ENGR 480 Manufacturing Systems Fall 2015 ENGR 480

ENGR 480 Manufacturing Systems Fall 2015

ENGR 480 Manufacturing Systems • Class Tue 2 -5 PM (CSP 165) • Lab Thur 2 -5 PM (KRH 105) • Read Syllabus for other info

Vertical Milling

Doing Vertical Milling • Select stock – material, dimension • Select workholding – usually vise or strap clamps • Select tools & create toolpath – Esprit, Feature. CAM, Creo or hand-edited G-code for CNC, by hand for manual – Mfg. Suite does accurate simulation of G-code. • Set work and tool offsets (for CNC) • Determine feeds, speeds, and cutting depth – Esprit and Feature. CAM help with this for CNC

Coordinate System

Example Program % (DRILL 6. 35 MM HOLES) O 0010 (SIMPLE EXAMPLE FOR NVX) (OP 1 - TOP SIDE) G 28 Z 0 (STOCK- 50 MM X 40 MM X 50 MM) T 9 M 6 (G 54 ZERO- LEFT FRONT TOP) G 43 H 9 G 54 S 2000 M 3 G 00 G 40 G 90 G 17 G 21 M 8 (SPOT DRILL HOLES) G 0 X 12. 5 Y 12. 5 Z 2. 5 T 7 M 6 G 83 Z-2. 5 Q 2. 5 R 2. 5 F 250. 0; (CANNED DRILL CYCLE) G 43 H 7 X 12. 5 Y 25. 0 S 2000 M 3 X 25. 0 Y 25. 0 M 8 X 25. 0 Y 12. 5 G 0 X 12. 5 Y 12. 5 Z 2. 5 G 81 Z-2. 5 R 2. 5 F 250. 0; (CANNED DRILL CYCLE) G 80 G 0 Z 2. 5; X 12. 5 Y 25. 0 X 25. 0 Y 25. 0 M 9 X 25. 0 Y 12. 5 M 5 G 80 G 0 Z 2. 5; (CANCEL CANNED CYCLE) M 9 G 28 Z 0 M 5 M 30 % (CANCEL CANNED CYCLE)

G-Codes for Milling G 00 Rapid positioning G 01 Linear interpolation (feeding) G 02 CW Circular interpolation G 03 CCW Circular interpolation G 04 Dwell G 20 Inch system G 21 Metric system G 28 Return to reference point G 43 Tool Length Compensation

G-Codes for Milling G 54 -G 59 Select work coord system G 65 Macro call G 81 Drill canned cycle G 83 Peck drill canned cycle G 84 Tapping canned cycle G 90 Absolute coordinates G 91 Incremental coordinates

M-Codes for Milling M 00 Program Stop M 01 Opt. Program Stop (panel controlled) M 03 Start spindle (normal rotation) M 04 Start spindle (reverse rotation) M 05 Stop spindle M 06 Tool change M 08 Start coolant M 09 Stop coolant

Work Offsets • Work Offsets – G 54 -G 59 – G 54 X & Y aligned with vice jaw left front – Set G 54 Z to height of top of work (type number, press F 1)

Offsets

Setting Work Offset

Tool Offsets • Enter tool data in offset table • Put tool in spindle • Indicate tool number in TOOL REGISTRATION screen

Tool Offsets • Enter G 324 as an MDI command start

Process • Rigidity: – use shortest tool and tool holder • deflection of tool or work causes form error – keep workpiece firmly clamped and supported – avoid speed/feed/depth combos that chatter • Heat: – use carbide tools when heat is a problem – keep chips cleared (liquid or air coolant) • hard chips get harder • soft chips stick to tool – don’t go too fast OR too slow • Chip load: – keep volume removed constant! – especially watch tool entry, exit, corners

Setting Feeds & Speeds • http: //www. custompartnet. com/calculato r/milling-speed-and-feed

Vibration

Vibration • For Max Material Removal Rate: – Choose highest spindle RPM – Tune tool length to stay in a stable lobe at top spindle RPM

Vibration