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| Introduction to Computer Numerical Control Manufacturing | |
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| Chapter Objectives | |
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| Introduction | |
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| Numerical Control Definition, Its Concepts and Advantages | |
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| Definition of Computer Numerical Control and Its Components | |
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| Advantages of CNC Compared with NC | |
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| Special Requirements for Utilizing CNC | |
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| Financial Rewards of CNC Investment | |
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| CNC Machining Centers and Turning Centers | |
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| Other Types of CNC Equipment | |
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| CNC Input and Storage Media | |
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| Chapter Summary | |
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| Review Exercises | |
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| Modern Machine Tool Controls | |
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| Chapter Objectives | |
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| Introduction | |
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| Different Types of System Control | |
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| Loop Systems for Controlling Tool Movement | |
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| Establishing Locations via Cartesian Coordinates | |
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| CNC Machine Axes of Motion | |
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| Types of Tool Positioning Modes | |
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| Units Used for Positioning Coordinates | |
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| Chapter Summary | |
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| Review Exercises | |
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| Tooling for Hole and Milling Operations | |
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| Chapter Objectives | |
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| Introduction | |
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| Tooling for Drilling Operations | |
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| Carbide Insert Technology | |
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| Tooling for Hole Operations that Follow Drilling | |
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| Tool Speeds and Feeds for Hole Operations | |
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| Tooling for Profile Milling and Facing Operations | |
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| Coated Tooling | |
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| Tool Speeds and Feeds for Milling Operations | |
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| Feed Directions for Milling Operations | |
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| Cutting Fluids for CNC Operations | |
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| Chapter Summary | |
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| Review Exercises | |
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| Exploring Features of CNC Machining Centers | |
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| Chapter Objectives | |
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| Introduction | |
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| Background on CNC Machining Centers | |
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| Tooling Systems Used with Automatic Tool Changers | |
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| Methods of Securing Tools in Tool Holders | |
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| Methods of Securing Tooling Systems to the CNC Spindle | |
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| Automatic Tool Changer Systems | |
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| Pallet Loading Systems | |
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| Chapter Summary | |
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| Review Exercises | |
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| Review of Basic Blueprint Reading for CNC Programmers | |
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| Chapter Objectives | |
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| Introduction | |
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| Sheet Sizes | |
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| Drawing Formats | |
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| Interpreting Lines in Drawings | |
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| Projection Conventions Used in Drawings | |
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| Visualizing 3D Objects from 2D Othographic Views | |
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| Auxiliary Views | |
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| Sectional Views | |
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| Reading Dimensions | |
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| Reading Threads and Thread Notes | |
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| Reading Surface Finish Symbols and Notes | |
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| Reading Material Specifications | |
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| Understanding Heat Treatment Notes | |
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| Interpreting Surface Coating Notes | |
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| Chapter Summary | |
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| Review Exercises | |
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| Bibliography | |
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| Review of Basic Geometric Dimensioning and Tolerancing for CNC Programmers | |
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| Chapter Objectives | |
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| Introduction | |
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| GDT Terminology | |
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| Part Form Controls | |
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| Datums | |
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| Part Profile Controls | |
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| Part Location, Orientation, and Runout Controls | |
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| Chapter Summary | |
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| Review Exercises | |
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| Bibliography | |
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| Mathematics for CNC Programming | |
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| Chapter Objectives | |
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| Introduction | |
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| Determining Sides of Right Triangles | |
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| Useful Angle Concepts | |
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| Determining Angles of Right Triangles | |
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| Oblique Triangles | |
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| Chapter Summary | |
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| Review Exercises | |
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| An Overview of CNC Shop Activities | |
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| Chapter Objectives | |
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| Introduction | |
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| Essential CNC Shop Activities | |
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| Part Drawing Study | |
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| Methodizing of Operations | |
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| Deciding on a CNC Machine | |
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| Methods of Holding the Part During Machining | |
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| Machining Determination | |
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| Cutting Conditions | |
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| Writing a Part Programming Manuscript | |
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| Inputting Programs to the MCU | |
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| Setup and Machining Documentation | |
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| Setup Procedure | |
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| Debugging and Verifying the Program | |
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| Part Production | |
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| Chapter Summary | |
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| Review Exercises | |
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| Word Address Programming | |
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| Chapter Objectives | |
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| Introduction | |
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| Programming Language Format | |
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| Programming Language Terminology | |
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| Arrangement of Addresses in a Block | |
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| Program and Sequence Numbers (O, N Codes) | |
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| Preparatory Functions (G Codes) | |
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| Dimension Words (X,Y,Z ... Codes) | |
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| Feed Rate (F Code) | |
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| Spindle Speed (S Code) | |
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| Miscellaneous Machine Functions (M Codes) | |
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| Automatic Tool Changing (M06 Code) | |
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| Tool Length Offset and Cutter Radius Compensation (H, D Codes) | |
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| Comments | |
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| Chapter Summary | |
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| Review Exercises | |
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| Programming Hole Operations | |
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| Chapter Objectives | |
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| Introduction | |
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| Fixed or Canned Cycles | |
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| Hole Operation Commands | |
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| Writing a Hole Operation Program | |
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| Chapter Summary | |
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| Review Exercises | |
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| Programming Linear Profiles | |
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| Chapter Objectives | |
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| Introduction | |
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| Linear Interpolation Commands | |
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| Writing a Linear Profiling Program | |
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| Determining Cutter Offsets for Inclined Line Profiles | |
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| Chapter Summary | |
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| Review Exercises | |
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| Programming Circular Profiles | |
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| Chapter Objectives | |
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| Introduction | |
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| Specifying the Plane for Circular Arc Interpolation | |
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| Circular Interpolation Commands | |
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| Circular Interpolation via Direct Radius Specification | |
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| Profiling Arcs at Constant Feed Rate | |
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| Determining Cutter Offsets for Line-Arc Profiles | |
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| Chapter Summary | |
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| Review Exercises | |
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| Programming with Cutter Diameter Compensation | |
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| Chapter Objectives | |
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| Introduction | |
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| Cutter Diameter Compensation | |
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| Advantages of Using Cutter Diameter Compensation | |
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| Some Restrictions with Cutter Diameter Compensation | |
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| Cutter Diameter Compensation Commands | |
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| Cutter Diameter Compensation with Z-Axis Movement | |
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| Cutter Diameter Compensation Interruptions | |
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| Chapter Summary | |
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| Review Exercises | |
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| Programming with Subprograms | |
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| Chapter Objectives | |
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| Introduction | |
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| Subprogram Concept | |
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| Fanuc Commands for Calling a Subprogram and Returning to the Main Program | |
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| Additional Subprogram Control Features | |
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| General Rules for Subprogramming | |
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| Chapter Summary | |
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| Review Exercises | |
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| Introduction to the CNC Lathe | |
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| Chapter Objectives | |
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| Introduction | |
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| Components of Modern CNC Lathes | |
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| CNC Lathe Axes of Motion | |
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| Basic Lathe Operations | |
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| Tooling for CNC Lathe Operations | |
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| Tool Speeds and Feeds for Lathe Operations | |
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| Feed Directions and Rake Angles for Lathe Operations | |
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| Chapter Summary | |
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| Review Exercises | |
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| Fundamental Concepts of CNC Lathe Programming | |
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| Chapter Objectives | |
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| Introduction | |
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| Establishing Locations via Cartesian Coordinates (CNC Lathes) | |
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| Types of Tool Positioning Modes (CNC Lathes) | |
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| Reference Point, Machining Origin, and Program Origin | |
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| Setup Procedures for CNC Lathes | |
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| Important Preparatory Functions (G Codes) for Lathes | |
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| Important Miscellaneous Functions (M Codes) for Lathes | |
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| "Zero Offset" Command | |
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| Feed Rate (F Code) | |
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| Spindle Speed (S Code) | |
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| Spindle Speed with Constant Surface Speed Control | |
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| Spindle Speed with Clamp Speed and Constant Surface Speed Controls | |
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| Automatic Tool Changing | |
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| Linear Interpolation Commands (CNC Lathes) | |
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| Determining Cutter Offsets for CNC Lathe Operations | |
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| Circular Interpolation Commands (CNC Lathes) | |
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| Grooving Commands | |
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| Return to Reference Point Command | |
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| Chapter Summary | |
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| Review Exercises | |
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| Techniques and Fixed Cycles for CNC Lathe Programming | |
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| Chapter Objectives | |
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| Introduction | |
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| Tool Edge Programming | |
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| Tool Nose Radius Compensation Programming | |
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| Setting Up Tool Nose Radius Compensation | |
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| Some Restrictions with Tool Nose Radius Compensation | |
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| Tool Nose Radius Compensation Commands | |
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| Turning and Boring Cycle: G90 | |
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| Facing Cycle: G94 | |
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| Multiple Repetitive Cycles: G70 to G75 | |
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| Stock Removal in Turning and Boring Cycle: G71 | |
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| Finish Turning and Boring Cycle: G70 | |
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| Peck Drilling and Face Grooving Cycle: G74 | |
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| Peck Cutoff and Grooving Cycle: G75 | |
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| Thread Cutting on CNC Lathes and Turning Centers | |
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| Single-Pass Threading Cycle: G32 | |
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| Multiple-Pass Threading Cycle: G92 | |
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| Multiple Repetitive Threading Cycle: G76 | |
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| Chapter Summary | |
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| Review Exercises | |
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| Modern Computer-Aided Part Programming | |
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| Chapter Objectives | |
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| Introduction | |
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| Modern Developments in the Process of CNC Programming | |
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| Using an Off-Line Computer to Write and Store Part Programs | |
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| An Introduction to Computer-Aided Programming Languages | |
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| Elements of the APT Programming Language | |
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| Writing a Complete Program in APT | |
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| An Introduction to CAD/CAM Technology | |
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| The Elements Comprising CAD | |
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| The Elements Comprising CAM | |
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| Creating a Complete Part Program Using Mastercam CNC Software | |
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| Chapter Summary | |
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| Review Exercises | |
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| Elements of the Computer-Controlled Factory | |
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| Chapter Objectives | |
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| Introduction | |
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| Computer-Integrated Manufacturing | |
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| Operational Strategies Within CIM | |
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| Flexible Manufacturing Systems | |
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| Important Elements of Flexible Manufacturing Systems | |
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| Flexible Manufacturing Cells | |
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| Important Elements of Flexible Manufacturing Cells | |
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| Networking Within CIM | |
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| Need for Training | |
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| Chapter Summary | |
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| Review Exercises | |
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| Verifying Part Programs | |
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| Chapter Objectives | |
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| Introduction | |
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| Predator Simulation Software | |
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| System Requirements | |
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| Conventions Used in This Chapter | |
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| Installation | |
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| An Overview of Writing and Verifying Programs | |
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| Types of Files Created by Predator | |
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| Running an Old Simulation Job Stored on Disk | |
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| Running an Old Simulation Job Stored on Disk | |
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| Running an Old Simulation Job from C Drive | |
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| Preparing a Disk for Storing New Simulation Jobs | |
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| Writing a Word Address CNC Program Via the CNC Editor | |
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| Using Edit Commands | |
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| Using Insert Commands | |
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| Using File Commands | |
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| Starting the Virtual CNC and Creating Simulation Files | |
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| Entering Data into the Setup File on C Drive | |
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| Directing the Virtual CNC to Process a Job | |
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| Using the Virtual CNC to Inspect a Machined Part | |
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| Entering the CNC Editor from Virtual CNC | |
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| Creating a New Tool in the Tool Library | |
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| Simulating Programs with Cutter Diameter Compensation | |
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| Appendix A | |
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| Important Safety Precautions | |
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| Appendix B | |
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| Summary of G Codes for Milling Operations (Fanuc Controllers) | |
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| Summary of G Codes for Turning Operations (Fanuc Controllers) | |
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| Summary of M Codes for Milling and Turning Operations (Fanuc Controllers) | |
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| Summary of Codes for Auxiliary Functions (Fanuc Controllers) | |
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| Appendix C | |
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| Recommended Speeds and Feeds for Drilling | |
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| Recommended Speeds and Feeds for Milling | |
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| Recommended Speeds and Feeds for Turning | |
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| Appendix D | |
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| Summary of Important Machining Formulas | |
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| Glossary | |
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| Index | |