Computer Numerical Control Machining - Report Example

CAD CAME Name of Student: Institution: Summary This paper explains the processes through which different machining activities take place in a machining shop, the tools that are used in the process of machining components, the use of Computer Numerical Control (CNC) machine during machining, the milling process using a 2 mill profile, 3 mill pocketing procedure, 4 mill pocketing, sunk hole drilling, clean circle drilling, and chamfering. It also explains the meaning of CNC, the benefits of a CNC machine, the benefits of using Carbide tooling instead of HSS, the concept of TCIAN, tool paths, and a visualization of its usefulness. Introduction There are many activities that take place during a Computer Numerical Control (CNC) machining such as the input of a command on the computer to enable machining a component to achieve the required product. During CNC machining, there are a number of activities that take place such as turning, phasing, chamfering, and filleting. In addition, a number of tools are used and a CNC machinist must know the type of tool used for a specific machining task. In this paper, the objective is to illustrate the tools used in a CNC machining, different machining processes and other concepts associated with CNC machining. Report Task 2 Task 2 represents a machine component that has been machined by the use of a CNC machine. The machining tasks that have been performed on the component are: drilling, chamfering, and cutting. Task 3 This task represents different tools used in a machining process. They include: 1. Axis CMC Mill This represents a mini mill that occupies a lesser floor space and in most cases has a 40-taper spindle that rotates at 6,000 rpm and has a 10-pocket automatic tool changer. Its main use is during the management of production of small components. It is effective in performing finishing work and cutting materials made of aluminum. It also has the ability to provide adequate-low-end torque when used to cut through steel. 2. Machine Vice Machine vice is a device that enables holding a work piece in the process of machining a component. A machine vice can be in the form of a drill press or a milling machine. It is a tool that is frequently used in a number of metal working applications. It also works during metal fabrication and when producing products from wood to enable fixing the component to be processed on the bench. Its benefit is that it enables reduction of risks of spinning of an object by gripping it in a tight manner. 3. Electronic Touch Probe 4. An electronic touch probe refers to a device that enables simplification of work tasks during precision set up of a job or measurement. A number of electronic touch probes have components such as sealed active electronic and breakaway ruby stylus can be used in the process of locating, digitization, and other purposes. In addition, there exist other kinds of electronic touch probes in the market which enables performance of automated functions such as measuring, setting up, and monitoring in addition to CNC controls to enable their operation through the program, which has a beneficial impact on cost reduction. A number of touch probes perform tasks in different ways such as in the process of handling work pieces and probes used in the process of measurement. 5. Tool Holder This is a CNC machine component that surfaces precision ground. Its gauge length is usually 3.0 inches while its body diameter is 1.5 inches. Its use enables screwing a drill chick onto the spindle on the end of mill holders. In addition, it is beneficial in that its length is unchanged, thus when the operator is working on a CNC machine, there is no need to make changes to the tool table. 6. Er 16 Collect Holder The function of ER collect tool holders is to handle different kinds of machining jobs and reducing the need to buy a new tool holder. This is achieved by selecting the recommended size of Collect for a specific job, making adjustments to the tool depth, and making constrictions to the collect nut and pulling the stud to the right torque using a torque wrench and tightening the fixture. 7. Face Mill 40 mm diameter This is a cutting tool that is usually 50mm, 80mm, 100mm, or 125mm diameter tool that is used during machining of non-ferrous metals such as aluminum using an internal coolant. They have high performance capabilities at reduced costs and can be utilized in regrinding tasks a number of times. A special kind of face mill is the Korloy Pro-X Mill index that enables shell milling during the removal of metal components in aluminum, copper and plastic materials. 8. End Mill 8mm Diameter This is a tool used during milling of aluminum and other non-ferrous metals. it has a high helix and high rake flute design that provides a high-end chip control which enables efficient machining. 9. Drill (HSS) 6mm diameter This is a drill bit that is made up of HSS material. It is designed by the use of a straight shank design, which enables it to performing electric drilling. It has a high drilling efficiency as a result of sharp and twist flute design. It is most suitable when drilling wood, metal, aluminum, and plastic. 1. Facing Th figure above represents a facing process. In the process, the required tool path is created by filling out the tool path creation to determine the path that the CNC machine will follow. A tool number of put in place with the consideration that each tool has its own number and they are not able to be the same. The spindle speed is the rate of spinning of the tool. It is recommnded that the correct speed should be set so that a smooth finish is obtained in the use of the tool. In the above figure, the colored lines represent the motion of the tool path as it move to get the right form. When values and input in the CNC machine, the following is the tool path creation during facing. 2 Mill Profile During the process of a 2 Mill profiling, the activities that are performed involves setting the work piece in place and determining the features to be machined. The tooling settings are done on the CNC as shown above. Different parts of the tool settings are done in order to align it to the work piece. Finally, 2 Mill profiling is done as shown above. 3 mill pocketing During 3 mill pocketing, the work piece is placed on the location in which the tooling is to be performed and settings of its coordinates is done. The tooling settings and coordinates are put in place. Finally, 3 Mill pocketing is done 4;mill pocketing {Open } During 4 Mill pocketing, the work piece to be machined is placed on the work station and its coordinates are set. The tooling settings are done by ensuring its coordinates are at the same alignment with the work piece coordinates. 4 Mill pocketing is done as shown in the figure above. 5:sunk hole,6mm bolt, Z-10 to Z-20 During the process of drilling a sunk hole, the work piece is placed on the surface of the bench and the coordinates are determined. The depth of the holes are established by making settings of coordinates. The coordinates of the tool to be used is set The preview of the location of the tool and the machine is established by the illustrations on the CNC interface. The cutting tool settings are done A preview of the location of the tool and the work piece is provided in the CNC interface. Holes are drilled as shown in the figure above. 7: Clean Circle During the process of drilling a clean circle, the work piece is placed on the surface of the bench and the coordinates are determined. The tool settings are done in accordance with the tool settings procedures to be followed when drilling clean circles Drilling is done as shown above 6; - chamfer During the process of chamfering a work piece, it is placed on the cutting surface and the corresponding coordinates are determined. The cutting tool coordinates are determined in order to align them with those of the work piece to be chamfered. In order to perform a chamfering task, the distance of the chamfer from the edges is determined and the point where chamfering begins is input in the CNC. The simulation is beginning to form the shape as required for it to do so. Post ( pst processor is a language definition file used to modify generic g-code such that it can be used on a particular cnc machine. Doubleclick in toolpath in right top And select post choose fanuc10 With the simulation being complete it was time to create the file for which could be transferred on to the machine so that the CNC process via the machine could take place, the Fanuc 10m was chosen as post. Then we post this to get the Fanuc file-001 The code has been achieved and this will provide the machine with the file that has been created using CNC Why use CAD Model The purpose of a computer aided design (CAD) model is that it enables attaching metadata to a 3D model during the process of dimensioning features and determining geometric tolerances (Tomar & Pandey, 2016). CAD model enables time saving and also improves accuracy and reduces waste, scrap, and rework. It also enables an automation of the design of a machine component which can be changes in a reprogramming process in order to integrate the components. What is CNC Computer Numerical Control (CNC) machining is the process in which computers are used during control of operation of machining operations. Tools that are controlled by a CNC machine include: lathe, routers, and grinders. The functioning of a CNC is under the impact of a computer program that is customized for a particular object and a machine language in the form of a G-Code controls the rate of coordination of tools. What is the Benefit of CNC Machine The use of CNC machines are beneficial because they reduce the cost of manufacturing a component by enabling accurate machining at a reduced cost. Losses during machining are significantly reduced, thus cutting the costs of producing components. CNC machine is also safer to use compared with conventional machining due to the fact that it is automated. There is also a high efficiency of operations during CNC machining due to the fact that it is equipped with quality assurance protection measures that are inbuilt (Singh, Verma & Jain, 2014). CNC machining is also advantageous in that it reduces the cost of production by promoting flawless working over a long duration of time without the need to fix the components. It is a fantastic way of manufacturing because it eliminates errors that may have been caused in the final products due to the role of human in the production of the components. There is also little direct contact between the operators and materials such as the components of the work pieces that have been removed from the final product. Used Carbide Tooling Instead of HSS Carbide tool is advantageous compared with HSS because it has a higher feed and speeds; it retains the cutting edge at a high temperature of machining, it is more effective in machining and contributes to a reduction of cycle time. Another advantage of carbide tooling is that it has an exceptional wear resistance cutting edge, it holds size far longer, and it has a far longer run before resharpening which results into a reduction in machine downtime. Carbide tipped tooling is advantageous compared with High Speed Steel because its structural strength is not compromised in the process of cutting; it has a more aggressive cutting edge geometries such as shear, rake angles, and cutting edge. What is TCIAN A technician is an employee who specializes in the field of technology and possesses particular skills and techniques as well as practical competence of the theoretical procedures of perform a task (Xu and Newman 2006). What is Tool Paths This is the path along space that the tip of a tool follows in the production of the required geometry of the work piece. Visualize what Useful about Tool Paths. The usefulness of tool path is that it provides the machinist with a guide regarding the direction that the tool should follow when it is used to produce a component. Discussion In Computer Numerical Control (CNC) machining, the work piece to be machined is placed in a tool holder which is usually designed to hold work pieces of different characteristics. The main forms of machining that take place in a CNC machining include: milling, turning, drilling, facing, chamfering, and grinding. CNC machines can be used to produce machine components such as gears, bearings, flanges, and handles. The cutting part of a CNC machine is usually made of a hard substance such as Carbide which is able to resist the strengths of metallic materials to be machined. There are programs in a CNC computer which enables the alignment of the tool in relation to the work piece to be machined. An example of a commonly used CNC tooling code is the G-Code that is used to determine the position of a tool in relation to the work piece in most CNC machining activities. When the right code has been input into a CNC machine, it is possible to perform tasks such as boring holes, creating threads, and creating a smooth surface on a machine component. The process of performing CNC machining is achieved by the use of a Computer Aided Design (CAD) model which enables creation of a component that represents a machine part to be produced. The resulting feature can be used a guide during the production of a device that is intended for production by the machinist. Conclusion This paper explains the concepts CNC machining by explaining the concepts such as inputting commands on the CNC machine to enable performing different operations on a work piece. It explains the concepts of tool positioning, work piece positioning, and performing a number of CNC operations such as drilling, milling, and chamfering. A number of concepts in CNC machining that are explained include: CAD Model, benefits of CNC machining, meaning of a TTIAN, meaning of tool paths, and visualization of tool paths. References Singh, M., Verma, S., & Jain, S. K. (2014). A literature review on machining of different materials with CNC. International journal of emerging research in management and technology. Tomar, A. S., & Pandey, R. (2016). Analysis of Surface Roughness for Cylindrical Stainless Steel Pipe (Ss 3163) In CNC Lathe Turning Process Using ANN Method. Sciences, 19, 386-396. Xu, X.W. and Newman, S.T., 2006. Making CNC machine tools more open, interoperable and intelligent—a review of the technologies. Computers in Industry, 57(2), pp.141-152. Read More