CAM Material

1) CAM Concept and definition

Concept:
An engineering industry based on needs of people, transform ideas into products which can then be
sold, so that the product can serve its purpose. The various phase of these operations have drastically
changed with the advent of of CAM technology.
The methods of manufacturing have also undergoes a tremendous change with the use of
Numerically Controlled (NC) and Computerised Numerically Controlled (CNC). NC technology is based on
controlling the motion of the drives of machine tool as well as the motion of the cutting tool via programming
code. The above tools allow integration of various phases of the product cycle.
Definition:
The use of computer system to plan, manage and control the operations of manufacturing is referred
to as Computer aided manufacturing (CAM).

2) NC, CNC and DNC: Concept, features and differences.

NC Machines:
NC machines used in industry for more than 40 years.
NC is a method of operating a manufacturing machine based on code of letters, numbers ans special
characters.
The complete set of coded instructions for executing an operations is called program.
NC machined can be programmed manually.
The drive units are either powered by stepping motors (for open-loop control), servomotors (for
close-loop control), pneumatic drives, or hydraulic drives.
A machine tool consists of.
o A worktable, One or more spindles, motors and controls, Cutting tools, Work fixtures, and
other auxiliary equipment needed in the machining operation.

Fig: NC machine and its components

NC machine tool components

Tape punch
Tape reader
Controller/MCU(Machine Control unit)
NC Machine

1) Tape Punch:
It converts written instructions into a corresponding hole pattern. The hole pattern is punched into
tape, which passes through the device. A micro-computer attached with a tape punch unit.
2) Tape reader:
It reads the hole pattern on the tap and converts the pattern to a corresponding electrical signal
code.
3) Controller (MCU):
It receives the electrical signal code from the tape reader and control the NC machine accordingly.
4) NC Machine:
It responds to a programmed signals from the controller. According to that machine executes the
required operations to manufacture a part.
Drawbacks of NC machine tool
Much time needed to correct any mistake in program.
Data input tapes damages easily.
Cutting and feed speed cannot be changed during cutting.
Mechanical moving parts for tape reading is not suitable for high speed operation.

CNC Machines:
A CNC machine is an NC machine with the added feature of an on board computer. The on board
computer is also referred to as the Machine control unit. The machine functions are encoded into computer
at the time of manufacture. They will not erase when CNC machine turned off. Computer memory which
holds such information is known as ROM. CNC machine has Alpha-numeric keyboard for direct or manual
data input of part programs. Such programs are stored in RAM of computer.

Fig: CNC machine and its components

Components/Elements of CNC Machine:

1) Input/ Output Devices: Part Program, Tape reader, Keyboard
2) ROM: Control program for different axis and store information and part programs
3) RAM: Run part programs
4) Machine tool: A worktable, ATC, APC, motors and controls, Cutting tools, Work fixtures, and other
auxiliary equipment needed in the machining operation.

Advantages of CNC machine Tools:

Enhanced product quality
Greater manufacturing flexibility
Reduced production lead time
Reduced inspection
Complex machining
Higher effective machining time
Effect of change of design of a part
Machine tool damage reduced
Less material handling
Reduce skill of operator
Significant reduction of cost
Disadvantages of CNC machine Tool
High Investment
High skilled programmer and electrician required
High rigidity and better dynamic characteristics are necessary to incorporate when building

DNC Machines:
In DNC, several NC machines are directly controlled by a computer, eliminating substantial hardware
from the individual controller of each machine tool. The part-program is downloaded to the machines
directly (thus omitting the tape reader) from the computer memory.
The DNC Central computer is designed to provide instructions to each machine tool on demand. The
central computer also receives data back from the machines. Thus there is two way information exchange
between central computer and each of machine tool.

Fig: DNC Machines

Automatic Tool Changer (ATC):

The CNC machines are designed to perform a number of operations in a single setting of the job. A number
of tools may be required for making a complex part. In a manual machine, the tools are changed manually
whenever required. In a CNC machine, tools are changed through program instructions. The tools are fitted
in a tool magazine or drum. When a tool needs to be changed, the drum rotates to an empty position,
approaches the old tool and pulls it. Then it again rotates to position the new tool, fits it and then retracts.
This is a typical tool changing sequence of an automatic tool changer (ATC).
The concept of the ATC is that the range of tools for a specific job shall be made available for automatic
selection and positioning. ATC cab be
Drum Type
For holding small number of tools usually not more than 30, Stored on periphery of drum and tool search
speed is faster.
Chain Type
For more number of tools (40 or more), tools search speed is less.
As soon as the tool selection command is received by the system, the selected tool comes to a fixed place
known as tool change position. The selected tool is transferred to the spindle from magazine after the previous
tool is transferred to the magazine from spindle. This is called tool change cycle.
Automatic Tool Changer Advantages
(a) Lines changed in seconds instead of hours.
(b) Increase operator safety by changing tools automatically.
(c) Change tools in seconds for maintenance and repair.
(d) Increase flexibility.
(e) Heavy and large multi-tools that are automatically exchanged.
Holding tools

Process:

Holds from 12 to 24 tools

Identified by either tool number or storage pocket number
Held in storage chain
When one operation being performed, tool required for next moved to pick-up position
Tool change arm removes and holds it; exchanges when operation complete; returns tool to
storage
Next tool selected upon completion of machining operation (~ 2.5 to 6 seconds)
Tool carriage mounted on shuttle that slides carriage next to tool spindle
Tool pocket aligned, spindle orients toolholder and tool lock releases
Tool changer rotates to number called, tool lock energized and carriage slides out of way

Automatic Pallet Changer (APC):

Automatic pallet change over systems are used in modern CNC machines. These pallets simply move for
interchanging their positions on the machine table. While machining is being done on a job kept on one
pallet, the other pallets are accessible to the operator for clamping and unclamping raw material or finished
product. This saves a lot of material handling and set up time, resulting in higher productivity.
Pallets
The workpiece is placed on a pallet (module) which can be oriented in different directions by the
machine.
Automatic Pallet Changers
When the workpiece is finished, automatic pallet changers remove it and replace it with another
workpiece

Machining center and automatic pallet changer with pallet holders arranged radially; parts storage capacity
=5

Machining center and in-line shuttle cart system with pallet holders along its length; parts storage capacity
= 16

Machining center with pallets held on indexing table; parts storage capacity = 6

Machining center and parts storage carousel with parts loaded onto pallets; parts storage capacity = 12