JF 504 CAD CAM

1.0 INTRODUCTIONCAD / CAM (computer-aided design and computer-aided manufacturing) is a term that refers to computer systems that are used to both design and manufacture products. While CAD is the use of computer technology for the process of design and design-documentation, CAD / CAM systems are used both for designing a product and for controlling manufacturing processes. The geometries in the CAD drawing are used by the CAM portion of the program to control a machine that creates the exact shape that was drawn. CAD / CAM software is most often used for product development, machine-tooling and manufacturing. Since the introduction of Autodesk AutoCAD software in 1982, Autodesk has been a leader in the development of CAD design software. The Autodesk Developer Network (ADN) offers a variety of CAM tools that work with AutoCAD and Autodesk Inventor software. With over 1,000 Partners for AutoCAD alone, ADN offers a full range of manufacturing partnered products. The CAM Industry is an important part of the manufacturing market, and Autodesk has partnered with the leading players to provide customers access to the tools they need. AutoCAD is fully interoperable with manufacturing products such as: EdgeCAM or InventorCAM, GibbsCAM and MasterCAM.Autodesk Inventor software is a useful tool to help with your CAD / CAM projects. It provides a comprehensive set of 3D modeling and mechanical design tools for producing, validating, and documenting complete digital prototypes. The Inventor model is a 3D digital prototype that helps you visualize, simulate, and analyze how a design will work under real-world conditions before a product or part is ever built - helping manufacturers get to market faster with fewer physical prototypes and more innovative products.A milling machine is a machine tool used to machine solid materials. Milling machines are often classed in two basic forms, horizontal and vertical, which refers to the orientation of the main spindle. Both types range in size from small, bench-mounted devices to room-sized machines. Unlike a drill press, which holds the workpiece stationary while cutting as the drill moves axially to penetrate the material, milling machines also move the workpiece radially against the rotating milling cutter, which cuts on its sides as well as its tip.Workpiece and cutter movement are precisely controlled to less than 0.001 in (0.025 mm), usually by means of precision ground slides and leadscrews or analogous technology. Milling machines may be manually operated, mechanically automated, or digitally automated via computer numerical control.Milling is a machining operation in which a workpiece is given the desired shape by the action of a rotating cutter, while the workpiece performs linear movements. In its simplest form the milling cutter is a circular disc whose rim is provided with specially shaped teeth (cutting edges). The cutters are of many different kinds and shapes. The work is fed against the teeth of the cutter, while the feed motion is longitudinal, transverse or vertical, depending on the type of milling machine and the nature of the work. Milling machines are of the horizontal or vertical type.Milling machines can perform a vast number of operations, from simple (e.g., slot and keyway cutting, planing, drilling) to complex (e.g., contouring, diesinking). Cutting fluid is often pumped to the cutting site to cool and lubricate the cut and to wash away the resulting swarf.Today many CNC milling machines are computer controlled vertical mills, and have the ability to move the spindle vertically along the Z axis. In CNC milling and turning, end to end component design is automated using CAD/CAM programs. The program is put into the lathe or milling machine and the machine is then ready for production. Some machined components will generally require a number of different tooling applications such as drilling, reaming and tapping etc, and most modern machines will combine tools within a single cell. This cell will move or rotate to apply the required tooling application, and this will also be controlled by the CNC system. With todays modern and complex machines, the machined part or workpiece can be moved from machine to machine automatically with the use of computer controlled robots, or human intervention, but in either case the steps needed to produce any part is highly automated and the finished part will closely match the CAD design.CNC machines were first built in the 1940s and were programmed by using paper tape with holes punched into it at specific points. These early systems were soon overtaken with the augmentation of analogue and digital computers.

Picture 1: CNC Milling MachinesA CNC Mill works much the way a regular mill does. A solid block of material is secured to a table. The mill then cuts away undesired material until only the object remains.The difference between a regular mill and a CNC mill is that a computer controls each and every motion of the mill. Code can either be written or programmed from a CAD file, and this code controls the X,Y, and Z components of the mill. Additionally, the code can command the mill to switch between different milling bits, drill holes, etc. All the human has to do is bolt the block of material to the table, load the code onto the mill, and watch. Different mills work different ways. Some mills have the drill bit move over the stationary block of material. Other mills feature a stationary drill bit, with the table securing the block moving in the X,Y, and sometimes Z planes. Finally, most mills have 3 axes (X, Y, Z), but some more expensive mills now feature 5 axes (X, Y, Z, pan, and tilt).Computer Numerical Control (CNC) Milling is the most common form of CNC. CNC mills can perform the functions of drilling and often turning. CNC Mills are classified according to the number of axes that they possess. Axes are labeled as X and Y for horizontal movement, and Z for vertical movement, as shown in this view of a manual mill table. A standard manual light-duty mill (such as a Bridgeport) is typically assumed to have four axes:1. Table X2. Table Y.3. Table Z4. Milling Head ZThe number of axes of a milling machine is a common subject of casual "shop talk" and is often interpreted in varying ways. We present here what we have seen typically presented by manufacturers. Afive-axisCNC milling machine has an extra axis in the form of a horizontal pivot for the milling head, as shown below. This allows extra flexibility for machining with the end mill at an angle with respect to the table. Asix-axisCNC milling machine would have another horizontal pivot for the milling head, this time perpendicular to the fifth axis..

Picture 2: CNC Milling Machines Process

CNC milling machines are traditionally programmed using a set of commands known asG-codes. G-codes represent specific CNC functions in alphanumeric format.Table 1 : Preparatory commands (G-code)

G00Point-to-point positioning

G01Linear interpolation

G02Clockwise circular interpolation

G03Counter-clockwise circular interpolation

G04Dwell

G05Hold

G33Thread cutting, constant lead

G40Cancel tool nose radius compensation

G41Tool nose radius compensation - left

G42Tool nose radius compensation - right

G43Cutter length compensation

G44Cancel cutter length compensation

G70Dimensions in inches

G71Metric dimensions

G90Absolute dimensions

G91Incremental dimensions

G92Datum offset

Table 2 : Miscellaneous commands (M-code)

M00Program stop

M01Optional stop

M02End of program

M03Spindle start clockwise

M04Spindle start counter-clockwise

M05Spindle stop

M06Tool change

M07Mist coolant on

M08Flood coolant on

M09Coolant off

M10Clamp

M11Unclamp

M13Spindle clockwise, coolant on

M14Spindle counter-clockwise, coolant on

M30End of tape, rewind

1.1Types of Milling Machines Milling machines are among the most versatile and useful machine tools due to their capabilities to perform a variety of operations. They can be broadly classified into the following types: Column and knee type of milling machines Bed type Rotary table Tracer controlled Computer Numerical Control(CNC) MachinesTable 3 : Types of Milling MachinesTypesEvidence

Column and knee type of milling machines

Bed type

Rotary table

Computer Numerical Control(CNC) Machines

Used for general purpose milling operations, column and knee type milling machines are the most common milling machines. The spindle to which the milling cutter is may be horizontal (slab milling) or vertical (face and end milling). In bed type machines, the work table is mounted directly on the bed, which replaces the knee, and can move only longitudinally. These machines have high stiffness and are used for high production work. Rotary table machines are similar to vertical milling machines and are equipped with one or more heads to do face milling operations. Various milling machine components are being replaced rapidly with computer numerical control(CNC) machines. These machine tools are versatile and are capable of milling, drilling, boring and tapping with repetitive accuracy.

2.0TOOLS / MATERIALS

2.1Edgecam Software

Edgecam is an industry leading solution for all your production machining needs. Applications include prismatic and 3D milling, complex multi-axis turning, mill/turn, rotary and multi-plane milling and family of parts machining. Innovative solutions for a more productive and profitable machine shop are supplied. These include excellent toolpath simulation, a unique wizard approach to post processing, a comprehensive tooling database, intuitive and flexible machine tool communications and a web-enabled job management system.

Edgecam is designed to cope with programming the simplest to the most complex components and offers full support for the latest CAD, machine tool and tooling technology.

Picture 3: Edgecam Production Milling

2.1.1Production Milling

Edgecamprovides the production machine shop with a wide range of flexible milling cycles. Machining efficiency is maximized on simple and complex prismatic parts as well as those incorporating sculptured surface geometry. With Edgecam you get prismatic machining combined with powerful 3D solid and surface machining strategies, all in one complete solution.2.1.24- and 5-Axis Simultaneous Machining

Edgecam 4 and 5-Axis milling products are designed to meet the production machining requirements of industries such as aerospace, automotive, medical and oil & gas. 4- and 5-Axis simultaneous machining offers key advantages over conventional indexed 3-Axis machining :

Reduced cycle time by machining complex components using a single setup. In addition to time savings improved accuracy can also be achieved as the potential for positioning errors between setups is eliminated. Improved surface finish and extended tool life by tilting the tool to maintain the optimum tool to part contact point at all times. Improved access to undercuts and deep pockets through tilting the tool or component allows shorter series tooling to be employed, further improving the surface finish and eliminating the need for secondary setups.

The ability to machine complex parts from solid that would previously have to be cast. This approach is highly beneficial for prototypes and small volume runs and is particular applicable with the latest Mill/Turn machines.

Edgecam provides the production machine shop with a wide range of flexible milling Operations and Cycles. Milling Operations allow the user to quickly produce a basic toolpath via a simple text and picture driven dialog box. An intuitive interface guides the user through a series of machining decisions. Ideal for irregular or novice programmers.

Underpinning Edgecams Operations is a full and comprehensive suite of Milling Cycles. Each cycle offers the very best that technology can offer thus allowing the modern day machinist to achieve total toolpath control.

Edgecams advanced roughing cycle for the machining of both 2D and 3D component parts can be applied to the complete model, providing consistent performance on all types of model. Laced, concentric and spiral machining strategies can be implemented as well as bottom to top intermediate slicing between Z-levels. This intelligent cycle automatically applies the most efficient approach move for each region of the model and creates trochoidal moves to avoid full width cuts. The ability to define 3D stock reduces machining time by eliminating air cutting.

Edgecams roughing cycle also incorporates rest roughing, where stock is automatically defined by the preceding roughing cycle, so the smaller tool only creates a toolpath in the areas that the larger tool could not access.

Within the inclusion of Prismatic and High Speed cornering controls, EdgeCAM offers the user total control over their NC output allowing consistent and accurate programming.

2.1.3Definition Of CAD-CAMComputer Aided Design - CAD

CAD is technology concerned with using computer systems to assist in the creation, modification, analysis, and optimization of a design. Any computer program that embodies computer graphics and an application program facilitating engineering functions in design process can be classified as CAD software.

The most basic role of CAD is to define the geometry of design a mechanical part, a product assembly, an architectural structure, an electronic circuit, a building layout, etc. The greatest benefits of CAD systems are that they can save considerable time and reduce errors caused by otherwise having to redefine the geometry of the design from scratch every time it is needed.

Computer Aided Manufacturing - CAM

CAM technology involves computer systems that plan, manage, and control the manufacturing operations through computer interface with the plants production resources. One of the most important areas of CAM is numerical control (NC). This is the technique of using programmed instructions to control a machine tool, which cuts, mills, grinds, punches or turns raw stock into a finished part. Another significant CAM function is in the programming of robots. Process planning is also a target of computer automation.

Computer Numerical Control - CNC

CNC is one in which the functions and motions of a machine tool are controlled by means of a prepared program containing coded alphanumeric data. CNC can control the motions of the workpiece or tool, the input parameters such as feed, depth of cut, speed, and the functions such as turning spindle on/off, turning coolant on/off.

2.2CAD/CAM And The New Environment

3.0STEPS OF WORK

3.1Design Mode

1. Please refer accordingly the specification from drawings

2. Please click the displays icon for line dialog and choose polyline type to start your drawing

3. Please key in the coordinates X50Y50, X-50Y50, X-50Y-50, X50Y-50 and X50Y50 into the provided design box

4. Please click the radius arc type from the line dialog icon

5. Please key in the coordinates X30Y30, X-30Y30, X-30Y-30 and X30Y-30 to create a center of hole

6. Please re-click the icon of arc radius and set a size of holes radius

7. Pick the arc icon and set up the radius of arc @ fillet.

8. Please click the isometric view icon and also click the stock icon

9. Please ensure your screen was displayed the isometric view after you set up the stock

10. Please click the machinning sequence icon at the right top side and set up a sequence name and machine tools

11. Please ensure your file name was displayed at instruction area

12. Please click the face mill icon and follow the next command was appeared at bottom command box

13. Please highlight all the area you requre to do the face mill

14. Set up the face mill tools

15. Please click the simulate machining icon to view the movement of milling process

16. Your screen was displayed the product after milling

17. Please click the roughing operation icon and set up the center of hole for drilling process (roughing)

18. Please choose the drill bit for your drilling process

19.Please click the simulated machining icon

20. Your screen was displayed the product after drilling process

21. Please re-click the roughing operation icon and setup the center holes for drilling process (finishing).

22. Screen was displayed the product after drilling process (finishing)

23. Please click profiling operation icon and follow the command given at bottom side

24. Please highlight all the fillet line

25. Please ensure the arrow in clockwise direction

26. Please highlight the surrounding line of product (model)

27. Please choose the suitable tools for profiling operation

28. Please follow accordingly the instruction and click the simulate machining icon

29. Screen was displayed the product after cut off the fillet

30. Please click the generate code icon

31. Key in the CNC name and Job name

32. Key in the program ID number and click OK

33. G CODE data was appeared on screen

34. End of G CODE data was appeared

4.0CONCLUSION

Alternative to older mainframe- and workstation based systems. Faster and more complex software could be run on Unix.Standardization of software.CAD voice control (CVC).Hologram Technology in CAD-CAM.Traditionally, CAM has been considered as anumerical control(NC) programming tool, wherein two-dimensional (2-D) or three-dimensional (3-D) models of components generated inCADsoftware are used to generateG-codeto drive computer numerically controlled (CNC) machine tools. Simple designs such as bolt circles or basic contours do not necessitate importing a CAD file.PC as input for CNC machine very dominant role in the performance of CNC machines. CNC machines are used to do things work with a high level of difficulty required PC with high performance.Although the last seven years nothing revolutionary happened in the CAD tools,the softwares vendors support that in the short run many things will change the way of the mechanical design. The CAD in the future will be more easy to use and learn, and geared to enhanceconcept design and construction planning, will be functional and powerful enough to satisfy the needs of engineering design and integration of all disciplines, and corporate functions, sectors and levels. It will be more than 2D drawings and more than 3D models, it has to handle Object and Symbolic Data with same ease. It will be a 4D (3D +time) modelling tool for better planning and scheduling. It will allow designers to exploit the best advantages of each CAD Technology 2D -> 3D -> 4D,to progressively refine the design until fully satisfying the customers' needs. It will be efficient to store, locate, visualize, and re-use data for integration of proven designs, and standard parts and equipment. It will enhance simultaneous(collaborative and concurrent) and distributed engineering eliminating all barriers that constrain communications. It will share one "data factory" that creates dataneeded by all disciplines.

5.0REFERENCESBuku :7.2 John Stark, What Every Engineer Should Know About Practical CAD/CAM Applications, Marcel Dekker Inc., New York, 1986.

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