Introduction and literature survey

1.1- Introduction1.2. Computer aided design (CAD)1.3. Computer aided manufacturing (CAM) 1.3.1-Advantages and disadvantages of CAD and CAM1.4. Process planning

1.3.1-Computer-Aided Process Planning 1.3.1.1 Variant Approach

1.3.1.2. Generative Approach

1.5. Computer numerical control (CNC) 1.5.1 . Advantages of Computer Numerical Control 1.5.2.Dis advantages of Computer Numerical Control 1.6. Part programming 1.6.1 Manual part programming 1.6.2- Computer aided part programming

1.7. Structure previous work1.7.1. Milling 1.7.2. Turning 1.8. Scope of work

TURNING

External Contour provide Linear

Internal Contour provide Linear

External Contour provide Linear or Circular interpolation

Internal Contour provide Linear or Circular interpolation

Threading Contour

Key Way Feature

MILLTURN

1. RADIAL HOLES FEATURE (WITH DEPTH )

2. RADIAL HOLES FEATURE (HOLO DEPTH )

We will take the following Part as example to Show how software is work

External Contour provide Linear or Circular interpolation & External Recess(Black continues line)

Internal Contour provide Linear or Circular interpolation & Internal Recess(Red – Dashed Lines)

Threading Contour provide External or Internal Contour(Blue– Dashed Lines)

MILLTURN

Reasons for using Mill Turn machines

1. Combination between milling and turning operations.

2. Reduce manufacturing time. 3. Reduce the misalignment in

manufacturing 4. Reduce cost

• Keyway• Radial holes• Axial holes

Operation can made by mill turn

Features added in feature recognition module

1. RADIAL HOLES FEATURE

2.KEYWAY FEATURE

• Radial hole part program:

N130 T1212 (Radial mill @5);N135 M52;N140 G96 S50G95 F0.055 M13;N145 C0N150 G0 X41 Z-32.5;N155 G1 X16;N160 G0 X41;N165 C72N170 G1 X16;N175 C144N180 G1 X16;N185 C216N190 G1 X16;N195 C288N200 G1 X16;

Fanuc21

T12 D12 M6 ;Radial mill @5 M52 G96 S85 G95 F0.09 M13 C0 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1 C72 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1 C144 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1

Sinumerik 810

C216 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1 C288 R11=0 R22=2 R24= 2 R25=2 R26= 28 R27=0 R28=1000 L98 P1

Sinumerik 840

T12 D12 M6 ;Radial mill @5 M52 G96 S0 G95 F0 M13 G96 S0G95 F0 M13 C0 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C72 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C144 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C216 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C288 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0) C360 CYCLE83(5,0,2,16,0,-5,0,2,0,0,1,0)

• KEYWAY PART PROGRAM

Fanuc21

N130 T1212 (Radial mill @6);N135 M52;N140 G96 S50G95 F0.055 M13;N145 C0N150 G0 X21 Z-25;N155 G1 X14;N160 G1 Z-35;N165 G0 X21;N165 C120N170 G0 X21 Z-25;N175 G1 X14;N180 G1 Z-35;N185 G0 X21;N185 C240N190 G0 X21 Z-25;N195 G1 X14;N200 G1 Z-35;N205 G0 X21;

FUTURE WORK

Turning

a) Calculation of Machining time.b) Identifying surface finishing allowance on inclined surfaces.c) Allow the software to deal with more controllers

Mill Turn

Cad

a) Identifying the rest of mill turn features.b) Introducing more controllers.

a) 3D Draftingb) Simulation for manufacturing process

PART PROGRAMMING

Manual part programming

1-Production of part programs directly in part program codes. 2-specialist skills and knowledge are required by the part

programmer.

Computer aided part programming

1-to enable a computer to generate the part program code required to finish-machine the component.

Part programming

Part ProgrammingGenerate the part program for Fanuc 21 controller for different advanced cycles

Part programming

Generate the part program for Fanuc 21 controller

Generate some of features of the part program for sinumerik 810 controller Adding operations parameters “feed &

speeds “ data base according to material type and operation type.

Part ProgrammingThreading

Perform calculations• We does our calculation to get thread parameter in

general case then we take the variable we needDmin= Dmax -2PP = 0.6134*pitch

Where:

P … depth of teeth.Dmin … Minimum Diameter.Dmax … Maximum Diameter.

Where: Q First … First Roughing Depth.Hr ... Roughing Full Depth. Ht ... Total Depth (0.613 × pitch).Hf ... Finish Allowance / Finish Offset.am ... min depth of cut (0.06 – 0.08)mm.

Where: n … Number of Bathes

• we use these parameter in fanuc21 ,sin810 .

Print out the part programming code

G78 X... Z... Q... P... F... R0

CASE STUDY

External Thread:G78 P020060 Q60 R0.04G78 X20.052 Z-16 Q0.311 P974 R0 F1.5

Internal Thread:G78 P020060 Q60 R0.04G78 X8.7 Z-25 Q0.256 P650 R0 F1

External & Internal Thread:For Fanuc :

For External Thread

G78 P020060 Q60 R0.04G78 X20.052 Z-16 Q0.311

P974 R0 F1.5

For Internal Thread

G78 P020060 Q60 R0.04G78 X8.7 Z-25 Q0.256 P650

R0 F1

Part ProgrammingPart programming consists of planning and documenting the sequence of processing steps to be performed on an CNC machine.Part program is classified in two categories: 1- Manual part programmingThe term manual part programming refers to the

production of part programs directly in part program codes.

2- Computer Aided Part ProgrammingThe concept of computer-aided part programming is to

enable a computer to generate the part program code required to finish-machine the component.

Part Programming Sequence

Parameters form feature recognition

moduleMachine selection

Machining Sequence1. Facing

2. External operations3. Drilling

4. Internal operations

- Tool selection- cutting parameters

selectionCNC part program

Case Study (Fanuc21M)

Mirror&Threaded holes

Case Study (Fanuc21T)

Results and Conclusion

1-The project•Idea of project•Aim•Advantages

2- Product design considerations3-the steps of a simulation study

3.1-Problem formulation3.2-Setting of objectives and overall project plan3.3-Model conceptualization3.4-Data collection3.5-Model translation3.6-Verification3.7-Validation3.8-Experimental design3.9-Production runs and analysis3.10-Repeatition3.11-Document and report

4-The relation between project and manufacturing in Egypt4.1-problems of industry in Egypt4.2-solutions of problem of industry in Egypt