cad and development 2 - part 3
TRANSCRIPT
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 1/49
0esigning
artsor
Fine-blanked
arts
cost
more
han
conventionally
lanked
parts-for
the first
few.
After
hat,
he reduction
n
secondary
achining
ssociated
ith
ine
blanking
begins
o
pay
off.
An
additional
enetit
Fine.bl;ked
pans
are
stronger
han
hose
onventionally
lanked.
lvarh.r
bt.ntld
from
OtS rt..t
t.
0.230 n.
thick
and
3.9 in,
in dhncta(
lolanncaa
aru
a0.0025
n.
Ramovd
t
bul| on
wlrhar
t. th ia
tia only rcondrry
FonMs-\Dlth
losc
tolctrnca
.
. . coln ,
rtnbo3sas,
or.pedorate
.
. .
rcducas
naad for sacondaty
DlE:
chlntng
._. cutJ
untt
colt
Jt
youte
tooH;8
to
e.proce$
that
har
thcle
chanctari flc
elong
rith
tlr
e. charectcdatlcl
allociatad
eith
convanfloDal
onn|<|ng,
ake
a look
at
llm blanldnr
..
Flno
blanldng
k a r -llnenoat
oll
convrnttonal
DranKmg_
n
phlch
rnatal
psn
er
punchad
rom
ooll or
shaet
tock.
Slrnilaritta
batsecn
thala
fi9o
Focesse
i.lclude
tha
typar
ot Detadal
thlt
cln
Da lonrad;
ltr
grltlcrll
natarlrh
thrt
can ba
cold
r.orfieo
can
atlo
b. flne
blEhked,
Table t. Thror erance betsacr: fltra and convandonal
blank-
hg
li. in
thc
fldlhed
colt
ard rhechantcat
DropeF
gas
of the
part .
Utor
lkr
toart
Clrcular psrtr
up
to
16 ln,
In dt|rn,
or
lqulrr
psrtr
up
to
tB ln.
crn b€
flne
blsnked.
Tha
nin
MARIO NOSEAIZO
Pratld.nt
Modorch
Die
Corp,
Mineola, N.
Y.
Guid. t3
btant.d
rom
lO3Sst..t,
O.t8g
n,
tnick,
lol.ranc .
on
loca0on
nd
daam.t.r
of hot.
ar.
0.0004
In.
tbr
th.
lmall hol.
.nd
10.002
in. ior
th.
Ptrt lor l.tch mcchrntrm t bt.nk.d
from
1020
Bt .t
that i3 0.325 n.
ttiick.
Lcngth
's
1.35
n. lot.rrnces
on hote
diamltfi
are
+0.001,
-0.003
in.
t05.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 2/49
t txt .BrAx|( tD
PAnlS
mum
natelial thtcknesss 0.030
n., and
}le max.
imum htckn€sss 0.5 n. Tlle tlrlckneGs irllmum
(no
fector
n conventionallanklng)
s need.al
o
permit
an npingementing to hold he
part
to be
blanled,
Fl8. .
llcr
Cbr lolcroncar?
'Fine-blanking
olerances
n
llneardirnensiots
t
I in.
or less can be a0.00O3n.: for dimensions
ovcr
I
in.. =0.0005-in.
oleranc* can be
held.
Tolerances
n
hole
diam€tels
epand n the ma.
terial
and
hickncls.In teel o 0.187ln.hick,
oler-
aDce
as small
as
*0.0002 n. can bc achievadi
lor lteel thicker ban 0.187n,, 10.0005n. tolel.
Ince
ate
piactlcal.
Th.re
arc no limitatlons n baxlmum
hole ize :
howcver,
practicel
mlnimum hole clianeteB
ar
summarized
elow:
?6le l -{eco;iraded mol.dol3 for
:'
' .
.
l lna
blqnking
Itilo
Bol. Dbr/stocl luct .rr
1008 hrcr8h 1024i&ft .nd
N
h .d
1030 lmuth
1095j
nly
in
lully an.
n .led, lDb.rcidlz.d cordition
{140, {140,
8630. nd
E640; l fllly
aM..l.d,
Dr.f.r.blt
|
rDlt.roidiz.d
Tr?G 302, 30,1,
305, .nd
40t
{nol
h..t-tr..t bl.); tyD.r 301,303, J00,
316,3 t?,
403,410, a2i
h lully
m-
solt,
t/.
hfd,
N
[r d,
X
h[d
Tlrh |,dnt
All
"H"
h.rdne &, (not
h.rt.
tLrt-i .rtd
"O"
l20la
.
d 2024,
''O" t.DDq onl* 60€l
r'd ?0?5Tl
d
T{)
Solt or roll h.rl.n..l, not h..t-
solt
Not
b.lt{c
Nol lln th.n 8% .oDD.r
t."l
D.dtn
Space
Batw.en
Hola*
Minlrnun
wall wldth
de.
pen&
oD
part
contiguratlon rnd 6toak thlcktar .
ln most
cales,
wall wldth shouldbe
equal
o at
,
leEst
elf
h€ naterial
hlckne ,Flg,2c.
Flattelr
.nd Edge
Enkh: Flatness l
0.001 n./
lD.
can
be expectld
l
parts
ar€ blankedron sheet
or
6ttip
materials.
Whe[
parts
are
bhnkrd trom
'l.d.d
d..l rld
br.r
.E no . €Dt .rd6d h..ru .
p|d
blllLd tro'r
t ar
do rot h.v. lnootl
.d8.r,
lPlllotyt.
rr.,tr
.hould ba
.wlu.r.d
9r'or
to tull...rl.
coil rtock. flatnc ot lbout 0,002 n./lr. csn be
obtalncd.
Fige
lurfaca tlnt,h depandron
meterlal
compG
tlon aDd 3tock tl
ckncai
The tlble
brlow lists
typtcel flnilhas lor verlour
thlckn$se
of
pa.ts
blanked fron
h.lt-he.d AISI
1008 eel.
Bhili|lo
Pdrci
t2
25
liZ
f
lflIfllflfinmll
ffidilt]lillillilllflhm
ie.
I
-Codprisn
or
conv.rdonal .rd lin..
bl,.n*ina
ie.s4.
Ac
tion of
.ih.
idpin8.oc.t
lrtc 2 d coua|.rDucn r..
idt io clot.
-
tol.Efte
p.ra
with r.liriv.lv
rdmth
c4.r
( o
die
I0 6
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 3/49
- f -
I
Fir. z-D.ri8I linit
iou of
finabtft.d
p.r .
Flnbh
0.030.0100
>o.t i7
l€-20
Parts
blanked
rom materlel such
aa alurninurn
and
brass
lloys rormally
have bette
edge ln.
ishcs
han Bteel
art3.
Dle
Roll .nd
Edge Squrencr :
Dle rolt,
Ft8.
2b, ls largely
a functloa
of rnaterial tblcloe$
and
6noothness
of the
part perimeter.
OD rtralght
lihes
aDdsrnootl
curves,
le
rolt
i3 $ually
llmited
to
l0% of
the matedal
hlck ess.
Hor
ever.
on
shnn
noints
(15_
or less).dl6 roll cen
be as much
as
:3oA
ot the naterial
thickn€ss.
Dcviation
rom edgesquarenes3or
parts
up to
ya-in.
hick is usually
betveer 0.0005 nd
0.001
iD.
On
parts
over
%-in,
hick, t may become
.002
' Coft€rs Sharp comeru contribute to lncreased
di€ roll
and, n
extreme ases, an even
cause
le
break.
€liminatirg
he sdvantage f
fine blanking.
Minirhum
adii
of outsidecomeri should
b€ et
least
07o
of stock hicknerEiadll
of inside
cor-
ners should
be at
least 5% of the tldckness,
Flg. 2c.
ColDh&
Fordhg, E[rbo$ln& Extrudin$
Fine.
blarking
car be used o
perforete,
oin, orm,
em-
boss,
an.l
extrude
parts
n a sinSle
press
Btroke.
In
genernl,
hete
aaeno limitations
on tlle com-
ple:'rity
f embossing
alts.
Coinirg
s subiect o
the sarne
imitations
as hole diameteE.
Formine
(bending'shouldnot exceed 0o, and tlle heighi
of
a step
should
ot
exceed
hree
stock
hicknesses,
Fig,2d.
o 2,000
4,000
5.ooo
3OO
Iun .l
ot Podr
Pi&
3-Corr <@r..iro,| of
corv.ndodt .nd
fin.
bl .t.
it:8 J9
r_
rrpiol" bLrt.d
p.ri
Toolina
(d.
fo. tinc
Dr .llnt
r.
ap4 .rEd
br u, , r.Fr.r.rrt
@li.[
cnn
Wh.l
Dc..
lf Co.t?
ToolinS osts or tiDeblanking reusuallyhlSher
than
firose
for
conventlonal
blanklhg.
Thus,
some
minimum
nunber
of
parts
must
be
produced
e-
fore
the
cost edvshtage
due
to the
ellmination
of
secondary
machining
begins
to accrue,
Fig. 3.
As
paft
c.tnplexity
incfeas€s,
he
cost ad ,antage
of
fine
blankirg
also
ilcr€ases;
the cost-vs-number
of
parts
curve
for conventional
blanking
will be
much
6teepei.
Another
cost-related
actor tiat
inlluences
the
choice
between ine blanking
and conventional
blanking
is
qrhetbe
or not
the
paft
Fill supporl
the required
o8d.
Colvendonal
blanking
tends to
weaken parts arould their perimeJerdue to the
dle
b.eak.
Equivalentine-blanked
arts
do
not
have
diebreaks, nd hus
aresttonger,
n,
Z
A.1l
at
z
a.o5/
t07
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 4/49
SPINNINC
&
I'LoW TlJXl,llNc
I Spinning
Metalrorking
by
spinning
is
a,versati le
process
fo 6haping
sheet
haterials.
It
is
a universal
uethod
foi producins
.t.pe"
.orro"" platr
section
ale
circular.
The
process
is general ly
usea
tor
;mpte
shapes
shere
the
quatrti t ies_do
dot
justi fy
coEpreh€neive
press
too:ing,
flared
shapes
where
press
tool ing
would
be diff icult
or
iopoisible,
,"_"i i .. i i
shapes
where
seS'ented
tool ing
can be
uti l ised
and
iarge
*oikpi.c"s
toi t,tr ictr
othet.for's
of fabrication
rould
involve.ptohibit ive
iapitat'-o"is.---Spinoiog
is ,rot
Dornally
applied
to oass groduction althougir there are so'e exceptioDs
to this
rule
(eg
kitchen
utensi ls).
spini i"g
"oiL-iJ
ci lr i"a
out
on
dachine
tools
of codv€ntional
design,
either
p""i"f iy
naiutactureltor
ttre
purpose
o
6iEply
adapted
cenrle
lathes,
uti l i ; i tr8
to;1ing
that is
siuple
and
relatively
inexpensive.
1o,
tur[ing,
whilst
at f i tst
6ithr
very
si-oi la ,
ha6
Eany
fundaeetrtal
9ift:::::":
both
ir
principle
and
application.
'rij,
i-i iru".r"t""
Ene dr.rrerent
concepts
of
spinning
end
f10v
turning.
rt
should
be
noted
that
spinninS
ie
essential ly
a fotEiDg
process
witi
no
significant
chante
in section-rhickness,
wheress,
shear
sfinning
i"
.
frogr""3i.,"
rorgirrg
operarioa
irvotvi lrg
cotrs
dersble
oetai
dispiaceoeni. '-
---
-
Th. technique
of_
spinning
is a
lanually
opeleted
plocess
where
E blank
of
r.larivety
thin
ducri. le
oetal- is
acied'up"n
"i l ;
-;1i";;_"osed
or
rolt.
tool,
sooetiEes
lever
assisted,
ia
o.aer
to'
persu"J"
-ti"
l"t". l"f
to
adouoe
the
shape
of
the
chuck-o
forDer
to
pioduce
irr" i""ii"a
corEponent.
A scheoatic
vie .
of aanual
erd
l.vei
.""i"r;;
ti;ni;;
iJ-s-io"n
iu rig.
z.
Siaple.Ehapec
can
usually
be
EadG-t
th
on€
pags,
rir i l6t
intersrage
aqr.alilg
ia ueed
or
the
loore
difficqlt
""i"ri r
s'-.i
-""ip
i *
"r,"p.r.
FolEeta
ceu
be DAnufactutad
floE
Boftwood,
hrrduood,
plastics
l€Eirretes,
aluoioir:o,
easr
iron
o 6teeLr
ttre
crroi
e'aeleiJiii'"i"i-iii
a".y
arra
ecorolrice.
spilnins
rools
ere usurlly of ,;*d:;;s;.;; ioir", typ"
""
llusrleted in Fig, 3 uounred
a lisid't;;e;;.
-
i iJ-uJi
ii 'r,,u"i..n.,
io
spiaafug
ia
essenrisl
atd
sorips
ena-taffowa-aie
*:.1'"f i-.". i . '
'
1o*
turEing
(Sheer
spinoing, powet
rol l
f,oroing,
power
spinniag,
rotary
ertlusion,
hydro
spinninS).
Itre coopotrerlts
of
a ftorr
tulning
rethe
are siuilar
to those
of
a 6tanararal
tethe,
but
are Buch
6tuldier.
Rolleti
.""
: i i i .J-
to-ti.-l iois
sliaes,
ana
these
shape
he
nork
ageitrst
a
lotetinS
,.1i4;;;";;";i:
- '"-
For irregula
shapes,
the cross.
slides-are
ttacaE
conrrolled.
lrai
slidea
nd cro6s
slides
are
senerarry
hydraulicalty
opJi.i"i-iJ"liJl
.r.n"
3;i.*irf;;:""
involved.
Marerial
lo.o
;-
.
-;;;i;;.;;;-ii=a""p
a".,' i,,s
Ploduct ralge
froD sDalt
iteEs Dade
ia
larSe
qaantities
(eg
Eetel
trlblerE)
to
lerte cottpodcBts
(aeroapace
applicationg)
iq
sEall
quantiti.r.
llar*s es large
ao 5 E in diaEeter a[d
plate
atock
up to
25
q
thick
ca be
powe spun
vithost
applyi 8
heat.
llhen heated,
blalrks
es
thick
a
14Oq
have beeo
auccessful ly
spuo.
I,lon turning ie a gevete cold working opelation aad has a Eerked effect
otr
the
Dechalical
propertie6
of the
nork
Detal.
craitr size i6 refined and alr isotropy le6ults.
Surface finiEh
is usuelly
good
alld
ao
additional f inishiag is usually
required.
StreEgth and
hardiess increase
ald ducti l i ty
decleases.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 5/49
rmEncfltNcplDlE
g
,|Ut c,tt RE
h. eih re 6or
for th. s. of r.t.M ol
nlirit
t
rlt.i i. to
lleiid.
.onpon.bt. vbich virr .srcDbl. t oA.ti.t .t r.ndo .
If
thi
i
..hi.v.rl then
"fittt4"
l .]hin t.it. il th.
.tt.
@
"i
Bt€
.hdg..b1.'
.
cen.fully th. co.t o
,roducltod
i. r.dE.il n...u. th.
Gllninrtion or th. tittins
volt r.tlu.. tb.
ti .
r.quir.d to hull.l tL.
DDduct.
A cdtrllc choic. aor tb.
ldtlu ldl rili.I lllitt ot.it. u to
h. rit to
dtlov r
..don.br.
MnufacturitrB
v.ri.tio
ln
rctu.l
.ir. oa thc conpoc.t ,
but
vtlich vill nlvly. givc
q.cc.pt& .
drl... of fit h.te.. n thd d a...rlt.
Th. i.t.rchaDs.*t.
sy6te ht. ib. lollwlDg
.cororlc
.ilyut a..:-
a) corponebt. cs n. eade in
quqilty sith 1.. iLuld otr .tllt sd.do't
if .uiilhlc
gaug.. ard
t@1ina
r. u.a. nr.
qr.dity
n.t [email protected] t
be
lutftci.Di
rD.ct.l relr.s co.t..
b)
cobpon€nt. cad b.
'as .Dbl.d '
in6t.d
dr
"fiit,.it"r
i.
ti.y viU not n..a
tinlI aiUuterts
o. srirha
ch.r.ctlr
it o d.r to
proiluc.
t.ti,a..tory
.) AsE.,bIl.. .o Dde can
n. ..nic.d by . .tpl. .t.t. or EDlicdat
i.lt.
ilraq frd otock. 1ti. is [email protected]
fo th. u. dd i. .h.. Gr thu
r.conilitionira, vhicb
woufil
irrolv. tb€ Nut ct@
ol
a.s
ttrt.
to.I.ct.t
(not.
thlt for tn. clsc o . .cir1
nobc-oft"
rcltmtr
lt b6c@. o.c....rt to
@nul.ctu6 [email protected]
pong
r'to
suit{ tb..tl.tih .qclF..t
rioc. th.
co.t
of. .cld toolina 6d
soDs.
c.nDoi
t.
j@ti i.tl.
th...
ptrt.
tb.t.for.
b.cG
Prc- couIsit.
B.foE a Bylten oa intelchlngeabl. E.lDbly c.n b. oD.r.t.d ccrtrl
lundeontll conditiont luBt
b. .t:-
i) rh.
D.hirribr.
va.latiotr
(torcrsc.)
ol .ich dien.loo
lut n. fired.
ii) I1r. utirS condition
6
..ch
D.ir
oa
ptrt.
...bl.d rust b. d.ciil.il.
Procedur€
To.h6urc thot cobpo .nt. ar. uitc
rr
n.lrlr ltl.ntlcrl d
Fo..ibl.,
tb6
Mnuflctuina
lrocerr..
to b. .hpfot.il rut h. c r.f Iu cho.eo.nd clEcili.a.
T1,o
?roceitu.
involve6 l,h. follosinA:-
1. A
Pro.e6s Plshin.
noutc
1t i. i. bcbeilur.
of
th.
indiviilutl
op...tions, oil th.ir d.qucnc.
rui
.t o bc il.cid.d.
2.
Iis- -&-. e
grEci.l
Lori's &it
'quip 'nt
N't
b' d"isD'tl
ln
'ccotduc'
titb
th'
te...
pla. cboic.
of tb. i6 E
Lc.
for th. co 'cuttr'
loc'doDs
ir tt.
p".t
"ttl.
tlo lnaiYiitu.I
o .. tion.
.r.
. lon6il
I
Y'ry
ilportqt'
Fu.tio ..l iLt@
rui h. c6n.ia.r.d.
3,
r,htt 0.u..
a o.uFirF Eoui@nt
llrrt
b. d..im.tl l
oritet
to .oDlrol
tb. .ccq'cv
ol
th'
worl '
lt..ccq..rr
ol ih.
.r|a..
..d.p.cl.I
t@)lda
u.t
b' cb'ct'il
to hrgts
F.ct.io
.teil.t& .
toG D.ti :ttlo .
ro Lllli. t
rlt
(...
Bsl'oo
(r.btc
uottt))
.bs4'-
Et.
t.r . et
to dt .rt.d.l
diEnrion of
'
c@tE"nt
qd
.oi
lut
to
circd.r
b.r..
"trol.i
-
tbi. i.r
t.t€n lot
odv to
th. di@te
ol cilcDlu
hol'
but
to Ev l.t.hil
itt .nrio .
iE
.ic
8tr."
-
l. th.
.tddltn.lzo
tor tb.
. t
4tr
i. th.
o lor
botl
tl.-.r"iii
-a
tr,. uiibs,'rb; ft,.
(^r o
cdr.d
,'&4I @s,')
t -
-7-\
| |
+'J-'t- | |
\ i
l l
I
i-.
aaa
Z. IlD.
-
laalc or,o
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 6/49
'LIrt .
of s&q"
-3 -
the ut u ed llnlM
.Et.Ibl.
.i:.r
o th.
?.rt.
Itilta.c. b.ty€.r
tb. tvo
1tdt. of.L..
'Mlni.
a l|dlt@ Clcc&c.'
-
(o
Irt. ...ac.
yh.n
n.cc ..ry)
s
rSol ' l
"0nd6
ol Tor.r.nc.'Lltr idlcrtlob or
h. d.gi.. oa &cqGy
ot lrut ctu. f,o_
-
.ult .Il,
b ic .tr.r. ttl.
l. d..laD.t.d br
th. r.ri.r.rrr.'
ltt.y ians.
frr
.d.
Im1
up to ttl5.
"Upcr
p.yi.tlon"
-
Th6 @ht Ircr th.
rb.llc
tr."
to
th.
sdr ttrit
of l ..
D.rianrt.d
rX|
lo
tor.r, ud
t..r
ror r ra ._
"Id.
6ri.tion"
-
lr .toy. but
for th. rtnt@
1ldt or.k..
D.rtB$r.d
rxl.
fot
no1€r,
t.tr
for
.r aft..
I
nE
a
lrrP r - 4Yg-gl
raild.dt.l
,.rl.ttd.
I. th. A.d.tlo
.d.rt
t th. r.E tb. aor .ttber bol.
or .h.ft,
lt ft ..
th.
Do.itloo
of
th. tollrsc.
,onc
In r.hlion
to
h. icro
tln6,
t ldd'
Ed
r idEF
"D. ic
[oI."
-
llLi{u
dil r.rllM
(shrlt
biss. the bo16)
tLl. i.
.
ho1.
eii
rqr
tude.lt^l
aertdtiotr
erl
tbis id
.clli.d ar
Xgr
bem. tL.
lov. lirit
or th. bol. .oinctde8
rith tt. .1c i . of th. itli.rsion requlr.d.
sl
E
.a . hol. tol.E.c. rith it vi.tlor fi nra tol.ranc.
g.nde IT?
i. d..tan.t.d 11.
lt. Er.l
Dnf....c.
i
to .I.t. tb. llEit
€t.t.tr to . Mg. ol
nrtlottaril
hol€s'r
{1.
. bol.-bsi .r.t. ). Thir vllr .trit rtdrarit to1r,
(cs
..u.F) fo.
DrcitrciDa
th. hol..
Ed
.ca .r th.
.n.fr.I
cd,lon.at
{i.
th.
r.halt')
.d be Dor
.dtrr Yut.a l .i .,
rftll.t
4o..ry b..ic rlt. th. . d.28
rD. 1b1.
itlfl€ .nt noI.t.
ti.
t.nil..cy
l. t odt G. r a.r,
..r,
1L 8, 19
^ d
[Ur tor
e6t
tir.hch.. ol .nAin..rirA.
6oEtlx.,vh.E
r
tndt
hE tb. r4 .lc .1' .
tbrougt.qt .tri l
cc l.. 6 v.ra1
Dal.
rtich
tut d.. bl
vltb
dilr.nnt flt li voulit . t.it. to s. d
".h. t-buir"
sylid.
.r. ih6 .r .ft l. uchlr.d to tb. d. liilt throlshout
&il t . oth.r
Frt
torlt o id. ncc.r.lrr.k. to
siy.
th6 .quiEil flts.
ft1.
.ft{?L
.4. .1r. Dcrrlnlns o tL. .h l .
g
3
I
T
rtude.ltlr
D.al.ttont'
-
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 7/49
-5 -
C.lcul.tton ol Tot. dc. CEtl.
Ibr
s'.d.6
IT5 to lfl6
q)
to I
l.cludins
roo
D.l.c -
ror.rdcc uir,
-
I
-
o. ,
1/54
+
o.oorD
$€r. D ir itr dr]iD.tr. and I li In icM.t .6-
{s..
BE.lr'oo lor
tohul&
ior
oth. tol.r.rc.
sr.n..).
A.lectiv.
toseoblY
It ir oe ti . fosil thlt lt lr &t .conoiic to
Eoufet@ [email protected] to tt.
Rquir.il des... of ac.ulcy
tor thci corm.t fu ctlo.irs.
Irrt.arl they 6 uil6 ln d lconortc db.t,
&uudt
. a
r .d.i i,
o. .or .d l.h
srcup. .ach or vhich cont.ir. tuir ol tb. .e .lr. eith t clo.. lbitr.
It.y ltc
th.r lrserbl.it vith utl.a
D.rt.
dtch t.E ..n.irlluly
sx d...
Ar . pl6 or thl. y.te.
occq. h D.ll .sioa . aet@.. i. o u.ldrt
.o$i.t. o lelic.Ily
q
lMel rlhg, s outd ritra rit sc .U.. 0r .....Ut
tb. iolloeirs
conitltion. cu b. .Ud.tt -
.) L s b.rl .r.
'rs6bl.d
lnto
.Ell.
ihn.r . r rdacr out.r rins .
r,) 6die b rl. c.n b. E.cnbt.il
ltrto edl6 lD.r 6d out.t
rt s.,
or
t. ae irnc.
nnil ofi.r lng., o .u11 [email protected]
on out.r thg..
c)
aE61r
} lI arc is.. bl.tt lDto
trrsel ld.r. it.DU.r out.r r .sr..
Usu.rlt .
r'rcl.ctiv.
adroblyr .r.td i.
Frtr.lrrlc
vb.r.
tt. u.. br.d
Ut
.q b.
lelldceil r.tn.r th.n it inillvlttu.l
Dt.c...
.a CorDlct. b 11 hr.rinA
.s . bll.. ar. ch.n gea eh.n tb.y
.c@ bn, lot
jut
ih. l inga or
th. r,rtrr.
-5 -
"Prdc. .
Clp.bility"
I. th. i h.r..
.ri.tioq
p..s.nt
l
th.
cdibr.lt.
ploduc.n
by th.
Friicnfc
ts.. r
rt.r
.U drlsubl.
ci@.. o
vei.ilo
U.* ..n .ri&iD6t.it.
Cofun c.u.r
or i n.r.nt v..latio .r-
I. Du. to th. }lalut.ctuin{
PF6c..r-
.g.lnor.
l D.bln.
b. .lES., r.cl of
t.p..t6b1tity ot eyeD.rr
..1oog
.llil.varr
ib.dl
di.toriio
id @chln. tool .
2.
Duc
to tl.ctdlcnl
F& .rtl.r,
.a.
.nr.d.A or
ib.
vorLt'l.c.
Et.rl.r,
r.ri.tlon. is
tb. .ir. oa
b rpl.c.
t.ror.
rchhirs
aivhA
r.rrl.s cqttiba
torc€..
l.
pu.
to Otsntor,
.&
Dlat.FdG.
h
tlght..i6S .,t
.hBL., or
cl&q'Iba cdtDr€ltr in . vic.
I
uE
to ?.D.hru..
.a. vcl.tlo .
l ubl.lt
t.tD.lrtui.t .ft
ctilg
th. colpooenr
.ire.
&g ,
lw t..t vhlcb
. . csrl.a out to tl.t.h1n.
th.
I)rc...
rut.btity
tlbtla dDiri..
th. ctt
ct. or a.ctor D.b
u i@t r.61 lc*iDs o.ry r cto 6 du.
r|bo
il.t.nbiDs
rDFc..
c.r'alllltrt
lt
l. .c.. .ry io
rcarc.
a
ube
or
cols.rtlr
ail i .t. rir. th.
ca .tiIity fto
q
edy |. oa thcs..
lnoinc.
ex@plc of d.lectiv. r..6}ly
i. tn 4tirs.ruinlu
Dl.ton.
t6
@toF.ar crltnii. bore€.
.s isluu.
5toE
noEtn.r
br.,
sil 6 2.0{rr. lolml
Dirtor
aia.
&rt .Lirt clelrlnc. lo
Dirton
r
O.r2-
(o
dt..)
Iol . i lo€ on bo 6
a.
Toldrucc on
l lr io:
dra
( r o.o2l
.
0
o2m.163
o+
o'o2l
-
o.o2E[62.88
+
o
J
I
63.01
62.69
aull..t
ll.torc
lb l ra..t lr6rc
rculil
SiY.
O.r
b ct..ru..
sil l.rAest
I'iston
io
66ll..t
bor.
| ,
0,1O n
.
Iot.v.r,
Dy
erzdinA
eit Ellina
th.
borcr
dil
pirto..r
y.
.6urA r.1.crtr.t,
$.. rr1. th.. a. folloer -
63.OO
Pi.to di r.
r.quir.d..
. . . . 5?.60
. ch
Arou
girios
Ur. d.slr.rl O.l2
ct.rr trco
63.02
62.9O
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 8/49
i
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 9/49
rz r 6.4
SurI.e n'shies eatB pmdrc.d
b, odtun
ptudrcdon
p&es6,
@ti, '
RoLshn.cs
vdu,
R.tin
@j
Ebcrc
dbchsrse
rdinins
-
awEse
apDtica
n
ls
L6s
toquenr,poticarjon
Ie r:
ssrlsi
pr2
re74
lollEplEFqe.EshrqeIijuoyEfule*.jtdfu'
*f;*."['fltrtr"l:trT'.:;fn
tFisur€1:
BS1134:
an2:
1972J
rl
12
t1
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 10/49
N
K
%
N
n
"if
slq
-
-T--o
-r_
l
l
_.9.
t0
ts
I8
-n
l
-q
IO
;i'
=i
-i
IA
6
l8
30
n
t0
E
30
40
l8
l0
40
50
l0
40
50
65
40
50
65
EO
m
50
65
IM
65
80
t00
120
m
I00
120
140
t00
t20
t4 0
t60
r20
l,l0
160
r8l0
t40
160
tm
2m
160
I80
\n
225
lm
2W
225
25fr
2m
D5
250 280 -t ' 225
2fi
280
3t5
zfl
280
ll 5
35 5
280
ll 5
355
400
ll 5
155
4{0
450
4m
500
400 450
450
5m
BRITTSH
STANDARD
SELECTED
SO
FITS-SHAFT
BASIS
4500B
a'
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 11/49
qd P
%
N
%.
%
w
@)
N
N
N .\)
';
'- "
\'',
V<
_-
6st
y-"1
cflr
.\SN
|
+
n r.
-if
l
6
-i
6
6 l0 12
t0
l8
l0
t8
t8 30
l8
4t)
30
q
()
50
40
50
50 65
50
65
65
80
65
80
80 100
80 100
lm
120
10., 120
t20 140
I20
l4t)
t40 t60
140
t60
t60 lB0
160 180
180
2m
180 2m
200 225
zm
225
225 250
225 250250
un
250
1m
280 3 t5
280
ll 5
I5 355
3 15 155
15 5
400
1 55 400
400
Afi
4m 450
500
450 500
ERITISH
STANDARD
SELECTED
SO
FITS-SHAFT
BASIS
45mB
3
\Z5.ooo
\zct.
Q6<>
l '\crr
C leAvhce
\ ls, \o6
iL\.q6o
, ' | \15
iot '
'
\ rz; .our
i I :
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 12/49
i c
nt
€*o
'Lo
tz
Lo.ao
\1 .cI46
D\O
r
\
Q1
_1_
S >
l - i
,)
' :o
- 3
\"1
'13.1
:i,
tr
2o
\ . .ec;
Zc,
?o*'*1
fo \\l
zo:6
>
Y',\a
).
?r.\q\
\q,
1
q,6
\ -e. ( ro:2
-,-\.qa
\^"\ .
I
I
l
l
\c\ ' \ 3
v\-i
-
\
v-
o^X
5
-1".r\1
\1.1\a
-z-.O(5
7r9.
(2o
o
I
cr-
n
Gv
^r)
'J. ,
Fctl
9
ro,.tq3
11.1"2
:o
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 13/49
SUn]IACE
E]ITURE
I rrgule
i i .
trhich
rould
be
4th
order
Ir cgul i ,t
ier
of
tb.
chip.
ES
tI34
-
1972
Eextute.
.,re
t{[derd
defides
2 cla86e€
of
e:<ture.
RouRhn r
the
Ndture
of Sulface
Texturg
?l:3,"i.f"""
produced
by
chip
reeoval
process
depalta
frod
the
:::.",:?
Tj.:::i:H
::,
;ii:ii.
ina.
"
pres
nr
i"iiil;;
-;;
desired
perfect
recoglise
fout
l s t Orde
I : : : : : ir i . i"f
arising
out
of
inaccuracies
in
the
Eachine
ool,
r.ck
of
lEai,gh trelr-in
lhe
l 'eys
or
guides,.or
out
of
defolDation
of
the
lrork
unde
ne
cur in8
forces dnd under lhe lrei.ghtof i rr"-r i".:- i i - i . i"r i .
2nd
Order
Irretularl ier,cEused
by vibralions
of
aDy
kild,
et chatrer-dsrk
due
o
acorrect
cuE ing
engles,
loo1 vibraEiol ls
etc.
3 d ord.
::::: -by
rhe.nachining
ts€If
end
characr.ri.rric
of
rh€ proces ,
preser
ev€n
f
the
i:chine
rre e
perfect
".a
fri"
ii"r'rifr"ii i",
arising
froE
lhe
ruptule
of
lhe
Eelerir l
drl l ing
the
lepes.tion
Centte-1i lre
.varage
height
Dethod
for
the
aEgGlssent
of
turface
IJavines
Roughnerr
(PriEaly
textule)
(secoDdary
t€*ture)
The
ir eguldti t ias
in the
lurtece
lextute
uhich
reault
fro6
thc
inhelent
ectiotr
rh. produc ion
p oces6.
rhe.e
ate
a"e.eJ-io
i;; i ;;"-;;;":;""
reed
,iarks
nd
the
irteguleri ies
lr i thin
Ehen.
Wavinca
lf. l :-"o.no""o.
of-surface
texrure
upon
Fhich
rouShness
s
3uperiDposed,
:;:i:ff:
ffi].':::i:,:::',:";:,;:ilo'",",,'*"t
in"'o.
*.t-a"ii"i.i".",
vibrarions,
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 14/49
Su
f
ace
topograpny
rz
trrrs wirh th.
*antcd .xcuEioE
of
thc
{vlus'
rnd
'n
oacricc
rr'c conUi.*io"
can
bc
lcc'Prcd
onlv
wh'n thc
'"i;".
"..
a*p
**et'
rnd
cldc
cnoush
rosdh'r
tor
Ji.'.".i"*
"rir'.
'li.fsi"cn
radis ro bc shau con'
orrcd
with thotc
ofthc
stylus.
Som. ryPrcrl
Profi
ca
oi rou8hnds
Iaturc'.honzon'3rr
comPrc$cd n
thc cu, l
w:Y i t '
5ho'Ln
n
R
r'
Fig. 4.
f,/Pictl
Profil.s
Mtgnification
is
3hown
thus: vert
icel
I hori2ontat
Fio. 3.
(.)
Skid
S tlidas
ov.r
crasts
of
sptciman
(i,
.cc.pt.bl.
.Pptoxim.tion
to
in't'Ptndent
'Jiti
t"t
'ieniiic."t
skid
.ttot.
n's'tiv'
ol
'i'jli,i
iii,anc
tu
whsth't
th'
skid
'nd
stvlus
dovc
in or
out
ol
Ph,sa
ld) acc.ePttbla
n;chanicat
filtrr.ian
of
wav.lengths
which
ara
iii
""^p-"a
with
s.P't'tion
of
skid
'nd
Thc di.mond
lrvlu
mav h'v'
tht
lorm
of a
90' con'
* l-,ia."
"i,".ia.
*'.t'
'tandardi 'd
'quival'nt
liP
rrdii
i "a
"p* i ' - .
ro**
"t :
rm
0.7hI
or
l0
/n
l6nN
whrlc
tha.
uD.
.rc
3h..P
cnough
or thc
gcn'r
'un
ot
."di..'ii"
i'i.r"".'.
'zrirg
do*n
ro 0
r/rn
.000r
s0
".i s. ui'o in lo.cialscd dtruhcnlr
to
grv'
b"tcr
i*.r",i"^
"t,1.
n".",*lu16
''
8
thd'
ofsaus'blo'trr'
Elccrric
iBduccr ,
follow.d
v hcir
'tr'nden(
mPr''
n.i..i..rr*.u"a.,
airplrc.mc't-5'Eitiv'
i'd'P'nd'n'
"i
lii.,
-a
rnotion'icnritivc
d'P'ndcn
on
ttllu
vclociN,. Tlc
djllincdon
i
ihPorlcni
and
thc
ut'r mult
ri"*
*uJ
ri'a
r'.
i' *l'g,
bc;au '
tb'
form'r
n'cd
h'vc
ii-'r-,i"""i
frcqucncv
rimn:rions,
rnd c"
rcProduc'
*.*ir"nn r"'c.[a
bv
thc ltvlu
r'lidvc
o lhc
datun
n.tuain""u-t
tingt.
gt*"s
and
rh' lonS'lr
w'vcl'ngtht
-iir. 'n'.
r"*'
hr'.
ficqucn*
UmiratioN
rhat
rcn'ct
thc ran . ofDrofild
ro
which rh'v
cln
b'
aPPIicd
wirhoui
scrious
misrcpr*cntation.
-r.
*.-"'r.r' Dhoto-clccrric
and
modulat.d-cldd
rranrduccB
r.
disPlaccm.nGscn'itif''
dovms
co'r
rrrnF
duccc.r . nonona.ntnv' Pi '2o-clccr f lc
dsDlrem.d-(smk
rn
hc
brntc
oi lcrx '9c^buI
(omr
-"1i".-**i,*.
*t'.'
-"."t'd
ro
rn ahPrific-
ni 6nn'
Th. cl.crncrl
5iqnJ
froh
a
disPlrccn'nrrnturc
,'"*i'*"
"ri..
".irin'"u"n
nav
Providc
thr"
kinds
;i
';;";,,;;
I)
n
a'arosu'
rc'ord
'
c
r
Pronr'
;";i;;';h"',
rcc".d<'
,ndtor
'2)
r disi'ar
rccord
li.'.:"r'-
"ir-a"
,p.-d
o.oinrtc
of
thc
Pro6l'
srrph
tal.n f.om
th. sidc
ol
thc
chai
bdng
rccord'o
on
oun.h.d
o
nden<uc
aP'
lor
" ' l_r lu ' r '
ProcA{ng
'n
:"" ; ; ; - , , ; " .
; ; ; ,
3
n*r
'n i rk ' r 'un5
o'
numci. r
ralucs ddcriprtlc
of
h.
Pro6lc-i i . , ; ; . t
dcr i 'cd
fr ;m
motion' 'nr i tnc
nnsduce^
^' . ; . ; ; ; r r '
u i tJor"
for
m'rd
no' 'auun'
ror
'h iLh
. , .* . - , r t .
f . '0, . " .1
fune/ \ r ' u ' ( d 'hb'r r rd '
NUM EFTCAL
SSESSMENT
Significanca
and
Prsparatlon
ForourDos
ofcommuDic' ioo,
aP'ci'llv
n
drlwirrgs'
r, ,i"i-'l.
.
a..;*,urf'cc
c' u(
nuhcncalY'
nd
mlnv
rDororchca
o
hit
hrvc
bc'n
cocid'rcd
A t m'nc
.;;i;";iJ;;i;-"
-p*,
"r
trr.
td(turc
i oRcn
cr'ncd
ro
s
i
p. ah. .r'. ThG
hciSh
tP:cng'
loP'
dcn
.--**.'"iii.
-0";1el'nJvrnou'
ditt'ibutiod
"d
corrcl.don
f:c@E
of th.
roushn'3
'nd
bc
cni 6cant
nd
conribu
G to
hc um
rottl
ot
rdorhruotr
ihrr-mav
bc rcq'ired:
t"t
no
3in8lc
PandclcrlrP'ndcn'
i" ,
.i""r.
*.Llt.
can
colnPkklv
dcrribc
,ti'
{rrrr
'
s...* 1,rr*'
h.vin.
qu'; difcrc'r
p'o6l'5
rrn
'"
num.nc. l lv
.qur l
Mth
raP"'
to
onc auch
Pirrm'r ' l
whil. b.inq uncqud
wilh
rcsP'a
(o
o(ncr3
rrdninrh
. . . ' 'a-" . ;*
ai .L", t ' .
tnc numb'radh{tcd t^ * ')rr '
shoD
us.
sbould
bc
dinidiscd'
"
ir."iJii
i"'"a
bv
rh.
Pic['uP
m'v
']hibit
d
"l l
r(jruvc
rc rhe,srruh.nr
darud.
(r\ gcncr.l cu^rr"'i
., i.*
**a*"*"
cls.d
d 'w.vind'
r'd
/ h'
.ho^*---.t.nrf"
cts.d
s
'oughn's
rhown
rcrrccc
i ' . r ' i " , r ' .
o."ni .
i "
r ig.
s( . '
Th'
f iFt
rwoorth6'
b ' ins
'.*r.';"i
,,i,i'"
lhird
".nd
rourth'
rcmc
Pr'Prrrtion
^f
'i.
or.nr.
i' *qu;.t
lcfo..
u3cful
cdu
r'm'n t
'rn
b'q'n
Prcrararion
ii"ot'c
rccognition
and
isolatron
t rh'
i . ;I i l ; ;;; '
; ; ; .
.* 'u' ia.
.no
rh' s'rbri5n-'d
r
. ,
' l " "u l .
' " . , . * .
rrn '
f ron
*hrch
Llcced.
Rt-oqnruon
olrhc
o t rcr 'nr
kind3of 'e\(ut
Jn ' r
or 'ha '
l ,ound.r cs 'na n orvc
omc
ocqr" ol-uds"rn"n '
I 'n
. ' " " ,1-, . " Broadtv.
oushnc$
n d"hcd
ro
it ' iud '
Jr r
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 15/49
Surface
opography
F2
Parameters
Erccpt lor lhc fai.ly
p.riodic
t.xiurca
3oh.tjh6 prG
dd.cd by dttihg pro.c$d, 3urfacc
rcxlure t.nd to vary
.nndomlyin h.ight .nd ipaciDg. Th€ problcm ofdecnbing
thc
diFcr.nt tin& ofr.itur. ofcF
full *oFt ior lhc
d.vic6
nf
(h.
ltttirticib. frod rhc aihplqt
fo.tu ofav.rrSing ro
ih.
<omplcxiti6 of cotrclatjon flucrioN-
Height
Th. mor
comho'lv
6.d and cdilv mc$urcd h.ight
par.mrr.r
n
'h.
av.r $ d.panur. from th. mc.r L'nc
Df thc fih.i.d pronlc. ft i tnowr i. rh. US.{ 3 rhc .{-A
rallc.
In Grcar
B.ihin
ir
wa
and
Bcndall_t
ir kno*n a
rhc ch v.lu.,
bu(
it is noq o b. knowD d rhc R.
val (
ro
lin. up
virh
ISO tfhinology
dcprh. B.a. ing r nr. rccp6 p.r
un' r
lcngth,r_J
giv.n rcvcl
har. rko br. . .oun, .d In a ncw d. thod' '
a l l thc con-
$iru.n$inusidal wrvcl.ngthr fou.d
within a
gilco w.t.-
band,
wcightcd
according to thci.
amplirudcs.
ar.
'al.
into account
in an avc.agirg
proccdurc.
Beaing
arca
A conccpt
rcqu.nd:/ cn.ount.rcd
i thar of
'b.tring
arca,
lhown in abltracr p.incipl€ in Fig.
8. th. l.vd
of
th.
intcB.cring linc bcing crprcscd cith*
a I
dcprh
bclow hc hi8h. p..l
(an
un.cftain
..icrcncc poiat)
or
a
an
ofs.r iron rh. ncah linc.
BEAFIIIG
LINE
_l
- i
-li-T_rJ
--
--t-
I INE
Fig.8.
Not tinsl bea.ing arc. of s.t
rple
3/a
a
\
100
It mulr
bc rchchb.r.d th.t thi Ec..ur. i connn.d o
a
m ll i.mDl.
of th. lurLcc
.nd do6 rot r.riacnt rhc
ov.rrll b..ring
.rc. taling
w.viD.s .rd orort or rorm
into .ccounr.
or do6 n .[ow for clrdc
deforftrtiotr
of
th. p.ak und.r load. Th6c atrd othd cotrlidcrlrjont
Crcst
curvaturesand height
distribution
Th€
.vcnsc
radiu of €u.v.r 'c
of
th. c'6t ,
tnd
thcir
hcigh dirributiotr, rr€ rcfcrcd
to in
conn€clion wnh thc
ol.lticilv ind.x in Sccdon
Fl.
whilc d. .r idic.tioru
..c
nor
gcncrally
vaihbl.,
thcr.
qu.Dridcac.t re.dil.r
bc cofrpulcd
rron
disi*cd
prc61.
cco.&-
Corelation techhiques
Thc . m.thod hav. b.cn
inilodu.cd a5
.n
.id
to dis-
tinguishing b. w.cn thc ah3pc
of
characrcrisric
profilcs.
An accourt ofthcir us i
tiv.n
in Rcfcrcncc
I L
STRAIGHTNESS,
LATNESS,
BOUNDNESS.CYLINDRICITY
AND ALIGNMENT
Alrhough
rhac
sp.cs
rE
g.ncrnllv.ons'dcr.d 3.PaF
aklv fron lurfacc t.rrur..
rhcy
can b.
highlv
iignifi.ant
'o
rhc lunclioninq of rurf.c6.
rnd mur
rh.r.forc
r.c.ive
1 lcd softc n.;don id th.
prdcrr
scction.
Th.sc sp.cls
ar.
gcncBUy
m.asurcd
wnh
a blunt nylu3
(h t
rrac.s onh
thc
crdts
oI thc roughnc$. a.d do.s
nor
appr.ci blr
.nrcr
rhc
nar.ow.r
scratch harks
Sfaiqhhc$ and fainc$ .c now b€ing ncasu..d wirh
rhc saoc basic tvpc
orappararus 6
io.
tciiure in
Fig. L
_ _-t
Fis.7. ta
-
Lf,
vtot.,-"
=
(Lrl|,^"|
Thc rtu v.lu. h bftn $cd in.pproximatc
forh,
obt.in€d by mulliplying th. AA v.lu. by l.ll
which is
thc
convcFio iacrcr
oi sincw.v6.
Thc hcight roh fi. hjghdt pcat to dccpcar l.y
lound
anyehcr. .long r
rclcckd
part of th.
pro6lc,
lnown
a
&,
i
u.d crpc.irlly
in Eu.opc, bul it
k un .d f.(or:-
bcc.ulc thc singl. crrcm. .r. loo grc.rl),d.pcnd..r on
th.
chanc.
porition
3cl.c .d.
An.v.rascd ovcrallhciFht k
morc r.prca.nt.tiv.
(han
R,.
Thc
'tcr
poirr hcishr Rr'
ir
obBincd
bv avcr.chs
thc
fivc Nghd p. b .nd frvc dc.p6r
vrllcy in th. tottl
tnver]e.
ln 1 rcccn
Gcrh.n v.n.nr, ttrown a
&.,
th.
avdagc
of fie R,
v.lu6 in fiv. coB.cutivc t.npl.3
or
cqual .ngth is tllcn.
'llhoosh
rhc rario ot on. h.jshr n.a r.
to rnothcr
,.r wirb rh. 3hrD. of th.
Drofil..
om. dcqrce
of
ron-
vcFion
is
g.ncrallv p$liblc.
lhown bclow:
l0pr
"1"
Ll8
to
l-30
t_25
5.o;
8.0
'
Wnh cLan cur .oB.ou.d-nd.
'@1.
spacing
Thc 5pi. inq
oi ih . norc sigt i f icanr
P.: i
r lonq thc
. : : r f . .c.
rd l 5.
tunct ional lv mpoi l in t
Pcrts pr '
' rn ' r
l . r { th hrvc bccn o i I .Lr '' p f r . 1r. , , ,1
htcd as o.1,
" f l \
r i
(hc
ld ja.ent
ra l lcv c\ . .cdr
r
c ' "n
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 16/49
'
'l-;a
r,r
-_._4_-t
:--
r ro.
Mil l ing heoret icol r oughnss.
Thc'otetical
oughness
$r{.*rr.t
.n,L.6lti.L.i
How a
wlper works
i--^;"'---
i
0.00t-0,005
l l
Fig.19
nr. l l f i r l C l l t
N
:
f r
Surfa e
(NB.
rou
9n
n ess
Ril l
2Rs
)
oi broad inish
rni l l ing
I
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 17/49
BS11:14:Part l : . |972
t
---g:-.-
.rtu
ro
E
du.a?|nldrn
.t rt. rk.
h
;ikr
.... rnt
t:l
SE
b.ka l:.--:+l /.
|-
-'z'g*"-
"
-L
hFiooL, L lL
tl*
ot
tr.t
.tlon .a rL rlr
h riLl
d4'-
lilUffiil*-.w
X
c.dt a I tD .lir aa{d
cl'lhrto t
Af
.aF4dlo..f
lhiLrh rr&l
.
tit
l b...d
M
C
lt .|brdr dn*
iliar.
-
L6ln
dfirn.
biL
R
A,' .d..ld,
,.3 irdn
b
t
dlr .a
t rtd k ru.l rl.
xtn l.t
aatt.-rriiat..dr..hde4.*ath.o-4.r-rr&.rr.r.E
IsrlIt,an,lYILrmalr.t r.rt,arFirIk.a.aJt
tfi
-antui
flo.r.
Swnu.latt'.t
r.cionolLy
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 18/49
-2
s MlcroDet169
NurnlEI_ F ln lsh Descr lp_t lon
apd Ttptc. l
Apptrcar loos
neco@ondod
lrodrod,
N6 /
v
N 4/
v
o
'/
V
or/
V
o 05/
v
Aelrrna
surfqce rh6r6 s 'oothucsr eosenr la l
rnd Turo
vtth
sqlaro
nos6
tool
e l t l r
draa
feed,
tool
bsrk. oDjoct loorbls
c.A. h lah
lpeod
ren , h&od
tl te
lnootb,
barro l 11rr ,
Bhal ts.
Jour:nr ls,
ro l l
bodles
and
o.cks
-
plano
broldcut,
co@orclo l g.t-nd.
hordetred
stacl
perts
-
runnlog aod
sl ld lDa f t tc
at b ls l vslocl ty. e-a. e€.r p lqtes
Sdooth l ln ls l r , r l thout
ccratches or oth6r
F l to
and
Potlsh,
l rp,
t lno rurr ,
roar,
d€fect lve Ddrk.. c.g.
cyl loder
r 'ored,
deol l l rat
c ls 6
cyl lndr lcr l
and
sur laco
gr lnd_
aur lacer,
Boootl
ruDnlna l r€
a. l uss ,
I l tah cldss gr lndlnA
( lntrh
-
hy.r .sul lc ron
Strst
c l rss c6ntro losr
cyt lndr lc i l ahd
.urtaco6
aho.r b l rder, hrgh
spoed lp lndl€.
-
6urtxco
gr lnd.
l rp, hotro.
bal l r rcer,
Audgoon
plos,
Iocat lns
bu her.
v l ro
dro* lng d lss. cold
str l ' ro l ls, )oc6t lon
Surntsb, pol tsh,
supor
I ln lsh, spccla l
p lnr ,
rebovrblo
burhos, very h lgh dp.od
cyl lndrtcal gr tnd,
lerres
8rrnd.
6plnd)s3. roDs,
ptsto la
cyl tnder bor€6.
EeIl
r rco tr ' rckr , cold
rtr lp
ro l r . ,
DrGclslon
ttone,
dor lee
srtbd.
AuuAe
bo.€r.
d los. l
purp
bo.ee.
O O?5/
ChroDlu
plated
Auuaoo,
. l lp
sdu8os,
opr lcsl
Dry lop brrror
r lntsh,
ret rap
'natr
t ln tr \
V
l l . ts.
d laoond tool i . spocl r l cold
' r r tp
rot l r .
scr los
art.d.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 19/49
II
I I
IF
Fl9 _ t_tr- r t
Pl
n1s
h
25 /
V
Tho
rel€vao
r
Aft
t lsh
a-S.3Oa; pdrr
9 9r.1-c 1etrg q_f,r,e
t gf,4 p1lsa: e
A
vory.ouAh
E.ch
tne
dresstnr
. t ,o€ns,on6iry
;. i l ; " : '
: ' ; ; ;" . ,
" : : : . : :"
urposes
only
_
^_r6rrondbt
y
-
, .oo
th
surtrce
wt
rr ,
tro
spr
lnt6rs
or rr r r rs
--s l lg trr l ) ,
t r reautqr
n,uy
vnry
-" :r j , .
-
(or
clearanc€.
Do
loe(r
Intrn
o.o62s"
_
trut
tdr
[so
,hore
r
unl to.D
cohroct
t6
reqrttre. l ,
surface
roqul r loa
good
flotBhed
oppaorance
or
l . t t"s.durrace
rtth
tatr ly
crose
toterance
br L
o
Eovl r 'a
I la,
s.g.
traso
ptares,
Dnror (e6r.
Sur l6ce
requtr lnA
clore
dloeosr(
surrocee
rirch
,;-;;;r;;";;:::i
;;ilT,
-
i?1r",, : i ,
surfacos,rth
runDrDa
,nd
srrdrns
rrrs
.t
to,
eoloclty
_
su.tsc€6
rachrnod
to r
l ' : . , :- : : .r"": ,
Do,r€..tery
crosc (orerunce.
o,g-
bore
dnd
deAt
ot
shertE
tor
DeurrnA
l l i l l . :
.*1r""
.nd
6rrdrns
.r td
tr ,
oedrxo
v€roctry _
IntGrteronce
aDd
irey
rtrc
\ rv
\2.5/
u.s/
3
2/
v
l fdch I ue, hrn.t gr tnr t , chtt , ssw,
ier t le
ili:";.
t;t
.tlil
ll999g9 d uethods
Shqpo,
rrrn,
o l l l ,
Shape,
be. l lur
t
urn,
pr€cle
loo
cdst
.
boro,
p.tano,
drt
I
l,
rot
I,
bo_ro,
p lano,
gr
lnd,
ro6a,
rrrosch,
oore,
coonarclat
tu.tr ,
Sbap6,
Drt l ,
rouAtl
o lot,
haod
ecrape,
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 20/49
SI'RIACE
OR
PART
J 0-@06
N
o
{;
N-
$
-t-
sssglg,$
Pislon gs
o
packings)
*
- louslnq
f l ls no
gaskets
or se
ets &
or
a9-cut
th.reads
Clearance
su
aces
(nachined)
Datue
surfaces
\rnder
O.@1 in)
ove O.OOl- n)
ng
sulfaces
Eatln9
DecianlsDs
or
Palts-PleclsioD
sut aces
brackecs
?
faces, bases,
etc.
Pressed
fl tss
genelal
keys
&
Rofl ing
surfaces
I{orE geals
-
Worr
qears
-
hea
af
foadlnos
eraL
cans
&
fol lowers
du
general
pjvot
otat. ihg
surfaces
and
holes
etc.
p.Ins
I
chased
thleads
tith
legul.ar
cross-hatch
patteln
sEootiest
possibfe
f inish
woviness
not
consideled
\6
\D
6
o
o
o
-L
n
o
valve
stens
(autorootive)
o/I inder
bores
(?u
Pist
n
pins
CaI0 Iobes
(autolor ive)
Rod bushings (autoDotive)
cyli-.lder
boles
(O-rings
or
1-artrer
Surfaces
for soft gaskets
sr:rfaces of
fl-ura seaL -sliainS
crorind scree
rhreads
a
iorE
Sl lde ways
8
gibs
Gear leeth
(hearr ] ,
Io
cea teeth
(ordjns-ry
servlce
over
to Dp)
l-
selvlce
over
lO Dp)
i ,
.TournaL bealinos
Push f i s
MilIed
threads
<Iiding
surfaces
of
Eatlng
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 21/49
yl
t
Guiclo
to
'tito
Gelecilion
o-f fi,i:s
Hll-cl l
U .d t
9 l
v. r l .x lb i l l ty
.da r
lo ia,
?.3y. t . Ib l t o.
. c los. l i r t . l .v. r , .d
rort
t n9
l.npcr. tu.e5,
12Ml4
OIA
H1i-c11
l9-d l0
U3.d ror
l i id
i€. t i . loot .
psl lay
r id vary l . rqe
44
t,1r l
OrA
f l9_d
lO
iat . r ' i r i r
on
I t r n
.
89
.9
ueed lor r ldely
,cpi . r t .d
b. . r ln9s o. r .v. r r l b.r r lngs
-
So .trDlA
t19
e9
AA-17
5 i
.b l
lo . rppl l . . t ion3
r q ir in9.90od
qu. l i
t
l i
I
th . l t
e.3, to
pr0duc. .
lAMMO
HA-
l7
l7-96
Slld l^9
r ' j
r rot
nornr l ly
03ed lor
co.-
l i . out ly run. ing
b. r i^9t
u^
ers
lo iC
i3
. l iqht .
Sui
r b l .
ror
oreclslon
r l ld l ig rnd locrt ion,
6
t,1^r
DtA
l l7 h6
Su trbl .
for
n.ny
non-.unn n9
12 lM OrA
Ir t - k5
Ur.d for
locrt lon l l 3 rn. .
I
r
l lght i i . r f . ro ic. ,
ih ich
. l l r l . . l . r ov.{ .nt
of or.
D. . t . .1. lv.
lo . o th. . ,
t t
Utrd
vhg.
th. dcgr. . of
cr. . rr ica
ihrt cr.
. . ru l
t
r .on |
.N/- t6
f t
I
i3 ioL
-
-
/80
rlM
clA
rl-F _;jpr
Hz-^6
cr.r,u
. r,
r
i | ; : : : f t
'h . r
I
r i
-
; .d
3h. t t
l t -p6
F.r .our
rr r t
r r . .ot
bv.r -
3 r r r .d
d r ln . t . .b ly o.
2OO
MNI
DIA
H7-p6
au$
* . , " ' t , r "o
lor
p.r
. . . . t
-1OO
rlNl
0lA
H7_
s6
It l
i r , l r r
I i r . r
i^
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 22/49
Ig4 Manual
oI Bnish Standads in Engin"
ln| Dnwing and Desiln
;
q
{
I
5
a
I
^9
22
21
20
19
18
17
12
11
'10
9
7
5
t+
2
1
005
01 0.2 01
0.8
1.6
3.2
6.3
12
25.0 500
(l i ' .
7 / , , .
. .
tn, f-) 'qa
in rn icfooe'res
Exarrplr.'
Should
a
giv€n
areaof surfscsbe surface
rcund
o 3.2
rm
q akingapproximatety
minute,
then
o achi.v€
2
/,m
would
ake pproximately
.5minutss.
{Figuret1:BS1134:part2:1972)
Ytsrue
6.2 Trpbol rcIatbnship
of swt'acee utc
to
production
ine
fot
connonty-used
ooh
@d md?nats
Nor.r
This ASure s
Dot intended
for makidS @st @mpaliens b.twed difierc-ni
prc@ses
0.025
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 23/49
192 Manual
of British Standards n Engineefing
Drahiing and DesiSn
T;bIE 6.4
Surface
uughness
values
produced
by
common
prcduction
prccesses
and motcfinls
Roughness alue,
R.(in
pm)
Flams
utting
Snagging
Sawing
Planing,
haping
Drilling
Chemicaimi l l ing
El6ctro-dischargeachining
[4illing
Broaching
Reaming
Boring,
u.ning
BEff6lfini3hing
El€ctrolytic
rinding
Roll6rbumighing
Gdndjng
Honing
Polishing
L3pping
Sup6rfinishlng
Sand
asting
Hot rolling
Forging
Pelmanentmould
casting
Inv6etm€nt
astrng
Exlrudlng
Coldrol l ing,rawing
Discasting
I Average pplicetion
Fs\r
Lessfrequentapplication
i l
t ' " . \
( -
+J
r€1t
6
[Iablo
1: AS 1134r art
2 1972)
V,rer
Th.
reg.s shoh above .r
rypical
of lhc
pro@$cs
lhte.L Higher or lower valucs dai b. obtained un<lq special @nditiotu.
,1 i
/Ahcs
,
N.. =
"
{\ va
tla
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 24/49
o sng neer nges gn
General
data on.manufacluring
s
readjly
vailable
rom
books,
ournals
no
teafned apers.
Srrr.irc
daia will
be
more
ditticutt
o
_obtaio
ecause
t
witi
be
;;d;ieJ;or particlrlar
ompany
a.5
prcducl
onslrainls.
The
use of
lrends,
ndices
nA ratios
"ito*,
oaa,qn"r,
o compare
processes
l hedesigt
gtage
ut
hese
would
ormally
e
vaiidated
y making pror otype
o
owed
0f1en
y
pre-proJUCtion
nS.
Tooling
is
an
inlegral
ad
of riJanulaclufe
nd
consicieration
ust
be
given
o
looting
t the
oesrgn
lage
of the
product.
Common
ses
oi
loots
nclude
hapjng
die-s),
ouldjng;oulds),
holding
tixlures),
maniputating
0igs),
nspeclrng
tc.
GENEFAL
ESIGN
ONSIOERATIONS
s :e;
form:
matet ia l :
quant l ty:
aconomyi
accuracy:
surtacS:
3ta
da
disat lo
:
assembly;
-ac,(agingi
lnsi fuc
ons:
the
q antity
l materiaj
nvotved;
he
dimensions
ndweight
o
be
fT|lj_"*
lo
break,down
nropans,
wirh ocations
n
rypes
f
oiFls:
reiauonsnlp
o
processing
lant;
elationship
o maletjal
ize
availlole.
shape f
component;
impticity/intricary
nd elatlonship
o
pfocessin-o:
:-ll i l]
":ldjtign'
famjtiariry
irh
propedjes
nd
processino:
r€tatroFship
elweenrcp8rtjes
nd
processing;
pro0uctionaies
eq ked;
lanl
nd
systems
vailablei
nvestment
required;
quantity,
and:in9,rocessing,
nspectjon,uatity
ontroj, astaoe:
relareo
o
ptant
nd
ools
vailabjlity;
kills
availability;
t0lefances;
its;
quality
f
surface
inish;
appearance;
esjstance
0
environment;
roperty
nhancsment:
It-.j.T19?19fl
rl'
bought.our
afl
:
conrormarton;,or
a,ery;
producl
iabitityrorecrion:
educlion
n costs:
manual
r auiomaljc;
vojdance
f
€rrors;
modularisaljon;
astening
and
oining;
t0ols;
tandards;
esponsibilities;
elationshlp
jth
specilica
n;
Prgtecli:n;
andling;
ize
nd
hape
f
packst;
eed or n.transl
,
insoeclion:
c'arily
or installer,
ser,
maintaineri
anguagEs
of
export
foducts:
Further
eading:
Dieter
Engineering
esign
A
Malerials
processing
Approach ( Mccr aw-H il |)
cci l
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 25/49
DESIGN OT{SIDERATIONSOR
MAJOR
PFOCESSES
Der3rls
f
processes
aEbe obtainedrom
manutacturing
echnologyexts. This
section
s
only
conce.ned ilh
he desjgn c0nsideralions
elated
o
types
f
process.
a) Ma
eria l Removal
R-a?sons
or
ahoice:
malerial
prOperties
equked
or producl
icfaleormSuiledo
process:
producl orm fiay be ditiiculto achieve
sing
thef
rocesses;
accufacyet dimension
nd/or
orm
woutd
theruise
e
impractical;
surlace
oughnessequired
emands
rocess:
ayailabillty
l
plant
and
expertise
n
company;
produclion
ates ndicate
rocess:
taclllty or
computar
onuol
of
process
kectly rom
design;
Nole:
Accufacyf torm
(controlled
y
goem.trical
ol€rances)
ithln
specified
imensional
rolerance
llows
nierchanoeabiliiy
nd
pre-detgrmlned
tirs,,
Accuracy
f surface
(conrrolled
by machining
ymbor)
€duces
tresF
oncentrations
ndcofrosion
nd imponant
h€n
urface
load
nlensily
s hjgh
eg:
ams,
ears
tc)
and
closelyi
ing
surtaces
re
equrfeo.
Both
heabove epend
n
he
specific
arerial
emovarrocess
sed
Detairs
re
shown
n
he
dala
heetn he
Engineedngfawing
ourse
oles),
l l2rat lac i^^lrA6
matefal
wastage;
re lat ively
xpenslve labour;
expenslve tools to maintain
ualltyi
Considerhe tollowino:
ma h
n
abi l l ty
ol
matsr ia l ;
c la
mpabl l ly
of shapei
mosl
apprcpriate
rocess
or
accuracy
equired;
aval la l l l ty of
plant;
accessability t surfaces
o
be
processed;
tool
location
ndclearance
provlde
un.out
t necessary;
cosl ot
processing;
lase of
ptoducing
eatur€s
n mating
arts:
In
general:
machlne
only
where
necassary
or lunctjon
o specilica
ni
sp€cily east
demandingolerancendsurfaceinishorcorrectunction;sometricalorms plane,apers,
cylindrical,onical, elical,rregular)
ay
be
produced
y
surlace
eneration,
urlace
orming
and
non-cutting
orming,
b) Shapingby Sol ld i f lcat lon
Relers
o casting sing
and r melal
moulds
ncluding
njection
oulding
f non-metals.
imjlar
principles
old
or
solidiiicaiionl
slurries
ike
concrete.
conv
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 26/49
Thc
m{nuficturing
ysrcm
shoniisr oo
shon?
not
crouSh nformalion?
CONCEPIUAL
DESIGN
(b)
ordinary
kcftlc
(d)
clectric
G)
plastics
ug
Drffcrcit
ways
ofhcatitrg
wa .r
ETAIL
EESIGN
breakdown conccpts
inro
deiail€dobjccrivc
manuincturi.€
oues
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 27/49
(..s,
a ldth.)
Iodcpcndcntly
dcbu.riDs c.ll)
Fl.xiblc
c.s.
MS, IAS,
dc.)
(c.9.
ct.hi6l
plart )
Produci
quaotily
6a)
As
p€r
igur€ bove
r similer
ithbricferplanation
f key
efrects.
A classifiC3tionf
typical
p.(iuctio
sysr..ms
nd
ndustrics pf,lina
this rcchnology
b)
Typical onfiguration
s n ig
6b.CNC
mrchineyp$, cortrolsy$cms
nd
handlinc
quipment.e
flerdbility
nd
koughput onsiderations.
Machini
oirding nddegre.efdtiicrtiorl
oolingor
ixturing
pecfic
o thecell.
MachineDerationime ncreased,eductionn operatornteractiofl.
Procossdu
updareapability,
ri ine
quality
hacHngf CMMas
p.r
of ce[.
c)
Fig6c.C0pabilityfouttcr
o addrcss
hc
surft4e
t
pre
dctrrmi&d nglc
llwvs
for optimisation
fsurface
infuh nd
t€ater
ccurasy,
hisalso llows
or eatutcs
such-ar
oler o be
placcd
t rpccifc
angleo thesurfacc. rcatcr
omplodtyf
zurfacc
eometr)'
llowable
s he
cutt€r armemanipulatedo
more
locise
onemauons,
True onncuttinrcaoabilities,
Cornmcnts
ncdmpl'adty
fprogranming
n cornparisono sifiPl€r axig
olutio$,
but hiscan eovercorncyutilising ADproduccdDmodels.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 28/49
'l -
@
oo*.,*@ocr,,:,.t.,r
ffi,r,rr**
DON'T
r,r^,rer
o*r,.",
rocrg,.
r
uul't
I t^ t6
${D3
or
Lflrs
'Ic
rt
fi
ooxt
:i'1r#i'"i$Tr
'
fA
DONT',.
'*o
.,,n
oo,
V
.-.S
1$/
Dol,l'T
r,',
r *..
,.^r. r,.-"
&
Do$I
^."r.
n
,,
ffixn
3: l
co5T-
R,{Tro
F8O'IA
t{otE
4t l
D..rarE
to
rturir edudut
lr,
6.
d| 'llotl@
ot
trtr .IbLl
dr y, tr
.volat
it, .ljce
iuci
ftts
c{
oty
tr.c-hld.it,
.ral rlE
dly..
s
qrprqrDttqr
by
.1tr9 v.ry
ctose
tot.rsces
qt.rrr.g
ut .
brr &d
hrgh
cgrr
turth.eE,
trEy
5u.tly
h.va
t]e
.ft€ct
of lt
larhg
tL
tuts.
ic
drtcrr
th.y
E .
jlr.rded.
s€. F19-{.
r r , t .
Avoldlnr
n dpdlnt
rrt .
.51orE
for ra€ttjlllttv
trl.
lr .
IEtetpL
etlrdr
t. Eguldr,
ofldat
il .s.tnst
rhen
atestgr
ls
IE
illc.d
doet
itE r€sud
rd
tb6 rhol. prcru .
ft6
Nuflcru€
thrd.h
& 6lt
ro
sfur66
ot op.r.tl6
.rc-
&.
Frs.s.
WILI
DO
nc
DO
WILL
WILL
DO
wrt-t-'lo
lESgt
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 29/49
-6 .
D..10
lor
cld.r
lrtt
PFvr.ro
ld t.cd
cl4tng
of ih. stt
I. uE
...enttal
coiuttE
td
n.cq.t
&chlnrlc.
rnh
Et b.
t.t n rjto
..fur
tlErrg
thc
ton tte.lgn
of th.
s*, .o
tn. t,l. ncc....rt,
teAtlo
i.e.,
hoir.rr
h9.,
.tc. c0
De
IEdIrl.d.
fftt. Ir
tllu.trarGd
ln Ft9.2-
rlr.
2a
D..tn
ror
ctptibfiri,
D..tot q
foi EtIrLlE
Toor laulEbt
crG
delqcrr.
tEttcy.hdtd
b. to
d€i lgD
tr
4ch.
yly
thlt,t€ct
I t@L
{.
Ft ..d.d.
EEry d..rgr*
oclt oEFf@
to b. r po, ..;
or .
urr
or
lval l .bl
r@t esulF€nt,
.o ti.t
b. .&.Fcrfy
tUsEId
td
s-srdrr'
orEltldE
cdrr..tly
.nd
.btd
Eing
'n-rlr#r{
.rr..
ro
a a..*rrq.-
r"
u.41e
ot
u't.
t. ahou
tD F.t9.3.
II
t
fl
- (
|
i "u
Ft..
3.
p..rE
rr
lo. E{.rt..
rool
eulrua
l mr't npErt
lllqa
--
(.)
t tnl l t
u4
44 .
(.)
n r.rr
t . .
(b)
Prahtnt
(d)
a.Ihdhs
( t)
prrr t$s
(
tr
4t -
r*
'
I:s4
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 30/49
lF.-
-r-1- - -1F+
tFr
J--f,.--,
a- --tt---fl-f
---1__t'_
,/a\ a
/ / / 'h \ t lF l
\yw
@€ff i
(D)
Am
@lEl
@
@
€
I
sg
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 31/49
Clo.&
Cro6.d
Tu
'i'
frfifr- fffrfi-frffi-
_uu'_
uuu\)J
b
...:>
.=l-_,
I
Notrp
(r)
n,
{\\ th
"\\--7l
V
H-
mt
v
r
Grp
({)
V
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 32/49
ChrtnLr
U
e
U
rF\
@
H*'""
{ri
ThE
noriod
cqoi.cd
for
ii..nioi5
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 33/49
(^i
'
LJ
i
Fig
2 Sinple
tiery
Dflkult to Orbnt
Easy
b Orient.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 34/49
Arear ol rolerare
lor
v.rlous mod6 o,
$iembly.
Nole tbl
lutotnilk
lssembly
demlDd5 n.rrow
o
Funclil(Dl l&6@
r
O-2
rlt .3seobly.qutpoE r
a
Ol-
Thl3
pl.strc
nhg
or u* ln ECG .letrcdE
.
requlrB oot
bor€ toleran.es ln orde lo fun.doo lcti,rilng io Eqults|Hrt
n tE
But dghler tder.ne5 on
th. rng.re Equtld h regatd to ih.
.si.rnw .qulpdErt
.spdclly lhe
te€dlDg nd hrndlng equlpneht
%WI
I
'
VZt-i%
lif
r
n
\_l
a
t -
r--r--l
fll
/ i \
ITT
:
|l
,U
I
@)
-
1'-
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 35/49
DESTGN
OR
ASSEMELY
INOIVIDUAL
SSEMILY
VALUATION
OR
I
lFrdosdur. '1rE*r
t.srr*dsu1r'r6
3
t^mmuDbuorunY
I I I I t r
' '^ ' ,s
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 36/49
CNCMACHINING
Programming,Tooling,Machine,Tool
Design,Plannlng
and Control
NC Numcrical Contsol
Codcd lsEuctioDs ed o tbe rnachine ool control
slide movcmcnt,
spitdlc rotatioD
and ool
fccd. The standald
roglanming
tecbrdquewascstablishcd n this
t].?e ofmachinc.
CNC CompulerNumerical Contol
-
the nstructions rc storcdss a
proglam
n a micro-computer
attaahed
o thc
machilc. Tle comput€twill also handlcmuch olthc contol logic
ofthe machidc,makiDg
t morc adaptablc
had
carlid hard-wiredcontrollcrs.As thc cost ofDiq@-dafiorics
6 d Ecmory lsr fsllc ,
fscilitils bva
Eow
to iD.ludc:
.
Scvcml
srcr€d
progra.qa
.
S€rccn
diting
.
'Ca cd
clcles', i.c, stored
pattcf,l-
.
subprolFsls
.
Enhrnc€d
cuttar compadatio
.
Optirdiscd
nschiEing
spc.ds
Program
provitrg
.
Diaglortic EcEsagcs
DNC Direct Numerical
Control
-
a c€ntal coirputarcomJlllrlicated
with cach
CNC tool, do*r oadilg
progasra
cld
scrup
nformation or tha opaBtors.
FMS Flcxiblc MaDufacturing
Syatcm
a
gloup
ofvaricd CNC tool6, o6ot aod
convcyorsundcr
ccntEliscd coDtol,
organircd
o
produce
a ralgr ofparts,
CNC Appllcatlons
Machlnlng
2.5D3D
. , r- . -T|rEilg::Iathes, fuEdlgcenEe .
.
Milli 8
-
Machi .ing Cc$tes
FomiEg
.
Plarna .nd I$cr
Cutting
Blankllg, Dibbljl1g nd
punchbg
D
.
RapidPrototypilg
Beneflts f CNC
.
Productivity
.
Quality
.
Rcduccdlventory
.
Machil]irgcomplex bapes
ManagcmcntoDtrol
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 37/49
Advantages
f CNC
ProductlvW
.
Ma.hinc
utilisatio is ircrtsscd
bccauscmorc imc is spclt
eutting aDd
css imc is ts.kc
by
positio[iDg.
.
Reduccd
.t p timc il]crcascs tilisatioa
oo.
.
R.duced nubnidg
lcv€ls; machi[cs run lrupcrvi.srd?
Qua
ty
.
Prlt
nrcmorc accuntc.
.
Partsalc
morc rcpaatablc.
.
Lc$ w8tc
duc to scrap
Reduced
nventory
.
Rcduccd.tup Llc
pcnnits
mallor cotroEic
atch
uantiti.s.
.
Inw€r
lcad irncallow, owar
Etockcvcls.
.
Lowd siock avcb cduccntdlst cbargcsnd worblg crpital cquiEDcDts.
-
Machlnlng
Comprex
tapes
.
Slidc rovcdrcltsuldd
coeputcr ontol.
.
Computrr
otrtollercancdcuhtc
tcps.
.
.
FirstNC
lioNnc built 1951 t
MIT for ailcraff kinmilling,
Manegdment
Contrcl
.
CNC .rds
o CAD
r
hoocss
pla .litrg
- - -.--- ?rb-dw$drurn@--
Dnwbacks
l CNC
.
Hig capifal ost
.
Rctrahilg
8Dd cctuitlctrt of strff
.
Ncw suppofiarilitics
.
.
Maiftcnancr o rulain
bighutilisation
.
RcdurdlDcicti
peratoricsist&c
CNCPROGRAMMING
.
Odlinc
prograrDmilg
ilkcd to CAD
prcgr&E.
.
Cotrvgtsatiolsl
rograi'miDg
y thc op6a or.
.
MDI
-
Manu8lData Dput.
.
MarNal
Contol usirgjog
buttolls 'clectotrichatdwh4l',
.
Word-Addrcss
odirg sing staidard -codrs
alldM-codcs.
A
Rpical
in. ofa
pan-prograu
rlnen
r
variabtc
ioct ornat:
N020G02X88.021
3.7T0202S500F0.05M03
Thecornpact,
rimitivc
s).ntaxcflccti heorigimlwisb
o keep
apd
ape
eclsshortand aiar o
makehc bcst
seof
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 38/49
Pan-progamwords'
N Sequenceumb€r.
G
Prcpararory irl1ction.
X,Y,Z
Slide
motion
alongaxes.
t,J, L|rclecenEes.
T Tool code ndoffser dendfication.
S Spindlespeed.
F Feed ate speed fslide ba elj.
M Miscellaneous imction.
% Progra& start.Rewind ape.
/ Optional lock-Skip,f
switched n.
*,;
Endofblock
The numbers ollowing
thesewords may
b€ subject o format es 'ictions (e.g.
2
figures or four
figures only.
or with
assuned ocation or a decimal
point.
Modem machines
rc siightly morc
forgiving.
Preparatory unctions
Prcparatory unctiotu
change hc modeof opeEtio
prior
to a machining
action. 8S3635
(1972)
now
obsolcte,
ut
mostmachincs ollow
theseconv€ntions,
C00
Ripid rbovemrnt
G01 Linear
interpolation
G02Circular nterpolation
-
clockwise
O03Cilcular lterpolation
-
anticlockwise
G04Dwell
G33Tbrcad uning
G40 Cancelcutter compcnsation
Gr'1Cu$er ompensation,efr
G42 Cuttd
coDpensatioD,
ighi
(J/l
MeElcuruts
G80ctcBuilt-incyclcs
G90 Absolutccoordillateg
. G9l llcremcatal coordinates
O94Fecd
er
minute
G95 Fced
per
rcvolution
G96
Constanl
surfaccspeed
Many
ofthese od€s remoda.l,hcy emainn
folceuntilcaDccll€d,
hisapplieso most
ofthe otber ode
erte$ oo,
allowing mor€ compaclcodc.
Miscellaneous
unctions
Tum oDandofvarious machine
ctivities-
M00 Programstop
M02 End ofprogram
M03 Spindle
un. clockwise
M04 SpiDdle talt anti clockwise
M05
Spindl.
stop
M08 Coolant
M09 Coolant ff
M30 Rewind
Axis nomenclatue
Z-a{is
pamllel
to main spindle
(tool
or workpiece).
Positive movementn dir€ction fincreasing
islanceetw€en orkpiece
rld ool.On vertical
machiningentses,
+Z
is upwards
tom
the
worktable;
or tuming certes
+Z
is away
&orn he spindle.
X-axis
always
hor;onial,
pa al1e1
o work-bolding surface nd
orthogonal o Z-axis.
If Z-a{is is venicai,+X is to ihe right whenviewed tom ihe spindle ooking tov'ards ts supponingcoltlmn.
If Z-axis s horizontal,
+X
is to the right looking fton the spindle owards
he workpiece.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 39/49
Y-axis
odhogonal o
Z
and
X, completinga rigbt handed et ofa,(es.
A lathehas
no Y-a-\is.Extraaxes
are desigdated
,
V and
W to correspondo X, Y
or
Z if th€
extsamovemen
s
parallei
o
one
ofthe
ar€s.
Extla rctary
movements
redesignated B or c.
Becauset is the wolk that mov€s,not the ool 6pi dle, the direction ofslide travel on a milling machirc canbe
confusiDg.The morc experienccdh€
operator, he more confusing
CNC axis notation€an
bel It is casier
or thc
prograob€r
io rcgard he
6iuer
as
a computer
en-plotler.
Coordinatesmay be absolute,i.c.clativ€ o
datunf or iDcrcmental,€lative
o thc cureDt
position.
Normally
selectcd
y
C90/G91,
but
FA\(JC contoller usesU.V aDdW as ncrcm€dal valu€s.
Dairm choicc and datumscttingarevital
opietations. c can dctrtify a
dlawing datnD,
component stur
pan
program
datun
and rDachine atum,Th€ ast wo mustcoilcide,
needingdocumentatioD
o commuticate
b€tween
Progammcl
and
opemlor.
Fixed datummachift
-
opcratormusl
set
work
n corcct
place.
Floatingdatum
-
opcrator csctd
datum o suit worq bul
plogarnmer
docsnot
know
preciscposition,
Datum shifi
-
O50
(sorDctimes
92) cao esctdrtum within
plogram,
or
<169>piesct
Absolute
Registcr<170>.
Zero offset- or <169>WorkShift<l7D can cpositionmachine atum.Ior a lalhe, dachinedaturn s often X=0 on
spindlccmtclide 6nd Z=0
at rear acc ofchuck.
Usc
Wolk
Shifr o resct
Z-0 at cnd facc of
finishcd
ob.
All Z values
ncgativc.
Rcfdcnc. Poinl
-
a fix€d
poinl
on thc ma.hine
o which thc slidcsmust
be
tnversed on start
up,
wh€re
preset
coordinalcvaluas
arc oaded,
CNCTOOLING
Clrbondteel. asily haped,or amateur
seonly.
HighSpccd tcel
HSS).
Solution ardening
t high cmpclaturc,
ough.Uscd
or drills.
Sint rcdCa$id.r
(Crmented
arbides). ard,
utbrittle,Highcutting arcs
with ow wcar.
Ildcxablecarbid€ 8erts.Many
gladcs
nd
shape6.ISOlassification,
- e[bi.'BordrMtrtdclcts\r); HardErdrdougfitr6an]rdbidas;-- - -
Sulface uttingSpceds
r/min)
Worl(pi.ci
Material
Tool Mild Stecl Csst on Al. alloy
Blass
Carbidc 170 100 250
180
HSS 28
18 t20 75
Spind/espeeds
Spirdles?eeds
givcn
n rcvolutioDs
er
mi u1€
pm)
by:
1000 cutting peed
m/min)
pi
*
work
or cutte diameter
fla)
e.g. o tum 30&mdiamctcr nssusing
carbideool:
S
=
1000 180 3.142 30
=
1910
-
say
1900
pln
Feed rates
or turning
Mld Steel Cast ron Al. alloy Bmss
0.25 0.25 0.3 0.3
mm/rcv
Finalchoicc ependsD
producrion
are.lool
wear
nd inisb equned.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 40/49
CNC
Machino
Tool Deslgn
Fcaturcs sscntiai
o CNC
opcratior:
Slidc
positio
mcasurcnlcit
atromovcmcD
.
CoDtol slstcd
fccdba.k
-
positioD
and sp€cd.
.
Spindlcspccd
control
Automatcdwor*holding?
Fcanrrcs cquircd
o c]cploit
CNC caspsbilitics:
.
Wcar ralist
l1cc o
copc with high
utilisationsnd
mpid slida
avcl.
Rcsolutio4 r€?eatability
od
&ccuacy o foUowprograo
cofiortds
and rciicvc quali,
{.ithout
human
iDtcrvcttio "
.
Swdfcotrtol
to rBtch high
mcblicmowl
stes achicvcd
by carbidc
ools
6nd high
udlisatio ,
Safcty
ot llrlmrnncd
opentiotr rpith
rapid slid.
t'avel, 6uddc
mov.Erclt
uDda
rogra$
control
rtrd
possibly
vioirot
collisioD .
CNCMachlne
oolDeslgn
Features
Somc olutio :
DC rcrvomoton
with
positiotrl
aDdrchogelcrator
ta&aal.
Lincar
gratilgs
snd
Moitt fritrgc .
Rldi6l
gratius
or rotarycncode$,
Rigidconstuction.
Covacdslidcwsyro
cxcludc uttilgr.
Pl.stic lidaray hetcdals.
Card scDlor
itiDg.
L.sdscrcwssplsccd
y r.cilcutating
ball-agraws,
Sklt-bcd hthc with
r.ar.hou
cd hrncl
Swrrf
oolvayors Dd
butcs.
TotslcDgloEu&
Ddntcdocks.
crcpbic.l dilplsy5
or
pmgran
proviDg.
'- - -sw?EfRfib-oTel
ftod cutting rca
or wsshitrg
tltioD
slad b.d
coolaDllood
arIJ€ltl
l'scuurn
ump
iom rnachilcaDdworlGiop
coDvcyof
uDdcrfloor
hutcs
toll€)s
&lrp scparatio o rcclamatio
Illurtation of Slsnt-Bcd
athc.
Mdnufacturing
ysteEr
Tnditionalapploachcstomulti-componc.DtproductioD:
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 41/49
I
l
HicellDemo
Program
one
on SmartCAM
%
02222
1*
*
*
r, r,,r,* r,* *
r*
* r.i *;i
-;
*i **;i)
/+****r**r+i I . lTaETT
* i t r * r .* * **
' r
, i \
G10P02250.0
G28UO
G28V0W0
G50S3600
G144M28
G99G18
G3OUO
G30V0W0
M01
Nl
(ROUGH
ACE& TURII)
G30U0V0W0
G10Ll0PlR0,8Q3II0
T010100M41
G144G18
G97S3000M08
'
G00G99Y0.020.3M03
x64.0
20.2
G0lx-1,6f0.25
21.4
x8.8
24.6
G00x65.023.0
x6s.u3.r
x59.0
@tz-39.8
@0xs9,23,1
x53.0
G0lz-39.8
G00xs3.223.1
x47.0
G0lz-39.8
cfi0x47.223.1
x41.0
G01Z-39.8
G00x41.223.1
x35.0
G01Z-9.8
G00x7
_22-5.9
I{iccll Programtom Slrta CAM
Page:
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 42/49
l
Calculate he maximumand
midmum
shsft and
hole sizes or the follbwing examples.
Also oslqrlate he amountofclearance
Hole
Sh8ft Cl€araoce/iot€f,ft
,€trc€
M.rx Min
ax
Mn Mrx lvtro
90mm
hl l
Cl
I
220mn h6
N7
or interference.
l)mm no b /
Within the box
provided,
draw he
path
ofthe centre ine oftlrc cr t€r that the
following
programmewould creale.
l0
20
30
40
50
60
70
80
90
10 0
l l0
100 lfiro
GX
00 50
01
00
01
FST
01
YZ
l l0 2
M
06
03
d'
00
l0
l0
50
30
lo
0
l0
l l0
l l0
60
60
0
-5
ut
s
0
Brieflv explainwhat he tems n bold mean.
GOO
c"p,/
Cfil
Fecl
FIOO
Fe")
loo
*k
Sroo
*eJ
M06
..
c\-
+o"L
Mol
14
*
J
"
s r
s
s8
T--
t""L
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 43/49
?he
File Fornnat
r . r ne.- \
I L t l le tormet
Jh: asTt
,.,"r"oiit-\oeraphy) fiie
is the
de-ibcto
srandard
AD
rep.ese.talion
t)r
Rp. It
was
established
by
iD
s;/sreiuin
rhe
ate
Bos.
he
srl format
ofa
cAD mociel
s a raceted
urlbce
elresertation,i.e.
list
ofihe
triansurar
su.faces
with ao
adjaceary
nrb.matio'.
This
is the
standard
nput
fol
most
Rp
-
syslems.he.e
are wo
format for
.sfl-
files:
biaar-l
and ASCII
which
difers
as
ollow:
. Binnry.STL file
The
bi*
,
S'Il-
fi]es ornat
consists
f
an
g0
b',t?s
heade.
used
o
describe
he
solid
contained
within
the file,
then 4
b),t€s epresent
he total
number
of{bcets
n
tle
file. A
facet
s described
s
fbilow:
the fust
12
bltes
(3
x
4 blres) represent
ts rlormal,
he next
36
bltes
(3
x
j
x 4
blres)
represent
ts
(tiree)
verrices,
hen
lro unuseC
ytes are
padded
o
achieve
a block
size
oi50
bltes.
.
ASCII .STi,
ritcs
AscII iiles
usekeywords
and are
selfexDlanalorv.
he
ASCILstl
file
must
start
with the
ower
case ey'vordsolid and endwith €ndsolid.Within thesekerrords are istingsofindividual
triangles
hat defile
he aces
fthe-sorid
model.
Each ndividuar
riangle
escription
efines
single
normalvector
directed
away rom
the
sorid's
urface
ollowed
by the xyz
components
or
all
th'ee
ofthe vertices.These
values
are
all in ca.rtesiatr
oordioates
nd are
floating
point
values.
The
iargle values
shourd
an be
positive
and
contained
within
the
bu
ding vorumi
The normal
veqtor s
a unil vecror
oflength
one
based t
theorigin.
fthe
normals
re
not ncluded
henmost
software
will
generate
hem using
he right
hand ule.
Ifthe
normal
nformation
s not included
then he
three valu€s
should
be set o 0.0.
There
s a
variety
ofenors
in ASCtr
6les
hat
do not
appear fl binary
iles. For
instance,
t happens
hat
keywords
are either
skipped
ofadraneous,
hind€ring
he extraction
fdata.
Here,s
n example
fan
.STL
ASCII
file:
60ttd sot tdnahe
faceN rormat
?.33a605e-01
3.226134e_A2
.?EOO3?._C1
.urer ro.p
vertex
-1,070000e+02
0.0000r1Ce+00
.AldOiOe+02
ve*€a
-1.060000er02
0,001]O00e+00
.?6O1OO.rO2
verre:
-1.010000c+02
1,200000€+00
,3133ooe+02
endi cel
fa.et nornal
9,324258e-01
9.2Cg56ie-02
I 623.r59€_Ot
r€: tex
-1.0r0000e+02
t.20000oer00
I .Bl3eOOe+O?
verre:r
- i ,C54000e+02
0.0000C0ea00
L.?boi0Oe O?
endloop
endfa.pt
4.
The .SLC
Iile formrt
.SLC
tiles are
used
n the
tuseddeposition
modeliry
(FDM)
process
romstsgtsgy ,bg
They describe
the contours
ot\ and
he
thickless
otl each
build
layer.
.
The .SLC
fite foruat
is an
ASCtr text
file format
.
Comments
may
be llcluded.
The
begin
with
a
"#"
and
End
at tlle end
oftiat
line
.
Units arc
n
inches.
h thecase frie FDM 1600 apidproLotypingystem:
.
x,y,z should
be
positive loats
n the
ftnge
from 0 to
9 inches'
.
Layer hicknesses
aL)
range
rortr
0.005 o
0.015 nches'
The
standard
ayer hickness
s 0 010
nches.
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 44/49
Eaa0ple:
The
bold
characten
should
be fyped
as s. Th€
talic
charactsrs
hodd be substituted .ith
th€ir
correspoadiag alues.
911c. Y0
+
0
=
zero
lIlJl
{fi.lcnanc)
#
fi.lenarte
tnay
include
fut L
path
srrer
o *
Z
z dz
#
z
=
absolute
z of
tayei, dz
-
taye
thlck:ness
x y #
plovida
th. cooldLnatca of the cornc polnt
x
y
#
along
cach
contou .
Do not
duptlcata
the
tr
y .
. .
#
f1 st
polnt.
lhe
ls.no upper
]. iel t
oE
the.
,
x
y
*
I1u&b6r
of
poiDts
1n a
contou.r.
xv
#
C
*
Talid.nate
tbc
contou
wl.th
a
trCtr.
x
y
t
Bcgin
thc.B6cond
colrtour
otr tbj .s
].avaL...
xy
#
xy
l l
xv
*
C
*
Tcrrlll.nrle
Eh.
sccond contouE.
Z z dz
*
BGgIn
s
nclr 1ay. i
(z
-
z.o1d +
dz)
x
y
# Ba91n a n€w contou on a lard Icv.I . . .
xy
l l
xy
*
xy
l l
xy
i l
c
*
?arfiinala
th.
colrtour.
tl| t
#
AII
foLl'owing
IlDc
e .
lgnor€d.
N.QX.yzTl '1
lom
a^
Av
(,
t l
3o
oo
o O
?- Ol
06
+o
t35
t5
-Z
50
1r5
15
6o
a5
4o
-icqt'6here
Jt"
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 45/49
Data
preparat-,i4.l
or numerical
ontrol
-h
.{ ,
Hole
statement
Explanation
G90
G7L
G00
J
G00
G01
,
G00
G00
G00
G00
.
GO1
;
-
Se]ect
bsolute
.
Select.metric
MoS
Load
centre
drill
Above
1st hole
Centre
ddll
Retract
2nd hole
'
Centre
drill
RetIact
M06
Load
10 mm
r l i rmaicr rt r i 1i
Above
1st hole
. .
Drill
Retmct
2nd hole
Ddll
.
Retract
Program
stoP
Retum o
start
XO
x100
zL7
LZJ
x150
277
225
XO
x100
z3
22,5
'x150
L5
zz5
YO
Y100
F400
M0s
2300
225
s3000
T01
M03
F400
,M05
YO
s3000
2300
M0i
T02
225
M08
s2000
M03
_lJ
Y100
r350
M05
F350
M05.
s2000
M09
G00
GO1
IAU
\rUV
_
M00'
80
M30
M03
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 46/49
DRILL.AND
REAM
40
D?JLL AND
TAP
6
Ho_[S
Mlo
EqJI.SPACED
I-frES
UT'IA
lOmm
DEEP
T-
Al
o
o
t^
DEfP
r)
5mm
rLr_nL I
zmm
DEEP
a-
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 47/49
CAM
Programmihg
ystems
nd
Postprocessors
BACKGROUND
The
NC
programs
equired
y Computer
Numedcally
Controlled
CNC)
machines
were
ahvays
riten
by hand
asa series
f lines
of code G
codes
nd
Nl
codes).
This
is
still
by far
the most
common
way
to create
heseprogmms.
However
t
was
recogmsed
hat
much
of the
code s
repetitive
nd
thir
theseprograms
ould
be
generated
utomatically
.
semi-automatically.
system
or
creating
lde in
this
way
is klown
as a
CAM
programming
ystem.
^
. _ _
As
with
manual
rogramming
he
stalting oint
s
the
selection
f the
oot.
The
CAM_ rogamming ystemequiresool data. This ncludes uch hingr-ar,o. ,,""
and
shape
fthe
tool, and
he
cutting
peeds
nd
eeds
which
are o
be-used
or
the
tool.
The
p.ogramming
oftware
as
a
graphical
ser
nterface
h"r"
tt
a opar"to,
"an
raw
he
path
hat
he
or shewishes
he ooi
to follow
The
software
wi
thli
comOine
the
ool
datawith
the
geometry
ata
n order
o
ffeate
he
NC code.
-
The
style
of a
program
varies
according
he
machinery
nd
the
particular
preferences
f the machine
perator.
The
codi
itself
s
depenient
n
the'machine
controller
and he
machine
o
which
that cottroller
is
fitted.
This
means
hat
the NC
code
generated
y
the software
must
be customised,
r
,,postprocessedii
to
suit a
l1,_gir
T":lti*
operating
n a
panicular
ornp*y.
ih.'C.tM
p.grurn*ng
sotf$ralerll
have
ostprocessors
rinen
or r
to
give
t
rhe
abilhyoouipuidiff.erentstyles f progam.
HISTORY
The
earliest
CAM
systems
used the
AIT
programming
anguage.
A
computer
programmer
would
use
statements
uch
as
GOTO
andPROFILE
olefirte
the
Dath
of
the
tool.
.
In other
words
he
early
CAM
systems ad
no graphics.
Later
Apa;$erns
had
graphical
Aort
ends n
which
a line
or a curve
drawninjhe
screen
woulJginerate
APT
commands.
-,
The.system
onverted
he nputs
to a
CL
(Cutter
ocation)
ata ile. ThisCLue was thenconvertedo the ISO
code G
codes
and
M codes)
equired
y the
parlicular
machine.
The
early
postprocessors
ere
writterl
ll
the Fonrao p.ogra.^ng
language
nd
then
compiied.
In
other words
lre
only people
to'.oiiJ.*"
modifications
o the
postprocessors
ere
he
programmeis
ho had
he souice
oOe.
Udil
recedly
Unigraphics
till used his
method
or
their
CAM
system.
Approximately
0
o
12
yeaxs
go
customjsableostprocessors
ppeared
n the
scene_based
round
a macroprogramming
anguage.
mportant
work
in
this
area
was
done
by Cambridge
CAD Certre;
many
cufent
CAM
sysiems
ollow
the
structure
hat
they
d€fined.
.
The
big
advartage
of
the macro_based
rogramming
ystems
was
that
you
did
not have
to be able programmer
o
use
them.
The
b-asis
f creatrne
a
t\4E338
Chris
Beatly
Post
rccessors
Pager
l
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 48/49
customised
ost-processo(
as to fiIl in the
fields a a
"1ook
up table" This
information
as hen
ntery.eted
y he
postprocessing
oftware
t run ime
Curent
stMd-alone
A,V
packages
such
asSmartCA"\4,
astercL:\l,etc)use
this
principle. The user
c.eates
eomettic
ines
and
points. Data
on
eachof
these
featufes
s held
n the CAM
system.
Thisdata s corveited
on a ineby i11easis
nto
theNC codeby the
postprocessor
hich
eferences
he ook up table
or a
particular
machine.
Some CAM
systems,
articularly the CAM
modules ofi high-end CAD
systems
till use CL
data
which s then
postprocessed.his s consideredo be
an
inferior approach.
In
spite of
the structure
of
modem
postprocessors,
which allows
non-
progranrlIrerso write or
modify them,
n
reality very few
people
ry to do this
job
themselves.
They
rely on
the CAM software
supplier
o do this
ob
for them. The
suppliers
unently
chatge
300
to 400
per
day to do this
ob.
HoweYer ecause
*riting
postprocessorss
relativelyeasy
n a macro
aryuage, engineers
amiliar
with
the
metal cuttiflg
process
and with
cNC machines
n
particular,
can carry out the
ob.
This is cleady
a much
better situation
han relyingon
computer
prograDmers
SMARTCAM
TheSmartCAM
rogradming
6ftware
omprises
he ollowing
modules;
r The
ob
plan
r Themodel
atabase
r The
machine
.SMF)
lle
r The implate
.TMP)
ile
TheJob
Plan
This
s where he user
must
nput data
on the
tools which
will
be
used Associated
witha oolatel
r
The ool number.
This
s the
position
which
he ool will
haven the unet or
magazine
f the
machine.
r The ool
geometry.
The
adius fa
tool is very mportant.
n
particular
or
turldrtg
ools,
the software
will make calsulations
or "tool
nose radius
compensation"
n
order
o
generate
he
correctool
path.
r Spindle
peed
hich
will be
used or cutting
moves ssociated
ith his ool.
r
Feed
ate
which
will beused
or cutting
moves ssociated
ith this ool
TheModel
Database
The main
process
n
using CAM
software
s to &aw
the tool
patls
The opelato
selects
he tool
which hey
wish he
machineo
useand hetrdBws
the
path
which
hey
wish the tool
to follo\r.
A tool
path
s
madeup of a
series f
geometdc
elements uch
as
poirts,
linesand
arcs.
The softwale maintains
a databaseof
geometric
elements
This database
contams:
ME338
Chris
Beatty
Post
rocessors
Page:
8/10/2019 CAD and Development 2 - Part 3
http://slidepdf.com/reader/full/cad-and-development-2-part-3 49/49
POSTPROP
OC
'
r,Thesequenceoftheelements.i.e.rvhatordertheyshouldbeperformedin.
r Data
about
each
lement;
hat ool s
used.what s he start
point,
what s
the
end
point,
he radius fan arc,at whatdepth he
cut
s
taking
1ace,
tc
Themachine
.SMF)
i le
This
consistsf
a lisr
of
quesrions
nd
oprions
hich
ellSmanCAM ow
ro formar
code or a
particular
machine. ome fthe nformationn
this ile s:
r How many
places
f decimalshould e
output
or X,Y,
andZ
positions
r
Which emplate
.TMP)
ile o use
r
How to outputbiock
numbers
r The udts
(mm
or inches)
r The ormat o output peeds,eeds rd dwells
r How to specifya tooi change
r The format or rapid moves,inear eedmovesandcircular
arc
eed
moves.
r andmanymore
pieces
fdata o coverall he unctions fa machine.
The
emplate
.TMP)
ile
The emplateile determineshe
final format
of the code
generuted
y
SmartCAM.
SmartCAM ombines
nformationrom he modeldatabase,be
ob
plan
ad the
-
machineile
andoutputs
t rhroughhe emplateile.
Template iles are organisednto functionalsections tartingwith the "@"
symbol nd ontaininghe
ollowingasicypes
finformation:
r
Literalcode o output
asentered
for program
ead€rs,ool headers,
tc.)
r Template ords
or
output fprogram
rformation
rd controlofthat output
r Condilional
>
brackets
o make ome utput
optional
Some xamplesfthe unctional
ectionsreas ollows:
r
@TOOLCITANGE
r
@STPROF
at
startof
profile
do he ollowing)
r @LINE ata inea eedmove o he ollowing)
Themodeldatabaseednes
hether nactions a ool change, linear
eedmove,etc.
The emplate
lle
defines
what he codeshould e
ike
for this
particular
ction,alld
referenceshe machine 1eo
de6nehe omat ofthe codewhich s
cenerated.
WRITING
POSTPROCESSOR
The
process
of writing
a
postprocessor
ormally avolves he following: