CNC Milling Machine
Encik Adib bin bin Amin Amin
Prepared Prepared for
Mazlin Azura Azura binti Usop Usop By
TA13019
Section / Group
02 / Group 6
Date
6 th ctob!r 201"
2.0 Abstract: This laboratory is to teach us about the CNC usage and explain briefly about the EDU CIM System. The most basic function of any CNC machine is automatic, precise, and consistent
motion motion control. control. A CNC user user must must underst understand and the makeup makeup of the CNC machin machinee tool tool being being utilized. utilized. The most important important thing is to understand the basic machining machining practice that goes into using the CNC machine tool. Four basic areas must be concentrated. First, we should understand the machin machines es most most basic basic compone components nts.. !econd, !econd, we should should become become comfor comfortab table le with with the machines directions of motion "axes#. Third, we should become familiar with any accessories
e$uipped with the machine. And fourth, we should find out what programmable functions are included with the machine and learn how they are programmed. There are a few important benefits offered by CNC e$uipment, where the first one is it has impro%ed automation. &esides, it is consistent, accurate workpieces and flexible. The last part is we need to be familiar with the '() *+ C-/0 "'() C- !ystem#. !ome of the things that we must know are 1/Axis itsubishi +obot with the function of Auto ode !witching, Auto !torage and +etrie%e "A!+!# !tation "aterial 2andling#, *ision -nspection !tation "*ision Camera and Computer !tation#, and the most important one, C- !ystem with !CA(A -nterface "Auto ode, anual ode, &ypass ode#. 3e must know all of the components to make us $uite familiar with the automation system to transfer the raw work piece from Automatic !torage and +etrie%al !tation "A!+!# to the F! station. The more the user knows about basic CNC machining practice and '() C- !ystem, the easier it will be to adapt to these two things.
3.0 Introdction:
CNC milling is a specific form of computer numerical controlled "CNC# machining. illing itself is a machining process, like drilling, milling uses a rotating cylindrical cutting tool. 2owe%er, the cutter in a milling machine is able to mo%e along multiple axes, and can create a %ariety of shapes, slots and holes. -n addition, the work/piece is often mo%ed across the milling tool in different directions, unlike the single axis motion of a drill.
CNC milling de%ices are the most widely used type of CNC machine. Typically, they are grouped by the number of axes on which they operate, which are labeled with %arious letters. 4 and 5 designate horizontal mo%ement of the work/piece "forward/and/back and side/to/side on a flat plane#. 6 represents %ertical, or up/and/down, mo%ement, while 3 represents diagonal mo%ement across a %ertical plane. ost machines offer from 7 to 8 axes, pro%iding performance along at least the 4, 5 and 6 axes. The de%ice is extremely useful because it is able to produce shapes that would be nearly impossible using manual tooling methods. Computer numeric controlled machining centers are used to produce a wide range of components, and tooling costs in%ol%ed ha%e continued to become more affordable. -n general, large production runs re$uiring relati%ely simple designs are better ser%ed by other methods, although CNC machining can now accommodate a wide range of manufacturing needs. CNC milling centers are ideal solutions to e%erything ranging from prototyping and short/run production of complex parts to the fabrication of uni$ue precision components. -n C- 9aboratory an '() *+ C-/0, which is a Computer -ntegrated anufacturing "C-# system for the purpose of teaching and learning has been setup. The '() C- !ystem is an automation system to transfer the raw work piece from Automatic !torage and +etrie%al !tation "A!+!# to the F! station which consists of a 1 (.:.F robot arm and a CNC illing. The main reason why this lab is being done is to demonstrate the ways to use the CNC milling machine. &esides, the CNC machine operation safety and the start/up procedure of the '() *+ ill CNC machine is being described. The other ob;ecti%e is to prepare the '() *+ ill CNC machine ready in the Automatic ode of the C- !ystem. From this lab demonstration, we fully understand the steps from starting the machine until it is being shut down. Now we are $uite familiar with the automation system and the relationships between the CNC milling machine and the '() C- !ystem.
!.0 Materials:
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!-''N! !-N)'+-< =0=( illing / The scope of applications ranges from basic standardized milling machines and basic machining centers to cycle/controlled turning machines through to basic full/CNC lathes.
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>C "installed with C- !ystem with !CA(A -nterface# / To run program with Auto ode or anual ode to start the process
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1/Axis itsubishi +obot "pick ? place# / *arious kinds of operation can be programmed, multitask processing, which enables the parallel processing of robot operation, external input@output signal processing and external de%ice communications programs at the same time.
".0#eslts $ Discssion:
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'ist do(n the )recations to be ta*en dring the CNC milling o)eration. o
ust ha%e knowledge about CNC illing achine and C-! before handling the machine.
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CNC machine door must be closed during the operation, if not, the operation will not start or stuck.
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A ma;or cause of crashes is setting the tool or fixture offset incorrectly. >ay particular attention to mo%es at the start of program and immediately after a tool change as the tool mo%es towards the part. )se single/block mode to ad%ance through the program one line at a time until the tool is at cutting depth.
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+emain at the machine with a hand on or near the emergency stop button. !top machine motion at the first sign of trouble.
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No horseplay or practical ;okes are allowed in the shop. 3ear AN!- appro%ed safety glasses or AN!- safety appro%ed glasses with side shields. 3e must wear safety glasses at all times in the shop, not ;ust when at the machine.
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(o not wear flip flops or sandals. 9eather shoes are best. !teel toe shoes are not necessary unless handling hea%y ob;ects that would crush regular shoes.
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+emo%e rings and watches when at the machine. Ne%er wear glo%es as they can be caught in the machine. 9atex glo%es are acceptable.
2&
E+)lain the )re)aration )rocedre ,or the EDU -#% Mill CNC machine is ready ,or the CIM System.
. The main switch of the machine and control is turned on. The machine power button is located in the upper/left corner on the control face. . After power on, the machine must first be referencedB After power on, the machine will be in the reference point approach mode "default#. -f the axis is not referenced, the non/referenced symbol "circle# is dis/played between the axis identifier and the %alue. The axes are referenced with the corresponding axis tra%ersing keys. The tra%ersing direction and keys are specified by the machine manufacturer. After completing the referencing procedure for all axes, the referenced symbol is displayed next to the axis identifier. 7. After returning to JOG mode, the axis tra%ersing keys is used to mo%e the machine manually.
. The machine can now be operated in JOG mode. (uring normal operation " JOG#, the referenced symbol is not shown on the screen. 8. A tool must be loaded to the spindle in a ;og mode. After that, go for AUTO mode. 1. The CNC program from your computer is downloaded to the machine control. -n this lab, a C- program is already loaded into the machine. The C- program is executed. D. The EC5C9' !TA+T key on the C> is pressed to run the program, using extra caution until the program is pro%en to be error/free. =. Tools from the spindle is remo%ed, the work area is cleaned, and the machine is properly shut down.
/E '1C/A# #1M AS#S 1 MS
CIM System (ith SCADA Inter,ace
Auto Mode Manual Mode
4A+is Mitsbishi #obot 5)ic* $ )lace&
Atomatic Storage and #etrie6al
Robot Zero Return
Station 5AS#S&
Auto Mode Switcin!
Robot Zero Return
7allet rac*ing Station
Continos4loo) Con6eyors
Machine ending Station 5MS&
Te $top $tation allow$ te P&' to control and #onitor te flow of pallet$ on te con(eyor wit te elp of $en$or$
to #ount te $top $tation$ and carry te pallet
%$ 3& Discss the relationshi) bet(een the CNC milling machine and the Com)ter Integrated Man,actring 5CIM& System
-n the industrial serial production of mass %olumes of goods, the use of one or more robots is a must to ensure that the manufacturing processes are working at maximum efficiency. -n our training system a robot operates in combination with CNC machines. This automated milling station can be used as a stand/alone work cell, or integrated within a C- system. 3hen used in a C- system, the robot loads and unloads parts to and from the C- con%eyor in addition to performing milling and part manipulation tasks. :ptional automation accessories permit integration of F! stations, e.g. for the coupling of the CNC machine to the robot station, which then performs the loading and unloading of the CNC machine. !ub;ecting the indi%idual station to full automation is the first step towards total integration in a production line. This is achie%ed with the aid of a robot that functions as a link between the machining e$uipment and the station. The robot undertakes the steady loading of the workpiece blanks and subse$uently the unloading of the machined "milled and cut# workpieces. The finished workpieces are then safely loaded into the magazine of the corresponding F! station. -n all of the C- systems, the working ranges of the robot are safeguarded by safety packages designed specifically for this application. As soon as the infrared beams of the light curtain are interrupted, the robot is disabled. The robot also immediately stops its work when the front flap of the milling machine is opened, thus pre%enting in;uries and material damage. After understanding the relationships between the CNC milling machine and C-, you will be able to construct, program, simulate and ultimately manufacture workpieces by yourself. The transition from indi%idual machine solutions to full integration into the F! system %ia robot proceeds without a hitch so that there is practically no additional technical know/how re$uired.
For o%erall, the A!+! storage station "a floor/mounted or a table top automated storage and retrie%al "A!+!# system# is dedicating the Cartesian robot transfers parts between storage cells and con%eyor pallets stopped at the A!+! station. The robot is controlled the C- !ystem with !CA(A -nterface. This package can be used as a stand/alone work cell, or integrated within a C- system. The robot tends the CNC machine and performs other part manipulation and@or assembly tasks. 3hen used in a C- system, the robot loads and unloads parts to and from the C- con%eyor. The robot is mounted on a linear slide base for mobility and larger work area. The robot is controlled by Controller/)!& and by a dedicated A!+! software module in the :penC- software. Any of the T! stations can be pro%ided as a standalone F!. The assembly and GC station is e$uipped with a %ariety of assembly and $uality control de%ices as well as with local storage de%ices. This turnkey station gi%es students training and skills in assembly, $uality control, robotic programming and automated manufacturing systems. This automated welding station can be used as a stand/alone workcell, or integrated within a C- system. 3hen used in a C- system, the robot loads and unloads parts to and from the C- con%eyor in addition to performing arc welding and part manipulation tasks. The con%eyor frame is constructed of extruded, black anodized aluminum, and its mo%ing belt is a double flexible/chain rail. The >9C ">rogrammable 9ogic Controller# can control and monitor the flow of pallets on the con%eyor with the help of sensors and actuators that are built into the stop stations. The stop station allows the >9C to control and monitor the flow of pallets on the con%eyor with the help of sensors and actuators that are built into the stop stations. The :penC- software is a computer/integrated systems management solution that contains all the elements found in fully/automated facilities. !hop floor management controls the operation of all the elements of automated factory. Administrati%e software connects the shop floor management to the production facilityHs 'nterprise +esource >lanning "'+>#. The :penC- software contains an '+> package which breaks down customer orders to analyse bill of materials, check a%ailability of raw materials, produce %endorHs purchase order and schedule production based on expected lead times.
The A!+! 71u has 71 cells arranged in six rows. 'ach cell can store a part/ holding template. The 71 templates supplied with the s ystem ha%e pin holes that allow the user to customize the templates holding area to accommodate ob;ects of %arious shapes and sizes. A template buffer supplied with the system can be attached to a C- con%eyor or to a table in a stand/alone A!+!@robotic work cell.
.0 Conclsion:
As a conclusion, from this lab, we are now familiar with the CNC usage and $uite clear about the EDU CIM System. 3e ha%e the knowledge about the CNC machine operation safety and the start/up procedure of the '() *+ ill CNC machine. 3e are $uite exposed on how to prepare the '() *+ ill CNC machine ready in the Automatic ode of the C- !ystem. 3e are also fully aware that a CNC user must understand and know how the CNC machine tool being utilized and how the CNC machine works. 3e must consider the basic areas including the machines most basic components, the machines directions of motion "axes, any accessories e$uipped with the machine and the programmable functions that are indicated with the machine. 3e know that this CNC machine has impro%ed automation and has its flexibility. About the '() *+ C-/0 "'() C- !ystem#, we are introduced to 1/Axis itsubishi +obot with its ad%anced function "Auto ode !witching, A!+!, *ision -nspection !tation, etc#. 3e must know all of the components in C- and CNC milling machine to make us $uite familiar with the automation system to transfer the raw work piece from Automatic !torage and +etrie%al !tation "A!+!# to the F! station. The more we know about basic CNC machining practice and '() C- !ystem, the easier it will be to adapt to these two things.
8.0 #e,erences:
Mikell P.Groover, “Automation, Production Systems, and Computer Integrated Book
Manufacturing”, Prentice all International, Inc., !SA, "##$
Web
%ttp&''(((.intelitek.com'pdf')S#$*+!*CIMA*$##-$.pdf %ttp&''(((me.nc%u.edu.t('/CIM'courses'Computer 0"#Integrated0"#Manufacturing'C%apter"0"#CIM introduction.pdf %ttp&''(((.lucas nuelle.com'inde1.p%p'fuseaction'do(nload'lrn*2le'$$#$ 3*cim*automation*g4.pdf
