Manufacturing Process Laboratory Telkom University
i Manufacturing Process Laboratory Telkom University ii CONTENT Process Manufacture Laboratory Assistants iii 1st MODULE: INTRODUCTION TO MANUFACTURING PROCESS AND PRODUCT DESIGN 1 2nd MODULE: PROCESS PLANNING 55 3rd MODULE: COMPUTER AIDED MANUFACTURING (MILLING) 81 4th MODULE: COMPUTER AIDED MANUFACTURING (TURNING) 142 5th MODULE: NUMERICAL CONTROL CODE 180 6th MODULE: MACHINING PROCESS - MILL 201 7th MODULE: MACHINING PROCESS - LATHE 234 8th MODULE: MACH3 CNC ROUTER ENGRAVER UNIT CONTROLLER 263 9th MODULE: ASSEMBLY, FINISHING AND MOLDING 274 REFERENCE 295 Manufacturing Process Laboratory Telkom University iii Process Manufacture Laboratory Assistants Muhammad Agung Agriza Dian Fatimah Putri Desi Ariska Nabilatushalihah R.H Diki Elfan Reksawana Yussiwi Purwitasari Rifky Iqbal Yuriandi Intan Geovani Fiky RiyanDarmawan Pratama Firda Ramadhena Fauzan Nurrahman Mohamad Walid Anshar Hilman Syahir Rizki Anggriawan Riskika Dea Pratama Lukfi Hafizh Dian Ayu Aprianti Miftakhul Huda Erik Permadi Yogi Purnama Putra R. Irwan Dwi Cahyo Siti Zahra Perdananingsih Muhamad Zamzam Anshori Putra Ramadhan Fauzi Ramadhian David Simangunsong Manufacturing Process Laboratory Telkom University 1 1st MODULE INTRODUCTION TO MANUFACTURING PROCESS AND PRODUCT DESIGN Objective 1. Students are able to understand about Manufacture, 2. Students are able to understand about Computer Aided Design, 3. Students are able to understand the usage of CAD in manufacturing processes, 4. Students are able to use Computer Aided Design Software. Tools 1. Computer 2. SolidWorks 2013 Basic Theory Introduction The word “manufacture” is derived from two latin words, manus = hand, and factus = made; the combination means made by hand. Technologically, manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; manufacturing also includes assembly of multiple part to make products. The processes to accomplish manufacturing involve a combination of machinery, tools, power, and manual labor, as depicted in Figure 1.1. Manufacturing is almost always carried out as sequence of operations. Each operation brings the material closer to desired final state. Manufacturing Process Laboratory Telkom University 2 Starting Material Processed Part Manufacturing Process Scrap ans Waste Figure 1. 1 Manufacturing Process From the economical side, manufacture is transforming raw material into an item with value added due to some process and or assembling. The example is transforming sand into glass, wood into table, and many more. Manufacturing Process Value Added $$ $ Starting Material Material in processing $$$ Processed part Figure 1. 2 Manufacturing Process From the Economical Side Manufacturing Process Laboratory Telkom University 3 Manufacturing Processes Manufacturing processes can be divided into two basic types: processing operations and assembly operations. a. A processing operation transforms a work material from state of completion to a more advanced state that is closer to the final desired product. It adds value by changing the geometry, properties, or appearance of the starting material. In general, processing operations are performed on discrete work parts, but some processing operations are also applicable to assembled items. b. An assembly operation joins two or more components in order to create a new entity, called an assembly, subassembly, or some other term that refers to the joining process (e.g., a welded assembly is called a weldment). A classification of manufacturing processes is presented in Figure 1.3. Figure 1. 3 Classification of Manufacturing Process Manufacturing Process Laboratory Telkom University 4 Fundamental Idea The fundamental idea of manufacturing or production is to create (or produce) something that has a useful form. This form is most likely predetermined, calculated, with a certain physical geometry. Usually this geometry has certain tolerances that it must meet in order to be considered acceptable. A tolerance outlines the geometric accuracy that must be achieved in the manufacturing process. The "tightness" of the tolerances or in other words the allowed variance between the manufactured product and the ideal product is a function of the particular application of the product. 1. Geometric Modeling in CAD / CAM Software The most important aspect of the product is the geometric design (including sizes and shapes). The design is so important due to specify the tools, machines, materials and manufacturing processes to be used. The design of the product should be made in detail and must consider various other aspects related. Designing products with the manual method will lead to higher costs and will spend a long time. To overcome these problems, the design should be created in a geometric model by using computer. Among the usages of computer in manufacturing, Computer Aided Design and Computer Aided Manufacturing (CAD/CAM) are by the far the best known as well the best applications to create, modify, analyze, and optimize the product design then translate it to real object. 2. Computer Aided Design (CAD) CAD may be defined as a design processing using sophisticated computer graphics technique, backed by computer software packages, to aid in the analytical, development, costing, and ergonomic problems associated with design work. The implementation of a CAD process on a CAD/CAM system is shown in Figure 1.4. Once a conceptual design is materialized, the geometric model can be started. The choice of a geometric model depends on the type of analysis to be performed. Manufacturing Process Laboratory Telkom University 5 Figure 1. 4 The CAD Process [Source: Alavala,2008, p.4] Computer-aided Design (CAD) is defined as any design activity that involves the effective use of the computer to create, modify, analyze, or document an engineering design. CAD is most commonly associated with the use of an interactive computer graphics system, referred to as CAD system (Groover, 2007). Benefit of CAD Today's CAD technology can provide the engineer/designer the necessary help in the following ways (Rao, 2006, p.6): 1. Computer aided design (CAD) is faster and more accurate than conventional methods. 2. The various construction facilities available in CAD would make the job of developing the model and associated drafting a very easy task. Manufacturing Process Laboratory Telkom University 6 3. In contrast with the traditional drawing methods, under CAD it is possible to manipulate various dimensions, attributes and distances of the drawing elements. This quality makes CAD useful for design work. 4. Under CAD you will never have to repeat the design or drawing of any component. Once a component has been made, it can be copied in all further works within seconds, including any geometric transformation needed. 5. You can accurately calculate the various geometric properties including dimension of various components interactively in CAD, without actually making their models and profiles. 6. Modification of a model is very easy and would make the designer's task improving a given product simple to take care of any future requirements. 7. Use of standard components (part libraries) makes for a very fast model development work. Also a large number of components and sub-assemblies may be stored in part libraries to be reproduced and used later. 8. Several professional CAD packages provide 3D visualization capabilities so that the designer can see the products being designed from several different orientation. This eliminates the need of making models of products for realization and explaining the concepts to the team. Geometric modelling involves the use of a CAD system to develop a mathematical description of the geometry of an object. The mathematical description called geometric model, is contained in computer memory. This permits the user of the CAD system to display an image of the model on a graphics terminal and to perform certain operations on the model. Type of Geometric Model There are various types of geometric models used in CAD, there are: a. Two-dimensional (2-D) models In two dimensions the drawings are built up with basic element as lines, circle bows, curves and text. Two dimensions CAD drawings are obtained through that the solid model is projected on a plane in a coordinate system. Manufacturing Process Laboratory Telkom University 7 b. Three-dimensional (3-D) models In three dimensions one builds up models with curves, surfaces, or solid models, depending on if you need wire frame, solid or surface model. By adapting an original one can obtain a projected image of the model. Surface and solid modelling are important in engineering industry. Surface modelling has been used for designing curves surfaces in shipping and consuming products. Software A typical CAD system consists of CAD software program. The software are: AutoCAD Catia Cadkey Hobbyists Solidwork Etc. Manufacturing Process Laboratory Telkom University 8 Labwork 1. Upper movable mold half part - Create a new Solidworks part. - Select sketch to make sketch 2D. Manufacturing Process Laboratory Telkom University 9 - Make Rectangular sketch and add dimension like the figure below. - Go to Feature and select Extruded Boss Manufacturing Process Laboratory Telkom University 10 - Enter 2.5 cm for depth and click ok - Add sketch on the surface of the object. Manufacturing Process Laboratory Telkom University 11 - Create “Centerline” 1cm upwards. - Make a Center Rectangle on the top point of the centerline as shown in the picture below. Manufacturing Process Laboratory Telkom University 12 - Create a centerline along the 9.5 cm upwards, and then make the centerline back laterally to the boundary lines of the rectangle. - Make 3 Point Arc sketch and add dimension like the figure below. Manufacturing Process Laboratory Telkom University 13 - Remove the Rectangle using the sketch tool “Trim to closest” - Use the Sketch Fillet with RADIUS 2 cm, until there is a yellow line like the figure below. Manufacturing Process Laboratory Telkom University 14 - Use the Sketch Fillet with RADIUS 15 cm, until there is a yellow line like the figure below. - Use the Sketch Fillet with RADIUS 4 cm, until there is a yellow line like the figure below. Manufacturing Process Laboratory Telkom University 15 - Go to Features and select Extrude Cut, enter 0.3 cm for depth and select Flip side to cut. - Make Corner Rectangle with dimension like the figure below. Manufacturing Process Laboratory Telkom University 16 - Go to Features and select Extrude Cut, enter 0.25 cm for depth. - And this is the Upper movable mold half part Manufacturing Process Laboratory Telkom University 17 2. Lower Fixed mold half part - Create a new Solidworks part. - Select sketch to make sketch 2D. Manufacturing Process Laboratory Telkom University 18 - Make Rectangular sketch and add dimension like the figure below. - Go to features and select Extruded Boss Manufacturing Process Laboratory Telkom University 19 - Enter 2.5 cm for depth and click ok - Add sketch on the surface of the object. Manufacturing Process Laboratory Telkom University 20 - Create “Centerline” 1cm upwards. - Make Center Rectangle on the point above centerline as figure below. Manufacturing Process Laboratory Telkom University 21 - Make centerline along the 9.5 cm upwards, and then make the centerline back laterally to the boundary lines of the rectangle. - Make “3 Point Arc sketch” and add dimension like the figure below. Manufacturing Process Laboratory Telkom University 22 - Remove Rectangle sketch using the tool “Trim to closest” - Use the Sketch Fillet with RADIUS 2 cm, until there is a yellow line like the figure below. Manufacturing Process Laboratory Telkom University 23 - Use the Sketch Fillet with RADIUS 15 cm, until there is a yellow line like the figure below. - Use the Sketch Fillet with RADIUS 4 cm, until there is a yellow line like the figure below. Manufacturing Process Laboratory Telkom University 24 - Go to feature and select Extruded Cut, enter 0.4 cm for depth and click ok. - Select sketch and click onto the surface so that the color to blue, and then click "Convert Entities". Manufacturing Process Laboratory Telkom University 25 - Create a centerline 8 cm and line like the figure below - Use the Offset Entities, click on the line and then navigate down to the yellow line at a distance of 0.4 cm and then click ok. Manufacturing Process Laboratory Telkom University 26 - Select "Linear Sketch Pattern" select blue line with a distance of 3 cm. - Use “Trim To Closest” in order the sketch like the figure below. Manufacturing Process Laboratory Telkom University 27 - Make “Centerline” like the figure below. - Make “sketch 3 Point Arc” with a radius 15 and line, like the figure below. Manufacturing Process Laboratory Telkom University 28 - Select “Offset Entities” then give a distance of 1.2 cm. - Select “Offset Entities” then give a distance of 1.8 cm. Manufacturing Process Laboratory Telkom University 29 - Use “Trim To Closest” in order the sketch like the figure below. - Make “Centerline” like the figure below. Manufacturing Process Laboratory Telkom University 30 - Create line may occur under and then click "Offset Entities", with a length of 0.4 cm towards the top. Manufacturing Process Laboratory Telkom University 31 - Create line sketch like the figure below. - Use “Trim to closest” in order the sketch like the figure below. Manufacturing Process Laboratory Telkom University 32 - Go to feature and select Extruded Cut, enter 0.4 cm for depth and click ok. - Make Corner Rectangle with dimension like the figure below. Manufacturing Process Laboratory Telkom University 33 - Go to Features and select Extrude Cut, enter 0.25 cm for depth. - And this is the Lower Fixed mold half part. Manufacturing Process Laboratory Telkom University 34 3. Hinge part - Create a new solidworks part and make sketch with dimension like the figure below. - Go to Features and select Extruded Boss. After that, enter 4.2 cm for depth and click ok. Manufacturing Process Laboratory Telkom University 35 - Make sketch like this. - Go to feature and select Extruded Cut. After that, select through all and click ok. Manufacturing Process Laboratory Telkom University 36 - Make sketch like this. - Go to feature and select Extruded Cut. After that, select through all and click ok. Manufacturing Process Laboratory Telkom University 37 - And this is the Hinge 1 part. 4. Hinge 2 - Create a new solidworks part and make sketch with dimension like the figure below. Manufacturing Process Laboratory Telkom University 38 - Go to Features and select Extruded Boss. After that, enter 4.2 cm for depth and click ok. - Make sketch like this. Manufacturing Process Laboratory Telkom University 39 - Go to feature and select Extruded Cut. After that, select through all and click ok. - Make sketch like this. Manufacturing Process Laboratory Telkom University 40 - Go to feature and select Extruded Cut. After that, select through all and click ok. - And this is the Hinge 2 part. Manufacturing Process Laboratory Telkom University 41 5. Steel - Create a new part and make circular sketch with dimension like the figure below. - Go to feature and select Extruded Boss. After that, enter 4.2 cm for depth and click ok. Manufacturing Process Laboratory Telkom University 42 - Make circular sketch like this. - Go to feature and select Extruded Boss. After that, enter 0.1 cm for depth and click ok. Manufacturing Process Laboratory Telkom University 43 - And this is the Steel part. 6. Assembly - Create a new Solidworks document and choose Assembly, and insert all of the parts by clicking browse. Manufacturing Process Laboratory Telkom University 44 - Go to assembly and select mate. The first step is assembly hinge 1 part and Lower Fixed mold half part. Click face like the figure below. - And then click this. After that click ok. Manufacturing Process Laboratory Telkom University 45 - Then click this face, until there is a blue like the figure below. - And click this face. After that click ok. Manufacturing Process Laboratory Telkom University 46 - Then click this face, until there is a blue like the figure below. - And click this face. After that click ok. Manufacturing Process Laboratory Telkom University 47 - The second step is assembly hinge 2 part and Upper movable mold half part. Click face on upper movable mold half part until there is a blue face like the figure below. - Then click this face, until there is a blue like the figure below. After that click ok. Manufacturing Process Laboratory Telkom University 48 - Then click this face, until there is a blue like the figure below. - Then click this face, until there is a blue like the figure below. After that click ok. Manufacturing Process Laboratory Telkom University 49 - Then click this face, until there is a blue like the figure below. - And click this face. After that click ok. Manufacturing Process Laboratory Telkom University 50 - The third step is assembly Steel part and Upper movable mold half part. Go to mate - and select advance mate, after that select Width. Choose width selection, and select face on the steel part like a figure below. - After that, choose tab selection and select face on the Upper movable mold half part, and click ok. Manufacturing Process Laboratory Telkom University 51 - The last steps is assembly between steel part and hinge. Go to mate and click face like the figure shown. - Then click this. Manufacturing Process Laboratory Telkom University 52 - After that click this. - And click this. Click ok. Manufacturing Process Laboratory Telkom University 53 - After that click this. - And click this. Click ok. Manufacturing Process Laboratory Telkom University 54 - All of the parts already assembled and this is the Shoe sole mold Product. Manufacturing Process Laboratory Telkom University 55 2nd MODULE PROCESS PLANNING Objective 1. Students are able to understand the concept of process planing 2. Students are able to make process planning of part Tools 1. Computer 2. Microsoft Excel Basic Theory Process planning, in the manufacturing context, is the determination of processes and resources needed for completing any of the manufacturing processes required for converting raw materials into a final product to satisfy the design requirements and intent and respect the geometric and technological constraints (ElMaraghy and Nassehi, 2013). Process planning is also described to be the interface between product design and manufacturing (Scallan, 2003), and the work often includes coordination of product design intentions and constraints imposed by the workshop (Ham, 1988). Process planning is called manufacturing planning, process planning, material processing, process engineering, and machine routing. Process planning can be defined as an act of preparing processing documentation for the manufacturing of a piece, part or an assembly. Process planning is the critical bridge between design and manufacturing. Design information can be translated into manufacturing language only through process planning. Manufacturing Process Laboratory Telkom University 56 Figure 2. 1 Process Planning The manufacturing process selected must be an economical balance of materials, manpower, product design, tooling and manpower, product design, tooling and equipment, plant space, and many factors influencing cost and practicality. The process must be selected in such a way that the produced product will be acceptable to the consumer functionally, economically, and appearance wise. The process planner therefore plays a desirable role not only to define a process plan but to contribute with manufacturing knowledge to a competitive product design (Bagge, 2009; Groche, et al., 2012; Inman, et al., 2013). These are the interaction between the process planner and collaboration parties while developing a process plan. Figure 2. 2 The Role of The Process Planner Manufacturing Process Laboratory Telkom University 57 Fundamental Rules Fundamental rules for the selection and planning of a manufacturing: 1. The process must assure a product that meets all design requirements of quality, function, and reliability requirements of quality. 2. Daily production requirement must be met. 3. Full capacity of the machine and its tooling should be utilized. 4. Idle operator and idle machine time must be reduced to minimum. 5. The process must provide the maximum utilization of the minimum amount of material. 6. The process should be flexible enough to accommodate reasonable changes in design. 7. The process should be designed to eliminate any unnecessary operations and combine as many operations as are physically and economically practical. 8. Capital expenditure that must be amortized over short periods must be kept as low as possible. 9. The process must be designed with the protection of both the operator and the workpiece in mind. 10. The process should be developed so that the final product will be produced at a minimum cost to the enterprise as a whole. The Engineering Approach - Establish the process objectives - Collect all the facts about the problem - Plan alternative processes - Evaluate alternative processes - Develop a course of action - Follow up to assure action and check results Manufacturing Process Laboratory Telkom University 58 Type of Process Plan To bring some clarity in different focuses for process planning, there are four process planning levels, these levels are placed in order from a very low level of detail to a very detailed level (ElMaraghy and Nassehi, 2013). In addition, the focus and output from each level are identified. Table 2. 1 Process Planning Levels (ElMaraghy and Nassehi, 2013) Process planning level Main focus of Level of Planning output at planning at this level detail this level Manufacturing Generic planning Selecting technology and rapid process technologies and Very low processes, conceptual planning plans, and DFx analysis results Macro planning Routings, nonlinear Multi-domain Low plans, alternate resources Detailed process plans Detailed Single domain, single planning process Detailed (sequence, tools, resources, fixtures, etc.) Manufacturing Process Laboratory Telkom University 59 Depending on the production environment divide in two which are as follows: 1. A Rough Process Plan Table 2. 2 Rough Process Plan by: T.C. Chang Route Sheet Part No. S1243 Part Name: Mounting Bracket 1. 2. 3. 4. workstation Mtl Rm Mill02 Drl01 Insp Time(min) 5 4 1 2. A Detailed Process Plan Table 2. 3 Detailed Process Plan PROCESS PLAN Part No. S0125-F Part Name: Housing Original: S.D. Smart Date: 1/1/89 Checked: C.S. Good Date: 2/1/89 Workstation ACE Inc. Material: steel 4340Si Changes: Approved: T.C. Chang Setup Date: Date: 2/14/89 No. Operation Description 10 Mill bottom surface1 MILL01 see attach#1 for illustration Face mill 6 teeth/4" dia 3 setup 5 machining 20 Mill top surface MILL01 see attach#1 Face mill 6 teeth/4" dia 2 setup 6 machining 30 Drill 4 holes DRL02 set on surface1 twist drill 1/2" dia 2" long 2 setup 3 machining Manufacturing Process Laboratory Telkom University Tool Time (Min) 60 Process Planning Approach There are basically two approaches to process planning which are as follows: 1. Manual Process Planning In industry, most process plan are still prepared manually. In order to prepare process plan, a process planner has to have the following knowledge: Ability to interpret an engineering drawing Familiarity with manufacturing processes and practice Familiarity with tooling and fixtures Know what resources are available in the shop Know how to use references books, such as machinability data handbooks Ability to do computations on machining time and cost Familiarity with the raw material Know the relative costs of process, toolings, and raw material 2. Computer Aided Process Planning (CAPP) Computer-aided process planning (CAPP) helps determine the processing steps required during a planning process. CAPP programs develop a process plan or route sheet by following either a variant or a generative approach. The variant approach uses a file of standard process plans to retrieve the best plan in the file after reviewing the design. The plan can then be revised manually if it is not totally appropriate. The generative approach to CAPP starts with the product design specifications and can generate a detailed process plan complete with machine settings. CAPP systems use design algorithms, a file of machine characteristics, and decision logic to build the plans. Manufacturing Process Laboratory Telkom University 61 Process Planning Step 1. Study the overall shape of the part. Use this information to classify the part and determine the type of workstation needed. For example, design wooden stool. The stool has one seat, four legs and four supports, resulting in a total of nine parts. These parts will be used for illustrations in the following sections. Figure 2. 3 Wooden Stool Design 2. Thoroughly study the drawing. Try to identify every manufacturing features and notes. 3. If raw stock is not given, determine the best raw material shape to use. Raw material are commonly used in the manufacturing process are alumunium, brass & cooper, plastics, stainless steel, wood and titanium. Each material has a different properties, for example: alumunium has a good formability, weldability, and corrosion resistance ; cooper has characteristics higher strength and excellent electrical conductivity; Steel has low carboon steel, poor machinability but good formabilty and weldability. 4. Identify datum surfaces. Use information on datum surfaces to determine the setups. A datum point is any point of known or assumed coordinates, which is used as a reference and from which calculations or measurements may be taken. A datum point can be used as a construction when modelling geometry. There are different types of datum points that can be used, especially in modelling. a. Absolut coordinates: Absolute positioning is moving to a defined point. It is absolute because it is a particular position from some point of reference known by the machine, like a home position. If Manufacturing Process Laboratory Telkom University 62 you give an absolute position, the machine moves to that same point from wherever it is every time. The G-code G90 is used to select this type of programming. Example of how to define absolute coordinate system: Figure 2. 4 Example of Absolute Coordinate Graph Step 1) Identify the co-ordinates of the origin in 3 dimensions Step 2) Assume the Datum is located at the origin Step 3) Create a table of X, Y, and Z co-ordinates of each letter labeled point; assume z=0 for all lettered positions The Datum for X, Y, and Z is the origin (0, 0, 0). The format for expressing X, Y, & Z is (x, y, z) so, for example “Point A” = (5, 4, 0) when the datum is located at the origin. “Point B” = (10, 5, 0) relative to the datum “Point B” is NOT relative to “Point A”. Table 2. 4 Absolute Coordinate System Point Datum 0 X 0 Y A 5 4 B 10 5 C -4 5 D -9 7 Manufacturing Process Laboratory Telkom University E -7 -3 F -4 -6 G 7 -5 H 5 -2 63 a. Incremental coordinates: Incremental coordinates are referenced from the previous point as though the previous point has become a new origin. The reference point is essentially moving with every new coordinate. The G-code G91 is used to select this type of programming. Example of how to define incremental co-ordinate system: Figure 2. 5 Example of Incremental Co-ordinate Graph Step 1) Identify the co-ordinates of the origin in 3 dimensions Step 2) Assume the Datum is located at the origin Step 3) Create a table of X, Y, and Z co-ordinates of each letter labeled point; assume z=0 for all lettered positions The format for expressing X, Y, & Z is (x,y, z). In incremental systems, every measurement refers to a previously dimensioned position (point-to-point). Incremental dimensions are the distances between two adjacent points. The opposite moving signed with (-). Manufacturing Process Laboratory Telkom University 64 For example downside move and left move. “Point A” = (2,3) “Point B” = Define that “Point A” is (0,0) so from “Point A” to “Point B” the moving of x is 3 to the right, and the moving of y is 1 to downside. So the incremental co-ordinate is (3,-1) “Point C” = Define that “Point B” is (0,0) so from “Point B” to “Point C” the moving of x is 10 to the left, and the moving of y is 1 to upside. So the incremental co-ordinate is (-10,1) And so on for define the other point. Table 2. 5 Incremental Co-ordinate System Point Datum 0 X 0 Y A 2 3 B 3 -1 C -10 1 D -2 2 E 0 -9 F 3 2 G 9 0 H -3 -3 5. Select machines for each setup. There are many operations in process machining, such as: Milling Milling operations are operations in which the cutting tool rotates to bring cutting edges to bear against the workpiece. Milling machines are the principal machine tool used in milling. Turning Turning operations are operations that rotate the workpiece as the primary method of moving metal against the cutting tool. Lathes are the principal machine tool used in turning. Drilling Drilling operations are operations in which holes are produced or refined by bringing a rotating cutter with cutting edges at the lower extremity into contact with the workpiece. Drilling operations are done primarily in drill presses but sometimes on lathes or mills. Manufacturing Process Laboratory Telkom University 65 6. For each setup determine the rough sequence of operations necessary to create all the features. Table 2. 6 Operation Operation Explanation Facing Facing is an operation of machining the Picture ends of a workpiece to produce a flat surface square with the axis Pocketing In pocketing, you have to remove material from the interior of a closed geometry. Profiling Profiling can be used as a finishing operation after a pocketing or facing toolpath, or it can be used alone. Slotting This method is used for cutting in, shaving, and has an angle, or doing surfaces that are difficult to reach.This operation generates a tool path along the centerline to the right or to the left of one or more profiles. Drilling This operation enables to perform drills and other canned drill cycles. Finishing This is the last step of process plan for making a part. In this process, the part will be done of finishing process. Note: (*) means this operation will be discussed more complete in the fourth module. Manufacturing Process Laboratory Telkom University 66 7. Select tools for each operation. Try to use the same tool for several operations if it is possible. Keep in mind the trade off on tool change time and estimated machining time. Some of tools that usualy used in manufacturing process: Table 2. 7 Cutting Tools Tools Explanation Face Mill This type of knife is usually used for facing Picture surfaces. End Mill This type of blade sizes vary from very small sizes to large sizes. Cutter is usually used to make grooves on a flat or wedge and the blade types are generally mounted in an upright position (vertical milling machine), but in certain circumstances can also be installed in a horizontal position and directly mounted on the milling machine spindle. Ball Nose Mill This type of knife has a blunt and rounded end. This knife is usually used for a smooth surface finishing. Drill This type of knives/chisel are used to make a hole. The cutting tool materials must process a number of important properties to avoid excessive wear, fracture failure and high temperatures in cutting. 8. Select or design fixtures for each setup. 9. Estimate the machining time 10. Prepare the final process plan document. Make a routing sheet. Manufacturing Process Laboratory Telkom University 67 Selection of Proper Tooling In selecting dies, jigs or fixtures for a given process, there are three essential processes, that demand the attention of considerations of process engineer: - Quality of the product - Total volume to be produced - Required rate of production Effect of Operational Speed Effect of operational speed on performance and economy: - Cutting speed influences the rate of production and performance economy. - Assuming product quality can be achieved independently from the speed, there are two different opinions: (1) The greater machine speed, the greater its output and lower product unit cost. (2) Speed should be held so that longer tool life is achieved. - With the change in tool life due to change in operational speed, the overall production speed and production time will be effected due to re-sharpening and resetting the tool. Cutting Tool Material Carbon Steels It is the oldest of tool material. The carbon content is 0.6-1.5 % with small quantities of silicon, chromium, manganese, and vandanium to refine grain size. This material has low wear resistance and low hot hardness. The use of these materials now is very limited. High- Speed Steel (HSS) They are highly alloyed with vandanium, cobalt, molybdenum, tungsten, and chromium added to increase hot hardness and wear resistance. Can be hardened to Manufacturing Process Laboratory Telkom University 68 various depths by appropriate heat treating up to cold hardness in the range of HRC 6365. The cobalt component give the material a hot hardness value much greater that carbon steels. The high toughness and good wear resistance make HSS suitable for all type of cutting tools with complex shapes for relatively low to medium cutting speeds. The most widely used tool material today for taps, drills, reamers, gear tools,end cutters, slitting, broaches, etc. Figure 2. 6 Thread tap made of High- Speed Steel Cemented Carbides These are the most important tool materials today because of their high hot hardness and wear resistance. The main disadvantage of cemented carbides in their low toughness. These materials are produced by powder metallurgy methods, sintering grains of tungsten carbide (WC) in a Cobalt (Co) matrix ( it provides toughness). There may be other carbides in the mixture, such as titanium carbide (TiC) and/ or tantalum carbide (TaC) in addition to WC. Figure 2. 7 Microstructure of Cemented Carbide Manufacturing Process Laboratory Telkom University 69 Ceramics Ceramic materials are composed primarily of fine- grained, high- purity alumunium oxide (AL2O3), pressed and sintered with no binder. Two types are available: white, or cold-pressed ceramics, which consists of only Al2O3 cold pressed into inserts and sintered at high temperature. black, or hot-pressed ceramics, commonly known as cermet (from ceramics and metal). This material consists of 70% Al2O3 and 30% TiC. Both materials have very high wear resistance but low toughness, therefore they are suitable only for continuous operations such as finishing turning of cast iron and steel at very high speeds. There is no occurrence of built-up edge, and coolants are not required. Cubic Boron Nitride (CBN) and syntetic diamonds Diamond is the hardest substance ever known of all materials. It is used as a coating material in its polycrystalline form, or as a single-crystal diamond tool for special applications, such as mirror finishing of non-ferrous materials. Next to diamond, CBN is the hardest tool material. CBN is used mainly as coating material because it is very brittle. In spite of diamond, CBN is suitable for cutting ferrous materials. Machining Time Formula Machining time is the total amount of time it take to finish processing a part. Machining time is a function of part size, depth of cut, feed, and speed. It can be calculated by dividing the tool-path length by the feed speed. Manufacturing Process Laboratory Telkom University 70 For drilling: 𝑡𝑚 = 𝐿 + ∆𝐿 𝑉𝑓 Where 𝑡𝑚 = 𝑚𝑎𝑐ℎ𝑖𝑛𝑖𝑛𝑔 𝑡𝑖𝑚𝑒, 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝐿 = ℎ𝑜𝑙𝑒 𝑑𝑒𝑝𝑡ℎ, 𝑖𝑛𝑐ℎ𝑒𝑠 ∆𝐿 = 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 ℎ𝑒𝑖𝑔ℎ𝑡, 𝑖𝑛𝑐ℎ𝑒𝑠 𝑉𝑓 = 𝑓𝑒𝑒𝑑 𝑠𝑝𝑒𝑒𝑑, 𝑖𝑛𝑐ℎ𝑒𝑠 𝑝𝑒𝑟 𝑚𝑖𝑛𝑢𝑡𝑒 For Milling: Machine speed (N) N = k* V * D1 Cutting Time (CT) 𝐶𝑇 = 𝐿 + 𝐿𝐴 + 𝐿𝑂 𝐹𝑚 Where: N : Machine speed in revolutions/minute (RPM) k is a constant to “correct” speed (V) and part diameter (Di ) units V is desired cutting speed, a Handbook Value D1 is cutter diameter V given in surface feet per minute (SFPM), D1 in inches: k = 12 V given in meters per second (MPS), D1 in mm: k = 60000 V given in meters per minute (MPM), D1 in mm: k = 1000 n: Number of Teeth on Cutter Manufacturing Process Laboratory Telkom University 71 W: Width of cut (may be full cutter or partial cutter) t: depth of cutter engagement V: cutting speed -- a Handbook value L: Length of pass or cut fm: Table (machine) Feed ft: feed/tooth of cutter -- a Handbook value D: Cutter Diameter LA: Approach Length LO: Length of “Over Travel” Manufacturing Process Laboratory Telkom University 72 Lab Work 1. Study the overall shape of the part. In this practicum, we make a process plan of a “shoe sole mold” that has been made in the first module (part design). This product consists of five parts, including upper movable mold, lower fixed mold, 2 hinges, and steel. The process plan that will be made by using the lower fixed mold part. Figure 2. 8 Part Design Manufacturing Process Laboratory Telkom University 73 2. Thoroughly study the drawing. 3. Determine the best raw material shape to use. Figure 2. 9 Stock Manufacturing Process Laboratory Telkom University 74 As we know that there are several raw material are commonly used in the manufacturing process such alumunium, brass & cooper, plastics, stainless steel, wood and titanium. In this practicum, we choose wood as the material to produce the product. The advantages of using wood, include: the low energy content needed for production, low cost of production, wood is an environmentally friendly material, wood has low density, etc. 4. Identify datum surfaces. P2 P3 (0,0) P1 P4 Figure 2. 10 Datum Surface Table 2. 8 Datum Coordinate Absolute Coordinate Incremental Coordinate X Y X Y P1 0 0 0 0 P2 0 150 0 150 P3 300 150 300 0 P4 300 0 0 -150 P1 0 0 -300 0 Manufacturing Process Laboratory Telkom University 75 5. Select machines for each setup. In this practicum we do milling operation as process machining because the part has a flat surface. Milling machine is able to work on a flat surface and grooved with the completion and accuracy, is also useful for smoothing or leveling the workpiece in accordance with the desired dimensions. Milling machines can produce a smooth flat surface. 6. For each setup determine the rough sequence of operations necessary to create all the features. Operation Explanation Picture Facing Facing is the first step in making a frame. In this process, materials will be flattened. It is because the surface of wood materials were uneven and jagged. Pocketing This is a process of forming part of the frame. Formation of the frame adapted to a predetermined size. Profiling Profiling can be used as a finishing operation after a pocketing or facing toolpath, or it can be used alone. Finishing This is the last step of frame making process. In this process, the main frame will be finished manually. Manufacturing Process Laboratory Telkom University 76 7. Select tools for each operation. Operation Explanation Facing Tool that will be used in the facing process Picture is "End Mill". The function of this tool is to flatten the surface of the workpiece. Pocketing In Pocketing, use the tool “ End Mill”. This tools is usually used to make grooves on a flat or wedge and the blade types are generally mounted in an upright position (vertical milling machine) Profiling Tool that will be used in the profiling process is "End Mill". The function of this tool is used to make grooves on a flat or wedge and the blade types are generally mounted in an upright position (vertical milling machine) Finishing In the finishing process requires sand paper. It is the process of smoothing the surface. In this Lab work, we are using the tool High Speed Steel (HSS). Because HSS has lower cost than the carbide. And it is commonly used in each process operation. The advantage of HSS over carbide is its strength to withstand cutting forces and the low cost of the tools. From the tool life point of view, HSS performs very well at intermittent cutting applications. Manufacturing Process Laboratory Telkom University 77 8. Select or design fixtures for each setup. 9. Estimate the machining time Terms used: N : Machine speed in revolutions/minute (RPM) k is a constant to “correct” speed (V) and part diameter (Di ) units V is desired cutting speed, a Handbook Value D1 is cutter diameter V given in surface feet per minute (SFPM), D1 in inches: k = 12 V given in meters per second (MPS), D1 in mm: k = 60000 V given in meters per minute (MPM), D1 in mm: k = 1000 n: Number of Teeth on Cutter W: Width of cut (may be full cutter or partial cutter) t: depth of cutter engagement V: cutting speed -- a Handbook value L: Length of pass or cut fm: Table (machine) Feed ft: feed/tooth of cutter -- a Handbook value D: Cutter Diameter LA: Approach Length LO: Length of “Over Travel” Manufacturing Process Laboratory Telkom University 78 Facing Operation Where: V: 18,84 mm/min D1: 6 mm L : 150 mm o Spindel Speed (N) N= 𝑁= k*V * D1 1 𝑥 18,84 3,14 𝑥 0,006 𝑁 = 1000 𝑅𝑃𝑀 o Cuting time (CT) 𝐿 + 𝐿𝐴 + 𝐿𝑂 𝐹𝑚 𝐷 𝐿𝐴 = 𝐿𝑂 = 2 6 𝐿𝐴 = 𝐿𝑂 = = 3 2 𝐿 + 𝐿𝐴 + 𝐿𝑂 𝐶𝑇 = 𝐹𝑚 𝐶𝑇 = 𝐹𝑚 = 𝐹𝑡 𝑥 𝑁 𝑥 𝑛 𝐹𝑚 = 0.05 𝑥 1000 𝑥 2 = 100 𝑚𝑚/ 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 𝐶𝑇 = 150 + 3 + 3 100 𝐶𝑇 = 1,55 = 93 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 Pocketing Operation Where: V: 18,84 mm/min D1: 6 mm L : 166 mm Manufacturing Process Laboratory Telkom University 79 o Cutting Speed (N) 𝑁 = 1000 𝑅𝑃𝑀 o Cutting Time (CT) 𝐶𝑇 = 𝐶𝑇 = 𝐿 + 𝐿𝐴 + 𝐿𝑂 𝐹𝑚 166 + 3 + 3 = 1,72 = 103.2 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 100 Profiling Operation Where: V: 18,84 mm/min D1: 6 mm L : 42 mm o Cutting Speed (N) 𝑁 = 1000 𝑅𝑃𝑀 o Cutting Time (CT) 𝐿 + 𝐿𝐴 + 𝐿𝑂 𝐹𝑚 (42 ∗ 2) + 3 + 3 𝐶𝑇 = = 0,26 = 15,6 𝑚𝑖𝑛𝑢𝑡𝑒𝑠 100 𝐶𝑇 = FINISHING It takes 5 minutes to finishing the frame by using the sanding tool. 10. Prepare the final process plan document. Make a routing sheet. Manufacturing Process Laboratory Telkom University 80 ROUTING SHEET Part No. 1 Material : Wood Part Name : Main part of Shoe Changes : ______ Date : ______ Sole Mold Approved : .......... Date : 14/1/2015 Original : Prosman Lab Date : 31/12/2014 Checked : Prosfams Date : 14/1/2015 No Operation Workstation Setup Tool Material Description 1 Facing top Pocketing Result (Min) MILL01 surface 2 Time MILL02 Setup End Tool Mill external 60 mm - End the surface HSS 93 minutes HSS mill 103,2 minutes 60 mm 3 Profiling PROF01 - End HSS mill 15,6 minutes 60 mm 3 Finishing FIN01 - Sanding sandpaper tools 5 minutes By summing all the available processing time, the total time required to perform the machining process part is 216,8 minutes or about 3 hours 37 minutes. Manufacturing Process Laboratory Telkom University 81 3rd MODULE COMPUTER AIDED MANUFACTURING (MILLING) Objective 1. Students are able to understand about machining process. 2. Students are able to understand about classification of CNC machine. 3. Students are able to create machining process using 2,5 axis and 3 axis CNC operations. 4. Students are able to simulate machining process using CAM software. Tools 1. Computer 2. SolidCAM 2013 3. Part Basic Theory Introduction Machining is a term used to describe a variety of material removal processes in which a cutting tool removes unwanted material from a workpiece to produce the desired shape. The workpiece is typically cut from a larger piece of stock, which is available in a variety of standard shapes, such as flat sheets, round tubes, rectangular bar and etc. Manufacturing Process Laboratory Telkom University 82 Classification Machining process can be divided into three basic types: conventional machining, abrasive process, and non-traditional machining. a. Conventional machining process is a machining process with a particular geometry. The three primary processes are turning, drilling, and milling. Turning Turning is a machining process to produce cylindrical parts of machine which is done with lathe machine. Drilling Drilling is a cutting process in which a hole is originated or enlarged by means of a multipoint, fluted, end cutting tool. Milling Milling is a process of slicing the workpiece using a cutting tool with a rotating multiple cutting point. b. Abrasive process is the removal of materials using abrasive materials, such as grinding processs. Grinding is the most popular form of abrasive machining. It involves an abrasive tools consisting of grain of hard materials which are forced to rub against the workpiece removing a very small amount of material. c. Non traditional machining process is carried out chemically and electrically with the help of optical power sources. Mechanical energy process Mechanical energy is used for removing material from workpiece. In this process, cutting tool with sharp edge is not used but material is removed by the abrasive action of high velocity of stream of hard, tiny abrasive particles. The particles are kept vibrating with very high velocity and ultra high frequency to remove the material. Electrochemical machining In this category of non-traditional machining electrical energy is used in the form of electrochemical energy or electro-heat energy to erode the material or to melt and Manufacturing Process Laboratory Telkom University 83 vaporized it respectively. Electrochemical machining, electroplating or electro discharge machining are the examples work on this principle. Thermal energy process According to this principle heat is generated by electrical energy. The generated thermal energy is focused to a very small portion of workpiece. This heat is utilizedin melting and evaporating of metal. The example based on this principle is electric discharge machining. Chemical machining According to this principle of working chemicals are used to erode material from the workpiece. Selection of a chemical depends upon the workpiece material. Example of this type of machining is electrochemical machining. The same principle can also be applied in reversed way in the process of electrochemical plating. A classification of machining process is presented below : Manufacturing Process Laboratory Telkom University 84 CNC Machine CNC (Computer Numerical Control) is a machine that controlled by a computer using a numerical language (movement command using character and digit) in its process. So, with a CNC machine we don’t need to control a turning, drilling, milling, and other conventional machining process manually, but we can use a computer. CNC can be analogous to a printer machine. When we want to make an article, we must make it first in computer then print it with a printer machine. It is similar when we want to make a product, we must make a design in computer then cast it with a CNC machine. CNC machine can be divided in two basic types, these are: a. CNC Machine Two Axis (Lathe Machine) CNC Lathe Machine can be divided in two basic types, these are: 1. CNC Lathe Machine Training Unit (CNC TU) 2. CNC Lathe Machine Production Unit (CNC PU) Both of these machines have the same working principle, but they have a different function. CNC TU is used for basic training of CNC programming and process that is equipped with EPS (External Programing System). It can only be used for light work with a soft material. Figure 3.1 Lathe Machine Manufacturing Process Laboratory Telkom University 85 CNC PU is used for a mass production. This machine is equipped with additional accessories such as automatic opening system that applies hydraulic principle, exhaust chips, and so on. The movement of this machine is controlled by a computer, so all the movements in accordance with a program. The advantages of this system is the machine enable to repeat the same movement constantly with the same level of carefulness. CNC lathe machines have the basic principle of the movement as well as conventional lathes, that is the movement to transverse direction and horizontal to the X and Z axes coordinate system. The working principle between two of them are same that the workpiece is mounted in moved dibble then the cutting tool is not moving. These are the symbols of lathe machine’s movement direction: X axis for transverse and perpendicular movement to rotary axis Z axis for lengthwise and in parallel to rotary axis The function of lathe machine’s axis can be seen below: Figure 3.2 Function of lathe machine’s axis b. CNC Machine Three Axis (Milling Machine) CNC Milling Machine can be divided in two basic types, these are: 1. CNC Milling Machine Training Unit (CNC TU) 2. CNC Milling Machine Production Unit (CNC PU) Manufacturing Process Laboratory Telkom University 86 Both of these machines have the same working principle, but they have a different function. CNC TU is used for basic training of CNC programming and process that is equipped with EPS (External Programing System). It can only be used for light work with a soft material. Figure 3.3 Milling Machine CNC PU is used for a mass production. This machine is equipped with additional accessories such as automatic opening system that applies hydraulic principle, exhaust chips, and so on. The working principle of this machine is the work table moves transverse and horizontal then the cutting tool rotates. These are the symbols of milling machine’s movement direction: X axis for horizontal direction movements Y axis for transverse direction movements Z axis for vertical direction movements Shaping Shaping is a process of slicing or cutting a static workpiece (the workpiece is clamped) then the cutting tool moves straight forward and backward. Shaping process can be divided into three basic types: a. Facing. Facing is used to create a flat surface. b. Pocketing. Pocketing is used to remove material in closed geometry. c. Profiling. Profiling is used to remove material in open geometry. Manufacturing Process Laboratory Telkom University 87 Drilling Drilling is a process of producing round holes in a solid material or enlarging existing holes with the use of multi-point cutting tools called drills or drill bits. Here are the classification of drilling processes: a. Reaming. Reaming is a process of enlarging the hole with a very high accuracy dimension. Figure 3.4 Reaming b. Tapping Tapping is a process of making an inside screw. Figure 3.5 Tapping c. Counter boring Counter boring is a process of enlarging the existing hole. Figure 3.6 Counter Boring Manufacturing Process Laboratory Telkom University 88 d. Counter sinking Counter sinking is similar with counter boring, but the point of cutting tool is conical. Figure 3.7 Counter Sinking e. Center drilling Center drilling is a process of making a short space which is not translucent. The cutting tool has a single point with a straight groove. The cutting point is on the side of the cutting tool which has a tapered shape. Figure 3.8 Center Drilling f. Spot facing Spot facing is a process of creating a flat surface around the hole to accommodate the bolt head or mur. Figure 3.9 Spot Facing Manufacturing Process Laboratory Telkom University 89 Definition of CAM Computer-aided manufacturing (CAM) is an application technology that uses computer software and machinery to facilitate and automate manufacturing processes. The example of CAM software are Solid CAM or Rhino CAM. In CAM software there are usually a simulation menu and options, where you can simulate the process you made in a program before machining it for real. The output from CAM software is NC Code, this code will be input for CNC machine for further processing into the machine. Manufacturing Process Laboratory Telkom University 90 Advantages of CAM The advantages of using CAM are (Rao, 2006, p.9): 1. Greater design freedom: Any changes that are required in design can be incorporated at any design stage without worrying about any delays, since there would Hardly be any in an integrated CAM environment. 2. Increase productivity: In view of the fact that the total manufacturing activity is completely organized through the computer, it would be possible to increase the productivity of the plant. 3. Greater operating flexibility: CAM enhances the flexibility in manufacturing methods and changing of product lines. 4. Shorter lead time: Lead times in manufacturing would be greatly reduced. 5. Improved reliability: In view of the better manufacturing methods and controls at the manufacturing stage, the products thus manufactures as well as of the manufacturing system would be highly reliable. 6. Reduced maintenance: Since most of the components of a CAM system would include integrated diagnostics and monitoring facilities, they would require less maintenance compared to the conventional manufacturing methods. 7. Reduced scrap and rework: Because of the CNC machines used in production, and the part programs being made by the stored geometry from the design stage, the scrap level would be reduced to the minimum possible and almost no rework would be necessary. 8. Better management control: As discussed above, since all the information and controlling functionsare attempt with the help of the computer, a better management control on the manufacturing activity is possible. Manufacturing Process Laboratory Telkom University 91 SolidCAM 2.5D SolidCAM offers you the following types of 2.5D Milling operations: Face Profile Contour 3D Pocket Drilling Thread Milling Slot T-Slot Translated Surface ToolBox Cycles a. Face Milling Operation This operation is enables to create smooth surface in flat stock.This process using end mill as the tool. Figure 3.10 Face Milling Operation b. Profile Operation This operation enables to remove material in open geometry Figure 3.11 Profile Operation Manufacturing Process Laboratory Telkom University 92 c. Pocket Operation This operation enables to remove material in closed geometry Figure 3.12 Pocket Operation d. Slotting Operation This method is used for cutting in, shaving, and has an angle, or doing surfaces that are difficult to reach. It can also be used for processs that require vertical cuts. Figure 3.13 Slot Operation Manufacturing Process Laboratory Telkom University 93 e. T-Slot Operation This operation enables to machine slots in vertical walls with a slot mill tool. Figure 3.14 T-Slot Operation f. Drill Recognition This Operation carries out a highlyefficient drill recognition and geometry creation with the functionality of the AFRM- module (Automatic Feature Recognition and Machining). In this operation drilling on different levels can be carried out. The drilling levels are automatically recognized but may be edited by the user. Figure 3.15 Drill Recognition Manufacturing Process Laboratory Telkom University 94 g. Pocket Recognition This Operation recognizes automatically pocket features at the target model and creates the necessary machining. Figure 3.16 Pocket Recognition h. Thread Milling Operation this operation enables you to generate a helical tool path for the machining of internal and external threads with thread mills. Figure 3.17 Thread Milling Manufacturing Process Laboratory Telkom University 95 SolidCAM 3D Solid CAM provides you with powerful 3D Machining functionality that can be used both for prismatic parts and for complex 3D Models. For complex shape models such as molds, electrodes and prototypes, SolidCAM offers powerful 3D Machining, including integrated options for material machining. This operation offers a wide range of roughing, semi-finishing and finishing strategies for free-form models. a. 3D Milling Operation Using this operation, you can calculate the tool path for the rough, semi-finish and finish machining of the 3D Model. A number of strategies can be applied to provide you with effective and high-quality machining. Figure 3.18 3D Milling Operation b. 3D Engraving Operation This operation enables you to perform the engraving of text or artwork on the part faces. Figure 3.19 3D Engraving Operation Manufacturing Process Laboratory Telkom University 96 c. 3D Drill Operation This operation enables you to perform drills that take into account the 3D Model Geometry. Figure 3.20 3D Drilling Operation Labwork Labwork Procedure 2.5 D Operation A. Setting Process 1. Open the part in SolidWorks software. Manufacturing Process Laboratory Telkom University 97 2. Go to SolidCAM Part. 3. On the SolidCAM Part menu, select New →Milling. 4. SolidCAM is started, and the New Milling Part dialog box is shown below. New Milling Part dialog box SolidCAM enables you to create a new CAM-Part using one of the following options: External mode in this mode, the part you create is saved in SolidCAM format (*.prt, *.prz). Internal mode in this mode, the part you create is saved inside SolidWorks part (*.sldprt, *.sldasm). Manufacturing Process Laboratory Telkom University 98 5. The SolidCAM interface can be seen below. 6. Choose the machine that will be used. 7. Define Coordsys Option. Click the Define button in the Coordinate System area to define the Machine Coordinate System. After click define button, click the upper surface of the part. Manufacturing Process Laboratory Telkom University 99 8. After determines the coordinates, CoordSys Data appears to show the coordinates of the machines that used in the machining process. This dialog box enables to define the machining levels such as Tool Start Level, Clearance Level, Part Upper Level, etc. There will be box like below, just click OK. Manufacturing Process Laboratory Telkom University 100 9. Select Stock from the Stock & Target model tab. 10. Add 5 mm on Z+ to be used in facing process then select Add box to CAD model →OK. Manufacturing Process Laboratory Telkom University 101 11. Select Target at Stock & Target model. 12. Click the part until the color of the part changes into purple and then select OK. B. Machining Process Facing Operation 1. Go to SolidCAM Operations. Manufacturing Process Laboratory Telkom University 102 2. To make a facing operation, in SolidCAM Operations select 2.5D →Face. 3. Go to Geometry page. Then select the geometry to choose a surface that will be faced. Click New button, the position is beside of facemill text. Manufacturing Process Laboratory Telkom University 103 4. Choose target in Base Geometry box, then click OK. 5. The yellow line shows the surface of the stock that will be used in facing operation. 6. Go to tool page. Manufacturing Process Laboratory Telkom University 104 7. Click Add Milling Tool to select the tool. 8. Choose FaceMill. 9. Define the Tool Parameters. Manufacturing Process Laboratory Telkom University 105 10. Go to Levels page then define the positioning levels and milling levels. 11. Switch to the technology page, then choose Hatch for the movement of the tools. Manufacturing Process Laboratory Telkom University 106 12. Click Save and Calculate button. 13. Do simulation of the facing operation. 14. Choose Solid Verify, then click play button. 15. After that click this icon to Exit → Manufacturing Process Laboratory Telkom University 107 Profiling Operation 1. After facing operation is complete, then the next step is Profiling. To make a profiling operation, in SolidCAM Operations select 2.5D → Profile. 2. Select icon New in Geometry page to define the geometry. Manufacturing Process Laboratory Telkom University 108 3. Choose side surface of the part that will be profiled, then click √ symbol in Chain List box and click OK. 4. Go to Tool page. The step to choose the tool is same like the previous operation. In profiling operation the tool is end mill. Manufacturing Process Laboratory Telkom University 109 5. Go to Levels page. Click and define the upper level and profile depth as shown below. For upper level click the upper surface of part (see the blue color). For profile depth, click the surface in area that shown in blue color. 6. Go to Technology page then define the technological parameters. First, click the geometry button. Manufacturing Process Laboratory Telkom University 110 If the position of red circle isn’t like the picture below, just change in Tool Side box. 7. Then fill the technology page like below. 8. Click offset button in technology page. For step over, just write 2. Manufacturing Process Laboratory Telkom University 111 Then click the line like below. Choose the line that shown in blue line. 9. Click Save and Calculate button, then simulate. 10. Do simulation of the profiling operation. 11. Repeat the steps of profiling process for other side. Manufacturing Process Laboratory Telkom University 112 Pocketing Operation 1. The next step is pocketing operation. To make a pocketing operation, in SolidCAM Operations select 2.5D → Pocket. 2. Go to Geometry page then define the geometry. Click all the under edges like shown below. 3. Go to tool page then select the tool tht will be used for pocketing operation. In pocketing process, the tool is end mill. Manufacturing Process Laboratory Telkom University 113 4. Go to Levels page then define the upper level and profile depth. For upper level For profile depth Manufacturing Process Laboratory Telkom University 114 5. Switch to Technology page and select Contour from Technology tab. 6. Click Save and Calculate and do simulation for the pocketing operations. Manufacturing Process Laboratory Telkom University 115 7. Repeat the pocketing steps for other side. Use multi-chain on the Geometry page, and select the chosen surface. It will automatically detect the existing line on the part. 1. In SolidCAM Operations select 2.5D → Pocket. 2. Go to Geometry page then define the geometry. Choose Multi-chain box and click add button. Then click the surface like below. 3. The interface will be like this. Manufacturing Process Laboratory Telkom University 116 4. Then choose end mill as the tool. 5. Fill the technology page like below. Manufacturing Process Laboratory Telkom University 117 6. Click Save and Calculate button then do simulation. Slotting Operation 1. After the pocketing operations done, the next step is slotting operation. To make a slotting operation, in SolidCAM Operations select 2.5D → Slot. 2. Define the slot geometry. Manufacturing Process Laboratory Telkom University 118 3. Go to Tool page then define the tool that will be used. Choose end mill. 4. Go to Levels page, the upper level is the highest level of parts that will be slotted. Manufacturing Process Laboratory Telkom University 119 5. Go to Technology page then define the Depth from Slot Levels tab. Manufacturing Process Laboratory Telkom University 120 6. Click Save and Calculate button then do simulation for slotting operation. Drilling Operation 1. The last process is Drilling. To make a drilling operation, in SolidCAM Operations select 2.5D →Drill. 2. Go to Geometry page then define it as shown below. Manufacturing Process Laboratory Telkom University 121 3. Go to Tool page then define the tool that will be used. 4. Go to Levels page then define it as shown below. Manufacturing Process Laboratory Telkom University 122 Manufacturing Process Laboratory Telkom University 123 5. Go to Technology page then define it as shown below. 6. Click Save and Calculate button then do simulation for the drilling operation. Manufacturing Process Laboratory Telkom University 124 T-Slot Operation 1. To make a T-slot operation, in SolidCAM Operations select 2.5D → TSlot. 2. Define the geometry. 3. Define the upper level and T-slot depth Manufacturing Process Laboratory Telkom University 125 4. Click Geometry button in Technology page. If the position of red circle isn’t like this, change in tool side box. 5. Fill the technology page like below. Manufacturing Process Laboratory Telkom University 126 For offset value, click the offset button, then choose the line like shown in blue color. 6. Go to Link Page. Manufacturing Process Laboratory Telkom University 127 7. Click Save and Calculate button then do simulation. 8. These are all of the machining process for the part above. Labwork Procedure 3D Operation A. Setting Process 1. Open the part in SolidWorks software. 2. Go to SolidCAM Part. Manufacturing Process Laboratory Telkom University 128 3. On the SolidCAM Part menu, select New →Milling. 4. SolidCAM is started, and the New Milling Part dialog box is shown below. New Milling Part dialog box SolidCAM enables you to create a new CAM-Part using one of the following options: External mode in this mode, the part you create is saved in SolidCAM format (*.prt, *.prz). Internal mode in this mode, the part you create is saved inside SolidWorks part (*.sldprt, *.sldasm). Manufacturing Process Laboratory Telkom University 129 5. The SolidCAM interface can be seen below. 6. Choose the machine that will be used. 7. Define Coordsys Option. Click the Define button in the Coordinate System area to define the Machine Coordinate System. After click define button, click the upper surface of the part. Manufacturing Process Laboratory Telkom University 130 8. After determines the coordinates, CoordSys Data appears to show the coordinates of the machines that used in the machining process. This dialog box enables to define the machining levels such as Tool Start Level, Clearance Level, Part Upper Level, etc. There will be box like below, just click OK. Manufacturing Process Laboratory Telkom University 131 9. Select Stock from the Stock & Target model tab. 10. Select Target at Stock & Target model. Manufacturing Process Laboratory Telkom University 132 11. Click the part until the color of the part changes into purple and then select OK. B. Machining Process 1. Choose 3D Milling Operation. 2. Define the geometry. Manufacturing Process Laboratory Telkom University 133 3. Define the tool. 4. Define the upper level and lower level in Level Page. Manufacturing Process Laboratory Telkom University 134 5. Define the Technology Page. 6. Click Save and Calculate button then do simulation. Manufacturing Process Laboratory Telkom University 135 7. The next step is choose engraving operation. 8. Define the geometry using multi-chain step. Click add in multi-chain box Manufacturing Process Laboratory Telkom University 136 9. Define the tool. Choose engraving as the tool. 10. Define the upper level and engraving depth. Manufacturing Process Laboratory Telkom University 137 11. Define the technology. 12. Click Save and Calculate then do simulation. Manufacturing Process Laboratory Telkom University 138 13. The last step is 3D Drilling Operation. Click 3D Dilling button. 14. Define the geometry. 15. Define the tool. Manufacturing Process Laboratory Telkom University 139 16. Define the upper level 17. Define the lower level. Manufacturing Process Laboratory Telkom University 140 18. Define the value of offset from model. 19. Define the technology. Manufacturing Process Laboratory Telkom University 141 20. Then save and calculate. Click the Simulate button to simulate. 21. These are all of the machining process for the part above. Manufacturing Process Laboratory Telkom University 142 4th MODULE COMPUTER AIDED MANUFACTURING (TURNING) Objective 1. Students are able to understand concept of turning process. 2. Students are able to understand the CNC Turning components and each function. 3. Students are able to create and simulate machining process by using SolidCAM 2013. Tools 1. Computer 2. SolidCAM 2013 Basic Theory Introduction Turning is a form of machining, a material removal process, which is used to create rotational parts by cutting away unwanted material. The turning process requires a turning machine or lathe, workpiece, fixture, and cutting tool. The workpiece is a piece of pre-shaped material that is secured to the fixture, which itself is attached to the turning machine, and allowed to rotate at high speeds. The cutter is typically a single-point cutting tool that is also secured in the machine, although some operations make use of multi-point tools. The cutting tool feeds into the rotating workpiece and cuts away material in the form of small chips to create the desired shape. Manufacturing Process Laboratory Telkom University 143 Figure 4. 1 Turning Process Turning is used to produce rotational, typically axi-symmetric, parts that have many features, such as holes, grooves, threads, tapers, various diameter steps, and even contoured surfaces. Parts that are fabricated completely through turning often include components that are used in limited quantities, perhaps for prototypes, such as custom designed shafts and fasteners. Turning is also commonly used as a secondary process to add or refine features on parts that were manufactured using a different process. Due to the high tolerances and surface finishes that turning can offer, it is ideal for adding precision rotational features to a part whose basic shape has already been formed. Component of CNC Turning Figure 4. 2 Component of CNC Turning Center Manufacturing Process Laboratory Telkom University 144 Table 4. 1 Description of CNC Turning No 1 Component Sheet metal Description Protective housing that contain cutting chips and capture coolant for recycling. 2 Door The door is closed during operation. Lathes can be dangerous if the part is thrown or a tool breaks during machining. The window is made from a special high impact glass. The lathe should not be operated if this glass is cracked. 3 Spindle The spindle is attached at one end the machine drive system. The other end attaches the chuck, which grips the part. 4 Turret The turret holds and moves the tools. Tools are bolted to the turret using a variety of specialized holders, depending on the type of tool. The turret indexes to present the tool to the work piece. 5 Control The CNC control used to operate the machine. The spindle turns the chuck. The chuck grips the part using hard jaws, soft jaws, or collet. The most common configuration is the three jaw chuck. The chuck requires air pressure to open and close the jaws, and set the gripping force. Pressure must be high enough to securely hold the part, but not so great as to deform fragile parts. Manufacturing Process Laboratory Telkom University 145 Figure 4. 3 Turret Turret, tool holders bolt to either the front or perimeter of the turret. Tool changes are made by the machine indexing the turret to place the appropriate tool closest to the part. The method by which the tools are attached to the turret, and the direction the tool faces in relation to the part, vary depending on the tool, operation, and cut direction. For example, a facing tool is oriented radially to the part, to maximize tool rigidity and work envelope. A boring bar is oriented axially to allow the bar to enter and exit the bore. Manufacturing Process Laboratory Telkom University 146 Table 4. 2 Description of Tool No 1 Component Tool Station Description The turret is divided into stations evenly spaced around the perimeter. Most lathes with tool turrets have about 10 tool stations. Tools are connected to the turret by a tool holder and tool block. The tool holder and block used depend on the type of tool and mount direction. 2 Tool Block Tool blocks act as the interface between the tool holder and the turret. They bolt to the face or perimeter of the turret. Different blocks are used depending on the type of tool and orientation. 3 Turn Tool Turning tools, which includes face, OD rough and finish, groove and cutoff, are usually mounted radially with respect to the part. The cutting tool is usually a ceramic insert mounted in a tool post designed for the specific shape and size insert. 4 Face Groove Face groove tools are mounted axially from the part. Tool 5 Turret The turret holds and moves the tools. To change tools, the turret unlocks, rotates to present the active tool to the work piece, and then locks again. Care must be taken that the turret is away from the part so that none of the tools collide with the part as the turret indexes. 6 Boring Bar A boring bar is used to create a precision size and finish hole through the bore of the part. These are mounted axially with the spindle 7 8 Live Tool A "live tool" is a tool that rotates, being driven by a mechanism in the (Radial holder. Radially mounted live tools are used for cross drilling or milling Mount) on the diameter of the part. Live Tool Axial mounted live tools mill or drill on the face of the part. (Axial Mount) Manufacturing Process Laboratory Telkom University 147 SolidCAM Turning SolidCAM offers you the following types of turning operations: Figure 4. 4 Turning Operation Types a. Face Turning Operation Facing is the process of removing material from the end of a workpiece to produce a flat surface. The principal working direction is the X-axis direction. Figure 4.5 Face Turning Manufacturing Process Laboratory Telkom University 148 b. Turning Operation This operation is one of the most basic machining processes. That is, the part is rotated while a single point cutting tool is moved parallel to the axis of rotation.. The resulting tool path can either use the turning cycles of the CNC-machine, if they exist, or it can generate all the tool movements. If the tool movements are generated by the program, then minimum tool movements length is generated taking into account the material boundary in the beginning of the particular operation. The profile geometry is adjusted automatically by the program, if needed because of the tool shape, to avoid gouging of the material. Figure 4.6 Turning Operation c. Drilling Operation This operation enables you to perform a drilling action along the rotation axis. A drill enters the workpiece axially through the end and cuts a hole with a diameter equal to that of the tool. There is no geometry definition for this type of operation since it is enough to define the drill start and end positions. Figure 4.7 Drilling Operation Manufacturing Process Laboratory Telkom University 149 d. Threading Operation Threading is the process of creating a screw thread.. The threading can be either longitudinal (internal or external) or facial. This operation can be used only if the CNCmachine has a thread cycle. SolidCAM outputs the tool path for the threading exactly with the same length as the defined geometry without any checking for material collision. Figure 4.8 Threading Operation e. Grooving Operation This operation enables you to perform a groove either on a longitudinal geometry (internal or external) or a facial geometry. A single-point turning tool moves radially, into the side of the workpiece, cutting a groove equal in width to the cutting tool. Multiple cuts can be made to form grooves larger than the tool width and special form tools can be used to create grooves of varying geometries.The resulting tool path can either use a single machine cycle, generate all the tool movements (G0, G1) or generate several machine cycles. Manufacturing Process Laboratory Telkom University 150 Figure 4.9 Grooving Operation f. Angle Grooving Operation This operation enables you to perform inclined grooves. The geometry defined for this operation must be inclined relative to the Z-axis of the CAM-Part Coordinate System. The Tool angle parameter enables you to adjust the angle of the tool cutting the material. Figure 4.10 Angle Grooving Operation g. Cutoff Operation Cutoff operation is use to create deep grooves which will remove a completed or partcomplete component from its parent stock and this operation can enables to produce flat surface. The cutting can be performed using CNC-machine cycles; chamfers and fillets can also be generated. Manufacturing Process Laboratory Telkom University 151 Figure 4.11 Cutoff Operation h. Balanced Rough Operation This operation enables you to work with two tools performing roughing cuts at the same time. The Master submachine and Slave submachine should include the same Table. Figure 4.12 Balanced Rough Operation i. Manual Turning Operation This operation enables you to perform turning according to your own geometry regardless of a stock model, target model, or envelope.The Reverse cutting path option enables you to machine undercuts effectively. Manufacturing Process Laboratory Telkom University 152 Figure 4.13 Manual Turning Operation j. Simultaneous Turning Operation This operation enables you to perform machining of curve-shaped tool paths using tilting capabilities of tools with round inserts. The tool tilting is defined by specifying lines that indicate the tool vector change. This operation is useful for machining of undercut areas in a single machining step. Figure 4.114 Simultaneous Turning Operation Manufacturing Process Laboratory Telkom University 153 Labwork The following steps for turning process will be followed: A. Setting Process. 1. Open the part in SolidWorks software. 2. On the SolidCAM menu, select New and then choose Turning. 3. SolidCAM is started, and the New Turning Part dialog box is shown below. Manufacturing Process Laboratory Telkom University 154 New Turning Part dialog box SolidCAM enables you to create a new CAMPart using one of the following options: External mode in this mode, the part you create is saved in SolidCAM format (*.prt, *.prz). Internal mode in this mode, the part you create is saved inside SolidWorks part (*.sldprt, *.sldasm) 4. Define Coordsys Option. Start the Coordinate System definition Click the Define button in the Coordinate System area to define the Machine Coordinate System. Manufacturing Process Laboratory Telkom University 155 With the Select Face mode choosen, click on the model face as shown. Make sure that the Center of revolution face option is chosen. With this option, the origin is placed automatically on the axis of revolution face. Click Change to opposite to change the Z-axis direction to the opposite along the revolution axis. 5. Click the Stock button, the Model dialog box is displayed. This dialog box enables you to define the stock model of the CAM-Part to be machined. In the Offsets dialog section, define the following offsets: Set +Z to 2 to define the front offsets from the model. Manufacturing Process Laboratory Telkom University 156 6. In the Turning Part Data dialog box, click the Target button. The Model dialog box is displayed. This doalog box enables you to define a 3D Model for the Target. Make sure that in the Type section Both is selected to consider both surfaces and solids for Target model. Click on the solid body, the wireframe model is displayed. Confirm the dialog box with . In the process of the Target model definition, SolidCAM creates the Envelope sketch in the CAM component of the CAM-Part assembly. The Envelope sketch is used later for the machining geometry definition. 7. Click in the Turning Part Data dialog box to save the CAM-Part data. Manufacturing Process Laboratory Telkom University 157 B. Machining Processes Face turn operation 1. Select the Face button from the Turning menu on the SolidCAM Operations. The face turn dialog box is displayed. 2. Define the geometry. Choose Wireframe option in the geometry section. Click the New icon . The Geometry dialog box is displayed. Make sure that the default Curve mode is chosen, and select the sketch segments as shown. Confirm the chain definition with the Accept chain button. Manufacturing Process Laboratory Telkom University 158 In the Edit Geometry section, click the Modify Geometry button. In the Start Extension/trimming and End Extension/trimming section set to Auto extend to stock. 3. Define the tool. Switch to the Tool page and click the Select button. Click the Add Turning Tool and choose the Ext, Rough from the solid tools. Set the tool holder width (A) value to 25. Set the tool height (D) value to 55. Set the tool tip angle (a°) value to 80. Set Cutting edge direction to Left and choose the Mounting type as shown Manufacturing Process Laboratory Telkom University . 159 4. Define the technology. Choose the front option in the mode area, and make sure that the Rough option is selected. In the Rough type, select the Smooth option. 5. Click the Save & Calculate, and the click Simulate button. Switch to Turning page for diplay the 2D simulation of the turning tool path. Click the Play button, and the simulation begin. Manufacturing Process Laboratory Telkom University 160 Switch to SolidVerify page to view the tool path in 3D Model, the click Play button. Rotate the model with the mouse wheel. Turning Operation 1. Select the Turning button from the Turning menu on the SolidCAM Operations. The turning dialog box is displayed. 2. Click the New icon in the Geometry page, and select the sketch segment as shown. Make sure that the default Curve mode is chosen. Manufacturing Process Laboratory Telkom University 161 Choose point to point option. It enables you to connect the specified points with a straight line. Click on the sketch point as shown, and the linear geometry segment is defined. Switch back to Curve mode and pick the rest of the sketch entities. Confirm the chain definition with button. 3. Use the tool defined in the previous operation. Click the Select button in the Tool page to choose the tool from the Part Tool Table. Choose the Tool #1 and click Select. Manufacturing Process Laboratory Telkom University 162 4. Define the Technology. Choose the Long external option in the Mode area. In the Work type, use the default Rough option. In the Rough tab, choose Smooth for Rough Type and set the Step down value to 2. In the Rough offset area, choose Distance option and set value to 0.5. In the Semi-finish/finish tab, select the ISO-Turning method in Finish section and choose Entire geometry from Finish on area. Manufacturing Process Laboratory Telkom University 163 5. Click the Save & Calculate, and the click Simulate button. External Grooving operation 1. Select the Grooving button from the Turning menu on the SolidCAM Operations. The grooving dialog box is displayed. Manufacturing Process Laboratory Telkom University 164 2. Click the New icon in the Geometry page, and select the sketch segment as shown. Confirm the chain definition with the Accept chain button. 3. Define the tool. Switch to the Tool page and click the Select button. Click the Add Turning Tool and choose the Ext. Groove from the solid tools. Set the width of the tool holder (A) to 25 Set the distance (B) to -8 Set the height of the tool tip (C) to 10 Set the lower width of the tool tip (G) to 3 Set the lengths of the tool tip cutting edges (D1 and D2) to 7 Set the tool tip angles a° and b° to 0 Set the nose radius Ra to 0.2 Set Cutting edge direction to Left and choose the Mounting type as shown Manufacturing Process Laboratory Telkom University 165 4. Define the technology. Choose the Long external option in the Mode area. In the Work type, use the default Rough option. Choose the distance option in rough offset area and set to 0.5. In the Step over area, set the value to 2. Manufacturing Process Laboratory Telkom University 166 Switch now to Semi-finish/Finish tab. Make sure that the ISO-Turning method option is chosen in the Finish area. Manufacturing Process Laboratory Telkom University 167 5. Click the Save & Calculate, and the click Simulate button. Angled Grooving Operation 1. Select the Angled Grooving button from the Turning menu on the SolidCAM Operations. The angled grooving dialog box is displayed. Manufacturing Process Laboratory Telkom University 168 2. Click the New icon in the Geometry page, and select the sketch segment as shown. Confirm the chain definition with the Accept chain button. 3. Define the tool. Switch to the Tool page and click the Select button. Click the Add Turning Tool and choose the Ext. Groove from the solid tools. Click Advanced button in top right corner to display the Mounting dialog box. Click to choose orientation as shown. Set the additional parameter to -45 to tilt the tool. Define the following parameters: Set the width of the tool tip (G) to 2 Set the distance the tool tip extends beyond the tool tip carrier (C) to 10 Set the cutting edge length (D1,D2) to 4 Set the tool nose (Ra) to 0.2 Set the Cutting edge direction to Left Manufacturing Process Laboratory Telkom University 169 4. Define the technology. Choose Long External option in Mode area. Make sure that the Rough option is chosen in the Work type area. Choose Constant in Step down section and set value to 0.5. In the Step over area set value to 2. Make sure that the Distance is choosen in Rough offset area and set to 0.5. Manufacturing Process Laboratory Telkom University 170 In Semi-finish/finish tab, choose ISO-Turning method in finish area. 5. Click the Save & Calculate, and the click Simulate button Manufacturing Process Laboratory Telkom University 171 Drilling operation 1. Select the Drilling button from the Turning menu on the SolidCAM Operations. The drilling dialog box is displayed. 2. Define the tool. Switch to the Tool page and click the Select button. Click the Add Turning Tool and choose the Drill. Set the D parameter to 15. Set the A parameter to180. Set the CL parameter to 90. Manufacturing Process Laboratory Telkom University 172 3. Define the drill start position. Switch to the Technology page of Drilling Operation dialog box. Click on the front face of the part as shown. Confirm this dialog box with button. 4. Define the drill end position. Click the Drill end button in the Position area. Click on the back face of the part. Confirm this dialog box with button. Manufacturing Process Laboratory Telkom University 173 In the Depth type section, select the Full diameter option. Click the Drill start button in the position area Change to integer number for more accurate result. 5. Click the Save & Calculate, and the click Simulate button. Manufacturing Process Laboratory Telkom University 174 Internal Turning operation 1. Select the Turning button from the Turning menu on the SolidCAM Operations. The turning dialog box is displayed. 2. Click the New icon in the Geometry page, and select the sketch segment as shown. 3. Define the tool. Switch to the Tool page and click the Select button. Click the Add Turning Tool and choose the Int. Rough from the solid tools. Set the tool holder width (A) value to 5. Set the width of the turret (F) value to 15. Set the tool nose radius (Ra) to 0.2. Set Cutting edge direction to Left and choose the Mounting type as shown Manufacturing Process Laboratory Telkom University . 175 4. Define the technology. Choose the Long internal option in the mode area. In the Work type area, choose the Rough option. In the Rough tab, choose Smooth for Rough Type and set the Step down value to 1. In the Rough offset area, choose Distance option and set value to 0.5. Manufacturing Process Laboratory Telkom University 176 Choose the ISO-Turning method for finish in the Semi-finish/finish tab. In the finish on, click Entire geometry. Manufacturing Process Laboratory Telkom University 177 5. Click the Save & Calculate, and the click Simulate button. External Threading Operation 1. Select the Grooving button from the Turning menu on the SolidCAM Operations. The grooving dialog box is displayed. 2. Click the New icon in the Geometry page, and select the sketch segment as shown. Confirm the chain definition with the Accept chain Manufacturing Process Laboratory Telkom University button. 178 3. Define the tool. Switch to the Tool page and click the Select button. Click the Add Turning Tool and choose the Ext. Thread from the solid tools. Set Cutting edge direction to Left and choose the Mounting type as shown 4. Define the technology. Choose Long External option in Mode area. Make sure that the Multiple option is chosen in the Work type area and set the step down to 0.2. Manufacturing Process Laboratory Telkom University 179 Switch to Data tab, Set value to 1.5 in Pitch unit. In the Minor diameter set to 56. Choose Yes under External finish and Thread finish. 5. Click the Save & Calculate, and the click Simulate button. Manufacturing Process Laboratory Telkom University 180 5th MODULE NUMERICAL CONTROL CODE Objective 1. Students are able to understand principal of NC-Code 2. Students are able to understand NC-code of milling operation 3. Students are able to understand NC-code of lathe operation Tools 1. Computer Basic Theory Introduction Today, along with the rapid advances in technology, the process of turning, drilling, milling, and other conventional machining processes are no longer conducted or controlled manually, but it use a computer. Such device, called CNC (Computer Numerical Control). CNC is a machine controlled by a computer using a numerical language (movement commands that use numbers and letters) in the process of operation. Figure 5. 1 CNC Machine Analogy We can analogize the CNC machine as a printer. When we are going to make an article, the first thing we do is made up in the computer first, then when it has finished, we will print the article Manufacturing Process Laboratory Telkom University 181 that we have made using the printer machine. Similarly, when we are going to make a product, the first thing we do is creating an image of the design on the computer, and when the design has been finished then we will print the design using the CNC machine. Before printing, the design must be translated into machine language called NC-code Type of CNC Machine In a medium and large industries we will found the use of CNC machines in favor of the production processes. Broadly speaking, the CNC machines are divided into two kinds, they are: a. 3-Axis/Fraise CNC machine (Milling Machine) b. 2-Axis/Lathe CNC machines (Lathe Machine) a. 3-Axis/Fraise CNC machine (Milling Machine) Milling is the machining process of using rotary cutters to remove material from a work piece advancing (or feeding) in a direction at an angle with the axis of the tool. Figure 5. 2 Milling Operation Manufacturing Process Laboratory Telkom University 182 These are the symbols of milling machine’s movement direction: - X axis for horizontal direction movements - Y axis for transverse direction movements - Z axis for vertical direction movements Figure 5. 3 Milling Operation b. 2-Axis/Lathe CNC machines (Lathe Machine) Figure 5. 4 Lathe Operation The definition of a lathe is a machine that shapes objects by rotating them while a shaping tool such as a chisel is applied to its surface or in other reference it called turning process. A lathe is a machine tool which turns cylindrical material, touches a cutting tool to it, and cuts the material. The lathe is one of the machine tools most well used by machining. A lathe machine can be used to create symmetrical shapes into a piece of wood, metal or other material. Manufacturing Process Laboratory Telkom University 183 Figure 5. 5 Part of Lathe machine Numerical Control Code A machine with computer technology are controlled by a numerical code. A software to translate form code language into movement axis are usually called machine Control Unit (MCU). This language which called programming language for communication between machine and operator using a numerical, alphabetical, and symbol. Programming language in a CNC machine known as Numerical Control Code (NC-Code). Below are the mostly used NC Code to operating a machine, these are: a. G-Code G-Code are used to command specific actions for the machine: such as movements of the machine. A functions of G code are already in International Standardization. G-code and simple definitions: G00 Rapid traverse G01 Linear interpolation with feed rate G02 Circular interpolation (clockwise) G03 Circular interpolation (counter clockwise) G2/G3 Helical interpolation Manufacturing Process Laboratory Telkom University 184 G04 Dwell time in milliseconds G05 Spline definition G06 Spline interpolation G07 Tangential circular interpolation / Helix interpolation / Polygon interpolation feed rate interpolation G08 Ramping function at block transition / Look ahead "off" G09 No ramping function at block transition / Look ahead "on" G10 Stop dynamic block preprocessing G11 Stop interpolation during block preprocessing G12 Circular interpolation (cw) with radius G13 Circular interpolation (ccw) with radius G14 Polar coordinate programming, absolute G15 Polar coordinate programming, relative G16 Definition of the pole point of the polar coordinate system G17 Selection of the X, Y plane G18 Selection of the Z, X plane G19 Selection of the Y, Z plane G20 Selection of a freely definable plane G21 Parallel axes "on" G22 Parallel axes "off" G24 Safe zone programming; lower limit values G25 Safe zone programming; upper limit values G26 Safe zone programming "off" G27 Safe zone programming "on" G33 Thread cutting with constant pitch G34 Thread cutting with dynamic pitch G35 Oscillation configuration G38 Mirror imaging "on" G39 Mirror imaging "off" G40 Path compensations "off" G41 Path compensation left of the work piece contour Manufacturing Process Laboratory Telkom University 185 G42 Path compensation right of the work piece contour G43 Path compensation left of the work piece contour with altered approach G44 Path compensation right of the work piece contour with altered approach G50 Scaling G51 Part rotation; programming in degrees G52 Part rotation; programming in radians G53 Zero offset off G54 Zero offset #1 G55 Zero offset #2 G56 Zero offset #3 G57 Zero offset #4 G58 Zero offset #5 G59 Zero offset #6 G63 Feed / spindle override not active G66 Feed / spindle override active G70 Inch format active G71 Metric format active G72 Interpolation with precision stop "off" G73 Interpolation with precision stop "on" G74 Move to home position G81 Drilling to final depth canned cycle G82 Spot facing with dwell time canned cycle G83 Deep hole drilling canned cycle G84 Tapping or Thread cutting with balanced chuck canned cycle G85 Reaming canned cycle G86 Boring canned cycle G87 Reaming with measuring stop canned cycle G88 Boring with spindle stop canned cycle Manufacturing Process Laboratory Telkom University 186 b. M-Code M-code are codes non-axis commands that used in CNC to define function of the machine. In application functions of Numerical, alphabetical and symbol codes are various, depends on the system and machine control type but still it used in a same principle. M-code and simple definition: M00 Unconditional stop M01 Conditional stop M02 End of program M03 Spindle clockwise M04 Spindle counterclockwise M05 Spindle stop M06 Tool change (see Note below) M19 Spindle orientation M20 Start oscillation (configured by G35) M21 End oscillation M30 End of program c. A-Code Alarm code (A-code) is a sign when machine found uncorrective program. This code help to stop machining process automatically if there are not corrections. Furthermore this code will decrease possibility of machine damage. A-Code and Simple defivnition: A00 Command G & M false A01 Command radius M99 false A02 X Value False A03 F Value False A04 Z Value False A05 Less command M30 A06 Extreme spindle rotation Manufacturing Process Laboratory Telkom University 187 A08 Disk full/empty A09 Cannot found program A10 Disk Locked A11 Load Disk false A12 False Checking A13 Unit false in object A14 unit false A15 H rate False A17 Subroutine program False Absolute and Incremental The addresses X, Y and Z within a program, when G90 (Absolute coordinates) is active, relate to a coordinate position from the work piece datum (the zero position). The addresses X, Y and Z within a program, when G91 (Incremental co-ordinates) is active, relate to the individual axis movements required to reach the new position, from the last position reached by the tool. Desciption The example move illustrated above can be written in two ways: G90 Absolute co-ordinates selected G01 Y60 F150 ; G03 X60 Y100 R40 ; G91 Incremental co-ordinates selected G01 Y60 F150 ; G03 X-40 Y40 R40 ; Figure 5. 6 Absolut and Incremental Coordinates Manufacturing Process Laboratory Telkom University 188 NC Code for Milling b. Corner Rounding and Chamfering Example: Figure 5. 7 Example of Mill Description O1234 (Tittle) T1 M6; G00 G90 G54 X0. Y0. S3000 M3; G43 H01 Z0.1 M08; G01 Z-0.5 F20.; G00 G90 G54 S M3 G43 M08 G01 F Y-5. ,C1.; X-5. ,R1.; Y0.; G00 Z0.1 M09; G53 G49 Z0.; G53 Y0.; M30; C R G53 G49 M30 : Rapid Traverse : Absolute positions commands : Select work coordinate system : speed of spindle : turn spindle on in forward direction : Path compensation left of the work piece contour with altered approach : Coolant On : Linear interpolation with feed rate : Feed rate in inches (mm) per minute : Chamfer : Fillet : Non-modal machine coordinate selection : G43/G44/G143 cancel : Program end and reset Manufacturing Process Laboratory Telkom University 189 c. Using the R address The R-value defines the distance from the starting point to the center of the circle. Use a positive R-value for radius of 180° or less, and a negative R-value for radius more than 180°. Programming examples: Figure 5. 8 Milling using R address Desciption G90 G54 G00 X-0.25 Y-.25 G01 Y1.5 F12. G00 : Rapid traverse G02 X1.884 Y2.384 R1.25 G90 : Absolute positions commands G54 : Select work coordinate system G01 : Linear interpolation with feedrate F : Feedrate in inches (mm) per minute R : Diameter G02 : Circular interpolation (clockwise Manufacturing Process Laboratory Telkom University 190 NC Code for Lathe a. G70 FINISHING CYCLE Figure 5. 9 G70 Finishing Cycle The G70 Finishing cycle can be used to finish to cut paths that are rough cut with stock removal cycles such as G71, G72, and G73, but it can be used alone. The G70 requires that a beginning block number (P code) and an ending block number (Q code) be specified. G71 and G72 are similar canned cycles with regard to tool nose compensation. The finishing and rough finishing passes of G71 and G72 recognize tool nose compensation; however, the roughing pass of these two G codes does not. The template below can be applied to either G71 or G72. (G70 P_Q_F_) P = Starting blok (N Blok) Q = Ending blok (N Blok) F = Feed rate (mm/rev) Manufacturing Process Laboratory Telkom University 191 Example : Figure 5. 10 Example of Lathe Description O00005 (Example 1) T101; (Select tool) G97 S1000 M03; (Spindle speed 1000 RPM) G00 G54 X40. Z2.; (Rapid to start point) G70 P1 Q2 F0.15; (Rough P to Q using G70, feedrate 0.15) N1 G00 X10; (Starting block with rapid to X10) G01 Z-5; (Linear interpolation motion to Z-5) G03 X20. Z-10. R5.; (CCW circ.interpolation radius 5) G01 Z-15.; X25. Z-20; Z-25.; G02 X35. Z-30. R5.; (CW circ.interpolation motion radius 5) N2 G01 X40,; (Ending block, linear motion to X40) G28 U0; (Back to starting point) M05; (Spindle stop) M30; (Program End) Manufacturing Process Laboratory Telkom University 192 b. G71 O.D./I.D. STOCK REMOVAL CYCLE Figure 5. 11 G71 Stock Removal This canned cycle will rough out material on a part given the finished part shape. All a programmer needs to do is to define the shape of a part by programming the finished tool path and then submitting the path definition to the G71 call by means of a PQ block designation. Any feeds, spindle speeds or tools within the block defining the path are ignored by the G71 call. Any F, S or T commands on the G71 line or in effect at the time of the G71, are used throughout the G71 roughing cycle. Usually, a G70 call to the same PQ block definition is used to finish the shape using the programmed feeds, speeds, tools and offsets defined within the PQ block definition. (G71 P_Q_U_W_D_F_) P = Start number of blok (N Blok) Q = End number of blok (N Blok) U = Finishing allowance, x-axis direction, diameter (mm) W = Finishing allowance, z-axis direction D = Depth of cut (mm) F = Feed rate (mm/rev) Manufacturing Process Laboratory Telkom University 193 ID Turning Example : Figure 5. 12 Ilustration of ID Turning Figure 5. 13 Example of ID turning O00002; T101; G97 S1000 M03; G00 G54 X0. Z2.; G71 P3 Q4 U0.1 W0.1 D0.2 F0.15; N3 G00 X40.; G01 Z-5.; OD Turning X30. Z-10.; Example : Z-15.; Manufacturing Process Laboratory Telkom University 194 G3 X25. Z-20. R5.; G01 Z-25.; N4 G01 X0.; G28 U0; M05; M30; OD Turning Example : Figure 5.13 Ilustration of OD Turning Figure 5. 144 Example of OD turning Manufacturing Process Laboratory Telkom University 195 OD Turning Example : O00001 T101; G97 S1000 M03; G00 G54 X40. Z2.; G71 P1 Q2 U0.1 W0.1 D0.2 F0.15; N1 G00 X10.; G01 Z-10.; G03 X20. Z-15. R5.; G01 Z-20.; X25. Z-25.; Z-30.; G02 X35. Z-35. R5.; N2 G01 X40.; G28 U0; M05; M30; Manufacturing Process Laboratory Telkom University 196 Labwork Please fill the blank ! A. Milling 1. Milling (Chamfer & Fillet) Study Case 1 In this case use tool number 1, absolute datum, spindle speed 1000 rpm, Z ( clearance) 0.1. Figure 5.16 Labwork Milling O1234 (Tittle) T1 M6; G__ G__ G__ X_. Y_. S___ M_; G__ H01 Z__ M__; G__ Z-0.5 F20.; ___. ,__.; ___. ,__.; __.; G_ _ Z_._ M_ _; ___ ___ Z_.; ___ Y_.; ___; Manufacturing Process Laboratory Telkom University 197 B. Lathe 1. Finishing Cycle Study Case 1 In this case, we use tool number 1, with spindle speed 1000 rpm. The finishing allowance of xaxis and z-axis in this process is 0.1 and 0.1. And the depth of cut is 0.2, while the feed rate is 0.15 mm/rev. Figure 5.27 Labwork Finishing Cycle O00005 T101; G97 S1000 M03; G00 G54 X40. Z2.; G70 P1 Q2 U0.1 W0.1 D0.2 F0.15; N1 G00 X10; G__ X__. Z__. ; Z___. ; Manufacturing Process Laboratory Telkom University 198 G__ X__. Z___. R_. ; G__ Z__. ; G__X __. Z___. R__. ; N2 G01 X40,; G28 U0; M05; M30; 2. OD Removal Stock Study Case 2 In this case, we use tool number 1, with spindle speed 700 rpm. The finishing allowance of x-axis and z-axis in this process is 0.1 and 0.2, and the depth of cut is 0.3, while the feed rate is 0.1 mm/rev. Figure 5.38 Labwork Finishing Cycle Manufacturing Process Laboratory Telkom University 199 O00005 T101; G__ S____ M__; G__ G__ X__. Z__.; G__ P_ Q_ U_._ W_._ D_._ F_._; N2 G__ X__.; ___ ___.; ___ ___. ___. __.; ___ __. ; __. __.; ___ ___. ____. __.; N3 G01 X40,; G28 U0; M05; M30; 3. ID Stock Removal Study Case 3 In this case, we use tool number 1, with spindle speed 1200 rpm. The finishing allowance of xaxis and z-axis in this process is 0.2 and 0.2, and the depth of cut is 0.3, while the feed rate is 0.15 mm/rev. Figure 5.49 Labwork Finishing Cycle Manufacturing Process Laboratory Telkom University 200 O00002; T101; ___ _____ ___; ___ ___ __. __. ; ___ __ __ __._ __._ __._ _.__; __ ___ ___.; ___ ____.; ___ ___. ___. __. ; ___ ____.; ___. ____.; __ ___ __.; ___ __; ___; ___; Manufacturing Process Laboratory Telkom University 201 6th MODULE MACHINING PROCESS - MILL Objective 1. Students are able to understand the principal of mill processing 2. Students are able to recognize the variety of HAAS Control Simulator keys 3. Students are able to understand about offset on CNC Milling Machine by using HAAS Control Simulator 4. Students are able to manually create and simulate Numerical Control Code (mill process program) by using HAAS Control Simulator Tools 1. Haas Control Simulator version 3.4 Basic Theory Milling Milling is the machining process of using rotary cutters to remove material from a work piece advancing (or feeding) in a direction at an angle with the axis of the tool (Brown and Sharpe 1914). It covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes in industry and machine shops today for machining parts to precise sizes and shapes. Manufacturing Process Laboratory Telkom University 202 Types of Milling Machine Types of milling machines based on the mill orientation Mill orientation is the primary classification for milling machines. The two basic configurations are vertical and horizontal. However, there are alternate classifications according to method of control, size, purpose and power source. a. Vertical mill A turret mill has a stationary spindle and the table is moved both perpendicular and parallel to the spindle axis to accomplish cutting. The most common example of this type is the Bridgeport. Turret mills often have a quill which allows the milling cutter to be raised and lowered in a manner similar to a drill press. This type of machine provides two methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by moving the knee. In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the spindle itself moves parallel to its own axis. Figure 6.1 Vertical milling machine Manufacturing Process Laboratory Telkom University 203 b. Horizontal Mill A horizontal mill has the same sort of x–y table, but the cutters are mounted on a horizontal arbor across the table. Many horizontal mills also feature a built-in rotary table that allows milling at various angles; this feature is called a universal table. While end mills and the other types of tools available to a vertical mill may be used in a horizontal mill, their real advantage lies in arbor-mounted cutters, called side and face mills, which have a cross section rather like a circular saw, but are generally wider and smaller in diameter. Because the cutters have good support from the arbor and have a larger cross sectional area than an end mill, quite heavy cuts can be taken enabling rapid material removal rates. These are used to mill grooves and slots. Plain mills are used to shape flat surfaces. Several cutters may be ganged together on the arbor to mill a complex shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed any section desired. These specialty cutters tend to be expensive. Simplex mills have one spindle, and duplex mills have two. It is also easier to cut gears on a horizontal mill. Some horizontal milling machines are equipped with a power-take-off provision on the table. This allows the table feed to be synchronized to a rotary fixture, enabling the milling of spiral features such as hypoid gears. Figure 6.2 Horizontal milling machine Manufacturing Process Laboratory Telkom University 204 Based on both figures above, the main different between the vertical and the horizontal milling machine is the spindle (spindle is the shaft to which the milling cutter is attached), the spindle of the horizontal milling machine is horizontal and in the vertical milling machine it is vertical. Classification of Milling Processes Two main classifications of milling processes are peripheral milling and face milling. Here are some differences between those two milling processes: (1) Peripheral milling : Cutter axis is parallel to surface being machined Cutting is accomplished by the peripheral teeth of the milling cutter Mostly performed on a horizontal milling machine (2) Face milling : Cutter axis is perpendicular to surface being milled Cutting is accomplished by both the flat face of the cutter and the peripheral teeth of the milling cutter Mostly performed on a vertical milling machine Figure 6.3 (a) Peripheral milling & (b) Face Milling Manufacturing Process Laboratory Telkom University 205 CNC Machine Controller The CNC controller is the brain of a CNC system. A controller completes the all important link between a computer system and the mechanical components of a CNC machine. The controller's primary task is to receive conditioned signals from a computer or indexer and interpret those signals into mechanical motion through motor output. There are several components that make up a controller and each component works in unison to produce the desired motor movement. The word “controller” is a generic term that may refer to one of several devices, but usually refers to the complete machine control system. This system may include the protection circuitry, stepper or servo motor drivers, power source, limit switch interfaces, power controls, and other peripherals. Owners, operators, designers, and builders of CNC devices should understand the tasks performed by these components and how they affect machine performance. In this chapter, HAAS Control Simulator will be explained more specifically. Function of buttons on HAAS Control Simulator a. General Machine Keys Button Table 6.1 General Machine Keys Function Power On Turns CNC machine on. Power Off Turns CNC machine tool off. Emergency Stop Stops all axis motion, stops spindle, tool changer and turns off coolant pump. Jog Handle Jogs axis selected, also may be used to scroll through programs, menu items while editing and also altering feeds and speeds. Cycle Start Starts program in run mode or graphics mode. Feed Hold Stops all axis motion. Spindle will continue to turn. Reset Stops machine, will rewind program. Manufacturing Process Laboratory Telkom University 206 Control functions in Haas machine tools are organized in three modes, those are Setup, Edit and Operation. Access Modes using the mode keys as follows: - Setup : ZERO RET, HAND JOG keys. Provides all control features for machine setup. - Edit : EDIT, MDI/DNC, LIST PROG keys. Provides all program editing, management, and transfer functions. - Operation : MEM key. Provides all control features necessary to make a part Figure 6.4 Keypad Operation Manufacturing Process Laboratory Telkom University 207 b. Keyboard Introduction The keyboard is divided into eight different sectors: Function Keys, Jog Keys, Override Keys, Display Keys, Cursor Keys, Alpha Keys, Number Keys and Mode Keys. In addition, there are miscellaneous keys and features located on the pendant and keyboard which are described briefly the following pages. Function Keys Button Table 6.2 Function Keys Function F1 F4 Perform different functions depending on which mode the machine is in. Example in offsets mode F1 will directly enter value that you give it into to offset register. Tool Offset Measure Will take machine Z position readout at bottom of offset screen and load it in to the highlighted tool offset register. After pressing Tool Offset Measure button in a set up this will Next Tool select the next tool and make a tool change. Releases tool from spindle in MDI, Zero Return or Handle Tool Release mode. A button on the front of the spindle will do the same thing. Part Zero Set Records work coordinate offsets into the highlighted register. Jog Keys Button Table 6.3 Jog Keys Function Chip FWD (Chip Auger Forward) Turns the optional chip auger in a direction that removes chips from the work cell. Chip Stop (Chip Auger Stop) Stops auger movement. Chip REV (Chip Auger Reverse) Turns the chip auger in reverse. CLNT UP (Coolant Up) Pressing this key will position the coolant stream one position higher. Manufacturing Process Laboratory Telkom University 208 CLNT DOWN (Coolant Down) Pressing this key positions the coolant stream one position lower. Coolant stream position will appear in tool length offset register when position is highlighted. AUX CLNT (Auxiliary Coolant) Turns on the optional Through-the-Spindle (TSC) coolant (in MDI mode). +X, -X (Axis) Selects the X axis for continuous motion when depressed. +Y, -Y (Axis) Selects the Y axis for continuous motion when depressed. +Z, -Z (Axis) Selects the Z axis for continuous motion when depressed. +A, -A (Axis) Selects the A axis. This key selects the B axis when used with the SHIFT key if the machine is configured with a fifth-axis option. Override Keys The overrides are at the lower right of the control panel. They give the user the ability to override the speed of rapid traverse motion, as well as programmed feeds and spindle speeds. Display Keys Table 6.4 Display Keys Button Function PRGM/ Selects the active program pane (highlights in white). In MDI/DNC CONVRS mode pressing a second time will allow access to VQC (Visual Quick Code) and IPS (Intuitive Programming System). POSIT (Position) Selects the positions display window (lower middle). Repeated pressing of the POSIT key will toggle through relative positions in the Memory Mode. In Handle Jog mode all four are listed together. OFFSET Selects one of two offsets tables: Tool Geometry/Wear and Work Zero Offset. WRITE/ will add the number in the input buffer to the selected offset, and the ENTER F1 key will replace the selected offset with the number entered into Manufacturing Process Laboratory Telkom University 209 the input buffer. Offsets can also be entered using TOOL OFSET MEASUR and PART ZERO SET CURNT Ten different pages; use PAGE UP and PAGE DOWN COMDS 1. Operation Timers displays Power-On Time, Cycle Start Time, Feed Cutting Time. Hitting ORIGIN will clear any display that is highlighted by the cursor. 2. Real time clock and date 3. System Variables, for machines with Macro Programming. 4. All Active Codes, displays current and modal command values. 5. Position information: Machine, Distance to Go, Operator, Work Coordinate. 6. Tool life, displays the usage of each tool. An alarm can be set for the number of times you want that tool to be used, and when that condition has been met (that is, the tool has been used the set number of times), the machine will stop, with an alarm for you to check the condition of that tool. Pressing ORIGIN will clear the cursor-selected display, and pressing ORIGIN when the cursor is at the top of a column will clear the whole column. 7. Tool Load displays the Tool Load Max % of each tool being used. You can use the Limit% column to set the maximum spindle load for a particular tool. When that condition has been met (the tool has reached maximum load), the machine will stop for you to check the condition of that tool. Pressing ORIGIN will clear the cursor-selected display, and pressing ORIGIN when the cursor is at the top of a column will clear the whole column. Setting 84 determines the Overload Action when this limit is met. Also vibration loads may be entered. 8. Maintenance times for various items may be loaded. 9. Advanced Tool Management (Optional) Manufacturing Process Laboratory Telkom University 210 10. Tool Pot Table: Gives information on which tool is in which Pot. Refer to Automatic Tool Change section on information on how to use this table. ALARM/ Displays messages and current active alarms. Press right arrow key MESGS gives alarm history. Press right arrow key again goes to the Alarm Viewer Page. Enter alarm number and press write will give detailed information on a particular alarm code. PARAM/ Lists machine parameters that are seldom-modified values which DGNOS change the operation of the machine. These include servo motor types, gear ratios, speeds, stored stroke limits, lead screw compensations, motor control delays and macro call selections. All of these are rarely changed by the user and should be protected by Setting 7, PARAMETER LOCK. A second press of PARAM/DGNOS will show the diagnostics display. The PAGE UP and PAGE DOWN keys are then used to select one of two different pages. This display is for service diagnostic purposes, and the user will not normally need them. SETNG/ Displays settings - machine parameters and control functions that GRAPH the user may need to turn on and off or change to suit specific needs. HELP/ Will bring up a help POP UP relevant to the screen you are in. This CALC provides information only pertaining to that screen. Pressing the HELP/CALC button again brings up a tabbed menu. With tabulated screens highlighting tab and pressing WRITE/ENTER key will open up respective tab. Pressing the CANCEL key will close the tab. Milling and Tapping Help you solve values for feed rates SFM, RPM, and chip load under different conditions. Manufacturing Process Laboratory Telkom University 211 Cursor Keys Cursor Keys the cursor keys are in the center of the control panel. They give the user the ability to move to and through various screens and fields in the control. They are used extensively for editing and searching CNC programs. They may be arrows or commands. Table 6.5 Cursor Keys Button Function Up/Down Moves up/down one item, block or field. Page Up/ Used to change displays or move up/down one page when viewing a Down program. HOME Will move the cursor to the top-most item on the screen; in editing, this is the top left block of the program. Will take you to the bottom-most item of the screen. In editing, this is the END last block of the program. Alpha Keys The Alpha Keys allow the user to enter the 26 letters of the alphabet along with some special characters. Depressing any Alphabet Key automatically puts that character in the Input Section of the control (lower left-hand corner). Table 6.6 Alpha keys Button Function SHIFT provides access to the yellow characters shown in the upper left corner of some of the alphanumeric buttons on the keyboard. Pressing SHIFT and then the desired white character key will enter that character into the input buffer. EOB enters the end-of-block character, which is displayed as a semicolon on the screen and signifies the end of a programming block. It also moves the cursor to the next line. Manufacturing Process Laboratory Telkom University 212 These keys are used to define negative numbers and give decimal ( ) and (.) posistion. These symbols are accessed by first pressing the SHIFT key and then the +=#*[] key with the desired symbol. They are used in macro expressions (Haas option) and in parenthetical comments within the program. These are additional symbols, accessed by pressing the SHIFT key, that ,?%$!&@: can be used in parenthetical comments. Numeric Keys The Numeric Keys allow the user to enter numbers and a few special characters into the control. Depressing any number key automatically puts it into the Input Section of the Control. Button Table 6.7 Numeric Keys Function Cancel The Cancel key will delete the last character put into the Input Section of the control display. Space Is used to format comments placed into the Input Section of the control display. Write/ General purpose Enter key. It inserts code from the input Enter section into a program when the program display is in EDIT mode. With offsets pages active, pressing the WRITE/ENTER key adds a number in the Input Section to the highlighted cell. Pressing the F1 key will input the number into the cell. - The (Minus Sign) is used to enter negative numbers. . The (Decimal Point) is used to note decimal places. Manufacturing Process Laboratory Telkom University 213 Mode Keys Mode keys set the operational state of the machine tool. Once a mode is set the keys to the right may be used. The current operation mode of the machine is displayed at the top thin pane of the CRT Button Table 6.8 Mode Keys Function EDIT The edit mode is used to make changes in a program stored in memory. When you press EDIT two panes appear at the top of the screen. In the left pane the active program appears. In the right an inactive program appears or the select program screen appears. On the bottom left a editor help pane appears and on the right a clipboard pane. Editing may be performed in either the active or inactive panes. Pressing EDIT toggles between the two panes, (changes background to white). To call up a program from memory and put it in one of the edit panes press SELCT/PROG. Highlight the program desired by using the up or down cursor buttons and press WRITE/ENTER. INSERT Enters commands keyed into the input panel in lower left pane of CRT after the cursor highlighted word in a program. ALTER Highlighted words are replaced by text input into the input panel. DELETE Highlighted words are deleted from a program. UNDO Will undo up to the last 9 edit changes. F1 KEY While in the edit mode pressing F1 will bring up an edit pop up window. Using the sideways cursor buttons will toggle thru HELP, MODIFY, SEARCH, EDIT AND PROGRAM MENUS. The up and down buttons will cursor thru the different options in each of the above. MODIFY Gives options on changing line numbers. Manufacturing Process Laboratory Telkom University 214 SEARCH Will perform a search and gives the option of replacing text. EDIT Gives option of cutting or copying and pasting to a clipboard and to another program. PROGRAM Gives options of creating new program, selecting a program from list to edit, duplication of programs, switching from left to right side of window panes. Background Edit When a program is being run pushing the edit will bring up the Background Edit pane in the Main Display Pane. Simple edits may be performed on the program that is being run or another program. The edits on the running program will not take place until after the current cycle has completed. MEM The memory mode is the mode used when running the machine and making a part. The active program is shown in the Program Display Pane. Keys in the memory mode line reflect different ways of running a part in memory. When the keys to the right are depressed they will show up highlighted in black on the bottom right of the CRT. SINGLE When depressed SINGLE BLOCK is highlighted in black BLOCK and will appear on the bottom of the CRT. When the machine is in SINGLE BLOCK mode only one block of the program is executed every time the cycle start button is depressed. Used when first test running a program or temporarily stopping a program when it is running. DRY RUN Used to check machine movement without cutting a part. In dry run the machine runs at one feed rate. With the availability of graphics which show visually what the machine tool path is this mode is rarely used. OPTION When OPTION STOP is depressed program will stop at any STOP M01 which is in the program. Normally M01s are placed after a tool is run in a program. When a job is being set up Manufacturing Process Laboratory Telkom University 215 the operator may put machine in op stop mode to check dimensions after every tool has completed cutting. BLOCK When this button is depressed any block with a slash (/) in it DELETE is ignored of skipped. MDI (MANUAL DATA INPUT mode) Usually short programs DNC are written in MDI but are not put into memory. DNC mode allows large programs to be drip fed from a computer into the control. COOLNT Turns coolant on and off manually. ORIENT Rotates and locks spindle to specific angle. Used when SPINDLE lining up tools where spindle orientation may be a issue such as boring heads. ATC FWD Rotates turret to next tool and performs tool change - also used to call up specific tools or pots. Enter tool number (T1) and press ATC FWD. HAND JOG Puts machine in jog mode for set ups. Top values (.0001, .001, .01, .1) represent distance traveled per click of jog handle. Bottom values (.1, 1., 10., 100) represent feed in inches/minute when jogging axis using jog buttons. ZERO RET On pressing position display becomes highlighted in Zero Return mode. ALL Returns all axes to machine home similar in similar fashion as a Power Up/Restart. ORIGIN Sets selected displays to zero or other functions. SINGL Returns a single axis to machine home. Select desired axis (X, Y, or Z) then press Singl axis button. Home/G28 Rapid motion to machine home; will make a rapid move in all axes at once - may also be used for a rapid home in oneaxis. Press axis to home then G28. Caution must be used that Manufacturing Process Laboratory Telkom University 216 fixtures or parts are out of the way before initiating this rapid move to home. SELECT After highlighting a program from List Program with up or PROG down cursor pressing this button will place the program in the Active Program Pane. This is the program that will run the CNC machine in the Memory mode. Use in the Edit mode in the Main Display will enter selected program in the Main Display pane for editing. SEND Will send a selected program or programs out thru RS-232 serial port ERASE Will erase highlighted program or programs. A prompt will PROG appear asking if you want to delete selected program asking for Y/N. Setting Offsets In order to accurately machine a work piece, the mill needs to know where the part is located on the table. Jog the mill with a pointer tool in the spindle, until it reaches the top left corner of the part (see the following illustration), this position is part zero. The value will be entered into G54 on the Work Offset page. Offsets can also be entered manually by choosing one of the offset pages, moving the cursor to the desired column, typing a number and pressing Write or F1. Pressing F1 will enter the number in the selected column. Entering a value and pressing Write will add the amount entered to the number in the selected column. Typical Work Offset Setup 1. Place the material in the vise and tighten. 2. Load a pointer tool in the spindle. 3. Press Handle Jog 4. Press .1/100. (B) (The mill will move at a fast speed when the handle is turned). 5. Press +Z (C). Manufacturing Process Laboratory Telkom University 217 6. Handle jog (D) the Z-axis appoximately 1’’ above the part. 7. Press .001/1.(E) (The mill will move slow speed when the handle is turned). 8. Handle jog (D) the Z-axis approximately 0.2” above the part. 9. Select between the X and Y axes (F) and handle jog (D) the tool to the upper left corner of the part (See the following illustration). 10. Press Offset (G) until the Work Zero Offset Pane is active. 11. Cursor (I) to G54 Column X. 12. Press Part Zero Set (J) to load the value into the X–axis column. The second press of the part Zero Set (J) will load the value into the Y axis column. CAUTION! Do Not Press Part Zero Set s third time; doing so will load a value into the Z-axis. This will cause a crash or Z-axis alarm when the program is run. Figure 6.5 Work Offset Setting the Tool Offset The next step is to touch off the tools. This defines the distance from the tip of the tool to the top of the part. Another name for this tool length Offset, which is designed as H in a line of machine code; the distance for each tool is entered into the Tool Offset Table. 1. Load the tool in the spindle. 2. Press Handle Jog (A). 3. Press.1/100.(B) (The mill will move at a fast rate when the handle is turned). 4. Select between the X and Y axes (C) and handle jog (D) the tool near the center of part. 5. Press +Z (E). Manufacturing Process Laboratory Telkom University 218 6. Handle Jog (D) the axis approximately 1” above the part. 7. Press .001/.1 (F) (The mill will move at a slow rate when the handle is turned). 8. Place a sheet of paper between the tool and the work piece. Carefully move the tool down to the top of the part, as close as possible, and still be able to move the paper. 9. Press Offset (G). 10. Press page up (H) until the page with “Coolant – Length – Radius at top and scroll to tool numbe 1. 11. Cursor (I) to Geometry for position #1. 12. Press toll Offset Measure (J). This will take the Z position located in the bottom left of the screen and put it at the toll number position. CAUTION! The next step will cause the spindle to move rapidly in the Z axis. 13. Press Next Tool (K). 14. Repeat the offset process for each tool. Tool length is measured from the tip of the tool to the top of part with the Z axis at its home position Figure 6.6 Tool Offset Manufacturing Process Laboratory Telkom University 219 Standard Operation of HAAS a. How to turn on Haas Control Simulator 1. Connect Haas Control Simulator to energy Figure 6.7 Simulator 2. Press Emergency Stop button before turn on the Simulator Figure 6.8 Emergency Stop Manufacturing Process Laboratory Telkom University 220 3. Press Power On (Green Button) button to turn on the Simulator Figure 6.9 Power On 4. Press Left to Choose Mill Operation Figure 6.10 Simulator Display Manufacturing Process Laboratory Telkom University 221 5. Follow the instruction from the screen and wait until it ready to start, release Emergency Stop button Figure 6.11 Screen of Setup Zero 6. Press Reset to enable servos Figure 6.12 Screen of enable servos Manufacturing Process Laboratory Telkom University 222 7. Press Power Up Button, wait until the machine configure the position (x, y, z) machine Figure 6.13 Screen of Zero all axes process 8. The Operation is ready to use Figure 6.14 Screen of Operation ready to use Manufacturing Process Laboratory Telkom University 223 b. How to turn off Haas Control Simulator 1. To turn off the simulator machine, press the Emergency Stop Figure 6.15 Emergency Stop 2. Then, press Power Off Button (Red Button) and wait until the simulator turn off Figure 6.16 Power Off Manufacturing Process Laboratory Telkom University 224 Labwork Procedure Tool and Work offsets must be set before an operation can be run. Enter values for each tool used on the Setup screen. The tool offsets will be referenced when that tool is called in the operation. On each of the following interactive screens the user is asked to enter data needed to complete common machining tasks. When all the data has been entered, pressing “Cycle Start” will begin the machining process. a. Tool Offset 1. Press MDI DNC → OFFSET ( Tool Offset default = 0 ) 2. Input Geometry (Length and Dia), Flutes, Actual Diameter, and Tool Type (depends on the measurement) Manufacturing Process Laboratory Telkom University 225 b. Work Offset 1. Press OFFSET ( Work Zero Offset default = 0 ) 2. Input X Axis, Y Axis, Z Axis ( depends on the measurement ) Manufacturing Process Laboratory Telkom University 226 c. Facing Operation Facing is an operation of machining the ends of a workpiece to produce a flat surface square with the axis. In this labwork, a facing program will be made manually. 1. To access a list of programs that already exist in the internal memory, press LIST PROG → choose “memory”, and then press ENTER. 2. Use the Cursor Keys or the Handle Jog to find some numbers of program that doesn’t exist yet. To make a new program, type “O (alphabet) + the number of program that haven’t exist yet” (ex: O40), and then press ENTER. Manufacturing Process Laboratory Telkom University 227 3. Press EDIT to make or edit codes for the program, and then type the required codes (it’s not necessary to use a SPACE), after writing a line of codes press WRITE/ENTER (to delete a code before ENTER was pressed, press CANCEL, and to delete a code after ENTER was pressed, press DELETE). Here is the case : o Work offset G54 o Tool = end mill (d=10 mm), tool number 3 o Workpiece length (y) = 250 mm, and width (x) = 200 mm o Depth of face = 2 mm o Tool clearance (a distance between workpiece and peripheral teeth of cutter) = 5 mm o Spindle speed = 582 rpm o Feedrate = 78,833 mm/minute o Stepover = 100% o R plane (a distance between workpiece and flat face of cutter) = 5 mm First, make a subprogram, a feed program. Note : Z value in line 4 = depth of face X value in line 5 = – (tool clearance + 0.5 tool diameter) Z value in line 6 = R plane X value in line 7 = workpiece width + tool clearance + 0.5 tool diameter Y value in line 9 = tool diameter * % stepover Manufacturing Process Laboratory Telkom University 228 Secondly, make a main program, a program that consists of a subprogram and another required codes in it. Press LIST PROG to go back to the program list, and make a new program like the previous step (step number 2 & 3), with a different number of program. Note : X value in line 4 = workpiece width + tool clearance + 0.5 tool diameter Y value in line 4 = – (stock length – 0.5 tool diameter) H value in line 6 = tool number Z value in line 6 = R plane P40 in line 7 means to call program number 40 (subprogram) L25 in line 7 means the subprogram will loop for 25 times Manufacturing Process Laboratory Telkom University 229 4. Press SETTING GRAPH, and then CYCLE START button to see the facing simulation Manufacturing Process Laboratory Telkom University 230 Manufacturing Process Laboratory Telkom University 231 5. Make a rapid move by using the size of workpiece as a reference, to see if the workpiece have been eaten or not. Press EDIT, then write the following codes below after the 7th line in main program, here are the codes for the case above : G00 G90 X0 Y0 ; Y-250. ; X200. ; Y0 ; X0 ; Note : The Y value in line 9 = - (workpiece length) The X value in line 10 = workpiece width 6. See the simulation by following the step number 4 Manufacturing Process Laboratory Telkom University 232 Extra Labwork Here is the second case : o Work offset G54 o Tool = end mill (d=10 mm), tool number 3 o Workpiece length (y) = 160 mm, and width (x) = 100 mm o Depth of face = 3 mm o Tool clearance = 2 mm o Spindle speed = 1200 rpm o Feedrate = 500 mm/minute o Stepover = 80% o R plane = 3 mm Fill the blank ! Sub Facing : O000__ ; (SUB FACING 2 FRI-XXX) G90 ; G00 ___ ; G01 ___ ___ ; G00 ___ ; G00 ___ ; G91 ; G00 ___ ; M99 ; Manufacturing Process Laboratory Telkom University 233 Main facing : O000__ ; (MAIN FACING 2 FRI-XXX) ___ M06 ; G00 G90 ___ ___ ___ ; ___ M03 ; G43 ___ ___ M08 ; M98 ___ ___ ; M09 ; M05 ; G28 G91 Z0 ; G00 G90 ___ X0 Y0 ; M01 ; M30 ; Manufacturing Process Laboratory Telkom University 234 7th MODULE MACHINING PROCESS - LATHE Objective 1. Students are able to understand principal of lathe processing 2. Students are able to understand about Numerical Control Code on Lathe Machine by using HAAS Lathe Simulator 3. Students are able to create and simulate NC code of lathe Processes by using HAAS Lathe Simulator Tools 1. HAAS Simulator Version 3.4 Basic Theory Introduction Turning is a machining process with a geometrically defined cutting edge, a rotational cutting motion and an arbitrary transverse translatory feed motion. For kinematical classification, one always takes into consideration the relative movement between the work piece and the tool. Turning methods can be classified from various standpoints. For example different objectives of the machining task lead to the distinction between finish and rough turning. In the case of rough turning, a high material removal rate is reached. The objective is to realize a high level of dimensional accuracy and surface quality via small cross-sections of undeformed chip. The flexibility of this manufacturing process allows for economical use from prototype and mass production. In the case of automated and NC operations, several tools can be engaged simultaneously during the machining process in order to reduce manufacturing times and to increase the material removal rate. Manufacturing Process Laboratory Telkom University 235 Figure 7.1 Illustration sketch of lathe process Figure 7.2 Styles of insert holders The turning tools of the various process variants are classified analogously to Figure 2 according to the design of their tool holder. Classification a. Face Turning Face turning is a turning method used to produce an even surface orthogonal to the axis of rotation of the work piece. Process variants include, amongst others, transverse face turning and transverse parting-off for sectioning workpiece components or the entire work piece (Figure 7.3). Figure 7.3 Process variants of face turning The cutting path of all transverse face turning variants lies on an Archimedean spiral. In the case of cylindrical face turning variants on the other hand, the cutting path is in the shape of a coil (helical line). Face turning operations are usually carried out with automatic lathes, especially in the case of small parts, which are manufactured from a bar. In transverse parting-off operations, the tools are designed to be slender in order to minimize Manufacturing Process Laboratory Telkom University 236 loss of material. Both minor cutting edges are tapered toward the tool shaft in order to avoid jamming. Under heavy strain, the tools tend to clatter due to their geometric design. During face turning processes, one must bear in mind that the cutting speed changes with the tool diameter when machining with a constant rotation speed. On conventional lathes, a certain cutting speed range is maintained, for example, by multiple, gradual adjustment of the rotation speed to the machining diameter. In the case of lathes with continuous rotation speed control, the cutting speed is kept constant. b. Cylindrical Turning Cylindrical Turning is used to produce a cylindrical surface that is coaxial to the axis of rotation of the workpiece. The use of this method extends from finishing very small parts (e.g. in the clock and watch industry) to heavy roughing forged turbine blades or drive shafts for plant engineering (e.g. cement mills with lengths of up to 20 m). The most important variants of cylindrical turning are longitudinal cylindrical turning and centreless rough turning (Figure 4). Longitudinal cylindrical turning is the most common method variant, which will be used to exemplify many different machining phenomena. Centreless rough turning is cylindrical turning with several major cutting edges arranged on a rotating tool. The feed movement is made by the workpiece and the rotation movement by the tool. This combination leads to a very high material removal rate. This process variant is predominantly used for removing oxide and roller coatings as well as the surface cracks of rolling and forging blanks such as is required, for example, in the manufacture of cold drawn steel. Figure 7.4 Process variants of cylindrical turning Manufacturing Process Laboratory Telkom University 237 c. Helical Turning Helical turning is used to manufacture helical surfaces with profiling tools. Feed corresponds to the pitch of the screw thread. Figure 5 shows a few important process variants that fall under this category: thread turning, thread chasing and thread die cutting. In the case of thread turning, the thread is manufactured by only one profiled cutting edge in several passes until the required thread depth is obtained. It is characteristic of this process variant that the pitch is produced by the feed. On conventional lathes, the translatory motion is mechanically linked to the rotation motion. In the case of numerically controlled lathes, this link is made electronically. Thread turning tools are available as both part and full profile tools. Part profile tools can only be used when the workpiece is brought to the required external diameter before thread turning, since only the pitch is cut and the external surface is no longer machined. After thread turning, the depth of the thread must be checked. Full profile tools on the other hand are shaped in such as way that the corresponding thread depth is directly cut from the material so that the output workpiece must not be prepared beforehand (Figure 7.5). Figure 7.5 Process variants of helical turning Manufacturing Process Laboratory Telkom University 238 Figure 7.6 Helical turning: part and full profile tools, chaser d. Profile Turning Profile turning is used to produce rotation-symmetrical workpiece shapes by reproducing he tool profile. Profile turning variants are classified according to their process kinematics. The most common methods, shown in Figure 7.7, are face profile grooving, transverse profile grooving and transverse profile turning. Figure 7.7 Process variants of profile turning In the case of profile turning, tools made of both high speed steel and cemented carbide are used. Profile tools made of high speed steel are very common, as they are very tough, easy to manufacture and to regrind. e. Form Turning Form turning is used to produce workpiece shapes by controlling the feed movements. Form turning is categorized as in Figure 7.8 into NC form turning, copy turning and kinematic form turning. Manufacturing Process Laboratory Telkom University 239 Figure 7.8 Process variants of form turning In NC form turning, the feed movement is realized by electronically linked feed drives. NC form turning is the state of the art today. Copy turning involves deriving the feed movement from a reference shape, a moulding or a masterpiece. Pure copy turning was developed further when machine tool controls were made available that could store a contour that had once been applied. These are called teach-in processes. Kinematic form turning was often used in the past to produce ball heads. In this case, the feed axes were kinematically linked via a transmission. This process variant has also been replaced by NC form turning. f. Further Process Variants Up to this point, selected process variants were basically explicated using the example of external machining. In principle, these process variants can also be used for internal machining as shown in Figure 9. Figure 7.9 Internal turning Manufacturing Process Laboratory Telkom University 240 When using internal turning to produce deep contours however, stability problems can arise due to the long protrusion length of internal turning tools. For this reason, the protrusion length and the shaft diameter, which depends on the size of the contour to be machined, should be taken into consideration when selecting the cutting parameters. Figure 7.10 shows some typical tools used in internal turning. Figure 7.10 Internal turning: tool design (Source: Sandvik Coromant) Type of Lathe Machine Generally lathe machine has four types, these are; Conventional lathe, Specified Purpose Lathe, Universal Lathe, and CNC Lathe. a. Conventional Lathe mostly use in low to middle industries, such as workshop garage, and home industry. Conventional lathe operated manually, and every conventional lathe have different function. For example drilling machine cannot be used for facing lathe. Of all Lathe mechine type, this one is the cheapest, but for routine using it would be increase inaccurate and precission decrease because it works really depends on operators skill. Manufacturing Process Laboratory Telkom University 241 Figure 7.11 Conventional Lathe b. Specified purpose lathe, this type is designed for specific function of operating or working material. Function of operation such as surface facing, shaping, drilling, etc. And specified working material such as steel, copper, etc. Figure 7.12 Sepcified lathe facing c. Universal lathe, is a combination of many operation of lathe process in one machine, so it can be handle more than one function on one machine. It able to create a finish product from the beginning process of material until finishing it very usefull and efficient and usually used in highscale industry. Manufacturing Process Laboratory Telkom University 242 Figure 7.13 Universal Lathe d. CNC lathe or Computer Numerical Control Lathe, is the most modern technology of lathe. It using numerial code to control the machine and using supprt of computer technology. For routine activity in turning process this machine is high accuracy and more precisive because it seems copying one code to the next activity. CNC lathe is devide into two purpose of machine, there are CNC Training Unit mostly used for training session for preparing basic skill of operator and using soft metal as the work material and CNC Production Unit is used for production way, mostly for highscale production capacity. Figure 7.14 CNC Lathe HAAS ST20 Manufacturing Process Laboratory Telkom University 243 Component of CNC Lathe There are several main parts of lathe with its own function: Table 7.1 – Several Component of CNC Lathe No Name Function 1 tool A kind of borr or knife in a machine 2 turret A place to plug a tool based on the list or dimension 3 Collet A tool to hold working material 4 Chuck A tool to hold working material on machining process 5 Holder A tool to place an eye of knife 6 Insert knife An eye of knife to inserted to holder Manufacturing Process Laboratory Telkom University Picture 244 No Name Function 7 Spindle A machine part to Picture move / turn the working material while machining process Cartesian Coordinate System The first diagram we are concerned is called a number line. This number line has a reference point zero that is called absolute zero and may be placed at any point along the line. Figure 7.15 The Cartesian Coordinate System The number line also has numbered increments on either side of absolute zero. Moving away from zero to the right or to the top are positive increments. Moving away from zero to the left or to the bottom are negative increments. We use positive and negative along with the increment’s value to indicate its relationship to zero on the line. Manufacturing Process Laboratory Telkom University 245 Absolute and Incremental Positioning By using WORK and TOOL OFFSETS a common point on the part is designated as “PART ZERO”. This is some point on our part that we can physically find. The programmer uses this point as a base to write the intended movement of the tooling. Programmers normally use the front end of our finish machined part as (Z Zero) and the centerline of part as (X Zero). There are two methods used by the programmer to “Steer” our machine. The first is “ABSOLUTE POSITIONING”. Absolute means that X and Z code values are based on the ZERO POINT on the part. If a diameter of 1.0000 inches is needed, it is input as X1.0000. If the print requires facing a shoulder that is 3 inches back from the front of the part, Z-3.0000 in input in the code. The letters X&Z represent ABSOLUTE POSTIONING. The programmer has another tool available to him called “INCREMENTAL POSITIONING”. This is movement based on where the machine is currently sitting. It is also called point to point programming. If a change of half inch smaller diameter is required of the machine from where it is currently sitting U- .5000 is put in the code. If a grooving tool is making a groove that is located ¾” behind a groove that is already finished, W-.7500 is input. The letters U&W represent INCREMENTAL POSTIONING Manufacturing Process Laboratory Telkom University 246 Figure 7.16 The Cartesian Coordinate System 2 Table 7.2 The Cartesian Coordinate System 2 P Absolute Incremental X Z U W 1 -5 0 -5 0 2 -4 -4 1 -4 3 -2 -5 2 -1 4 4 5 6 10 Manufacturing Process Laboratory Telkom University 247 Machining Cycle for Lathe a. G70 FINISHING CYCLE Example 1: Figure 7. 17 Sketch example 1 Manufacturing Process Laboratory Telkom University 248 O00005 (Finishing Cycle) T101; G97 S1000 M03; G00 G54 X40. Z2.; G70 P1 Q2 U0.1 W0.1 D0.2 F0.15; N1 G00 X10; G01 Z-5; G03 X20. Z-20. R10.; G01 Z-20.; X25. Z-25; Z-30.; G02 X35. Z-40. R5.; G01 Z-45.; N2 G01 X40,; G28 U0; M05; M30; Manufacturing Process Laboratory Telkom University 249 Example 2: Figure 7. 18 Sketch example 2 Manufacturing Process Laboratory Telkom University 250 O00002 (ID TURNING); T101; G97 S1000 M03; G00 G54 X0. Z2.; G70 P3 Q4 U0.1 W0.1 D0.2 F0.15; N3 G00 X40.; G01 Z-5.; X25. Z-10.; Z-15.; G03 X20. Z-20. R5.; G01 Z-25.; N4 G01 X0.; G28 U0; M05; M30; Manufacturing Process Laboratory Telkom University 251 b. G71 O.D./I.D. STOCK REMOVAL CYCLE Example : Figure 7. 19 Sketch example 1 Manufacturing Process Laboratory Telkom University 252 O00001 (OD TURNING) T101; G97 S1000 M03; G00 G54 X40. Z2.; G71 P1 Q2 U0.1 W0.2 D0.2 F0.15; N1 G00 X10.; G01 Z-15.; X20. Z-25.; Z-33.; X35.; Z-48.; N2 G01 X40.; G28 U0; M05; M30; c. G75 O.D./I.D. Grooving Cycle, Peck Drilling Figure 7. 20 G75 O.D/I.D Grooving cycle, peck drilling The G75 canned cycle can be used for grooving an outside diameter with a chip break. With this canned cycle, either a single pecking cycle can be executed (as for a single groove), or a series of pecking cycles can be performed (as for multiple grooves). Manufacturing Process Laboratory Telkom University 253 (G75 X..Z..I..K..F..) X = Axis Absolute Grooving Depth, Diameter Value (mm) Z = Axis Absolute Location to The Furthest Peck (mm) I* = X- Axis Pecking Depth Increment, Radius Value (mm) K*= Z- Axis Shift Increment Between Pecking Cycles (mm) F = Feed Rate (mm/rev) Example : Figure 7. 21 Sketch example 3 Manufacturing Process Laboratory Telkom University 254 O00007 (OD GROOVING); T101; G97 S500 M03; G00 G54 X30. Z-20.; G75 X20. Z-12. I0.2 K1.5 F0.15 G28 U0; M05; M30; Figure 7. 22 Sketch example 4 Manufacturing Process Laboratory Telkom University 255 O00008 (ID GROOVING); T101; G97 S500 M03; G00 G54 X38.; Z-20.; G75 X44. Z-12. I0.2 K1.5 F0.15; G28 U0; M05; M30; d. G81 DRILL CANNED CYCLE Figure 7. 23 G81 Drill canned cycle Z = Absolute Z-Depth (Feeding to Z-Depth from R- Plane) (mm) R =Rapid to R- Plane (Where Your Rapid, to start feeding) (mm) F = Feed Rate (mm/rev) Manufacturing Process Laboratory Telkom University 256 Example : Figure 7. 24 Sketch example 5 O000013 (DRILLING); T101; G97 S500 M03; G00 G54 X0. Z10.; G81 Z-20. R2. F0.05; G28 U0; M05; M30; Manufacturing Process Laboratory Telkom University 257 Labwork Study Case 1 Manufacturing Process Laboratory Telkom University 258 In this case, we use tool number 1, with spindle speed 1000 rpm. The finishing allowance of x-axis and z-axis in this process is 0.1 and 0.2, and the depth of cut is 0.2, while the feed rate is 0.15 mm/rev. ( The initial position cutting tool is X = 40 mm, Z = 2 mm) O00--- (OD TURNING) Roughing Cycle T101; G97 S1000 M03; G00 G54 X40. Z2.; G71 P1 Q2 U0.1 W0.2 D0.2 F0.15; N1 G00 X10.; G01 Z-15.; X35. Z-25.; Z-33.; X35.; Z-48.; N2 G01 X40.; G28 U0; M05; M30; Manufacturing Process Laboratory Telkom University 259 Study Case 2 Manufacturing Process Laboratory Telkom University 260 In this case, we use tool number 1, with spindle speed 500 rpm. The finishing allowance of xaxis and z-axis in this process is 0.15 and 0.21, and the depth of cut is 0.3, while the feed rate is 0.13 mm/rev. ( The initial position cutting tool is X = 45 mm, Z = 2 mm) O00--- (OD TURNING) Finishing Cycle T101; G97 ____ M03; G00 G54 ___ ___; G70 P3 Q4 U0.15 W0.21 D0.3 F0.13; N3 G00 ___; ___ ___; G02 ___ ___ R10.; ___ ___; G03 ___ ___ R10.; ___ ___.; ___.; N4 G01 X45.; G28 U0; M05; M30; Manufacturing Process Laboratory Telkom University 261 Study Case 3 Manufacturing Process Laboratory Telkom University 262 In this case, we use tool number 1, with spindle speed 1050 rpm. The finishing allowance of x-axis and z-axis in this process is 0.1 and 0.2, and the depth of cut is 0.1, while the feed rate is 0.2 mm/rev. ( The initial position cutting tool is X = 60 mm, Z = 2 mm) O00--- (OD TURNING) Roughing and Finishing Cycle T101; G97 ____ M03; G00 G54 ___ ___; G71 P1 Q2 ___ ___ ___ ___; G70 P1 Q2 F0.2; N1 ___ ___; ___ ___; ___ ___ ___ ___; ___ ___; ___ ___; ___ ___ ___ ___; ___ ___; ___; N2 G01 X60.; ___ ___ ; ___; ___; Manufacturing Process Laboratory Telkom University 263 8th MODULE MACH3 CNC ROUTER ENGRAVER UNIT CONTROLLER Objective 1. Students are able and understand about MACH3 CNC controller software 2. Students are able to operate programs that have been made to the CNC Router Engraver 3. Students are able and understand how to operate CNC Router Engraver using MACH3 CNC controller software 4. Students are able and understand how to calibrate CNC Router Engraver using MACH3 CNC controller software Tools 1. Artsoft MACH3 2. CNC Router Engraver 3. Vernier Calipers 4. Stock 5. Glove 6. Fixture Basic Theory Component of CNC The main components of a CNC system are : a. Computer Aided Design/Computer Aided Manufacturing (CAD/CAM) program. The part designer uses the CAD/CAM program to generate an output file called a part program. The part program, often written in “G-Code” describes the machine steps required to make the desired part. You can also create a G-Code program manually. b. A file transfer medium such as a USB flash drive, floppy disk, or network link, transfers the output of the CAD/CAM program to a Machine Controller. Manufacturing Process Laboratory Telkom University 264 c. A Machine Controller. The Machine Controller reads and interprets the part program to control the tool which will cut the workpiece. Mach3, running on a PC, performs the Machine Controller function and send signals to the Drives. d. The Drives. The signals from the Machine Controller are amplified by the Drives so they are powerful enough and suitably timed to operate the motors driving the machine tool axes. e. The machine tool. The axes of the machine are moved by screws, racks or belts which are powered by servo motors or stepper motors Figure 8.1 Main parts of CNC system Manufacturing Process Laboratory Telkom University 265 Artsoft Mach3 Software Figure 8.2 Artsoft MACH3 Mach3 is a software developed by Artsoft to user to interpret/define the product part that has been translated into a G-Code that can be done using CNC production process. Mach3 is a very flexible program designed to control machines such as milling machines, lathes, plasma cutters, and routers. Features of these machines that are used by Mach3 include: Some user controls. An emergency stop (EStop) button must be provided on every machine. Two or three axis of motion, which are usually at right angles to each other (referred to as X, Y, and Z). A tool which moves relative to a workpiece. The origin of the reference axes is fixed in relation to the workpiece. The relative movement can be by (1) the tool moving (e.g. the quill of a milling spindle moves the tool in the Z direction, or a lathe tool mounted on a cross-slide and a saddle moves the tool in the X and Z directions) or by (2) the table and workpiece moving (e.g. on a knee type mill the table moves in the X, Y, and Z directions while the tool remains fixed in the spindle). Manufacturing Process Laboratory Telkom University 266 a. MACH3 Program Run Figure 8.3 MACH3 Program Run Mach3 Program Run Interface allow the users to do the main set up for the CNC machine, which in our case is the CNC Router Engraver, such as: a) Register zero point for your designed part b) Insert G-Code from designed part c) Display the G-Code of your part d) Run G-Code that have been inserted Specifically the Program Run Interface can be defined as below: a) Display G-Code from part b) Customize the G-Code program in accordance with the requirements c) Menu to run inserted G-Code d) Code directory that have been inserted e) DRO (Digital Readouts). Numbers listed on the menu will indicate the position of the X, Y, Z, A, B, C in accordance with program requirements. f) Toolpath Display, picture / simulation is given when G-Code is executed Manufacturing Process Laboratory Telkom University 267 g) A menu that provides information about the tools used, the speed of rotation. In addition the user can also adjust the specification tool that is used through this menu. b. Manual Data Input (MDI) Figure 8.4 MACH3 MDI This Menu is used to review whether the assigned G-Code is moving the machine to the designated place or not. The main function is to control the inserted G-code one by one. c. Toolpath Figure 8.5 MACH3 Toolpath Manufacturing Process Laboratory Telkom University 268 When the program is executed, it shows the tools movement path. d. Offsets Figure 8.6 MACH3 Offsets This menu is used to set the adjustments that will be processed by the CNC machine in accordance to the shape of the desired product. e. Settings Figure 8.7 MACH3 Settings Used to manually set the calibration of CNC machine. Manufacturing Process Laboratory Telkom University 269 f. Diagnostics Figure 8.8 MACH3 Diagnostics Is a menu that the function shows the position of the machine at the time of the operation, it is similar to the toolpath display menu but have different display and different interface indicators. Manufacturing Process Laboratory Telkom University 270 g. MPG (Manual Pulse Generator) Figure 8.9 MACH3 Settings To open the MPG menu we can press the "tab" button on our keyboard. MPG is one form of controls, to control the CNC machine manually. You do this by pressing the arrow keys on the keyboard or by clicking the buttons X- X+ Y+ Z- Y- Z+ as you needed. CNC Router Engraver CNC is a machine controlled by a computer using a numerical language (some code that use numbers and letters in order to give movement command) as the inputs for the operation process. Manufacturing Process Laboratory Telkom University 271 With CNC Router Engraver only can do milling operation. CNC Router Engraver is included in the CNC milling machine. CNC milling machine use the axis system of the basic Cartesian coordinate system. The working principle of CNC milling machine is the table are moving transversely and horizontally, while the blade / chisel rotates. The axis symbol for the axis motion direction of the machine are given as follows: a. X axis for the horizontal direction of motion. b. Y axis for the transversal direction of motion. c. Z axis for the vertical direction of motion. Figure 8.10 CNC Router Engraver Figure 8.11 Fixture Manufacturing Process Laboratory Telkom University 272 Figure 8.10 displayed the whole part of CNC Router Engraver, which will be controlled by MACH3. The CNC Router Engraver has the capability of executing 2.5 axis and 3 axis operation. Figure 8.11 is fixture, To lock the workpiece in the work table so that the workpiece isn’t thrown during the machining process CNC Router Engraver, as mentioned in Figure 8.10 has 7 main part with it’s specified function, which is: a. CNC Control Box It had on/off button which functioned as the power supply for the CNC Router Engraver. It also had E-Stop in case some emergency occur during the machine’s execution. b. Spindle Place where you put your drill / chisel to be used for the part engraving on the work piece. c. Working Table Place for holding up your part stock. The stock is tighten using a clamp to hold still during the process.. d. X Axis Stepping Motor Is the motor driving the direction of the X axis (vertical direction) forward and backward e. Y Axis Stepping Motor Is the motor driving the direction of the Y axis (vertical direction) forward and backward f. Z Axis Stepping Motor Is the motor driving the direction of the Z axis (vertical direction) forward and backward g. Cable Chain As a place for the movement of the cable - the cable each axis stepper motors on the CNC machine Manufacturing Process Laboratory Telkom University 273 h. Fixture To lock the workpiece in the work table so that the workpiece isn’t thrown during the machining process Manufacturing Process Laboratory Telkom University 274 9th MODULE ASSEMBLY, FINISHING AND MOLDING Objective 1. Students know and understand the concept of Assembly. 2. Students understand the assembly process and method used in the manufacturing process. 3. Students know and understand type of joints that is used in the manufacturing process. 4. Students know and understand type of finishing process that is used in the manufacturing process. 5. Students know and understand type of molding process that is used in the manufacturing process Tools 1. Stock that has been created in the previous process. 2. Screw driver 3. Sandpaper 4. Markers 5. Ruler / Calipers 6. 4 Hingers (Engsel) 7. 8 Screw Joints Manufacturing Process Laboratory Telkom University 275 Basic Theory Assembly Assembly is a process of drafting and unification of some component parts into an instrument or machine that has a particular function. The work of the assembly started when an object is ready to install, and ended when the object was have fused perfectly. a. Types of Assembly There are several types of commonly used assembly in industry. Usually a factor of form and amount of products that would yield of decisive importance. In general there are two types of assembly: Manual Assembly The assembly process worked conventionally or using manpower without using any supportive tools. Automated Assembly Automated assembly refers to a manner of producing goods by use of automated machinery or assembly robots and a systematic approach to assembling goods that operates at least partly independently from human control. b. Methods of Assembly 1) Cascade Method Cascade method is a method of assembly between components with a step sequence. The method is widely used for coupling system between components using the rivet. 2) Balance Method A method of balance in assembling is process of grafting components by using spot welding. Assembly with spot welding is widely used for grafting thin plates. The application process of grafting by spot welding it is commonly used in the auto industry and trains, as well as aircraft industry. Manufacturing Process Laboratory Telkom University 276 3) Knockdown Method Knockdown method is a widely used in assembly process. The main purpose of this method is: 1. Facilitate the mobility or transportation 2. For the maintenance or replacement of components in sections. 3. Facilitate in operational work 4. Simplifying product construction Assembly process with this method generally using bolts and nuts or screws. Assembly with this method must be done carefully, especially in the case of drilling the holes that will be assembled Factor Affecting Assembly a. Types of Metal Every materials have its own characteristic, this characteristic will determine which assembly method is the most suitable to be used in our assembly process. So before we do an assembly process we must know the type and characteristic of the material that we pick. b. Strength Consideration of the power required for a construction, should have been counted when planning what will be explained, in this case by considering what the construction is used. On this basis we can choose the connection method in the basic assembly process for the construction of the power connection required. c. Selection of Joining Method Selection of joining methods are closely related to the type of materials and the power connection required because each method of connection has its own privileges. d. Strengthening Method Selection The strengthening of plates aims to give rigidity on the plate subjected to the process of formation. Because the plate material is relatively thin, the plate is usually required reinforcement at both the edge and the body. Manufacturing Process Laboratory Telkom University 277 e. Tolerance Tolerance in assembly envisaged under pair between an element are assembled into bigger components. f. Form / Display The appearance of a product intensely affecting against the value of selling the product itself. The appearance really prompted by a picture or design. A display adapted to use of construction in the field. g. Ergonomic Ergonomic is defined in this assembly is a match between the products with the convenience of the user (end user). This means that if the product used does not cause fatigue, dangerous, boring, etc h. Finishing Finishing or the final work is really an important part in the process of assembly. Finishing this will give the final appearance of an object to the sale value. Joint According to Darma Adjie (2012) joint function is to fasten a machinery construction, whether permanent or not. There are two kinds of joint in general: a. Semi Permanent Joint A temporary joint, so it still can be disassembled while still in normal condition. Riveted Joint Riveted joints are being replaced by the more economical welded and glued joints. Until the appearance of welding, riveting was the main joining method used in the construction of metal bridges and hoisting cranes (stress-relieved or strong joints), boilers (tight stress-relieved or tight strong joints), and low-pressure tanks (tight joints). Riveted joints are used for parts made of materials that cannot be welded or heated, such as thin-walled parts (made of sheet material) in aircraft construction and in the manufacture of bus and trolleybus bodies, as well as for heavily loaded joints subject to impact and vibratory loads under operating conditions. Riveted joint can be used to: Manufacturing Process Laboratory Telkom University 278 a) As the strength joint in light metal construction (multilevel construction, bridges construction and aircraft construction) b) As an impermeable joint for water tank, chimney plates, and pipes c) As a joint nails for aircraft and vehicle construction Figure 9. 1 Riveted join on global spec Bolt Joint The bolt joint is one of the non-permanent joint. This connection can be assembled or disassembled according to the desired state. In machinery construction the bolt itself divided by it’s function : 1) Translucent Bolt Translucent bolt used to tie the two elements or parts through the hole to penetrate. 2) Tap Bolt These bolts are used to clamp two parts of the machine elements. 3) Stud Bolt This bolt does not have a head, but there are screw on each side. Screw Joint A screw joint is a special type of sleeve joint that enables screws to be tightened into surrounding joint sleeves. These are often used for metal rod assembly or corners that require a threaded screw for structural stability. Manufacturing Process Laboratory Telkom University 279 Figure 9. 2 Screw Joint Bolt In general, hexagon-shaped nut. However, for the use of a variety of shapes made various nut head, including: a. Hex b. Heavy Hex c. Nylon Insert Lock d. Jam e. Nylon Insert Jam Lock f. Wing g. Cap h. Acorn i. Flange j. Tee k. Square l. Prefailing Torque Lock Manufacturing Process Laboratory Telkom University 280 Figure 9. 3 Bolt b. Permanent Joint Is a fixed joint, so they could not detachable forever, except by ruining it first. • Weld Joint Welding is a process of grafting of metal being one due to heat with or without the influence of pressure or can also be defined as a bond metallurgy inflicted by the force of attraction draws between the atoms. There are 2 types of welding: 1) Caribide welding / Autogenus welding A welding that uses a propellant of oxygen gas (acid) and acetylene gas (acetylene). In steel construction, this welding is used for light work or secondary construction such as metal fences, trellises, and so on. 2) Electric Welding Electric welding is the process of heating and welding two pieces of metal together using a powerful electric current. It was invented by prof. Elihu Thomson. It requires the use of a specialized device called a dynamo that releases the current used for welding. Manufacturing Process Laboratory Telkom University 281 Finishing Finishing processes required for the objects or components to obtained maximum precision object size. Some finishing process that is often performed are grinding, sanding process, and varnish. Finishing processes has to be done for the purpose of cleaning, removal the unwanted parts and protect the desired parts to make it more interesting. And the cleaning process is done to remove impurities such as dust, oil or crust which is resulted from machining process. The finishing process itself can be done after or before the assembly process, depending on the shape of the part being processed, whether it can be assembled (knock down) or not. If the part can be apart pairs in the finishing process is usually done first prior to the assembly process. However, if parts can not be assembled the assembly process will be done first and followed by the finishing process. Kinds of finishing: 1. Grinding Process Grinding machine is a equipment used for the installation of the grinding wheel, to remove the surface of the workpiece. Types of Grinding Process: a. Angle Grinder Grinding wheel used in Angle Grinder is a thin grinding disc. Angle Grinder can be used to scrape the surface of the workpiece (grinding) and cut the workpiece. Angle Grinder is usually used for smoothing the surface of the workpiece after welding process, especially in large-sized workpieces. Manufacturing Process Laboratory Telkom University 282 Figure 9. 4 Angel Grinder b. Bench Grinder Similar to Angle Grinder, grinding machine position just attached to the holder. To perform grinding, the workpiece is approximated and affixed to the rotating grinding wheel to the workpiece surface is eroded by the grinding wheel. Grinding wheel used in Bench Grinder is thicker than the size of the grinding wheel in Angle Grinder. Bench Grinder is widely used for sharpening a chisel, scrape and smooth the surface of the workpiece after the workpiece welding process. Figure 9. 5 Bench Grinder c. Drop Saw Drop Saw is a grinding machine to cut the material of the workpiece plate or pipe. Grinding wheel used is a thin grinding disc that is played at high speed. Drop Saw can cut the workpiece cutting plates or pipes of steel materials quickly. Manufacturing Process Laboratory Telkom University 283 Figure 9. 6 Drop Saw 2. Sanding Process Sanding process is one important step in the woodworking process. To produce a wood product with good quality, it is necessary to have flat and smooth surface which is only achieved with the sanding process. The quality of finishing is largely determined by the quality of the sander required. Type of Sander: a. Hand Sander Hand sander is hand sanding machine. This tool is more accurately described as a small tool or machine. This tool must be moved manually by hand and still need to employ skilled operators to be able to get a good sanding results. Nonetheless sanding machine has been very helpful in doing sanding the wood. This sanding machine can do the job to sanding the wood surface with a faster , more consistent with the use of human labor that much smaller. Hand sander is available in various sizes and shapes that can be selected according to the shape and size of the material are sanded. Manufacturing Process Laboratory Telkom University 284 Figure 9. 7 Hand Sander b. Wide Belt Sander Wide belt sander is a sanding machine for a wide surface. Wide belt sander is a machine that uses a belt sanding sandpaper. This tool has a set of abrasive belt contact with a roll to do the sanding. This machine could have some sandpaper belt to do some sanding process at once. There are also machines that have double head that could work to do sanding on both sides of the panel surface at once. Workpiece in the form of flat panels inserted into the machine by using a feeding conveyor to undergo a series of processes in the sanding machine. This machine is most appropriate tool to perform calibration on the surface of the big panels. If we require the panels with the same thickness then we need a wide belt sander machine with good quality. Wood panels put into this tool and came out with the same thickness in each side. Wide belt sander with good quality is needed in the modern woodworking industry that makes products with the size of the panels of the same thickness with high precision . Manufacturing Process Laboratory Telkom University 285 Figure 9. 8 Wide Belt Sander c. Stroke Sander Stroke sander sanding machine is a tool that has a long sanding belt. A long sanding belt rotates to make the process of sanding the surface. These machines still require the operator to perform sanding with sandpaper belts by pressing the surface to be sanded. This machine can produce the sanding surface with excellent quality. The operator can do the setting and control of the sanding process with a set time and sandpaper belt presses. Stroke is also relatively flexible to do the sanding process on a slightly uneven surface. These machines are more widely used to do the final sanding on wood panels before entering the finishing process. Manufacturing Process Laboratory Telkom University 286 Figure 9. 9 Stroke Sander d. Brush Sander This sanding machine is not using sandpaper belt as a tool to do the sanding. Instead, this tool uses a brush consists of fabric that is cut thin sandpaper and a buffer as a tool to do the sanding. Brush sander sanding machine that is designed to make the process of sanding work on objects that are not flat. Sanding with a brush sander will not be able to produce a flat surface and smooth like other ampals tool but is enough to cut and reduce feathering existing wood on the wood surface. Figure 9. 10 Brush Sander Manufacturing Process Laboratory Telkom University 287 3. Polishing Process Polishing is a finishing process that is generally performed on a wooden stock that serves as a coating to the color of the wood stock. Polish process is done on the outer portion of stock directly exposed to the sun. 4. Painting by using Spray Gun Spray gun is a tool used in the finishing process to give color to the stock. The workings of the spray gun in general is, by inserting dye into the tube of paint, and spray it on the stock by utilizing the thrust of air (usually coming from the compressor). Shape Spray Gun: a) HVLP (High Volume Low Pressure): the position of the tube is under the gun most widely used for applications that require a base coat as much as the amount of material covering the wood pores. Figure 9. 11 High Volume Low Pressure Manufacturing Process Laboratory Telkom University 288 b) Gravity Spray Gun: Tube located on top of the spray gun and it is usually used for final finishing (top coat) with a higher viscosity. Figure 9. 12 Gravity Spray Gun c) Airless Spray Gun tube connected directly to the large (20 liters) of finishing materials and instantly have two channels at the base. This type is usually used for staining in bulk material mixing color finishes that are not too large deviations. Figure 9. 13 Airless Spray Gun Manufacturing Process Laboratory Telkom University 289 Molding Molding is the process of manufacturing by shaping liquid or flexible raw material using a rigid frame called a mold or matrix. This may have been made using a pattern or model of the final object. A mold or mould is a hollowed-out block that is filled with a liquid or flexible material like plastic, glass, metal, or ceramic raw materials. The liquid hardens or sets inside the mold, are adopting its shape. A mold is the counterpart to a cast. The very common bi-valve molding process uses two molds, one for each half of the object. Piece-molding uses a number of different molds, each creating a section of a complicated object. This is generally only used for larger and more valuable objects. a. Injection Molding Injection molding is a thermoplastic material processing method in which the molten material for heating injected by the plunger into a mold which is cooled by the water where the material will be cool and harden so it can be removed from the mold. This is the molding process: Figure 9. 14 Injection Molding Manufacturing Process Laboratory Telkom University 290 Sequence in a simple injection molding process is as follows: 1. Door closing. Injection process begins when the safety door is closed 2. Mold clamping. Moveable platen moves forward so that the mold is closed and locked. 3. Injection. Injecting molten resin into the mold has 4. Holding Maintain the shape of the resin that has been injected with a pressure which is then called holding pressure 5. Cooling The process of cooling the resin in the mold that has been injected to harden and form unchanged 6. Charging / Recovery / Dosing At the time of the cooling process, the resin that has been previously in the drying hopper then scaled through the feeding hopper and in shatters through the round screw in the injection unit and ready for the next injection process 7. Mold open Moveable platen moves backward / open mold after the injection process is completed 8. Eject b. Blow Molding Blow molding is a manufacturing process by which hollow plastic parts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and injection stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or in the case of injection and injection stretch blow molding (ISB) a preform. The parison is a tube-like piece of plastic with a hole in one end through which compressed air can pass. The parison is then clamped into a mold and air is blown into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected. There are several different types of blow molding. Manufacturing Process Laboratory Telkom University 291 c. Injection Blow molding Injection blow molding is used in the production of large quantities of hollow plastic objects. Figure 9. 15 Injection Blow Molding d. Extrusion Blow Molding In extrusion blow molding (EBM), plastic is melted and extruded into a hollow tube (a parison). This parison is then captured by closing it into a cooled metal mold. Air is then blown into the parison, inflating it into the shape of the hollow bottle, container, or part. After the plastic has cooled sufficiently, the mold is opened and the part is ejected. Figure 9. 16 Extrusion Blow Molding Manufacturing Process Laboratory Telkom University 292 e. Stretch Blow Molding The main applications of stretch blow molding includes jars, bottles, and similar containers because it produces items of excellent visual and dimensional quality compared to extrusion blow molding. The process first requires the plastic to be injection molded into a 'preform' with the finished necks (threads) of the bottles on one end. Figure 9. 17 Stretch Blow Molding Labwork 1. Prepare a stock that has been created in the previous module Manufacturing Process Laboratory Telkom University 293 2. Prepare the tools used ( Hinges (Engsel), Drill, Sandpaper, Screwdriver, ) 3. Measure stock (frame cover) using a ruler/calipers to determine the dimensions that will be embed the hinges and marked it, with dimensions as follows (1,5cm x 0,8cm ). Manufacturing Process Laboratory Telkom University 294 4. Make holes for the joint on the hinges in accordance with the position of the hinges in stock, after that hinges can be interconnected with stock. On the other hinges part do the same on the press stock so that molding stock and press stock can be interconnected. 5. To refined the stock, finishing process will be performed by using a sandpaper. Manufacturing Process Laboratory Telkom University 295 REFERENCE Alavala, C.R. 2008. CAD/CAM: Concepts and Applications. India: Prentice-Hall Black, J.T. (2008). Degarmo’s: Materials and Processes in Manufacturing tenth edition. America: John Wiley & Sons, Inc. Bodemyr, Emma and Vallin Daniel. 2005. How Improve a CAD/CAM/CNC-process. Adelaide: Lulea University of Tehcnology. Bralla, James. 2007. Handbook of Manufacturing Process. New York: Industrial Press. Inc. Computer Aided Process Planning: Unit 9 Computer Aided Process Planning. Retrieved from http://www.ignou.ac.in/ Dixit, Prakash M. and Dixit, Uday S. (2008). Modeling of Metal Forming and Machining Processes. London: Springer. Doctoral Thesis 2014 KTH Royal Institute of Technology Engineering Sciences Department of Production Engineering SE-100 44 Stockholm, Sweden. El-Hofy, Hassan Abdel-Gawad. (2005). Advanced Machining Processes. USA: McGraw-Hill. G and M Programmingfor CNC Milling Machines Denford Limited Birds RoydBrighouse West Yorkshire England HD6 1NB. Groover. 2001. Automation, Production Systems, and Computer Integrated Manufacturing., second edition. New Jersey: Prentice Hall. Groover. 2007. Fundamentals of Modern Manufacturing. New Jersey: Prentice Hall. Haas Automation, Inc.2800 Sturgis Road Oxnard,California HAAS Mill Operator Manual Book Halevi Gideon,1955. Principles of Process Planning: A logical Approach. London:Chapman & Hall. Mach3 Tutorial, Mach3 CNC Controller Configuration Version. Manufacturing Process Laboratory Telkom University 296 Machining. 2009. p. http://www.custompartnet.com/wu/machining Mambohead.com, CNC 6040 Router Engraver System Installation Manual. Manufacturing Process Laboratory. 2013. Modul Praktikum Proses Manufaktur. Bandung: Institut Teknologi Telkom. Manufacturing Process Laboratory. 2014. Modul Praktikum Proses Manufaktur. Bandung: Universitas Telkom. Marinov, Valery. (2010). Manufacturing Processes For Metal Products. St.Louis: Kendall Hunt. Pandey, Pulak M. Selecting and Planning the Process of Manufacture. Retrieved from http://web.iitd.ac.in/ Rajput, R. (n.d.). Compherensive Basic Mechanical Engineering. p. 153. Rao, P.N. 2006. CAD/CAM: Principles and Applications. India: Tata McGraw-Hill Publishing Company. Schey, John A. Introduction to Manufacturing Processes. Third Edition. SolidCAM 2013 Mill Turn Training Course web http://www.solidworks.com SolidCAM 2013 Milling Training Course 2.5D Milling http://www.solidworks.com Subagio, Ganjar Dalmasius. 2008. Teknik Pemrograman CNC. Jakarta: LIPI Press. Youssef Helmi, 2008. Machining Technology: Machine Tools and Operations. USA:Taylor and Francis Group. Manufacturing Process Laboratory Telkom University
© Copyright 2024