A8,NC /A8, /6.: /8C=54> <5445N? <AC65N/ <AC65N/<544, 01 C4/8N, .N5,S/<< 5N,C4/0.01 C.,,>8/+0.0 8><A8K /oints are e!ine +0 mm 'elo( %art u%%er sur!ace to %ro-i e !ull en&a&ement o! cutter. /,A8? A /C5N,/-+0.0, -30.0, -+0.0 /0 A /C5N,/0, 0, -+0.0 /1 A /C5N,/73.0, 0, -+0.0 /+ A /C5N,/130.0, 70.0, -+0.0 /3 A /C5N,/30.0, 1+3.0, -+0.0 /4 A /C5N,/0, 1+3.0, -+0.0 41 A 45N>//0, /1 4+ A 45N>//1, A,AN?4, 33 43 A 45N>//+, />8/,C, 41 44 A 45N>//+, /A84>4, 41 43 A 45N>//3, />8/,C, 41 46 A 45N>//4, /3 47 A 45N>//0, /4 C1 A C58C4>/H4A8?>, 43, I4A8?>, 44, 8A;5.S, 30.0 /41 A /4AN>//0, /+, /4 =8C<//,A8? S/5N;4/1:7:, C4W =>;8A,/3:7, 5/< ?C/,C, 41, ,C, /41, ,C, 47 ?C8?,/41, /AS,, 4+ ?C=W;/4+, /AS,, 43 ?C4=,/43, /AS,, 44 ?C4=,/44, ,AN,C, C1 ?C=W;/C1, ,C, 43 ?C=W;/43, /AS,, 46 ?C4=,/46, /AS,, 47 ?C4=,, 47, /AS,, 41 ?C,C//,A8? S/5N;4/C== =5N5 7.37 Write the A/, &eometr* statements to e!ine the outline o! the cam sho(n in =i&ure /7.37. Solution: . /oints are e!ine 13 mm 'elo( %art u%%er sur!ace to %ro-i e !ull en&a&ement o! cutter. ;e!ine the ori&in o! the a"is s*stem at the 'ottom le!t #shar%$ corner o! the %art.

40

NC-3e-S 11-14, 14/06, 06/04/07

C2
100 rad.

P2

P3
20 rad.

L3

C1
150

C3
20

P4 L4 C4 L5 P0 L1
150

L2 P1

75

/0 A /C5N,/0, 0, -13.0 /1 A /C5N,/73.0, 0, -13.0 /+ A /C5N,/0.0, 130.0, -13.0 /3 A /C5N,/70.0, 130.0, -13.0 /4 A /C5N,/-37.+, 37.7, -13.0 /3 A /C5N,/-10.0, 10.0, -13.0 41 A 45N>//0, /1 C1 A C58C4>/C>N,>8, /+, 8A;5.S, 100.0 C+ A C58C4>/C>N,>8, /3, 8A;5.S, +0.0 C3 A C58C4>/C>N,>8, /4, 8A;5.S, 17.7 C4 A C58C4>/C>N,>8, /3, 8A;5.S, 10.0 4+ A 45N>//1, 85?6,, ,AN,C, C1 43 A 45N>/85?6,, ,AN,C, C+, 85?6,, ,AN,C, C3 44 A 45N>/85?6,, ,AN,C, C3, 4>=,, ,AN,C, C4 43 A 45N>//0, 85?6,, ,AN,C, C4 /41 A /4AN>//1, /4, /3 7.3: ,he outline o! the cam in =i&ure /7.37 is to 'e machine in an en millin& o%eration, usin& a 1+.3 mm iameter en mill (ith t(o teeth. ,he %art is 7.3 mm thic0. Write the com%lete A/, %ro&ram !or this 2o', usin& a !ee rate A 70 mm/min an a s%in le s%ee A 300 re-/min. /ost%rocessor call statement is <AC65N/<544, 03. Assume the rou&h outline !or the %art has 'een o'taine in a 'an sa( o%eration. 5&nore clam%in& issues in the %ro'lem. Solution: See ra(in& in %re-ious solution. /A8,NC /A8, /6.17 /8C=54> <5445N? <AC65N/ <AC65N/<544, 03 C4/8N, .N5,S/<< 5N,C4/0.01 C.,,>8/1+.3 8><A8K /oints are e!ine 13 mm 'elo( %art u%%er sur!ace to %ro-i e !ull en&a&ement o! cutter. /,A8? A /C5N,/-+0.0, -30.0, -+0.0 /0 A /C5N,/0, 0, -13.0 /1 A /C5N,/73.0, 0, -13.0 /+ A /C5N,/0.0, 130.0, -13.0 /3 A /C5N,/70.0, 130.0, -13.0 /4 A /C5N,/-37.+, 37.7, -13.0 /3 A /C5N,/-10.0, 10.0, -13.0 41 A 45N>//0, /1 C1 A C58C4>/C>N,>8, /+, 8A;5.S, 100.0 C+ A C58C4>/C>N,>8, /3, 8A;5.S, +0.0 C3 A C58C4>/C>N,>8, /4, 8A;5.S, 17.7 C4 A C58C4>/C>N,>8, /3, 8A;5.S, 10.0

41

NC-3e-S 11-14, 14/06, 06/04/07 4+ A 45N>//1, 85?6,, ,AN,C, C1 43 A 45N>/85?6,, ,AN,C, C+, 85?6,, ,AN,C, C3 44 A 45N>/85?6,, ,AN,C, C3, 4>=,, ,AN,C, C4 43 A 45N>//0, 85?6,, ,AN,C, C4 /41 A /4AN>//1, /4, /3 =8C<//,A8? S/5N;4/300, C4W =>;8A,/70, 5/< ?C/,C, 41, ,C, /41, ,C, 43 ?C8?,/41, /AS,, 4+ ?C4=,/4+, ,AN,C, C1 ?C=W;/C1, ,AN,C, C+ ?C=W;/43, ,AN,C, C3 ?C=W;/C3, /AS,, 44 ?C=W;/44, ,AN,C, C4 ?C=W;/C4, ,C, 43 ?C=W;, 43, /AS,, 41 ?C,C//,A8? S/5N;4/C== =5N5 7.40 ,he %art outline in =i&ure /7.40 is to 'e %ro!ile mille in se-eral %asses !rom a rectan&ular sla' #outline o! sla' sho(n in ashe lines$, usin& a +3 mm iameter en mill (ith !our teeth. ,he initial %asses are to remo-e no more than 3 mm o! material !rom the %eri%her* o! the %art, an the !inal %ass shoul remo-e no more than + mm to cut the outline to !inal sha%e. Write the A/, &eometr* an motion statements !or this 2o'. ,he !inal %art thic0ness is to 'e the same as the startin& sla' thic0ness, (hich is 10 mm, so no machinin& is re)uire on the to% an 'ottom o! the %art. Solution: Cnl* the &eometr* an motion statements are re)uire . /art &eometr* (ill 'e e!ine (ith /0 as ori&in at %oint o! tear ro% sha%e %art, circle C1 at ri&ht en o! %art, an t(o lines 41 an 4+ lea in& to each si e o! the circle, res%ecti-el*. 4+ (ill 'e on the u%%er si e o! the %art. ,he startin& %asses (ill use lines %arallel to 4+ that are s%ace at 3 mm inter-als a'o-e 4+ an lar&er circles than C1 (ith ra ii at 3 mm inter-als. ,hese a itional lines an circles (ill 'e esi&nate (ith an H to in icate that the* are not elements o! the actual %art sur!ace. Consi erations relate to %art !i"turin& are i&nore . A/, &eometr* statements: .N5,S/<< 8><A8K /oints are e!ine +0 mm 'elo( %art u%%er sur!ace to %ro-i e !ull en&a&ement o! cutter. /,A8? A /C5N,/-+0.0, -30.0, -+0.0 8><A8K =ollo(in& &eometr* elements e!ine the %art outline. /0 A /C5N,/0, 0, -+0.0 /1 A /C5N,/100.0, +3.0, -+0.0 C1 A C58C4>/C>N,>8, /1, 8A;5.S, +3.0 41 A 45N>//0, 85?6,, ,AN,C, C1 4+ A 45N>//0, 4>=,, ,AN,C, C1 8><A8K =ollo(in& &eometr* elements are use to e!ine tool %ath imme iatel* %rior to !inal %ass. /1H A /C5N,/0, -+.0, -+0.0 41H A 45N>//1H, /A84>4, 41 C1H A C58C4>/C>N,>8, /1, 8A;5.S, +7 /+H A /C5N,/0, +.0, -+0.0 4+H A 45N>//+H, /A84>4, 4+ 8><A8K =ollo(in& elements are use to e!ine %reliminar* %asses in u%%er le!t o! sla' an aroun circle. /3H A /C5N,/0, 7.0, -+0.0 /4H A /C5N,/0, 1+.0, -+0.0 /3H A /C5N,/0, 17.0, -+0.0 /6H A /C5N,/0, ++.0, -+0.0 /7H A /C5N,/0, +7.0, -+0.0 /7H A /C5N,/0, 3+.0, -+0.0 /:H A /C5N,/0, 37.0, -+0.0 /10H A /C5N,/0, 4+.0, -+0.0 /11H A /C5N,/0, 47.0, -+0.0 4+

NC-3e-S 11-14, 14/06, 06/04/07 /1+H A /C5N,/0, 3+.0, -+0.0 /13H A /C5N,/0, 33.0, -+0.0 43H A 45N>//0, />8/,C, 41 44H A 45N>//+H, /A84>4, 4+ 43H A 45N>//3H, /A84>4, 4+ 46H A 45N>//4H, /A84>4, 4+ 47H A 45N>//3H, /A84>4, 4+ 47H A 45N>//6H, /A84>4, 4+ 4:H A 45N>//7H, /A84>4, 4+ 410H A 45N>//7H, /A84>4, 4+ 411H A 45N>//:H, /A84>4, 4+ 41+H A 45N>//10H, /A84>4, 4+ 413H A 45N>//11H, /A84>4, 4+ 414H A 45N>//1+H, /A84>4, 4+ 413H A 45N>//13H, 4>=,, ,AN,C, C1H C+H A C58C4>/C>N,>8, /1, 8A;5.S, 3+ C3H A C58C4>/C>N,>8, /1, 8A;5.S, 37 C4H A C58C4>/C>N,>8, /1, 8A;5.S, 40 /41 A /4AN>//0, /1, /13H A/, motion statements: =8C<//,A8? 8><A8K /reliminar* %ass aroun %art. ?C/,C, 41H, ,C, /41, ,C, 43H ?C8?,/41H, ,AN,C, C4H ?C=W;/C4H, /AS,, 413H ?C=W;/413H, /AS,, 43H 8><A8K 1ac0 an !orth %asses %arallel to 4+ to remo-e u%%er le!t %ortion o! sla'. ?C4=,/43H, ,C, 414H ?C4=,/414H, /AS,, 413H ?C=W;/413H, ,C, 413H ?C1ACK/413H, /AS, 43H ?C4=,/43H, ,C, 41+H ?C4=,/41+H, /AS,, 413H ?C=W;/413H, ,C, 411H ?C1ACK/411H, /AS, 43H ?C4=,/43H, ,C, 410H ?C4=,/410H, /AS,, 413H ?C=W;/413H, ,C, 4:H ?C1ACK/4:H, /AS, 43H ?C4=,/43H, ,C, 47H ?C4=,/47H, /AS,, 413H ?C=W;/413H, ,C, 47H ?C1ACK/47H, /AS, 43H ?C4=,/43H, ,C, 46H ?C4=,/46H, /AS,, 413H ?C=W;/413H, ,C, 43H ?C1ACK/43H, /AS, 43H ?C4=,/43H, ,C, 44H ?C4=,/44H, /AS,, 413H ?C=W;/413H, ,AN,C, C3H 8><A8K 8ou&hin& %asses aroun concentric circles. ?C=W;/C3H, /AS,, 41H ?C8?,/41H, ,AN,C, C+H ?C8?,/C+H, /AS,, 413H ?C4=,/413H, ,AN,C, C1H ?C1ACK/C1H, /AS,, 41H 8><A8K <o-e to /,A8? to e"ecute !inal %ass aroun %art %eri%her*. ?C,C//,A8? ?C/,C, 41, ,C, /41, ,C 43H 43

NC-3e-S 11-14, 14/06, 06/04/07 ?C8?,/41, ,AN,C, C1 ?C=W;/C1, /AS,, 4+ ?C=W;/4+, /AS,, 43H ?C,C//,A8? 7.41 ,he to% sur!ace o! a lar&e cast iron %late is to 'e !ace-mille . ,he area to 'e machine is 400 mm (i e an 700 mm lon&. ,he insert-t*%e !ace-millin& cutter has ei&ht teeth an is 100 mm in iameter. ;e!ine the ori&in o! the a"is s*stem at the lo(er le!t corner o! the %art (ith the lon& si e %arallel to the x-a"is. Write the A/, &eometr* an motion statements !or this 2o'. Solution: Cnl* the &eometr* an motion statements are re)uire . Since the ori&in is e!ine at the lo(er le!t corner o! the rectan&ular sla', at x A 0 an y A 0, (e e!ine the sur!ace to 'e cut as the %lane at 9 A 0 %arallel to the "-* %lane. ,he tar&et %oint (ill 'e esta'lishe at x A -60, y A -60, an z A 0. .nits are mm. Cuts (ill 'e ta0en %arallel to the x-a"is at 73 mm inter-als. With a 100 mm iameter cutter, this (ill %ro-i e an o-erla% o! 13 mm !or successi-e %asses 'ac0 an !orth across the %art sur!ace. A/, &eometr* statements: .N5,S/<< /,A8? A /C5N,/-60.0, -60.0, 0 /0 A /C5N,/0, 0, 0 /00 A /C5N,/760.0, -60.0, 0 /14 A /C5N,/0, 73.0, 0 /+4 A /C5N,/0, 170.0, 0 /34 A /C5N,/0, +33.0, 0 /44 A /C5N,/0, 340.0, 0 /34 A /C5N,/0, 4+3.0, 0 /18 A /C5N,/700.0, 73.0, 0 /+8 A /C5N,/700.0, 170.0, 0 /38 A /C5N,/700.0, +33.0, 0 /48 A /C5N,/700.0, 340.0, 0 /38 A /C5N,/700.0, 4+3.0, 0 /41 A /4AN>//0, /34, /38 44 A 45N>//14, /34 48 A 45N>//18, /38 41 A 45N>//14, /18 4+ A 45N>//+4, /+8 43 A 45N>//34, /38 44 A 45N>//44, /48 43 A 45N>//34, /38 A/, motion statements: =8C<//,A8? ?C/,C, 41, ,C /41, ,C, 44 ?C8?,/41, /AS,, 48 ?C4=,/48, ,C, 4+ ?C4=,/4+, /AS,, 44 ?C8?,/44, ,C, 43 ?C8?,/43, /AS,, 48 ?C4=,/48, ,C, 44 ?C4=,/44, /AS,, 44 ?C8?,/44, ,C, 43 ?C8?,/43, /AS,, 48 8><A8K <o-e tool to /,A8? (ithout mo-in& across ne(l* cut sur!ace. 8A/5; ?C,C//00 ?C,C//,A8? 7.4+ Write the A/, &eometr* statements to e!ine the %art &eometr* sho(n in =i&ure /7.4+. Solution: ;e!ine ori&in o! a"is s*stem #0, 0, 0$ as in icate in =i&ure /7.4+. See ra(in& 'elo(. .N5,S/<<

44

NC-3e-S 11-14, 14/06, 06/04/07 /00 A /C5N,/0, 0, 0 /010 A /C5N,/0, 0, -10.0 /013 A /C5N,/0, 0, -13.0 /1 A /C5N,/37.3, -+3.0, 0 /+ A /C5N,/-30.0, -+3.0, 0 /40 A /4AN>//00, /1, /+ /4010 A /4AN>//010, /A84>4, /40 /4013 A /4AN>//013, /A84>4, /40 C1 A C58C4>//013, 8A;5.S, 1+.3 C+ A C58C4>//013, 8A;5.S, 30.0 C3 A C58C4>//013, 8A;5.S, 37.3 /3 A /C5N,/-+3.0, 0, 0 C4 A C58C4>//3, 8A;5.S, 37.3 C3 A C58C4>//3, 8A;5.S, +3.0 C6 A C58C4>//+, 8A;5.S, 1+.3 C7 A C58C4>//1, 8A;5.S, 1+.3 /4 A /C5N,/-+3.0, -+3.0, 0 C7 A C58C4>//4, 8A;5.S, 1+.3 /3 A /C5N,/1+.3, -+3.0, 0 C: A C58C4>//3, 8A;5.S, 1+.3 /6 A /C5N,/-+3.0, -1+.3, 0 /7 A /C5N,/1+.3, -1+.3, 0 41 A 45N>/ /6, /7 4+ A 45N>//+, 4>=,, ,AN,C, C3 43 A 45N>//1, 85?6,, ,AN,C, C3 C10 A C58C4>/HS<A44, 43, ,AN,C, C7, 8A;5.S, 1+.3 C11 A C58C4>/H4A8?>, 4+, ,AN,C, C6, 8A;5.S, 1+.3 44 A 45N>/4>=,, ,AN,C, C4, 4>=,, ,AN,C, C+ 43 A 45N>/4>=,, ,AN,C, C3, 4>=, ,AN,C, C3 46 A 45N>/4>=,, ,AN,C C6, 4>=,, ,AN,C, C4 47 A 45N>/85?6,, ,AN,C, C7, 85?6,, ,AN,C, C+
y 12.5 dia., 3 holes 50.0 rad. y

PL010 PL015 PL025

L4 L5
37.5 rad.

C2 C3
37.5 rad.

C4
25.0 rad.

C5 L2
25

C1 P00

12.5 rad.

P00 L3
x z

P3 C8 P6 L1
25

P010 P015
-z

L6

C11 P2

P7
12.5

C9

C10 L7 P1 C7
12.5 rad. 5 10 15

P4 C6

P5
37.5 87.5

12.5 rad.

Note: P010 & P015 located at P00

7.43

,he %art in =i&ure /7.4+ is to 'e mille , usin& a +0 mm iameter en mill (ith !our teeth. Write the A/, &eometr* an motion statements !or this 2o'. Assume that %reliminar* %asses ha-e 'een com%lete so that onl* the !inal %ass #Lto si9eM$ is to 'e com%lete in this %ro&ram. Cuttin& s%ee A 300 re-./min, an !ee rate A +30 mm/min. ,he startin& sla' thic0ness is 13 mm, so no machinin& is re)uire on the to% or 'ottom sur!aces o! the %art. ,he three holes ha-e 'een %re rille !or !i"turin& in this millin& se)uence. Solution: ,he A/, &eometr* statements are the same as in %re-ious /ro'lem 7.4+. We a 43 a startin& tar&et

NC-3e-S 11-14, 14/06, 06/04/07 %oint /,A8? !or locatin& the cuttin& tool at the 'e&innin& o! machinin&. We assume the cuttin& tool is a !laten mill #no corner ra ius$, an that the (or0%art is !i"ture so that its 'ottom sur!ace is +0 mm a'o-e the machine tool ta'le. ,hat means that the x-y %lane o! the a"is s*stem is 33 mm a'o-e the ta'le sur!ace. ,o accom%lish the %ro!ile millin& o%eration aroun the outsi e %eri%her* o! the %art, (e e!ine a %lane /40+0 'elo( the actual 'ottom sur!ace o! the %art. See ra(in& in %re-ious solution. A/, &eometr* statements: 8><A8K See %re-ious /ro'lem 6.++ !or most &eometr* statements. 8><A8K ,he !ollo(in& &eometr* statements are a e to !acilitate tool %ath motions. /,A8? A /C5N,/0, -30.0, 0 /0+0 A /C5N,/0, 0, -+0.0 /40+0 A /4AN>//0+0, /A84>4, /40 4H0 A 45N>//00, />8/,C, 41 A/, motion statements: 8><A8K ,he %ro!ile millin& o%eration aroun the outsi e %eri%her* (ill 'e accom%lishe !irst. =8C<//,A8? ?C/,C, 41, ,C, /40+0, CN, 4H0 ?C8?,/41, /AS,, C: ?C=W;/C:, ,AN,C, C7 ?C=W;/C7, /AS, 47 ?C=W;, 47, ,AN,C, C+ ?C=W;/C+, /AS,, 44 ?C=W;/44, ,AN,C, C4 ?C=W;/C4, /AS,, 46 ?C=W;/46, ,AN,C, C6 ?C=W;/C6, /AS,, C7 ?C=W;/C7, ,C, 41 ?C=W;/41, /AS,, 4H0 ?C,C//,A8? 8><A8K ,he !ollo(in& statements accom%lish the %oc0etin& o! the insi e sur!aces. ?C/,C, 41, ,C, /4010, CN, 4H0 ?C8?,/C1, /AS,, 41 ?C=W;/C1, /AS, 4H0 ?C=W;/C1, /AS,, 41 ?C=W;/41, /AS,, C: ?C=W;/C:, ,AN,C, C7 ?C1ACK/C7, /AS,, C10 ?C=W;/C10, ,C, 43 ?C=W;/43, /AS,, C3 ?C=W;/C3, ,C, 43 ?C=W;/43, /AS,, C3 ?C=W;/C3, ,C, 4+ ?C=W;/4+, /AS,, C11 ?C=W;/C11, ,AN,C, C6 ?C=W;/C6, CN, C7 ?C4=,/C7, CN, 41 ?C=W;/41, ,AN,C, C1 ?C,C//,A8?

46