IRJET- Experimental Review of Machining Time Cycles between Manual Programming Vs CAM Programming on Vertical Milling Machine with General Observation
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This document compares the machining time cycles of manual CNC programming versus CAM programming on a vertical milling machine. An experiment was conducted machining a part with pockets and chamfers from aluminum alloy 6082. The CAM program took 7.36 minutes while the manual program took 10.05 minutes. CAM programming was found to be easier and faster than manual programming which requires mathematical calculations. CAM software provides optimized toolpaths and flexibility compared to manual programming.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1913
3. DRAWING OF EXPERIMENT:
Engineering drawing of the part mainly having the pocket
operation (open & close) and general chamfer.
Fig. 1: Drawing of Experiment
The drawing shown in Fig. 1: has the standard General
Tolerances: ISO 2768-mk for the dimensions. For this
drawing both manual & cam program is madetoanalysisthe
machining time cycle.
4. RESULTS AND DISCUSSION:
Manual and CAM program made for the given drawing&run
on the machine to analysis the time cycle. The time taken by
the CAM Program is 7.36 Minutes and Manual program is
10.05 Minutes respectively.
5. CONCLUSIONS:
This experiment isstudyofthemachiningtimecyclebetween
the manual CNC programming Vs CAM programming under
the same cutting parameter. As result strong result were
observed. Observed result as following:
1. Less Machining timetaken intheCAMprogramming
over the manual programming.
2. CAM programming is easy over the manual
programming.
3. No mathematical calculation required in cam
programming while manual programming basedon
mathematical calculation.
REFERENCES
[1] https://www.mazakusa.com/news-events/blog/what-
cnc-programming-style-best-suits-your-operations/
[2] https://www.productionmachining.com/articles/simpli
fying-cadcam-programming
[3] https://bobcad.com/cad-cam-programming-vs-
conversational-programming/
[4] https://www.cncci.com/resources/tips/manual%20con
v.htm
[5] http://www.aalco.co.uk/datasheets/Aluminium-
Alloy_6082-T6~T651_148.ashx
[6] https://www.quora.com/What-is-CAM-Software
[7] https://en.wikipedia.org/wiki/Computer-
aided_manufacturing
[8] https://www.mastercam.com/en-us/
[9] M. Young, The Technical Writer’s Handbook. Mill Valley,
CA: University Science, 1989.
[10] R. Nicole, “Title of paper with only first word
capitalized,” J. Name Stand. Abbrev., in press.
[11] K. Elissa, “Title of paper if known,” unpublished.](https://image.slidesharecdn.com/irjet-v6i6421-191122095322/85/IRJET-Experimental-Review-of-Machining-Time-Cycles-between-Manual-Programming-Vs-CAM-Programming-on-Vertical-Milling-Machine-with-General-Observation-3-320.jpg)
IRJET- Experimental Review of Machining Time Cycles between Manual Programming Vs CAM Programming on Vertical Milling Machine with General Observation
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1911 Experimental Review of Machining Time Cycles between Manual Programming Vs CAM Programming on Vertical Milling Machine with General Observation Mahendra Singh Rajawat1, Pradeep Kumar Sharma1 1Deparment of Mechanical Engineering, Dr. K.N.Modi University, Niwai ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - This paper is review of CNC machiningtimecycle study and general observation between manual CNC programming Vs CAM programing under same cutting parameter & material. In CNC machining, reducing the machining time cycle for simple & complex part is a key to increase the production. CAM software’sprogramsareplaying a significant role to reducing machiningtimecycle, toimprove quality, to better utilization of machines & tools. Key Words: CNC, Machining time cycle, MasterCAM, CAM Program, manual CNC program. 1. INTRODUCTION In the metal cutting industriesCNCmachinesareused.These machines required program to cut the material as required shape, dimension & tolerance.Therearemainlythreetypeof mode for CNC programming 1. Manual CNC programming 2. Conversational programming 3. CAM programming Manual CNC programming required the numerous calculation, a better understanding of the controller and codes. For error free execution of manual program, it must be prepared as per the controller language and definition. Conversational programmingisfeaturewizardprogramming mode that hide the codes. Conversational controls don’t require any Calculation and programmercaneasilygenerate the part programs with defining the feature data. CAM stands for computer aided manufacturing. CAM programming offer a great control onpartprogrammingand flexibility. CAM software provides different toolpath cutting strategy for rouging and finishing. They make easy of programming for simple & complex part,savethemachining time, increase efficiency and better utilization of tool & machines. In CNC manufacturing the part program and the optimization of program is important to reduce the machining time cycle. This demands the highly skilled programmer. Generation of manual programming need mathematical calculation to find-out the tool movement as per desired profile. CAM programmers are very helpful intheatmosphereofless skilled programmer, lower cost of the part program, avoid the calculation and provide the optimize program. All method has their own advantage and dis advantage. We made analysis of machining time cycle for simple object between manual programming & CAM programming. 2. EXPERIMENTAL DETAILS: This experiment is involved mainly five type of setup 1. Machine setup 2. Cutting tool material 3. Work piece material 4. Cutting data sheet 5. CAM software 2.1 Machine Setup: This experiment is performed on the CNC milling machine.X & Y movements on the table and Z movement on the spindle which represent the depth of cut. All the tools used for this experiment were measured by the standard tool measuring machine and data (tool length & diameter) feed to tool offset section in the machine controller. After defining the workpiece zero point, tools move as per coordinatesdefined in the program. 2.2 Cutting tool material: Selection of the cutting tool is very important in the metal cutting. It’s depend on the type of material to be cut. For our experiment, HSS and carbide tools are used. HSS Co-8%,end mill is used for roughing & finishing operation. Inserted carbide tool is used for the facing operation. The cutting tools used for different operations are represented in Table.1. 2.3 Work piece material: This experiment is performed on standard Aluminum alloy workpiece, grade 6082. It is a medium strength alloy with excellent corrosion resistance. It has the highest strength of the 6000 series alloys and known as a structural alloy. In plate form, most commonly used for machining purpose.
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1912 Chemical composition and mechanical properties of the work piece material are indicated in Table. 2. and Table.3. respectively. Table -1: Cutting tool material Tool material Operation Size (mm) Inserted carbide (face mill) facing Dia. 50 HSS (End mill) Roughing Dia. 10 HSS (End mill) Finishing Dia. 8 HSS(Spot drill) Gen. Chamf. Dia. 10 Table -2: Chemical Composition Chemical Element % Present Manganese (Mn) 0.40 - 1.00 Iron (Fe) 0.0 - 0.50 Magnesium (Mg) 0.60 - 1.20 Silicon (Si) 0.70 - 1.30 Copper (Cu) 0.0 - 0.10 Zinc (Zn) 0.0 - 0.20 Titanium (Ti) 0.0 - 0.10 Chromium (Cr) 0.0 - 0.25 Other (Each) 0.0 - 0.05 Others (Total) 0.0 - 0.15 Aluminium (Al) Balance Table -3: Mechanical Properties Mechanical Property Value Proof Stress 240 Min MPa Tensile Strength 295 Min MPa Hardness Brinell 89 HB 2.4 Cutting data Sheet: Machining parameter selectedbasedonrecommendation by manufacturer of cutting tools. Cutting data sheet as per the operation given in Table. 4: and Depth of cut (DOC) and step over for different operation are shown in Table. 5. Table -4: Cutting Data Sheet Facing Cutting Speed 400 m/min FPT 0.05 mm Roughing Cutting Speed 80 m/min FPT 0.06 mm Finishing Cutting Speed 80 m/min FPT 0.05 mm Gen. chamfer Cutting speed 50 m/min FPT 0.04 mm 2.5 CAM Software: CAM software are used to control machine tools and manufacturing of workpiece. Software create the codes for CNC machine to follow during the metal cutting. Different types of software are available. In this experiment MasterCAM version 2019 is used for the programming. MasterCAM is one platform solution for CNC machines such as Lathe, Milling, Turn-mill, Router and Wire cut Table -5: Depth of cut (DOC) and step over for different operation Operation DOC(mm) Step over Facing 0.2 70% of tool dia. Roughing 2 50% of tool dia. Finishing 8 20% of tool dia.
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 06 Issue: 06 | June 2019 www.irjet.net p-ISSN: 2395-0072 © 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 1913 3. DRAWING OF EXPERIMENT: Engineering drawing of the part mainly having the pocket operation (open & close) and general chamfer. Fig. 1: Drawing of Experiment The drawing shown in Fig. 1: has the standard General Tolerances: ISO 2768-mk for the dimensions. For this drawing both manual & cam program is madetoanalysisthe machining time cycle. 4. RESULTS AND DISCUSSION: Manual and CAM program made for the given drawing&run on the machine to analysis the time cycle. The time taken by the CAM Program is 7.36 Minutes and Manual program is 10.05 Minutes respectively. 5. CONCLUSIONS: This experiment isstudyofthemachiningtimecyclebetween the manual CNC programming Vs CAM programming under the same cutting parameter. As result strong result were observed. Observed result as following: 1. Less Machining timetaken intheCAMprogramming over the manual programming. 2. CAM programming is easy over the manual programming. 3. No mathematical calculation required in cam programming while manual programming basedon mathematical calculation. REFERENCES [1] https://www.mazakusa.com/news-events/blog/what- cnc-programming-style-best-suits-your-operations/ [2] https://www.productionmachining.com/articles/simpli fying-cadcam-programming [3] https://bobcad.com/cad-cam-programming-vs- conversational-programming/ [4] https://www.cncci.com/resources/tips/manual%20con v.htm [5] http://www.aalco.co.uk/datasheets/Aluminium- Alloy_6082-T6~T651_148.ashx [6] https://www.quora.com/What-is-CAM-Software [7] https://en.wikipedia.org/wiki/Computer- aided_manufacturing [8] https://www.mastercam.com/en-us/ [9] M. Young, The Technical Writer’s Handbook. Mill Valley, CA: University Science, 1989. [10] R. Nicole, “Title of paper with only first word capitalized,” J. Name Stand. Abbrev., in press. [11] K. Elissa, “Title of paper if known,” unpublished.