Programs for CNC machines are a complete set to get started. Creation of programs for CNC machines of higher professional education

MINISTRY OF EDUCATION AND SCIENCE OF THE RF

MOSCOW STATE TECHNICAL UNIVERSITY MAMI

Faculty: “Mechanical and Technological”

Department: “Automated machine tools and tools”

COURSE WORK

by discipline

Programmed processing on CNC and SAP machines

Development of a control program for a numerically controlled machine

Moscow 2011

Maintaining

Technological preparation of the control program

1 Selection of technological equipment

2 Selecting a CNC system

3 Sketch of the workpiece, justification of the method for its production

4 Tool selection

5 Technological route for processing a part

6 Purpose of processing modes

Mathematical preparation of the control program

1 Coding

2 Control program

Conclusions from the work

Bibliography

coding machine part software control

2. Introduction

Currently, mechanical engineering has received widespread development. Its development is in the direction of significantly improving product quality, reducing processing time on new machines due to technical improvements.

The current level of development of mechanical engineering places the following requirements on metal-cutting equipment:

high level of automation;

ensuring high productivity, accuracy and quality

manufactured products;

reliability of equipment operation;

High mobility is currently due to the rapid replacement of production facilities.

The first three requirements led to the need to create specialized and special automatic machines, and on their basis automatic lines, workshops, and factories. The fourth problem, most typical for pilot and small-scale production, is solved using CNC machines. The process of controlling a CNC machine is presented as a process of transferring and converting information from a drawing to a finished part. The main function of a person in this process is to convert the information contained in the drawing of a part into a control program understandable by the CNC, which will allow the machine to be controlled directly in such a way as to obtain a finished part that matches the drawing. This course project will examine the main stages of developing a control program: technological preparation of the program, and mathematical preparation. To do this, based on the drawing, the parts will be selected: workpiece, CNC system, technological equipment.

3. Technological preparation of the control program

3.1 Selection of process equipment

To process this part, we select a CNC lathe model 16K20F3T02.

This machine is designed for turning parts of rotating bodies with stepped and curved profiles in one or several working strokes in a closed semi-automatic cycle. In addition, depending on the capabilities of the CNC device, various threads can be cut on the machine.

The machine is used for processing parts from piece workpieces with clamping in a power-driven chuck and, if necessary, pressing with a center installed in the tailstock quill with mechanized movement of the quill.

Technical characteristics of the machine:

Parameter name Parameter value Largest diameter of the workpiece: above the bed above the support 400 mm 220 mm Diameter of the rod passing through the hole 50 mm Number of tools 6 Number of spindle speeds 12 Spindle speed limits 20-2500 min -1Limits of working feeds: longitudinal transverse 3-700 mm/min 3-500 mm/min Speed ​​of fast strokes: longitudinal transverse 4800 mm/min 2400 mm/min Discretion of movements: longitudinal transverse 0.01 mm 0.005 mm

3.2 Selecting a CNC system

CNC device - part of the CNC system is designed to issue control actions by the executive body of the machine in accordance with the control program.

Numerical program control (GOST 20523-80) of a machine - control of the processing of a workpiece on a machine according to a control program in which the data is specified in digital form.

CNCs are distinguished:

-contour;

-positional;

positional-contour (combined);

adaptive.

With positional control (F2), the movement of the working parts of the machine occurs at specified points, and the movement path is not specified. Such systems allow processing only straight surfaces.

With contour control (F3), the movement of the working parts of the machine occurs along a given path and at a given speed to obtain the required processing contour. Such systems provide work along complex contours, including curved ones.

Combined CNC systems operate at control points (nodal points) and along complex trajectories.

Adaptive CNC machine provides automatic adaptation of the workpiece processing process to changing processing conditions according to certain criteria. The part considered in this course work has a curved surface (fillet), therefore, the first CNC system will not be used here. The latest three CNC systems can be used.

From an economic point of view, it is advisable in this case to use contour or combined CNC, because they are less expensive than others and at the same time provide the necessary processing accuracy.

In this course project, the CNC system “Electronics NTs-31” was chosen, which has a modular structure, which allows you to increase the number of controlled coordinates and is intended mainly for controlling CNC lathes with feed servo drives and pulse feedback sensors.

The device provides contour control with linear-circular interpolation. The control program can be entered either directly from the remote control (keyboard) or from an electronic memory cassette.

3.3 Sketch of the workpiece, justification of the method for its production

In this course work, we conditionally accept the type of production of the part in question as small-scale. Therefore, a rod with a diameter of 95 mm of simple rolled section (round profile) for general purpose made from steel 45 GOST 1050-74 with hardness HB = 207...215 was selected as a blank for the part.

Simple sectional profiles for general purpose are used for the manufacture of smooth and stepped shafts, machine tools with a diameter of no more than 50 mm, bushings with a diameter of no more than 25 mm, levers, wedges, and flanges.

During the blanking operation, the bushings are cut to a size of 155 mm, then on a milling and centering machine they are trimmed to a size of 145 mm, and here the center holes are simultaneously made. Since when installing a part in the centers, the design and technological base are combined, and the error in the axial direction is small, it can be neglected.

A drawing of the workpiece after the milling-centring operation is presented in Figure 1.

Figure 1 - workpiece drawing

3.4 Tool selection

Tool T1

To process the main surfaces of roughing and finishing, we select a right-hand cutter with mechanical fastening of a DNMG110408 plate made of GC1525 hard alloy and a clamp of increased rigidity (Fig. 2).

Figure 2 - right through cutter

K r b, mmf 1, mmh, mmh 1, mml 1, mml 3, mm γλ s Reference plate93 02025202012530,2-60-70DNMG110408

Tool T2

Figure 3 - prefabricated cutting tool

l a , mma r , mmb, mmf 1, mmh, mmh 1, mml 1, mml 3, mmReference plate4102020,7202012527N151.2-400-30

Tool T3

To drill a given hole, select a GC1220 carbide drill for drilling for an M10 thread with a cylindrical shank (Fig. 4).

Figure 4 - drill

D c , mmdm m , mmD 21max, mml 2, mml 4, mml 6, mm91211.810228.444

Tool T4

To drill a given hole, select a GC1220 carbide drill with a cylindrical shank (Fig. 5).

D c , mmdm m , mml 2, mml 4, mml 6, mm20201315079

Tool T5

For making internal thread M 10×1 select a tap

GOST 3266-81 made of high-speed steel with helical grooves (Fig. 5).

Figure 5 - tap

3.5 Processing route

The technological route for processing a part must contain the name and sequence of transitions, a list of surfaces processed during the transition and the number of the tool used.

Operation 010 Procurement. Rental Cut the workpiece Ø 95 mm in size 155 mm, make center holes up to Ø 8 mm.

Operation 020 Milling and centering. Mill the ends to size 145 mm.

Operation 030 Lathe: Place the workpiece in the front drive and rear rotating centers.

Installation A

Transition 1

Tool T1

Pre-sharpen:

· cone Ø 30 mm to Ø 40

· Ø 40

· cone Ø 40 mm to Ø 6 0 mm from length 60 mm to length 75 mm from the end of the workpiece

· Ø 60

· Ø 60 mm to Ø 70 along an arc with a radius of 15 mm from a length of 85 mm from the end of the workpiece

· Ø 70

· Ø 70 mm to Ø 80 mm at a length of 120 mm from the end of the workpiece

· Ø 80 mm to Ø 90

· Ø 90

Leave a finishing allowance of 0.5 mm per side

Transition 2

Tool T1

Finish sharpening according to transition 1:

· cone Ø 30 mm to Ø 40 mm to a length of 30 mm from the end of the workpiece

· Ø 40 mm from a length of 30 mm to a length of 30 mm from the end of the workpiece

· cone Ø 40 mm to Ø 60 mm from a length of 60 mm to a length of 75 mm from the end of the workpiece

· Ø 60 mm from length 75 mm to length 85 mm from the end of the workpiece

· Ø 60 mm to Ø 70 along an arc with a radius of 15 mm from a length of 85 mm from the end of the workpiece

· Ø 70 mm from a length of 100 mm to a length of 120 mm from the end of the workpiece

· Ø 70 mm to Ø 80 mm at a length of 120 mm from the end of the workpiece

· Ø 80 mm to Ø 90 mm along an arc with a radius of 15 mm from the length from the length of 120 mm from the end of the workpiece

· Ø 90 mm from length 135 mm to length 145 mm from the end of the workpiece

Transition 3

Tool T2

· Sharpen a rectangular groove 10 mm wide from a diameter of 40 to a diameter of 30 mm at a distance of 50 mm from the end of the workpiece.

Installation B

Transition 1

Tool T3

· Drill a hole Ø 9 40 mm deep.

Transition 2

Tool T4

· Drill a hole with Ø 9 to Ø 20 to a depth of 15 mm.

Transition 3

Tool T5

· Cut the thread with an M10 tap ×1 to a depth of 30 mm.

Operation 040 Flushing room.

Operation 050 Thermal.

Operation 060 Grinding.

Operation 070 Test.

3.6 Purpose of processing modes

Installation A

Transition 1 - rough turning

Tool T1

2.When pre-turning steel with a through cutter with a carbide plate, we select the depth of cut t = 2.5 mm.

.When turning steel and depth of cut t = 2.5 mm, select feed S = 0.6 mm/rev.

.

.Cutting speed

WITH v

TO MV = 0.8 (Table 4 p. 263)

TO PV = 0.8 (, table 5 p. 263)

TO IV = 1 (, table 6 p. 263)

6.Spindle speed.

7.Cutting force.

where: C R

(, table 9 p. 264)

8.Cutting power.

Transition 2 - finishing turning

Tool T1

.Determination of the working stroke length L = 145 mm.

2.When pre-turning steel with a through cutter with a carbide insert, we select t = 0.5 mm for the depth of cut.

.When turning steel and depth of cut t = 0.5 mm, select feed S = 0.3 mm/rev.

.Tool life T = 60 min.

.Cutting speed

WITH v = 350, x = 0.15, y = 0.35, m = 0.2 (Table 17 p. 269)

KMV = 0.8 (Table 4 p. 263)

TO PV = 0.8 (, table 5 p. 263)

TO IV = 1 (, table 6 p. 263)

6.Spindle speed.

7.Cutting force.

where: C R = 300, x = 1, y = 0.75, n = -0.15 (Table 22 p. 273)

(, table 9 p. 264)

8.Cutting power.

Transition 3 - grooving

Tool T2

.Determination of the working stroke length L = 10 mm.

2.When cutting grooves, the depth of cut is equal to the length of the cutter blade

.When turning steel and depth of cut t = 4 mm, select feed S = 0.1 mm/rev.

4.Tool life T = 45 min.

.Cutting speed

State educational institution

higher professional education

Moscow State Industrial University

GOU VPO MGIU

Scientific and educational material

Round table on the topic “Development of control programs for CNC machines using modern CAD/CAM systems”

Composition of the scientific and educational team:

Burdina E.A., Ph.D., Associate Professor

Egorkina E.B., leading engineer

Chichekin I.V., Ph.D.

Moscow 2010

Development of control programs for CNC machines using modern CAD / CAM – systems.

The purpose of this course is to improve the qualifications of higher education teachers related to the operation and training of CNC machines.

The process of preparing a control program, checking it on the CNC and final testing on the machine requires special training in this area.

The program provides a theoretical course, as well as practical training using a three-axis vertical milling multi-purpose machine MIKRON 600 Pro with a Heidenhain TNC530 CNC system, and an INDEX ABC turning and milling machining center with a Sinumeric CNC system.

"Preparation and control of control programs for CNC machines of the milling group"

Topic 1. Introduction. CNC vertical milling machine model MIKRON 600 Pro. Purpose and area of ​​use of the machine. Main components and technical characteristics of the machine. Cutting modes.

Topic 2. Pro ENGINEER . Constructing a geometric model using the Sketch element. Create a solid body that forms a typical body part.

Topic 3.

Topic 4. GPost .

Topic 5. Heidenhain TNC 530. Design of a simulation control panel. File management. Working with tool tables. Tool data. Tool correction.

Topic 6. Heidenhain . Tool movement. Trajectory functions. Circuit programming. Working using cycles.

Topic 7. Manual programming of circuits in codes ISO .

Topic 8. Visual control of the tool trajectory. Operator checking programs. Direct processing of the part on the machine.

"Preparation and control of control programs for CNC machines of the turning group"

1. Thematic content of the course

Topic 1. Introduction. CNC turning and milling center model INDEX ABC. Purpose and area of ​​use of the machine. Main components and technical characteristics of the machine. Cutting modes.

Topic 2. Basics of geometric modeling in the environment Pro ENGINEER . Constructing a geometric model using the Sketch element. Create a solid body that forms a typical part for turning.

Topic 3. Development of control programs. Workpiece design. Calculation of technological parameters of production. Creating a tool table. Construction of a processing trajectory. Obtaining the control program.

Topic 4. Generate control programs using a post processor using a built-in application GPost . Main functions. Selecting a postprocessor.

Topic 5. Basics of Manual Programming SINUMERIC . File management. Working with tool tables. Tool data. Tool correction. Synchronization of tool heads.

Topic 6. Manual programming of contours using standard cycles. Turning cycles. Drilling cycles. Trajectory functions. Circuit programming. Working using cycles.

Topic 7. Manual programming of circuits in codes ISO . Main functions. Secondary functions. Frame format. Circuit programming.

Topic 8. Visual control of the tool trajectory using a virtual machine. Operating principle, main functions. Operator checking programs.

Topic 9. Equipment training. Drawing up control programs. Work on equipment. Direct processing of the part on the machine.

Turning.

The INDEX multi-purpose lathe, model ABC, is designed for processing a wide range of parts of bodies of rotation of relatively simple geometric shapes, both on an automatic machine (rod version of the workpiece), and as on a CNC machine for parts of complex geometric shapes (processing of individual workpieces). Thus, the INDEX machine model ABC combines the advantages of a cam-controlled automatic bar processing machine and a universal CNC lathe.

The need to combine two principles of processing parts on one machine is determined by the currently developing technology for processing small parts, the high processing efficiency of which is achieved using the principle of longitudinal turning with a feed collet.

Automatic machines with a feed collet can work with bars with a diameter of up to 22 mm. Most of these machines are CNC controlled. Almost always, the machine is equipped with a special device that automatically feeds the rod into the processing zone through a collet chuck.

The expanded technological capabilities of the machine are provided by a wide range of cutting tools and a corresponding number of tool heads. The presence, for example, of 19 tools on the machine ensures complete processing of an overwhelming range of parts made from rods.

For the machine version under consideration today, the cutting tool set is an optimized set that provides the following parts processing operations: turning, threading, cutting, grooving, and boring.. These tools take advantage of all the advantages of modern carbide materials with wear-resistant coatings and replaceable inserts that are completely use the capabilities of the machine.

The tool requirements for small-scale machining are somewhat different from conventional requirements. These requirements should ensure the following features of small-sized processing: higher accuracy and quality of processing; the ability to process any materials; more careful control over the process of chip formation; perform processing with high productivity.

Rice. 1 . Varieties of multifaceted inserts recommended for the use of small-sized machining: 1 – for cutting and turning grooves; 2 – for thread cutting; 3 – for cutting pipes and parts of small diameter; 4 – for external turning; 5 – for boring internal diameters; 6 – for cutting, grooving, threading; 7 – grooving; 8 – external thread; 9 – external turning; 10 – internal thread; 11 – for internal turning, grooving and threading

Layout and main components of the machine

The base of the machine is a welded steel structure on which an inclined bed with two independent turrets is installed. This design has good damping capacity and also creates optimal conditions for precision machining, since the structure of the supporting part of the machine is highly resistant to bending and torsion resulting from the cutting process.

All linear coordinate movements occur along rolling guides, which are manufactured with high precision and are particularly sensitive to small movements. Force-locked connections between the spindle box and the frame, as well as safety clutches on all ball screws, protect the operation of the machine from possible unexpected collisions and other unusual situations.

Favorable thermodynamic operating conditions of the machine are ensured by the symmetrical design of the spindle box and control of the temperature changing during the cutting process, as well as the perpendicular location of the spindle box to the tool plane.

The main advantages of the machine are as follows:

Compact design of the machine, occupying a relatively small area;

Reducing piece time by processing the workpiece on both sides and using up to 3 tools working simultaneously;

Ability to operate driven (rotating) tools on all machine supports;

Possibility of processing multi-faceted steel bars;

Convenient and accessible machine working space for adjustment.

In Fig. Figure 2 shows the main components included in the machine. For clarity, the machine is presented as open from protective devices and external fencing.

Fig.2 . Units of a multi-purpose CNC lathe Index ABC series: 1 – base; 2 – second turret support; 3 – motor spindle; 4 – main drive; 5 – support for processing the back side of the part; 6 – first turret support; 7 – inclined bed; 8 – feed drive

Rice. 3. Working area of ​​the machine: 1 - right side of the workpiece; 2 – collet chuck; 3 – spindle; 4 – support for processing the back side of the part; 5 – small diameter drill; 6 – drill; 7 – left side of the workpiece; 8 – cutter; 9 – synchronous spindle; 10 – first turret spindle; 11 – drill; 12 longitudinal cutter; 13 – second turret support; 14 – carriage

Right side of the workpiece 1 can be processed with any type of through (or scoring) cutter 12 located in the second caliper 13 , which has linear coordinate movements along X 2, Y 2, as well as the ability to set the angle along the coordinate c1. Linear movements of the caliper are carried out by carriages 14 . In addition, on this part of the workpiece from the first caliper 10 Can process central or side surfaces with tools 11 .

After complete processing of the right part of the workpiece, a synchronously rotating spindle 9 is brought to it and captures the processed right part. Using a transverse cutter located on the second support (not shown in the figure), the right part is cut off from the workpiece and the first support 10 brings the workpiece 7 into position, as shown in Fig. 3, for final processing with tools 5, 6, 8 of additional support 4. The finally processed part is released from the clamp and falls into the magazine of finished parts.

When processing bar material, after completing the first part of the processing, the workpiece is fed from the loading device to the stop in order not to interrupt the processing cycle from the combined mode of simultaneous processing of the right and left parts of the workpiece.

Thus, when processing workpieces on a machine, you can use several variants of technological processing strategies.

Rice. 4 Samples of parts made on ABC series machines INDEX : a - aluminum part; b – bronze bushing; c – steel washer; g - copper fitting; d – steel bushing; e - fork

Control system INDEX C200-4

The INDEX C200-4 control system (Fig. 4.9) is based on the Siemens 840 D system and is designed to implement intelligent control of cutting processes on INDEX machines.

Rice. 5. INDEX control system C 200-4

A distinctive feature of the INDEX C200-4 system is the independence of process control and the ease of programming workpiece processing cycles.

Independence of control allows test indications to be made without affecting the machine control process. On the control panel screen, you can carry out a general overview of the operation of all spindles and axes of movement of supports, determine the location and cause of errors that appear, and have online information about the operation of the machine or the necessary service documentation at any time.

The convenience of programming is, first of all, determined by the presence of more than 70 prepared cycles, which have found greater application in the technological processes of manufacturing various parts. During the cutting process, the system provides the operator with detailed information support and also guarantees reliable program execution with maximum flexibility in solving specific customer problems. In addition, the system can solve problems of ensuring optimal loading of the machine.

The control system provides quick setup for:

Locking, if necessary, all axes of the machine;

Step-by-step supply of tool supports;

Testing overlapping processing cycles in the state before the command to start processing was turned on;

Operator control before each turret switching.

The starting position of the machine is ensured:

Returning to the initial position (to zero) by pressing the corresponding key;

- “rewind” the program to the desired location while maintaining channel synchronization;

Approach using REPOS exactly to the starting (new) point;

Using starting conditions.

Management system structure

Figure 6 shows the structure of the INDEX C200-4 CNC system.

To process a workpiece, as a rule, several programs are developed. These programs are stored in a directory named the workpiece. Each processing program contains commands that follow each other in time to independently move a specific machine unit (for example, a tool carriage / turret).

Execution of a separate machining program, i.e. Primary frame processing and path interpolation occur in a separate channel. Multiple channels are required to perform multiple operations simultaneously. These channels are coordinated by the PLC (Programmable Logic Controller).

The channels correspond to the controlled axes, spindles and switching functions of the machine, i.e. managed nodes.

All part processing programs must be assigned numbers by which they can be uniquely identified in the common memory.

Fig.6. Management system structure

One channel processes its own part program. All channels of the machine are numbered. Since several channels and often additional special operations (i.e. part processing programs) are required for one clamping of the workpiece, the following structure of the program number must be observed.

The normal machining (main program) for channel 1 (turret 1) is called: %_N_1_0_MPF or %_N_1_MPF.

The normal machining (main program) for channel 2 (turret 2) is called: %_N_2_0_MPF or %_N_2_MPF,

The program for making a part from a bar (bar start program) for channel 1 is called: %_N_1_7_MPF.

Main programs and subroutines are stored in program memory.

Along with them, there are a number of file types that can be written to intermediate memory and, if necessary (for example, when processing a certain workpiece) are transferred to RAM (for example, for initialization).

All blanks are saved in the directory " _ N_WKS_DIR", forming subdirectories. Each subdirectory consists of ordered workpiece machining programs.

%_ N_1_0_ MPF

; Program name:...

;-- Start of program ---

N10 L100

N20 GX73

N9999 M30

%_N_2_0_MPF

;$PATH=/_N_WKS_DIR/_N_TEST_WPD

; Program name:...

;-- Start of program ---

N10 L100

N20 GX73

N9999 M30

Subroutine in the workpiece "Test"

%_N_L10_SPF

;$PATH=/_N_WKS_DIR/_N_TEST_WPD

Subroutine in the subroutine directory

%_ N_ L700_ SPF

;$ PATH=/_ N_ SPF_ DIR

Practical lessons.

Construction of a shaft model.

File > Set Working Folderc:\users\student\* .

· Set the model name to VAL, then press OK .

OK .

· A new file called VAL will be created.

icons, respectively Reference planes on/off And On/off coordinate system .

Set up your measurement system.

From the main menu, click Edit > Settings > Units. In the dialog box Unit Manager millimeter kilogram sec and press Set, OK .

In the window Unit Manager click Close (Close).

Save > ENTER .

The next step is to create a sketch of the shaft, see Fig. 3.

Drawing Sketch

Bindings bindings click OK .

Select an icon Create a line Construct the contour of the shaft in a longitudinal section as shown in the figure.

Select an icon center line, and draw through the origin as shown in Figure 3.

To complete the sketch in the Sketch panel

click the icon Continue with current section. The finished sketch is shown in Figure 3.

On the main toolbar, click the icon List of saved views and select from the drop-down list Standard Orientation .

On the feature creation panel, click the icon Rotate. Next, in the design tree, select the created sketch “SKETCH 1”. The system will automatically rotate the sketch with default parameters. In the dialog panel, enter the 360° rotation parameter. See Figure 4.

………

………

The model should look like shown in the picture

VERTICAL MILLING MULTIPURPOSE MACHINE

CNC MODELS MIKRON V.C.E. 600 Pro

Purpose and area of ​​use of the machine

Vertical 3-axis milling multi-purpose machine model MIKRON VCE 600 Pro, the appearance of which is shown in Fig. 7 is designed for drilling, boring, threading holes (without the use of a compensation chuck) and milling work when processing complex-profile surfaces of parts made of steel, cast iron, high-alloy steels, non-ferrous and other materials.

Rice. 7. Appearance of the machine model MIKRON V.C.E. 600 Pro

The positive feature of the machine is determined by the high cutting power, accuracy and ease of programming directly on the machine using standard cycles (for example, when milling open and recessed planes). The high rotation speed of the tool spindle (up to 10,000 rpm) and tool life (due to internal cooling) make it possible to process high-strength aluminum alloy with small-diameter cutters, which is extremely important when processing long parts in the aviation and space industries. An important area of ​​use of the machine is the production of molds and dies using spherical cutters, which provide a finishing operation for milling surfaces.

The area of ​​use of a multi-purpose CNC machine is mechanical engineering.

Main components and technical characteristics of the machine

In Fig. Figure 8 shows the main components included in the MIKRON VCE 600 Pro machine.

Rice. 8 . Main nodes MIKRON V.C.E. 600 Pro : 1 – bed; 2 – desktop; 3 – tool spindle; 4 – tool magazine; 5 – pneumohydraulic pressure booster; 6 – spindle head; 7 - stand; 8 – feed drive

Bed 1 and rack 7 of the machine are the constructive basis of the communication system of all nodes that provide form-building movements during cutting. The highly stable and rigid base of sufficiently large dimensions is adapted to successfully dampen vibrations even under full load and in continuous operation. This feature is useful when carrying out milling work, when it is necessary to ensure high quality when processing various surfaces of parts with the required accuracy in shape and geometry.

Desk 2 designed for installation, securing and positioning of the workpiece relative to the cutting tool. The work table in the machine performs linear movements along coordinates X And Y. On the open surface of the desktop there are T-shaped slots with parallel coordinates X. The front part of the table has a compressed air connection for clamping pallets.

Tool spindle 3 located in the spindle head 6 on high-precision ball bearings, the supports of which are located at a distance from each other, ensuring high rigidity of the spindle. The bearings are lubricated with grease for a long period. Front bearing protection is based on the use of an "air" flap, which is a simple and reliable bearing seal. The cutting tool is clamped by a spring located in the spindle, and released by a hydraulic system. When changing tools, the internal “steep” cone is blown with compressed air. The tool spindle provides high-force operation when milling and boring, as well as high spindle speeds when processing aluminum alloys. The tool spindle head is water cooled. Coolant is pumped from the coolant reservoir. Cooling is constant, but not controlled or regulated. The use of active spindle cooling has a positive effect on the performance of ball bearings, while maintaining high thermal stability of the spindle and maintaining a long service life. The rotation of the tool spindle occurs from the spindle motor through a belt gear drive.

Tool magazine 4, included in the automatic tool changer. The tool changer is designed as a drum-type magazine, which is equipped with the tools necessary for the processing process. The auto operator feeds the tool from the magazine into the working spindle and unloads the used tool from the spindle into the magazine. Shift management occurs automatically in the overall operating cycle of the machine. In a drum magazine, instruments are placed in sockets (cells) and, using a spring device, are mechanically supported in the socket from falling out. The standard procedure for loading a magazine is done manually, by installing the tool in the machine spindle. Then the auto operator transfers the tool from the spindle to the corresponding magazine cell.

Pneumohydraulic pressure booster 5 creates the high pressure necessary to activate (unclamp the tool) the hydromechanical tool installation device. The tool spindle has a passive tool mounting system. This means that the tool is held in the spindle by a spring and released hydraulically. The pneumohydraulic booster is located above the tool spindle.

Movements on the machine (8 feed drives) carried out by a table along two coordinates ( X And Y) and spindle head 6 vertically along the coordinate Z. Each coordinate represents a system consisting of a high-torque electric motor and a ball screw coupling. Ball screws, fixed on both sides, are mounted with preload. This ensures precision movement, which in turn is an important condition for achieving high quality product manufacturing on the machine. The movements of the machine's executive bodies (table, spindle head) are carried out along linear guides (made of hardened steel) with ball blocks. These solutions have excellent dynamic properties and do not require large amounts of energy. The magnitude and accuracy of coordinate movement is ensured by resolvers built into the motors. The signal from the resolver is transmitted to the control system.

Machine control and manual adjustment of its individual functions

Description of controls. In Fig. Figure 9 shows the screen and machine control panel of the Heidenhain CNC system, where the horizontal and vertical function buttons are programmed by the company. The remaining buttons, the functional purposes of which are indicated in the figure descriptions, are intended to enable the corresponding control function.

Rice. 9. Screen and control panel: 1 – horizontal panel of functional keys; 2 – switch to the horizontal control panel; 3 – selection of screen sector; 4 – switch to the vertical control panel; 5 – vertical panel of functional buttons; 6 – key for switching the screen to machine operating modes or programming modes

Practical lessons

Launch Pro/ENGINEER by double-clicking on the icon on the desktop.

Set the working folder. Click File > Set Working Folder A window will open where we select the desired folder where all the models of our task will be stored, for example c:\users\student\* .

Create a new model using the default template.

· Set the model name to PLITA_V, then click OK .

· Leave the selected template unchanged and click OK .

· A new file called PLITA_V will be created.

If the reference planes and coordinate system in the part are not shown, on the main toolbar, enable their display using

icons, respectively Reference planes on/off And On/off coordinate system .

Select each object in the design tree to highlight it in the work window.

Planes in the modeling window.

Set up your measurement system.

From the main menu, click Edit > Settings > Units. In the dialog box Unit Manager(Fig. 2) pay attention to the active system of units of measurement, if it differs from the GOST standard, then select millimeter kilogram sec and press Set, in the window that appears, select interpret 1 mm = 1” and click OK .

In the window Unit Manager click Close (Close).

Figure 2: Window for selecting the active unit system.

On the main toolbar, click Save > ENTER .

Next we will create a sketch for the top plate

On the toolbar, click the icon Drawing. Specify the TOP reference plane as the sketch plane (in the design tree or directly on the model). In the Sketch dialog box, click Sketch. After which, you should enter sketching mode.

As bindings if a window appears Bindings, select the PRT_CSYS_DEF coordinate system. In the dialog box bindings click OK .

From the sketch toolbar, select the icon Circle. Construct a circle of arbitrary radius with the center at the origin point, double-click on the mouse wheel, select the size that appears by double-clicking and enter the value 90 mm, click Enter .

Select an icon Create a rectangle build a rectangle as shown in Figure 3 (200X170) with the beginning at the center of the circle, draw a second circle with the center at the vertex of the rectangle.

Select an icon Create a line construct four tangents to the circles at an angle of 45°.

Set the working directory c:\users\student\* .

Click File > New .

Select type Production and subtype CNC Assembly .

Enter the name PLITA_V and click OK .

In the menu manager, click Setup > Units in the window that appears, select Millimeter.Kilogram.Second and click Set, in the window that appears, select interpret 1 mm = 1” and click OK .

In the menu manager, click Production Model > Assemble > Reference Model .

Select PLITA_V.PRT and press Open. A model will appear as shown in the following image

Reference model.

Securing the workpiece. Use the cursor to specify the assembly coordinate system, and then the part coordinate system as shown in the figure. Click OK .

: Select bindings.

Click Done / Return .

Creation of a blank.

Click in menu manager Production Model > Create > Procurement .

Enter PLITA_V_ZAG and click OK .

Click Solid State >Protrusion

Click Drawing. Select the bottom plane of the part and click the Sketch button. The Sketch menu will open, in the menu Bindings select the part coordinate system as a reference.

: Bindings .

Draw a rectangle as shown in using the commands , , and click Finish.

: Sketch of the workpiece.

In the menu manager, click Made .

Enter a projection value of 55mm, make sure that the extrusion occurs into the body of the part and click

The model will take the form as shown in the figure.

: Preparation.

Figure 24: Operation settings window.

3.2. Click [Machine Settings] in the Operation Setup dialog box.

The Machine Setup window appears. Fill in the machine name and CNC control fields according to Figure 25.

The text of the finished program in CL code looks like this:

$$* Pro/CLfile Version Wildfire 4.0 - M040

$$->MFGNO/PLITA_V_MFG

PARTNO/PLITA_V_MFG

$$->FEATNO / 2437

MACHIN/UNCX01,1

$$->CUTCOM_GEOMETRY_TYPE/OUTPUT_ON_CENTER

$$->CUTTER / 0.472441

$$->CSYS / 1.0000000000, 0.0000000000, 0.0000000000, 0.0000000000, $

0.0000000000, 1.0000000000, 0.0000000000, 0.0000000000, $

0.0000000000, 0.0000000000, 1.0000000000, 0.0000000000

SPINDL/RPM, 2000.000000, CLW

FEDRAT / 500.000000, IPM

GOTO / -0.3515327633, 2.4880299013, 0.0000000000

CIRCLE / -0.6299212598, 2.7664183978, 0.0000000000, $

GOTO / -0.2362204724, 2.7664183978, 0.0000000000

GOTO / -0.2362204724, 5.1075973502, 0.0000000000

CIRCLE / -0.6299212598, 5.1075973502, 0.0000000000, $

0.0000000000, 0.0000000000, 1.0000000000, 0.3937007874

GOTO / -0.3515327633, 5.3859858467, 0.0000000000

GOTO / -1.4197813323, 6.4542344157, 0.0000000000

CIRCLE / -0.0000000000, 7.8740157480, 0.0000000000, $

GOTO / 1.4197813323, 9.2937970803, 0.0000000000

GOTO / 2.4880299013, 8.2255485113, 0.0000000000

CIRCLE / 2.7664183978, 8.5039370079, 0.0000000000, $

0.0000000000, 0.0000000000, 1.0000000000, 0.3937007874

GOTO / 2.7664183978, 8.1102362205, 0.0000000000

GOTO / 6.6928980436, 8.1102362205, 0.0000000000

CIRCLE / 6.6928980436, 7.8740157480, 0.0000000000, $

GOTO / 6.9291185160, 7.8740157480, 0.0000000000

GOTO / 6.9291185160, -0.0000000000, 0.0000000000

CIRCLE / 6.6928980436, -0.0000000000, 0.0000000000, $

0.0000000000, 0.0000000000, -1.0000000000, 0.2362204724

GOTO / 6.6928980436, -0.2362204724, 0.0000000000

GOTO / 2.7664183978, -0.2362204724, 0.0000000000

CIRCLE / 2.7664183978, -0.6299212598, 0.0000000000, $

0.0000000000, 0.0000000000, 1.0000000000, 0.3937007874

GOTO / 2.4880299013, -0.3515327633, 0.0000000000

GOTO / 1.4197813323, -1.4197813323, 0.0000000000

CIRCLE / 0.0000000000, -0.0000000000, 0.0000000000, $

0.0000000000, 0.0000000000, -1.0000000000, 2.0078740157

GOTO / -1.4197813323, 1.4197813323, 0.0000000000

GOTO / -1.4197813323, 1.4197813323, 3.9370100000

CAM (English) Computer-aided manufacturing) - preparation of the technological process for the production of products, focused on the use of computers. The term refers to both the process of computerized production preparation itself and the software and computing systems used by process engineers.

The Russian analogue of the term is ASTPP - an automated system for technological preparation of production. In fact, technological preparation comes down to automation of programming equipment with numerical control (2-axis laser machines), (3- and 5-axis CNC milling machines; lathes, machining centers; automatic longitudinal turning and turning-milling processing; jewelry and volumetric engraving).

CAM systems are very widespread. Examples of such systems are NX CAM, SprutCAM, ADEM.

NX CAM is a system for automated development of control programs for CNC (computer numerical control) machines from Siemens PLM Software.

Depending on the complexity of the part, turning, milling on machines with three to five controlled axes, turning and milling, and wire EDM are used. The system has all the capabilities to generate tool paths for the corresponding types of processing.

In addition, the system has a wide range of built-in automation tools - from wizards and templates to programming capabilities for processing standard structural elements.

The CNC program generator includes machining strategies designed to create programs with minimal engineer intervention.

The master model concept is the basis on which the distribution of data between the design module and other NX modules, including CAM modules, is built. The associative relationship between the original parametric model and the generated toolpath makes the process of updating the toolpath quick and easy.

In order for a program to be run on a specific machine, it must be converted into machine codes for that machine. This is done using a post processor. The NX system has a special module for setting up a postprocessor for any control racks and CNC machines. Basic settings are performed without the use of programming, however, it is possible to connect special procedures in the Tcl language, which opens up ample opportunities for making any necessary unique changes to the postprocessor.

NX CAM includes the following elements:

Turning;

3-axis milling;

High speed milling;

5-axis milling;

Programming multifunctional machines;

Electrical discharge machining;

Visualization of the processing process;

Automation of programming;

Expandable library of postprocessors;

Management of data related to processing;

Development of technological processes;

Creation of shop documentation;

Resource management;

Data exchange tools;

Simulation tools in the CAM environment.

The NX CAM program interface is shown in Figure 2.1

Figure 2.1 – NX CAM program interface

NX CAM provides enormous flexibility in machining methods and the broadest programming capabilities for CNC machines. The system has become widespread in industrial enterprises around the world.

Another example of CAM systems is SprutCAM.

SprutCAM - software for developing control programs for CNC equipment. The system supports the development of CP for multi-axis, electrical erosion and turning-milling equipment, taking into account a complete kinematic 3D model of all components, including.

The program allows you to create 3D diagrams of machines and all its components and perform preliminary virtual processing with kinematics control and 100% accuracy, which allows you to visually program complex multi-axis equipment. Currently, more than 45 schemes of various types of machine tools are available for free use.

SprutCAM is used in the metal, wood, and manufacturing industries; for electrical discharge, milling, turning, turning-milling, laser, plasma and gas processing; in the production of original products, stamps, molds, prototypes of products, machine parts, templates, as well as engraving of inscriptions and images.

Any owner of a CNC machine faces the question of choosing software. The software used for such technological equipment must be multifunctional and easy to use. It is advisable to purchase licensed software products. In this case, programs for CNC machines will not freeze, which will increase the efficiency of production processes.

Set of software for CNC machines

The choice of software largely depends on the type of equipment and the tasks that the user intends to solve. However, there are universal programs that can be used for almost all types of CNC machines. The most widely used products are:

1. . This software package was developed for the modeling and design of products manufactured on machine tools. It is equipped with the function of automatically generating models from flat drawings. The ArtCAM software package contains all the necessary tools for designing creative products and creating complex spatial reliefs.
It is worth noting that this software allows you to use three-dimensional templates to create designs for future products from simple elements. In addition, the program allows the user to insert one relief into another, as in a two-dimensional drawing.

2. Universal control program LinuxCNC. The functional purpose of this software is to control the operation of a CNC machine, debug a part processing program, and much more.
A similar software package can be used for machining centers, milling and lathes, and thermal or laser cutting machines.
The difference between this product and other software packages is that its developers partially combined it with the operating system. Thanks to this, the LinuxCNC program has advanced functionality. You can download this product completely free of charge on the developer’s website. It is available both as an installation package and as a LifeCD.
The user interface of this software is intuitive and accessible. For the software to function smoothly, your computer’s hard drive must have at least 4 gigabytes of free memory. A detailed description of the LinuxCNC program can be found freely available on the Internet.

3. . This software has a huge army of fans all over the world. The software is used to control milling, turning, engraving and other types of CNC machines. This software package can be installed on any computer running the Windows operating system. The advantage of using this software is its affordable cost, regular updates, and the presence of a Russian version, which makes it easier for an operator who does not speak English to use the product.

4. Mach4. This is the latest development from Artsoft. Mach4 is considered the successor to the popular Mach3 program. The program is considered one of the fastest. Its fundamental difference from previous versions is the presence of an interface that interacts with electronics. This new software can handle large files on any operating system. The user has access to a manual for using the Mach4 program in Russian.

5. MeshCAM. This is a package for creating control programs for CNC machines based on three-dimensional models and vector graphics. It is noteworthy that the user does not need to have extensive CNC programming experience to master this software. It is enough to have basic computer skills, as well as accurately set the parameters by which products will be processed on the machine.
MeshCAM is ideal for designing two-sided processing of any 3D models. In this mode, the user will be able to quickly process objects of any complexity on the machine.

6. SimplyCam. This is a compact and multifunctional system for creating, editing, saving drawings in DXF format. This software generates control programs and G-codes for CNC machines. They are created using mortar designs. The user can create an image in one of their computer's graphics programs and then upload it to SimplyCam. The program will optimize this drawing and convert it into a vector drawing. The user can also use a feature such as manual vectorization. In this case, the image is outlined using standard tools that are used in AutoCAD. SimplyCam creates toolpaths for CNC machining.

7. CutViewer. This program simulates material removal machining on two-axis CNC machines. With its help, the user can obtain visualization of processed workpieces and parts. The use of this software allows you to increase the productivity of the technological process, eliminate existing programming errors, and also reduce the time spent on debugging work. CutViewer is compatible with a wide range of modern machine tools. Its effective tools allow you to detect serious errors in the technological process and eliminate them in a timely manner.

8. CadStd. It is an easy to use drawing program. It is used to create projects, diagrams and graphics of any complexity. Using the advanced toolset of this program, the user can create any vector drawings that can be used to design milling or plasma processing on CNC machines. The generated DXF files can then be loaded into CAM programs to generate correct part paths.

You can write control programs on a computer in a notepad, especially if you are good at mathematics and have a lot of free time. Or you can do it right on the machine, and let the whole workshop wait, and you don’t mind the extra workpiece. There is a third way of writing - a better one has not yet been invented.

A CNC machine processes a workpiece according to a G-code program. G code is a set of standard commands that CNC machines support. These commands contain information about where and at what speed to move the cutting tool to machine the part. The movement of the cutting tool is called a trajectory. The tool path in the control program consists of segments. These segments can be straight lines, circular arcs, or curves. The intersection points of such segments are called reference points. The text of the control program displays the coordinates of the reference points.

Example program in G codes

Program text	Description
	Set the parameters: processing plane, zero point number, absolute values
	Calling tool number 1
	Spindle activation – 8000 rpm
	Fast travel to point X-19 Y-19
	Accelerated movement to height along Z 3 mm
	Linear movement of the tool to the XZ point Y3 with feed F = 600 mm/min
	Moving the tool along an arc of radius 8 mm to point X8 Y3
	Spindle shutdown
	Completing the program

There are three methods for programming CNC machines:

1. Manually.
2. On a machine, on a CNC rack.
3. In a CAM system.

Manually

For manual programming, the coordinates of reference points are calculated and the sequence of movement from one point to another is described. This can describe the machining of simple geometries, mainly for turning: bushings, rings, smooth stepped shafts.

Problems

Here are the problems encountered when a program is written on a machine manually:

- For a long time. The more lines of code in the program, the higher the complexity of manufacturing a part, the higher the cost of this part. If the program contains more than 70 lines of code, then it is better to choose another programming method.

- Marriage. We need an extra blank for implementation to debug the control program and check for overcuts or undercuts.

- Equipment or tool failure. Errors in the text of the control program, in addition to defects, can also lead to breakdown of the machine spindle or tool.

Parts for which programs are written manually have a very high cost.

Rack-mounted CNC machine

On the CNC rack, the processing of the part is programmed online. The machine operator fills out a table with processing conditions. Indicates which geometry to process, width and depth of cut, approaches and departures, safe plane, cutting modes and other parameters that are individual for each type of processing. Based on this data, the CNC rack generates G commands for the tool path. This way you can program simple housing parts. To test the program, the machine operator starts the simulation mode on the CNC rack.

Problems

Here are the problems encountered when a program is written on a rack:

- Time. The machine does not work while the operator writes a program to process the part. Machine downtime means lost money. If the program contains more than 130 lines of code, then it is better to choose another programming method. Although, of course, it’s faster to write a program on a CNC machine than by hand.

- Marriage. The CNC machine does not compare the machining result to the 3D model of the part, so the CNC machine simulation does not show gouges or positive allowance. To debug the program, you need to lay down an extra workpiece.

- Not suitable for complex profile parts. It is not possible to program processing of complex-profile parts on a CNC rack. Sometimes, for specific parts and standard sizes, manufacturers of CNC racks make special operations to order.

While the program is being created on the rack, the machine does not bring money to production.

In SprutCAM

SprutCAM is a CAM system. CAM is short for Computer-Aided Manufacturing. This is translated as “computer-assisted manufacturing.” A 3D model of a part or a 2D contour is loaded into SprutCAM, then the sequence for manufacturing the part is selected. SprutCAM calculates the trajectory of the cutting tool and displays it in G-codes for transmission to the machine. A post-processor is used to output the trajectory into G-code. The post processor translates internal SprutCAM commands into G-code commands for the CNC machine. It looks like
for translation from a foreign language.

The principle of operation in SprutCAM is presented in this video:

Advantages

Here are the advantages of working with SprutCAM:

- Fast. Reduces the time to create programs for CNC machines by 70%.

- Implementation without unnecessary workpieces. The program is checked before running on the machine.

- Rules out marriage. According to reviews from our users, SprutCAM reduces the occurrence of defects by 60%.

- Collision control. SprutCAM controls collisions with the part or working units of the machine, and incisions at rapid feed.

- Processing of complex-profile parts. In SprutCAM, for multi-axis operations, 13 strategies for moving the tool along the surface of the part and 9 strategies for controlling the tool axis are used. SprutCAM automatically controls the angle of inclination and calculates a safe processing path so that there is no collision of the holder or cutting tool with the workpiece.

Drawing up a control program for your CNC machine is possible in the full-featured version of SprutCAM. It needs to be downloaded and launched. After installation you will need to register. Immediately after registration, SprutCAM will start working.

For those who have just started trying, we provide a 30-day fully functional free version of the program!

SprutCAM has 15 configurations, including two special versions: SprutCAM Practitioner and SprutCAM Robot. To find out which configuration is suitable for your equipment and how much it costs, call 8-800-302-96-90 or write to info@site.