Computer Controlled Cutting of wooden object

Aim: Computer controlled Cutting for wooden Object

Objective:

1. To generate CAM toolpath for 2D profile to cut on CNC Router

2. To simulate toolpath and cutting parameters

Theory:

Utilization of computers in manufacturing applications has proved to be one of the most

significant developments over the last couple of decades in helping to improve the productivity
and efficiency of manufacturing systems.

What is Metal cutting operation?

The metal cutting operations (also called machining) is one of the most important
manufacturing processes in industry today, Machining is the removal of materials in forms of
chips from the workpiece by shearing with a sharp tool.

What are the main functions of Machine tool?

The main function of a machine tool is to control the workpiece-cutting tool positional
relationship in such a way as to achieve a desired geometric shape of the workpiece with
sufficient dimensional accuracy.

Machine tool provides:

 work holding
 tool holding
 relative motion between tool and workpiece
 Primary motion -cutting motion & cutting speed.
 secondary motion-feed motion and feed rates

CLASSIFICATION OF MACHINE TOOLS

Singlepoint cutting Tools Multipoint cutting Tools Abrasive Tools

Lathe Machine Drilling Machines Grinding Machines

Shaper Machines Milling Machines Honing Machines

Planer Machines Broaching Machine

Boring Machines Hobbing Machines

Numerical Control (NC) and Computer numerical control (CNC) Numerical control refers
to the operation of machine tools from numerical data. Data for the operations may be stored
on paper tape, magnetic tape, magnetic disks, etc. Because numerical information is used,
the concept is called numerical control. Numerical control is the operation of machine tools
and other processing machines by a series of coded instructions. With a built-in computer
controlling the machine tool functions and the system is known as computer numerical control
(CNC).

Figure:

A typical numerical control machine tool system contains three basic components:

1. A program, that is, a set of instructions

2. A machine control unit (MCU)
3. The machine tool.

In the NC system, all the information which is required for producing a component, viz.
dimensional information. speed, feed, and cutting speed is stored in the coded form as a part
program.

The MCU is further divided into two elements: The data processing unit (DPU) and control
loops unit (CLU). The DPU processes the coded data read from the tape or other storage
media and passes information on (i) the position of each axis, (ii) required direction of motion,
(iii) speed, feed, and (iv) auxiliary function control signals to CLU. For example, a typical part
program may contain an instruction

X + 100, Y + 50, S + 90

This instruction is interpreted as: to move by a distance of 100 mm in the X-positive direction,
50 mm in the Y-positive direction and rotate the spindle at 90 rpm clockwise. These information
pieces are decoded by the DPU and sent to CLU.

The CLU operates the drive mechanisms of the machine to move the table in X and Y
directions, and to rotate the spindle as specified. Then it receives feedback signals concerning
the actual position and velocity of each of the axes, and signals for completion of the operation.
When execution of one line (instruction) as noted by the CLU is complete, another instruction
is read. A data processing unit consists of some or all of the following parts:

 Data input device such as a paper tape reader, magnetic tape reader, etc.
 Data reading circuits and parity checking logic
 Decoding circuits for distributing data among the controlled axes
 An interpolator, which supplies machine-motion commands between data points for
tool motion.
 A control loops unit, on the other hand, consists of the following:
 Position control loops for all the axes of motion, where each axis has a separate control
loop
 Velocity control loops, where feedback control is required
 Deceleration and backlash take up circuits
 Auxiliary functions control, such as coolant on/off, gear changes, spindle on/off control.
Geometric and kinematics data are fed from the DPU to the CLU. The CLU then governs the
physical system based on the data received from the DPU. Processing equipment is the third
basic component of the NC system. It is the machine tool that performs the useful work. The
machine tool is designed or modified to be controlled, operated, and interfaced with the Control
Loop Unit (CLU).

Advantages of NC system

NC systems offer several advantages over the conventional manufacturing methods. These
are:

1. High machine utilization

2. Need for special tooling is mostly eliminated
3. High quality products can be manufactured
4. Consistency in quality
5. Quality is not dependent on the operator's skill
6. Lesser production cost per unit
7. Reduced scrap
8. Reduced in-process inventory
9. Higher productivity
10. Reduced set-up time.

Disadvantages of 'NC system

1. Very high initial investment on specialized equipment

2. Redundancy of labour
3. Downtime of NC is highly expensive
4. Special skill is required for programming and operating equipment.

Comparison between conventional machines and NC machines

1. The NC machine differs from a conventional machine in many ways. Different aspects
of the two are compared here.
2. New NC machines cost around two to five times more than the similar capacity
conventional machines, depending upon the sophistication of the control system and
the size of the machine.
3. Conventional machines require a high order of skill and trained personnel to operate
to produce complex contours.
4. The machine hour rate is generally higher for the NC machines or the down time of
these machines is very costly.
5. Maintenance of NC machine is costlier than the conventional machine.
6. The production rate of NC machines is higher than that of the conventional machines
and they can produce complicated profiles consistently with good accuracy.
7. NC machines require special tooling. Because, these machines are designed to
operate at the very high operating conditions (today, NC machines are capable of
operating at 50,000 rpm) Tools made from carbon tool steel and HSS cannot be used
at such a high speed.
8. Use of automatic tool changers to change the tool automatically and simultaneous
machining by multiple tools are the features available with high-end NC machines.
These features help to reduce down time set-up time.

Coordinate systems and Program Zero Point

To describe the geometry of a workpiece for NC programming, we use coordinate systems
with X-, Y- and Z-axes. The origin of the frame and the alignment of the axes are chosen in
such a way that any point on the workpiece can be defined by naming its X, Y and Z coordinate
values. A coordinate frame attached to the corner of a prism is shown in Fig.2. The directions
of X, Y, Z axes illustrated in Fig. 2 are treated as the positive directions and the movement of
the tool in the opposite direction is treated as negative.

The point of intersection of the three axes (the origin) is called zero point. A point at a distance
60 mm from the zero point in positive X direction and 30 mm in positive Y direction is denoted
as: X + 60, Y + 30 and a point 10 mm below the top surface at the above location is denoted
as: X + 60, Y + 30, Z - 10 It is also possible that we can locate the origin of another coordinate
frame anywhere in the workpiece. This new origin of frame is called program zero point. All
coordinate values in the program may be referred relative to the program zero point. The
different locations of program zero point are illustrated in Fig. 3

With a program zero point at the lower left corner of a workpiece, the coordinate values of X
+ 50, Y + 60, Z + 30, for example, would mean that the tool is required to move to a point
located 50 mm away from the program zero point in positive X direction, 60 mm away in
positive Y direction and 30 mm away in positive Z direction. This is shown in Fig.4
Classification of Numerical Control Machines.

Numerical control machines can be generally classified using the following categories:

1. Type of motion
2. Programming method
3. Control system

Type of motion According to the type of motion, NC machines can be classified as:

1. Point-to-point systems
2. Contouring or continuous systems

Point-to-point systems in case of point-to-point (PTP) motion machine tool, the cutting tool
moves to a numerically defined location, the motion is stopped and the task is performed. After
completing the task, the tool moves to the next point and the cycle is repeated. In a PTP
system, the path of movement of the tool and its velocity, when the tool moves from one point
to another, is of no significance.

Contouring or continuous systems The tool has to move in a predetermined path in the
case of contouring or continuous systems. For example, consider the component ABCD, as
shown in Fig. 5 (b), to be cut from the material. To manufacture this component, the tool has
to move in a predefined contour (path) A-B-C-D. The intermediate points of the contour are
obtained by interpolator, which is contained in DPU of the processing systems. That is, while
moving from A to B (or B to A) in Fig. 5 (b) we just need to input the coordinates of points A
and B, then define whether these points A and B are joined by a straight line or an arc then
interpolator automatically calculates all the intermediate points between A and B and
accordingly gives the signal such that the tool is moved in the respective path.

Programming method According to programming method used, NC system can be

classified into two categories as:

1. Absolute positioning

2. Incremental positioning (or Chain positioning)

Absolute positioning

In absolute positioning, the coordinates of the target point are defined with respect to a fixed
program zero point. Absolute dimensions tell the control to what point the tool is to move,
regardless of its current position. Figure 6 shows absolute positioning for point B,
irrespective of whether the tool was at A or at C. It can be observed from Fig. 6 that all the
values are based on the program zero point. The positional command for the tool to reach
point B would be X + 70, Y + 30

Contouring or continuous systems The tool has to move in a predetermined path in the
case of contouring or continuous systems. For example, consider the component ABCD, as
shContouring or continuous systems The tool has to move in a predetermined path in the
case of contouring or continuous systems. For example, consider the component ABCD, as
shown in Fig. 5 (b), to be cut from the material. To manufacture this component, the tool has
to move in a predefined contour (path) A-B-C-D. The intermediate points of the contour are
obtained by interpolator, which is contained in DPU of the processing systems. That is, while
moving from A to B (or B to A) in Fig. 5 (b) we just need to input the coordinates of points A
and B, then define whether these points A and B are joined by a straight line or an arc then
interpolator automatically calculates all the intermediate points between A and B and
accordingly gives the signal such that the tool is moved in the respective path.

Programming method According to programming method used, NC system can be classified

into two categories as:

1. Absolute positioning
2. Incremental positioning (or Chain positioning)

Absolute positioning

In absolute positioning, the coordinates of the target point are defined with respect to a fixed
program zero point. Absolute dimensions tell the control to what point the tool is to move,
regardless of its current position. Figure 6 shows absolute positioning for point B, irrespective
of whether the tool was at A or at C. It can be observed from Fig. 6 that all the values are
based on the program zero point. The positional command for the tool to reach point B would
be X + 70, Y + 30

own in Fig. 5 (b), to be cut from the material. To manufacture this component, the tool has to
move in a predefined contour (path) A-B-C-D. The intermediate points of the contour are
obtained by interpolator, which is contained in DPU of the processing systems. That is, while
moving from A to B (or B to A) in Fig. 5 (b) we just need to input the coordinates of points A
and B, then define whether these points A and B are joined by a straight line or an arc then
interpolator automatically calculates all the intermediate points between A and B and
accordingly gives the signal such that the tool is moved in the respective path.

Incremental positioning

Incremental or chain positioning tells the control by what amount the tool is to move from its
present position. The present position of the tool acts as the program zero point. Chain
positioning for point B from point A and from point C are shown in Figs. 7 and 7(b),
respectively. Each coordinate value is based on the end point of the previous location. The
positional command for the tool to reach B from A would be X + 50, Y + 20 and to reach B
from C would be X + 30, Y – 10.

Procedure:

1. Select wood size and thickness

 2. Click "submit" button
3. Click on given shape symbol
4. Set the parameters of selected shape. e.g. set Radius/Diameter of circle and select
the anchor points/ XY origin offset
5. Click "Submit" button
6. Select cutting direction of tool e.g. Clockwise/Anticlockwise
7. Click "Start Cutting" button to see the cutting process of wood
8. Click "Reload" button to seee process of cutting for other shapes

Conclusion: