PowerPoint to accompany Technology of Machine Tools 6th Edition Krar • Gill • Smid CAD/CAM Unit 79 Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 79-2 Objectives • Define CAD and CAM • Explain the purposes of solid modeling • Know the differences between Cadworthy and Camworthy • Describe process chaining and list the steps in the process • State the purposes of pocket, contour, drill, and surface toolpaths 79-3 CAD/CAM • Marriage of computerized forms of drafting/design and manufacturing – Computer graphics is CAD part – NC is CAM part • Covers creation of part from initial design to finish-machines part produced on numerically controlled machine tool • Progressed quickly in past 10 years • Amount of math increasingly exponential 79-4 CAD Development • Primarily centered around – Modeling techniques to present conventional drawings – Production for solid models • Should provide means for designer to do job faster and more accurately • Should be closely integrated with techniques for modeling shape and structure of design 79-5 Systems Presently In Use • No longer consist of only 2D or 3D wireframe units and simple toolpaths • Software – enables manufacturers to produce parts faster, more economically and more consistent quality • Manufacturers continually revising modeling technology, improving machining capabilities and automated processes 79-6 Solid Modeling • Rapidly becoming industry-modeling standard • Solids provide more accurate picture of where material lies – Wireframe data is less easy to understand • Geometric model outlining edges • Lines in back of object show through from front 79-7 Solid Modeling and CAD/CAM • PC-based solid modeling make it available to smaller machine shops – Increases adaptability • Gives shop capability to use data it wants – Wireframe taken from solid – Surfaces taken from solid – Solid itself • Gives shop more choices for programming 79-8 How CAD/CAM Works "Art to Part" • Step one: Inputting the geometry – Creating geometry in CAD • Imported via translators from another CAD system – IGES, DXF, ASCII, STL, VDA, SAT, Parosol – System imported in 2D, 3D wirefrace, 3D surfaces or solids – Import geometry in form of XYZ coordinates • Points converted to splines 79-9 Cadworthy Geometry • Created from a drafting point of view • All details and edges of part represented Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 79-10 Camworthy Drawing • Purpose strictly for CNC machine use – Contains fewer lines – only lines needed to create toolpath included • Make toolpath creation easier and less confusing • Sometimes geometry modified to control toolpath • Applies to 2D, wireframe, surfaces Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 79-11 Camworthy Drawing • To make camworthy drawing from cadworthy drawing, geometry edited so all endpoints are connected and no gap remains Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display. 79-12 Defining Where the Cut Takes Place • After geometry, next step is selecting order in which geometry to be machined – Process chaining (where cuts are to take place) – Geometry evaluated as to appropriate toolpath • Many different toolpath types in various CAD/CAM softwares 79-13 How the Cut Takes Place • Next step after toolpath assigned to geometry • Parameters used to identify – – – – – What tool to use Size of tool Speeds, feeds and depth of cuts (up and down) Width of cut (side to side) Cutter compensation 79-14 Backplotting • Process of displaying toolpath once the parameters have been set • Displayed – Showing centerlines – Solid model with material removed or being removed • Onscreen visualization helps to catch errors prior to actual cutting of part 79-15 Converting the Toolpath to G- and M-Codes • Next step • Called post processing – Converts toolpath to NC file customized for a particular machine control • Possible to process one toolpath through several different post processors – Run on several different brands of controls 79-16 Downloading Program to Machine • Next step in process • Download G- and M-codes into NC controller – Via direct cable connection if networked – Via floppy disk • Usually programs too big 79-17 Setting Up the Machine • Once loaded, part must be securely held in holding fixture and machine set up – Set home position on machine at same point as program home position or origin • Standard for location of point is with X and Y zero positions at part's lower left corner and Z zero on top surface • If circular part, X and Y zero is center an Z is top – Tip of tools or tool zero position must be set – Set size and tool number of all tools used 79-18 Final Step: Running the Part • After machine setup, time to press cycle start button – Begin machining process • When finished machining, CAD/CAM process completed "art to part" 79-19 Toolpaths • Pocket toolpath – Purpose to remove material from cavity in stock – Material left standing in pocket called islands • Contour toolpath – Purpose to cut along line/surface to form shape • Drill toolpath – Purpose to create holes and/or enlarge them • Surface toolpath – Purpose to remove material from part designed as surface or solid 79-20 Functions • Constant Volume Removal – Feedrate optimization carries feedrate based on volume of material being removed • Can set upper and lower limits to match machine • Optimize Entire Shop – Feedrate optimization helps find each machine tool's maximum efficiency zone • Smart Cornering – Adjusts feedrate around corners and small radii