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06-2012 C. Koenig
Introduction to Introduction to
CNC & CAMCNC & CAM
ENGI 7928ENGI 7928
Getting startedGetting started……
0606--20122012 C. KoenigC. Koenig
The CNC LabThe CNC Lab
�� Introduction to new software: Mastercam (2D milling) Introduction to new software: Mastercam (2D milling)
�� You will draw a model in SolidWorks You will draw a model in SolidWorks -- sketches must be sketches must be fully defined fully defined
�� You will use a tutorial handout to You will use a tutorial handout to ““machinemachine”” a part in a part in MastercamMastercam
�� Tutorial: Mill_1_handout available in the 7928 folder on the Tutorial: Mill_1_handout available in the 7928 folder on the S:S:\\engrengr\\coursescourses\\7928 folder7928 folder
�� When working in MastercamWhen working in Mastercam-- you must be diligent with the you must be diligent with the values you input, a typo could equal a crash.values you input, a typo could equal a crash.
�� Mastercam Labs: Thurs., July 5, Fri. July 6 with TA availableMastercam Labs: Thurs., July 5, Fri. July 6 with TA available
�� CNC DemonstrationCNC Demonstration-- in groups of 6 between July 11&12, 2in groups of 6 between July 11&12, 2--4pm4pm
�� NOTE :Mastercam is limited to 12 licenses only, therefore NOTE :Mastercam is limited to 12 licenses only, therefore you will need to find time when a station is available for you will need to find time when a station is available for you to complete the lab you to complete the lab
0606--20122012 C. KoenigC. Koenig
Memorial Engineering Memorial Engineering
Student Machine ShopStudent Machine Shop
�� Haas Super Mini CNC Mill, 15 hpHaas Super Mini CNC Mill, 15 hp
�� 10,000 rpm, 833 10,000 rpm, 833 ipmipm feed cutting ratefeed cutting rate
�� 10 Pocket umbrella tool changer10 Pocket umbrella tool changer
�� Travel: X=16Travel: X=16””, Y=12, Y=12””, Z=10, Z=10””
0606--20122012 C. KoenigC. Koenig
Memorial Engineering Memorial Engineering
Student Machine ShopStudent Machine Shop
�� MazakMazak Quick Turn Nexus 100Quick Turn Nexus 100--II CNC Lathe, 15hpII CNC Lathe, 15hp
�� 6,000 rpm, 1180 6,000 rpm, 1180 ipmipm cutting feed ratecutting feed rate
�� 12 position tool changer12 position tool changer
�� Travel: X= 11Travel: X= 11””, Z=12, Z=12””
0606--20122012 C. KoenigC. Koenig
Many types of CNC machines & Many types of CNC machines &
many outcomes!many outcomes!
�� Lathes, MillsLathes, Mills
�� 2 to 5 Axis2 to 5 Axis
�� Lathe bar feedersLathe bar feeders
�� Pallet Changer Pallet Changer CentresCentres
Photos compliments of Vincennes University Photos compliments of Vincennes University www.vuhtec.orgwww.vuhtec.org
0606--20122012 C. KoenigC. Koenig
Simple to complexSimple to complex
0606--20122012 C. KoenigC. Koenig
What is CNC?What is CNC?
�� Used to automate machine tools to perform Used to automate machine tools to perform simple to complex machining operationssimple to complex machining operations
�� Many controller languages are used Many controller languages are used
i.e. conversational & G codei.e. conversational & G code
�� Manually: code is used to build a program by Manually: code is used to build a program by manually entering commands using the key padmanually entering commands using the key pad
�� Software: for more complex or feature intense Software: for more complex or feature intense components we use CAM software to generate components we use CAM software to generate code for lengthy machining processes and /or code for lengthy machining processes and /or complex surfaces complex surfaces
0606--20122012 C. KoenigC. Koenig
Writing CodeWriting Code
�� GG--CodeCode
�� ConversationalConversational
0606--20122012 C. KoenigC. Koenig
What is CAM?What is CAM?� Computer Aided Manufacturing
� Used to assist manufacturers to generate CNCprograms
� Not a simple “click of a button”
� CAM can be parameter heavy: tools must be selected, speeds, feeds, depth of cuts, efficient tool paths selected & verified, clearances checked, reduce program times etc.
�� CAM software allows us to machine components CAM software allows us to machine components VIRTUALLY! VIRTUALLY!
0606--20122012 C. KoenigC. Koenig
79287928-- Using MastercamUsing Mastercam
�� Introduction to MastercamIntroduction to Mastercam
�� Importing SolidWorks modelsImporting SolidWorks models
�� Selecting stock sizeSelecting stock size
�� Setting up machining parametersSetting up machining parameters
�� Selecting machining operations, tool types, feeds, Selecting machining operations, tool types, feeds, speedsspeeds
�� Determine axial & radial depth cutsDetermine axial & radial depth cuts
�� Decide on rough & finish passesDecide on rough & finish passes
�� Verify Verify toolpathstoolpaths & cycle times& cycle times
�� Generate tool list, set up sheet & post operationsGenerate tool list, set up sheet & post operations
0606--20122012 C. KoenigC. Koenig
Design a solid model in SolidWorks: Design a solid model in SolidWorks:
TIP: TIP: keep it simplekeep it simple�� Note: the front plane in SolidWorks will become the top Note: the front plane in SolidWorks will become the top
plane in Mastercam.plane in Mastercam.
�� Use the recommended approach to drawing the solid Use the recommended approach to drawing the solid
model. In Mastercam we will make some minor model. In Mastercam we will make some minor
modifications to reposition the origin.modifications to reposition the origin.
�� Save the SolidWorks model Save the SolidWorks model
as an .as an .x_tx_t parasolidparasolid filefile
�� Fully define allFully define all
sketches in SWsketches in SW
-- OR potential OR potential m/cm/c
CRASH!CRASH!
0606--20122012 C. KoenigC. Koenig
We will use We will use Mill_1_ Mill_1_
2012handout2012handout in 7928 folder in 7928 folder
and follow follow the steps and follow follow the steps
to set up stock size & stock to set up stock size & stock
originorigin
Mastercam is limited to 12 licenses in this labMastercam is limited to 12 licenses in this lab
-- It is available also available in your home roomIt is available also available in your home room
0606--20122012 C. KoenigC. Koenig
The project: Pivot ClampThe project: Pivot ClampConsider: Consider:
�� How we will hold the partHow we will hold the part
�� Type of operationsType of operations
�� Facing, contours, pockets,Facing, contours, pockets,
spot drilling, drilling, spot drilling, drilling,
& type of milling& type of milling
�� Feeds, Speeds. Tool typeFeeds, Speeds. Tool type
0606--20122012 C. KoenigC. Koenig
The Mill 1 handout provides the order & type of machining The Mill 1 handout provides the order & type of machining
operations required, as well as tool selection & operations required, as well as tool selection &
recommended feeds & speeds:recommended feeds & speeds:
(note the location of the origin in Mastercam)(note the location of the origin in Mastercam)
0606--20122012 C. KoenigC. Koenig
Machining steps:Machining steps:
Tip: Tip: Think about rough cuts & finish cutsThink about rough cuts & finish cuts
In Mastercam the In Mastercam the
Operations ManagerOperations Manager
shows the machining shows the machining
operations, parameters, operations, parameters,
geometry & geometry & toolpathtoolpath-- we willwe will
create these operations.create these operations.
0606--20122012 C. KoenigC. Koenig
Select tools from the library:Select tools from the library:Tip: Filter, None, then select the tool required.Tip: Filter, None, then select the tool required.
0606--20122012 C. KoenigC. Koenig
Enter parameters as show in handout.Enter parameters as show in handout.Tip: Tip: Always enter a clear comment for each operation, this Always enter a clear comment for each operation, this
will appear in the code.will appear in the code.
0606--20122012 C. KoenigC. Koenig
Enter the parameters for each machining Enter the parameters for each machining
operation in Mastercamoperation in MastercamTip: Tip: Be sure proper clearance is given along all axis around Be sure proper clearance is given along all axis around
all work holding devices!all work holding devices!
0606--20122012 C. KoenigC. Koenig
Use Verify & Use Verify & BackplotBackplot to check to check toolpathstoolpaths, depth cuts, , depth cuts,
machining direction and moremachining direction and more……
Tip: Tip: ““Make your Make your virtual mistakesvirtual mistakes in Mastercamin Mastercam””
0606--20122012 C. KoenigC. Koenig
BackplotBackplot will show the detailed machining will show the detailed machining
steps created in each operation, tool, steps created in each operation, tool,
toolholdertoolholder, rapids moves & more., rapids moves & more.
0606--20122012 C. KoenigC. Koenig
Generate a detailed Tool ListGenerate a detailed Tool List
0606--20122012 C. KoenigC. Koenig
Generate a detailed Setup SheetGenerate a detailed Setup Sheet
0606--20122012 C. KoenigC. Koenig
Post the G Code to the post processorPost the G Code to the post processorTip: Tip: Learn how to read code and check your work!Learn how to read code and check your work!
0606--20122012 C. KoenigC. Koenig
G Codes Preparatory FunctionsG Codes Preparatory Functions
0606--20122012 C. KoenigC. Koenig
M Codes M Codes –– Misc. FunctionsMisc. Functions
0606--20122012 C. KoenigC. Koenig
Project Report RequirementsProject Report Requirements
�� Cover pageCover page
�� SolidWorks detail drawing: Pivot ClampSolidWorks detail drawing: Pivot Clamp
�� Print all Print all toolpathstoolpaths page Mastercampage Mastercam
�� Print tool list page MastercamPrint tool list page Mastercam
�� Print set up sheet page MastercamPrint set up sheet page Mastercam
�� Print the 1st page of the NC Code & Print the 1st page of the NC Code &
Annotate the major G & M code operations Annotate the major G & M code operations
on this page on this page –– see G & M Code sheets see G & M Code sheets
provided)provided)
0606--20122012 C. KoenigC. Koenig
Some parts modeled in SolidWorks (CAD) Some parts modeled in SolidWorks (CAD)
toolpathstoolpaths created using Mastercam (CAM)...&?created using Mastercam (CAM)...&?
0606--20122012 C. KoenigC. Koenig
OhOh……one last thing!one last thing!
When opening Mastercam you will need to:When opening Mastercam you will need to:
Select:Select:
�� Start Start
�� All ProgramsAll Programs
�� Mastercam X4 Mastercam X4
�� NhaspNhasp XX
�� Select Select NetHASPNetHASP buttonbutton
�� ReadRead
�� Click Activate Licenses buttonClick Activate Licenses button
�� OKOK