Compose exercises and operation materials on the 5 axis CNC milling machine for teaching CAD CAM CNC subject

OVERVIEW

The old version of the CNC machine

In Vietnam and globally, there is a growing interest in developing affordable CNC machines for home and small factory use At HCMC University of Technology and Education, students have successfully designed and built a 3-axis CNC milling machine for educational purposes, which has since been enhanced to a 4-axis model.

Figure 1.1 3-axis CNC milling machine

In last semester, the machine was placed at CAD/CAM-CNC LAB and has been used for teaching basic CAD/CAM-CNC experiment after cheking, testing machine operation

Figure 1.2 4-axis milling machine Figure 1.3 CAD/CAM-CNC LAB

The necessity of this project

Currently, students at the University are engaged in research and development of CNC machines, successfully upgrading a 4-axis milling machine to a 5-axis model However, despite the completion of the machine, it is not yet operational for manufacturing purposes Additionally, there is a lack of textbooks and manuals on programming and operating 5-axis CNC milling machines in Vietnam, which poses significant challenges for students as they encounter difficulties in learning and working with this technology.

Figure 1.4 5-axis CNC milling machine

Scientific and practical significance

Researching and manufacturing on the CNC milling machine supports students to have many new solutions, new development directions

Students engaged in the research and manufacturing of CNC machines must possess a foundational understanding of mechanics, electronics, and CNC software This knowledge presents valuable opportunities for them to explore and learn about advanced CNC technologies Ultimately, students can design and build CNC machines tailored to their specific skills and requirements.

CNC milling machine project helped to knowledge and skills system When the project completed, we could use it for teaching or processing some components not require too high precision.

Researching object of the project

Having knowledge of structures, principles of operation, transmission, programming and control this CNC milling machine Applying knowledge to research, development and manufacture of CNC milling machines Programming,

3 controlling the CNC machine to produce the product for demand The machine's features enough to serve for teaching and researching.

Researching object and scope

 5-axis CNC milling machine made by students of HCMC University of Technology and Education

Researching, manufacturing and completing the remaining of 5-axis CNC milling machine

Researching methods

Based on the knowledge about CNC milling machine have been studied, we checked, studied and discovered the restrictions and solved this problems

Survey of practices: Learning about the 5- axis CNC milling machine

Contraction and experimentation model: manufacturing 5- axis CNC milling machine, checking operation and processing products.

Technical and practical significance

Students will have knowledge of automatically programming (programming, simulation, adjusting and creating NC program)

Manufacturing on the 5-axis CNC milling machine, which was designed and machined by HCMC University of Technology and Education’s students

The project meets requirements about:

 Declearing zero points on the 5-axis CNC milling machine

 Using basic G, M-files to program manufacturing simple components on the 5-axis CNC milling machine

 Using manufacturing cycles of CAD/CAM software to automatically program

 Mastery of basic skill and bare minimum of the machine’s principles of operation

THEORATICAL BASIC

General information about CNC machine

Computer Numerical Control (CNC) refers to the automation of machine tools through computers that execute pre-programmed sequences of commands Unlike traditional machines that rely on manual control via hand wheels or levers, CNC technology enhances precision and efficiency by utilizing advanced programming.

Modern CNC systems automate the design and manufacturing process of mechanical parts Computer-aided design (CAD) software defines the mechanical dimensions, while computer-aided manufacturing (CAM) software translates these dimensions into manufacturing directives These directives are then converted into specific machine commands by post processor software, which are subsequently loaded into the CNC machine for production.

General configuration about CNC machine

A CNC machine consists of two primary components: the control unit and the mechanisms control The control unit utilizes program control, which sends a series of encoded signals using alphanumeric characters and symbols such as plus, minus, and dots This programming is structured similarly to binary code found in computer memory, enabling precise operation of the machine.

The control mechanisms receive signals from the structured reading program, converting them to align with the machine's movements, while feedback from sensors verifies the actions taken Key components involved include reading mechanisms, decryption, speed measurement, signal units, changing mechanisms, interpolation, amplification mechanisms, and various input-output devices Additionally, the machining unit encompasses cutting machines and automation mechanisms such as manipulation systems, lubrication, and tool holding, which are essential for cutting metal to produce components.

Machining units in machine technology are composed of components such as speed boxes, working tables, tool holders, spindles, and manipulators, resembling traditional multi-functional machines However, they differ in key aspects that enhance automated control, ensuring greater stability, precision, productivity, and technological versatility.

Speed box: is usually infinitely transmission, which uses the electromagnetic clutch to change pace easier

Toolholding has transmission source is step motor, use lead screw slit to guide

Machine bed: stiffness, reasonable structure to change tool automatically, escape chip

In CNC machines, can use many controls to ensure one or more parameters such as cutting force, noise level, vibration, cutting mode…

Coordinate system of CNC machine

Figure 2.2: Coordinate system of CNC machine

CNC machines operate along three primary movement axes: X, Y, and Z The Z axis is perpendicular to both the X and Y axes, forming a coordinate system based on the right-hand rule, and typically aligns with the main spindle axis In this system, the positive direction of the Z axis extends away from the cutting tool's width component Rotational dimensions follow a clockwise direction when viewed from the origin The X axis is designated for maximum reciprocating motion, while the Y axis is perpendicular to both the X and Z axes, adhering to the right-hand rule.

Machine reference zero (M) is processing in digital machine is setting by program, which presents relationship between tools and components To ensure

6 exactly manufacturing, tools’ movements are compared to machine reference zero

M M is point which limits area’s machine It’s regulated by creator In milling machine, it is usually point of limitation movement’s machine

Machine reference point (R) has not changes to M, regulated by creator

Workpiece zero point (W) is original coordination of components and can configure by programmer With milling components, W is opted in out corner of border workpiece

Programmed point (P) is P point of tools

Benchmarking of set tools T and point set tools N: T point is used to determine tool’s coordinate Usually setting tool in machine, T and N is once

Figure 2.6 Benchmarking of set tools T and point set tools N.

Types of control systems in CNC machine

Open control system: use step motor to move working table Because of not feedback work table position, exactly system depend on features of the step motor is used

A closed control system utilizes a DC servo motor to accurately measure the real position and velocity of a machine It continuously compares these measurements to the desired values through feedback If there is a discrepancy in the signal, the system will actively adjust the motor until the signal values align, ensuring precise control and performance.

GENERAL INTRODUCTION 5 AXIS CNC MILLING MACHINE IN THE

The available mechanism 5-axis CNC milling Machine

Figure3.2 The hardware Available 5-axis CNC milling Machine

3.2.1 The limited itinerary of the axes:

The limited itinerary of X axes: 400 mm

The limited itinerary of Y axes: 320 mm

The limited itinerary of Z axes: 300 mm

The limited itinerary of A axes: 180 degrees in the direction of the Y axis

The limited itinerary of Z axes: 360 degrees

The Mach3 Mill controling software

3.3 The Mach3 Mill controlling software:

The initial setting in the software:

3.3.1 Setting Mach3 Mill software parameters

Figure 3.3 The interface of Mach3 Mill software

Units of Measure: to install used utnits in this software, please follow the below instruction: Select MM’s in Config/Select Native Units on The background

Figure 3.4 Units in the software

 Choosing LPT gate and speed of pulse generator Kernel

To configure the electrical pulse pins of a Step Motor, navigate to Config/Ports and Pins to open a new window From there, select Motor Outputs and set the appropriate pins for optimal motor control.

Figure 3.6 Setting the Pins Motor control

 Setting input signal: Input Signal Head to set its (Estop button, cruise switches…)

- Opting for Output Signals set output signal, such as: On/Off the Spindle, water pump …

- Configuring parameters of X, Y, Z, A, C Motors: Setup it in Config/Motor Tuning

Steps per blank: based on Step Motor, step 0,72 degree /pulse => 1 revolution = 360 degrees = 500 pulses A full step = 500 pulse/revolution

Using 5-step ball screw => If Motor rotaries 1round, The working table will reciprocate 5mm  1mm = 200 pulse

Blank Velocity: Set up The acceleration then click OK (The acceleration is automatically selected from available accelerations to fitting)

Steps per Blank: Basing on Step Motor, step 0.72 degree /pulse

=>1 revolution = 360 degrees = 500 pulses A full step = 500 pulse/revolution

 Using 5-step ball screw => If Motor rotaries 1round, the working table will reciprocate 5mm  1mm = 200 pulse

 Blank Velocity: Set up The acceleration then click OK (The acceleration is automatically selected from available accelerations to fitting)

Steps per Blank: Basing on Step Motor, step 0.72 degree/pulse

 Using 5-step ball screw => If Motor rotaries 1round, the working table will reciprocate 5mm  1mm = 200 pulse

 Blank Velocity: Set up The acceleration then click OK (The acceleration is automatically selected from available accelerations to fitting)

Figure 3.12 Configuring Z-axis Parameters Steps per Blank: Basing on Step Motor, step 0.72 degree /pulse

A-axis Motor relate the gearbox, Ball Reducer whose transmission ratio is 1:20, Therefore gearbox rotates a round , Motor need to rotate 1000.20 20000 pulse The Gear-box Cluster rotate 360 degrees = 20000 pulse => 1 degree

Steps per Blank: Basing on Step Motor, step 0.72 degree /pulse

A-axis Motor relate the gearbox ,Ball Reducer whose transmission ratio is 1:508,235Therefore gearbox rotates a round , Motor need to rotate 1000.50 508235 pulse The Gear-box Cluster rotate 360 degrees = 508235 pulse => 1 degree = 508235/360 pulse ≈ 1411.764705 pulse

Mach3 Mill is the software packaged movement on personal computers, it is very useful and convenient to replace the machine control

To run the Mill Mach3 need preparing the computer using Windows

XP or Windows 2000 or more

Mach3 Mill communicate by printer port (DB25) Depending on the requirements that can choose the machine has 1 or 2 printer ports

The Driver that controls each axis of the machine must to accept the pulse and direction

3.3.2.2 Interface and functions of the Mach3 Mill

Mill Mach3 controller screen when booting the machine includes 6 screen page:

The diagnostics section (Alt-7) features a user-friendly interface divided into several groups, each displaying relevant information and control buttons This organization allows for easy observation and quick management of the system.

Figure 3.14 The main interface of Mach3 controller

This is the main screen page when starting the Mach3

The Reset (Emergency Stop) function halts the machine's operations instantly, disconnecting all motor activities to address critical situations such as short circuits, collisions, or hazardous impacts After activating the Reset button, it is essential to reposition the machine to its reference points or reset the cutting coordinates for safe operation.

G-Code: Show commands G in NC programming and what they mean M-Code: Show commands M in NC programming and what they mean Each axis-control group: Including the controlling button of axes and show the position of tools

Figure 3.15 Location coordinates of the axes

The meaning of the buttons in the control group:

Zero X, Zero Y, Zero Z, and Zero 4: Set up zero (0) to each axis corresponding to the current coordinates (There are 6 coordinates cut from G54 to G59 installed in Offset page)

Ref all Home: Back to the original reference coordinates for all

Offline: When this mode is selected the offline lights will light up and the Mach3 Mill will lock all the movements of the machine

Machine Coords: Absolute coordinates (coordinates)

Soft limits: This is a Soft limits function of the machine, we set up the Cruise limit by software

To set up, on menu bar select Config > homing/soft limits

Figure 3.16 The program control group

To initiate a cutting program, load the desired program into the G-Code and press the Cycle Start button on the Control Panel or use the Alt-R key combination This action will automatically execute the detailed milling program on the machine.

The Feed Hold (Spc) button is designed to pause the milling head during operation By pressing this button, the milling head will stop, and to resume movement, simply click the Cycle Start button This feature is particularly useful for addressing issues that require an immediate halt to the cutting process.

 Stop (Alt-S): stop the cutting program

 Edit G-Code: Edit the current G-code

 Recent File: Load recently cutting programs

 Close G-code: Close current G-code in the G-code area

 Load G-Code: Upload milling programs to the G-code area

 Set Next Line: Set the next line

To resume milling, click the designated button, prompting the system to navigate to your selected line and await the Cycle Start command Upon pressing Cycle Start, a dialog box labeled "Preoperational Move" will appear, inquiring whether to move to the coordinates of the previous command.

 Rewind (Ctrl-W): Coming back beginning program

To activate the Single Block mode in the program, press the Single Block key or use the keyboard shortcut Alt + N This mode highlights a Single Block and allows the program to pause at each block command during execution By utilizing this feature, users can effectively verify and check each command within the block To exit this mode, simply press the Single Block key again.

 Auto Tool Zero: Return to point electrodes installed

 Remember: Remember the current position instead into the position of the electrode when press the Return button

 Return: Back to the point electrode, When press this button, a dialog box will appear and the system will ask us turn on Spindle (the engine main axis) or not

 Jog ON/OF Ctrl-Alt-J: Turn on/off the manual control function

Feedrate: Show the cutting speed Feedrate Override The cutting speed(Feedrate) In the program will find the adjustment to increase or decrease the selected percentage on the button

Hình 3.18 Speed Rate Spindle Speed: The speed of main spindle

A Spindle button : Turn the spindle head

Speed Override: Authorize us change the spindle speed

MDI Alt-2Page (Manual Data Input): this is the mode which controls machine by NC code in MDI mode

Mach 3 retains all input lines and saves the Mditech.tap file in the "C:/Mach3/Gcode/" directory To load the Mditech.tap file, press the Load/Edit button, which will transfer the MDI file into the F-code area Please note that the current G-code must be closed before loading the Mditech.tap file.

To save the entered line before pressing the Start Tech button, simply click the Stop Tech button, which will store the lines in the Mditech.tap file If you wish to remove the line currently being entered, you can either press the Esc key or click the Stop button (ESC).

 To remember the current position press the Set Variable Position button and to return the saved position we press the Goto Variable Position button

Figure 3.21 Interface of Tool Path page

Figure 3.22 Interface og offsets page

 Setting the cutting coordinates: work coordinate system is the system of coordinates which associated with the workpiece, when programming must to select G54 or G59, Mach3 Mill default is G54

Figure3.23 Interface of settings page

The page allows me to install parameters for machine this section due to manufacturer settings

Note: The operation must not to change the parameters in the page

This page allows us to diagnose the fault of machine

Figure 3.24 The Interface of Diagnostics page

3.3.2.3 How to use the Mode in the Mach 3 Mill

- To enter Jog Mode (manual control) we press Jog

ON/OFF button or press the key combination (Ctrl-

When the Jog ON/OFF light is illuminated, the cutting head can be maneuvered using the keys To choose a mode, simply click on Shuttle mode, and the corresponding light will activate for each mode In Continuous Mode, pressing the Jog keyboard shortcut allows the axis to jog a distance based on how long the button is held down, stopping when the button is released The jog speed is adjustable via the DRO box below Slow Jog Rate, with values ranging from 0.1% to 100%.

To apply the newly entered values, simply click to execute You can also adjust the parameters by clicking the triangle button next to them to increase or decrease the values Each press will result in a corresponding increment or decrement of the selected parameter.

5%.If you hold down the Shift key attached then speed will reach 100% value as the max speed for help moving to the desired position faster

- In mode Step: Pressing Jog button of each axis, each shaft will move according to ratio appearing in

The DRO function adjacent to the Cycle Jog Step allows users to set a specific ratio for movement, which will be executed based on the current feed rate Alternatively, movements can occur without a preset step ratio, defaulting to the ratio established by pressing the Cycle Jog Step button.

Figure 3.25 Dialog box of Using Jog mode and MPG (Handle)

Arrow buttons facilitate movement in a three-dimensional space, with horizontal arrow buttons controlling X-axis movement, vertical arrow buttons managing Y-axis movement, and the Page Up and Page Down buttons adjusting movement along the Z-axis.

THE 5-AXIS CNC MILLING MACHINE OPERATION AND COMPOSE

The 5-axis CNC milling machine operation

4.1.1 Introduce about 5-axis CNC milling machine

The 5-axis CNC milling machine Panel

Figure 4.1: The 5-axis CNC milling machine Panel

The 5-axis CNC milling machine button

Figure 4.2: The 5-axis CNC milling machine button

Reset button: Delete error message, pause program

Cycle Start button: the machine run automatic the program which selected the Memory or the DNC (Direct Numerical Control)

Single BLK button: execute the program step by step command

Stop button: stop running program and rotating spindle.

X+ button: move the X axis in positive direction (Positive direction is thumb direction the right-hand rule).

X- button: move the X axis in the negative direction

Y+ button: move the Y axis in positive direction (Positive direction is forefinger direction the right-hand rule)

Y- button: move the Y axis in negative direction.

Z+ button: move the Z axis to the main direction (Positive direction is the main axis direction which moves from workpiece to far)

Z- button: move the Z axis to backward the main direction (Negative direction is the main axis direction which moves nearly workpiece)

Note: The working table movement is backward with buttons.

Zero X, Zero Y, Zero Z, Zero A, Zero C button: setting up the coordinates zero

(0) for each of the axes coordinates cutting current (G54-G59), Mill Mach3 's default is G54

4.1.2 The basic operations on 5 axis CNC milling machine

4.1.2.1 Turn on and turn off a Turn on

Log in the computer controlled machines.

Turn on source CNC machine

Figure 4.3 Turn on CNC machine

Open Mach3 Mill software with 6-axis interface

Figure 4.4 Open Mach3 Mill soflware

Click Mode [Home All] to set reference machine When buttons change from red light to blue light, reference machine (Home point) are set

Figure 4.5 Reference all home b Turn off

Shut down program and control computer

Figure 4.6 Close Mach3 Mill software

Figure 4.7 Power off CNC control

4.1.2.2 The axis system show on interface

Figure 4.8 The axis system show on interface

Zero X, Zero Y, Zero Z, Zero B, and Zero C: set zero (0) for axes to the same as current cutting coordinates There are 6 cutting coordinates from G54 to G59, installed in Offset

Home all:The axes move on home point

Offline:When this mode is selected, the offline lights will light up and the Mach3 Mill will lock all the movements of the machine.

Machine Coords:Absolute coordinates (coordinates).

Soft limits:Cruise limitation are set in this software To set, on menu bar select Config > popular/soft limits

4.1.3 Operation and Determination about workpiece reference in 5-axis CNC milling machine

Figure 4.9 Workpiece reference in CNC machine

The programmer config a point in drawing, which is workpiece zero reference ( X = 0, Y = 0, Z = 0)

Workpiece zero reference and machine zero reference is cofiged to be one This reference will be chosen throughout processing FANUC system has 6 positions (G54-G59).

4.1.3.2 Determining reference in edge point workpiece (X, Y)

1 Installing tool into collect This machine has one cutting shark tool, so we shouldn’t change tool by MDI commands

2 Moving tool to workpiece edge (using the JOG mode)

3 Running spindle: Sxxx M3 [MDI] (xxx: spindle speed velocity)

4 Engraving tool to workpiece edge (using wet paper)

5 Pressing zero X (calculation based on tool radius) Entering tools radius in zero X (calculation based on workpiece midpoint) or press zero X button on control panel

Figure 4.11 Position about zero X and enter X scope

Step 2: Determination about Y reference: the same as determining X reference

1 Moving Z axis to workpiece surface [JOG]

A, C reference are configed by programmer When processing, we rotate to any positions Then, press Zero A, Zero C to set 0

Now, all axes were set 0 ( X = 0, Y = 0, Z = 0, A = 0, C = 0)

3 Control running step by step commands

4 If setting is right, X, Y, A, and C show 0 and Z show 50 on screen If setting is wrong, we should press Reset button in control panel or software

4.1.4 Load G-code, edit and check errors

To load G-code into the machine, click on "Load G-code" to open the text box Please note that the G-code file should be named in the format 0xxxx.tap, where "xxxx" represents a numerical order and ".tap" is the file type.

Figure 4.15 Load G-code and choose G-code file

Click Edit G-code if you want to fix code

When the program was loaded in machine, in the right of screen will show peripheral running tool Observing that we can know the tool run when processing

Step 1: Adjusting FEED RATE to 0

Step 2: Click Single Block mode to run each command If the machine move to exactly coordinates, turn off Single Block mode

Figure 4.19 Turn on/off Single Block mode

Step 3: Click Cycle Start to run G-code and fast up speed Feed Rate

Step 4: If want to stop running program but don’t stop rotating spindle, click Feed Hold

Note: If machine movement or program have errors, click Reset on screen or Reset button in control panel.

Compose exercises on the 5-axis CNC milling machine

4.2.1 Programming process by Creo parametric 3.0 a Processing environment

Select New in menu File or click left mouse to

Select Manufacturing in option Type and click NC Assembly

In the Name box, rename working file > Ok

Choose the unit measure (click: mmns_mfg_nc) > Ok

Figure 4.22 Create processing environment b Put component into processing environment

Click Reference model > Assemble Reference Model

Choose processing component, click Open > Default (Assemble component at default reference) > Click

Figure 4.24 Assemble component at default reference c Create Workpiece

Click Workpiece > Create Workpiece Writing workpiece name in Enter Part Name [PRT000] >

In Menu FEAT CLASS click Solid > Protrusion > Solid opts In here, choosing method of creating the volume > Done

Figure 4.25 Create Workpiece text box

Click Extrude > Solid > Done Click Sketch to create 2D environment > After finish, click

Enter the height for workpiece Click to finish When complete, workpice is green

Figure 4.27 Workpiece is created d Choose Work Center

Click and choose Work Center > Mill > appear Milling Work Center text box > 3 Axis > Ok e Create a datum coordinate system

Click Coordinate System > and choose three tangent plane In Coordinate System, flip axes coordinates coincide with NC coordinates

Figure 4.28 Choose Coordinate System f Set Retract plane

Click Operation, we can select in Type: Plane, Surface, Cylinder, Sphere, None

Type: Click Plane or Surface Reference: select one any planes or one plane on workpiece, enter measure in Value and tolerance in Tolerance box

Type: Click Sphere Reference: choose coordinate system Value: enter radius Type: Click Cylinder Reference: choose coordinate system Value: enter radius

In Orientation: choose X, Y, Z axis to enter measure, which we need to offset, enter full import parameters Click to end

Figure 4.29 Set Retract plane g Tool manager

Click Cutting Tool to edit needing tool

Figure 4.30 Edit tool h Set processing type

Click Mill on Toolbar, we can choose processing methods

Figure 4.31 Choose processing methods in Mill text box

The article highlights various processing methods in machining, including Volume Roughing, Surface Milling, Face Milling, Profile Milling, Pocketing, Trajectory Milling, Thread Milling, Engraving, Plunge Roughing, Corner Finishing, Finishing, Re-Roughing, Manual Cycle, and Holemaking It emphasizes the importance of declaring parameters for each processing technology to ensure optimal results.

In the Edit Parameters dialog of the Sequence, continue to declare the parameters of technological processes The declaration of these parameters varies based on the chosen processing method However, the team did not specify a particular processing method in this discussion.

Way 1: Menu Manager > NC SEQUENCE > Play Path In Play Path menu with options:

 Screen Play: simulation of running tool in path.

 NC Check: simulation of running tool in 3D format.

 Gouge Check: checking location of collision between the tool and the components.

Click Play Path, Play Path dialog box, tool and processing model will appear

Way 2: Click OP010 > Play Path

Way 1: Menu Manager > NC SEQUENCE Choose NC Check, Vericut software appear

Way 2: doing follow the picture: OP010 > Material Removal Simulation VERICUT dialog appears to allow emulate.

After programming complete, exporting commands of Creo parametric 3.0 will export file G-Code to control machining.

To export processing programs, should do following:

To save your work in the Play Path dialog box, navigate to File and select "Save as MCD." This will open the Post Processor Options dialog box Choose your desired output and specify the saving file location, then click OK In the Menu Manager text box, select UNCX01 and press Enter to complete the file export.

4.2.5 Compose exercises on the 5-axis CNC milling machine

 The exercise will present about using Profile milling, Pocketing, Finishing and Drilling cycles and adjusting parameters of this cycles to manufacture external profiles, pockets and holes

 The exercise meets learning outcomes which has been mention in section 1.7 a Drawing

Figure 4.37 Exercise 1 drawing b Processing technology

Step 1: Profile milling: Endmill ỉ8, t = 2 (mm), S = 1800 (r/m), F = 600 (mm/m)

Step 2: Pocketing: Endmill ỉ8, t = 2 (mm), S = 1800 (r/m), F = 600 (mm/m)

Step 3: Finishing: Endmill ỉ8, t = 0.2 (mm), S = 2500 (r/m), F = 300 (mm/m)

Step 4: Drilling ỉ6 x 4 hole: Drill ỉ6, t = 10 (mm), S = 800 (r/m), F = 100 (mm/m)

Step 5: Benchwork: rotary file, burr and hole

Profile Milling is used to format the border, faỗade, horizontal surface, or cylinder holes

For that reasons, the cutting tool is endmill

Edit tool: choose tool type, tool diameter, tool length

Reference: select object needs processing

Parameters: having 4 parameters we must declare: Step_depth, Cut_feed, Clear_distance, Spindle_speed

For Profile Milling, the mandatory parameters STEP_DEPTH is parameter mandatory The results as follows:

Figure 4.40 Standard Orientation view and Front view

Comment : However when tool cutting down, tool cut directly into wprkpiece (figure 5.45), this will affect to tool life and vibration to machine Having to

 Cut_entry_exit : Lead in

 Cut_ext_ext : Lead out

When configuring cutting tool parameters, it is essential to ensure that the tools do not abruptly cut in and out, as this should occur in a tangential direction By using larger cut-in and cut-out radii, the cutting process becomes smoother, although this can lead to increased cutting times due to the extended tool movement Additionally, selecting entry and exit angles of less than 90 degrees can optimize the cutting efficiency.

To ensure cut in and cut out stabilize, special wear cutting tools, cutting compensation should be attention In Parameter Model Tree, adjust the following parameters:

Cut_com refers to Cutting Compensation, while Cut_com_register is used to define the memory box and input the radius of the cutting tool on CNC machines To verify this, click the icon adjacent to the file content The CL Data indicates that Cutting Compensation mode is currently enabled, as shown in the circled command line.

48 parameter of radius tool entered the box remember 11 th and the first cut into workpiece is the left cutting compensation

Figure 4.43 Turn on CLDT Cut_com mode

Pocketing is akin to Volume Mill, but while Volume Mill requires the creation of a mill volume, Pocketing simplifies the process by allowing users to select just the bottom surface or the bottom and side edges of the component.

Having 6 parameters need to declare: Step_depth, Cut_feed, Clear_distance, Spindle_speed, Step_over Step_type

In finishing, having 5 parameters need to declare: Cut_feed, Spindle_speed, Step_over, Clear_dist, Ramp_angle

To make commands drilling in Creo, in file processing ( prt) the holes must be created by Hole or Sketch (Point) This command can processing holes simultaneously

In reference, click Details to more choose components The best method is choosing hole follow axis The holes processing having common are going to be selected, such as:

The hole surface in a face.

In the Drill Group (Similar to the Mill Surface feature)

Having 4 parameters need to declare: Cut_feed, Clear_distance, Spindle_speed, Scan_type

 Click Play Path to observe cutting perimeter:

Note: In case that the step hole, when to declare parameters as above has error such as following:

Figure 4.49 Tool move wrong when cut 2 nd hole

When tool move from 2 left holes to 2 right holes, drill cuts on workpiece Therefore, parameter needs to fix

PULLOUT_DIST 10 Table 4.2 PULLOUT_DIST Parameter

The meaning of PULLOUT_DIST is explained by drawings here:

Worpiece dimension (mm) Material Clamp

No Technology step Tool type ỉ (mm)

Table 4.3 Processing Technology of Exercise 1

Figure 4.51 Simulation result and product about exercise 1

 The exercise will present about using volume rough and finishing cycles and adjusting parameters of this cycles to manufacture external and internal profiles

Step 1: Volume Rough: Endmill ỉ6, t = 1 (mm), S = 2000 (r/m), F 800 (mm/m)

Having 10 parameters need to declare: Cut_feed, Step_depth, Step_over, Clear_dist, Spindle_speed, Prof_tock_allow, Rough_tock_allow, Bottom_stock_allow, Scan_type, Rough_option

Note : 2 parameters affect to the processing, is Rough_option and

Scan_type Because Rough Volume is general, it can be used to instead of the Profile, Face, Pocketing, Roughing, Re-rough, Finishing by declaring Rough_option parameter

 Comment and edit a few parameters:

Tool cut on workpiece with Step_depth, this engender tool wear, working table vibration So, need to fix parameters to overcome:

Plunge:Tool cut straight down workpiece according to Z axis This way is used when in that had been drilled a hole

Ramp: Cut on following tool angle Declaring parameters as following:

RAMP_ANGLE: Corner cut on compared to Z axis The default is 90 0 , tool will damage Therefore, RAMP_ANGLE need to declare accordant

Steel and Cast Iron ≥ 15 ≥ 10 ≥ 5 Aluminium, Copper, Plastic ≥ 30 ≥ 20 ≥ 10

RAMP_FEED: Often added by 0.5 times the CUT_FEED value If the default values to RAMP_FEED will be automatically taken to the CUT_FEED value

Helical: RAMP_ANGLE and RAMP_FEED is enter similar Ramp parameters HELICAL_DIAMETER parameters need to fix Enter additional values:

No Technology step Tool type ỉ (mm) S

 The exercise will present about using Engraving cycles and adjusting parameters of this cycles to manufacture Engraving on faces

Step 3: Engraving: Grooving, t = 0.3 (mm), S = 2300 (r/m), F = 1000 (mm/m)

Having 10 parameters need to declare: Cut_feed, Step_depth, Step_over, Clear_dist, Spindle_speed, Prof_tock_allow,

Rough_tock_allow, Bottom_stock_allow, Scan_type, Rough_option

Engraving is used to be decoration, create pattern To engraving, you must create the geometric decorative element, which is called Groove

In edit tool, click Grooving and choose tool diameter, tool length

Having 7 parameters need to declare: Cut_feed, Step_depth, Pluge_feed, Groove_depth, Number_cuts, Clear_dist, Spindle_speed

Note : An important affects cutting tool couldn’t damage is the

Figure 4.62 Edit Pluge_feed parameter c Technology parameters:

 The exercise will present about using Profile Milling, Pocketing, Finishing cycles and adjusting parameters of this cycles

Step 1: Profile Milling: Endmill ỉ8, t = 2 (mm), S = 1800 (r/m), F 600 (mm/m)

Step 2: Pocketing ỉ 34 x 4 holes: Endmill ỉ8, t = 2 (mm), S = 1500 (r/m), F = 500 (mm/m)

Step 3: Pocketing ỉ60x40xH15 (mm): Endmill ỉ8, t = 2 (mm), S 1500 (r/m), F = 500 (mm/m)

No Technology step Tool type ỉ

 The exercise will present about using Roughing, Surface Milling cycles and adjusting parameters of this cycles to manufacture complex surfaces

Step 1: Roughing: Endmill ỉ6, t = 2 (mm), S = 1800 (r/m), F = 600 (mm/m)

Step 2: Surface Milling: Ballmill ỉ6, t = 0.3 (mm), S = 2500 (r/m), F 1000 (mm/m)

Edit tool: select tool type, length and diameter of tool Depending on the volume surface, we can choose Endmill or Ballmill

Reference/ machining Reference: choose processing volume

Parameters: 6 parameters must declare: Cut_feed, Step_over, Max_step_Depth, Clear_dist, Spindle_speed, Ramp_angle

Note: ROUGH_STOCK_ALLOW parameter should NOT be 0 There for, needing to have surplus stock for workpiece

In Re-Rough, need to edit tool and parameters

Edit tool: tool diameter smaller than tool diameter before

Having 6 parameters need to declare: Cut_feed, Step_over, Clear_dist, Spindle_speed, Clear_dist, Max_step_Depth d Technology parameters:

Worpiece dimension (mm) Material Clamp

This exercise focuses on utilizing trajectory cycles and adjusting their parameters for the production of complex surfaces It also includes guidance on setting zero points to program the manufacturing of 4D models, making it a valuable resource for milling intricate 4D surfaces.

 The exercise meets learning outcomes which has been mention in section 1.7

4.2.5.3.1 Set Zero points in 4-axis CNC milling machine

Step 1: Set X reference, moving tool to touch workpiece surface according to X axis direction After that, moving tool up according Z axis direction and moving a distance on workpiece by tool radius Then, tool center point and W reference of machine is one by X direction

Step 2: Set Y reference, moving tool to touch workpiece surface according to Y axis direction After that, moving tool up according Z axis direction and moving a distance on workpiece by tool radius Then, tool center point and W reference of machine is one by Y direction

Step 3: Set Z reference, moving tool center point coincides with A – axis center rotation by Z axis direction Then, set Zero Z in Mach 3 Mill software

Step 4: Set A – axis reference Because A – axis is rotation axis, choose Zero A in initial coordinates

Figure 4.73 Exercise 4D drawing b Processing technology

Step 1: Trajectory: Endmill ỉ6, t = 0.3 (mm), S = 2500 (r/m), F = 1000 (mm/m)

Step 2: Trajectory: Ballmill ỉ4, t = 0.2 (mm), S = 2500 (r/m), F = 300 (mm/m)

Edit tool : choose Endmill to processing follow line current and Ballmill to finishing

Edit parameters : Cut_feed, Clear_dist, Spindle_speed, Number_cuts When programming Trajectory cycles to roughing, programmer need adjusting step_depth parameters appropriately

Set up tool motions: choose trajectory curve cut, start height, height and axis control

Figure 4.75 Set up tool motions

Edit post to export 4-axis G-code: Applications > NC post Processor

Appearing Option File Generator dialog box to edit Post export 4-axis G- code and Save, then export G-code

 choose 4-axis CNC milling machine

Figure 4.77 choose 4-axis CNC milling machine

Figure 4.78 Set height tool to 4 – axis movement

Worpiece dimension (mm) Material Clamp ỉ60x170 PP plastics Three-jaw chuck

The reference of A-axis is adjusted suitably

Table 4.10 Processing Technology of 4D Exercise

Figure 4.79 Simulation result and product about 4D exercise

4.2.5.4.1 Set reference in 5-axis CNC milling machine

Step 1: Set X reference, moving tool to touch workpiece surface according to X axis direction After that, moving tool up according Z axis direction and moving a distance on workpiece by tool radius Then, tool center point and W reference of machine is one by X direction

Step 2: Set Y reference, moving tool to touch workpiece surface according to Y axis direction After that, moving tool up according Z axis direction and moving a distance on workpiece by tool radius Then, tool center point and W reference of machine is one by Y direction

Step 3: Set Z reference, moving tool center point coincides with A – axis center rotation by Z axis direction Then, set Zero Z in Mach 3 Mill software

Step 4: Set A – axis reference Because A – axis is rotation axis, choose Zero A in initial coordinates

Step 5: Set C – axis reference Because C – axis is rotation axis, choose Zero C in initial coordinates

This exercise focuses on utilizing cut line milling and drilling cycles, along with parameter adjustments for programming in manufacturing It emphasizes the importance of setting zero points for 5D models and is particularly beneficial for creating holes and milling surfaces on complex 5D designs.

Step 2: Cut Line milling: Ballmill ỉ4, t = 0.2 (mm), S = 2500 (r/m),

Step 3: Driling ỉ5x4(mm): Driling ỉ5, t = 2 (mm), S = 2500 (r/m),

Used to processing 4 – axis and 5 – axis

Edit tool: choose Ballmill to cut line

To make commands drilling in Creo, in file processing ( prt) the holes must be created by Hole or Sketch (Point) This command can processing holes simultaneously

In reference, click Details to more choose components The best method is choose hole follow axis The holes processing having common are going to be selected, such as:

The hole surface in a face.

In the Drill Group (Similar to the Mill Surface feature)

Having 4 parameters need to declare: Cut_feed, Clear_distance, Spindle_speed, Scan_type

 Edit post to export 5 – axis G-code

Figure 4.90 Edit post to export 5 – axis G-code

Figure 4.91 Choose 5 – axis CNC milling machine

(mm) Material Clamp ỉ60x50 PP plastic Three – jaw

The Reference A, C axis are adjusted suitably

Figure 4.93 Simulation result and product

This exercise focuses on utilizing trajectory and engraving cycles while adjusting their parameters for effective programming in manufacturing It includes guidance on port adjustments and selecting zero points for 5D models Additionally, the exercise is beneficial for creating keyseatings and engraving on intricate 5D designs.

Step 1: Volume Rough: Endmill ỉ6, t = 1 (mm), S = 1800 (revolution/ min), F = 600 (mm/min)

Step 2: Trajectory: Endmill ỉ6, t = 0.2 (mm), S = 2500 (revolution/ min), F = 1000 (mm/min)

Step 3: Engraving: Grooving, t = 0.3 (mm), S = 2300 (revolution/ min),

Step 4: Benchwork: File Rotary and burr

Having 10 parameters need to declare: Cut_feed, Step_depth, Step_over, Clear_dist, Spindle_speed, Prof_tock_allow, Rough_tock_allow, Bottom_stock_allow, Scan_type, Rough_option

 Enter Edit tool: Choose the Grooving tool, tool diameter, suitable tool

 Length Reference / machining Reference: chọn thể tích gia công

Edit tool : choose Ballmill to processing follow line current Edit parameters : Cut_feed, Clear_dist, Spindle_speed, Number_cuts

Engraving is used to be decoration, create pattern To engraving, you must create the geometric decorative element, which is called Groove

 Enter Edit tool: Choose the Grooving tool, tool diameter, suitable tool length

 Reference: Choose Sketch surface need to handle

 Parameters: There are many parameters but has seven parameters that are required to declare : Cut_feed, Pluge_feed, Step_depth,Groove_depth, Number_cuts, Clear_dist, Spindle_speed

(mm) Material Clamp ỉ60x55 PP Plastic Three – jaw

The Reference A, C axis are adjusted suitably.

No Technology Step Tool type ỉ

This exercise focuses on utilizing trajectory and drilling cycles while adjusting their parameters for effective program manufacturing It also covers port adjustments and selecting zero points for a 5D model Additionally, the exercise is beneficial for holding and creating keyseating on intricate 5D models.

 The exercise meets learning outcomes which has been mention in section 1.7

Figure 4.101 Exercise 3 drawing b Technology Processing

 Tool: Endmill ỉ6, t = 1 (mm), S = 1800 (revolution/min), F 600 (mm/min)

 Tool: Endmill ỉ6, t = 0.2 (mm), S = 2500 (revolution/min), F 1000 (mm/min)

 Tool: Driling ỉ5, t = 2 (mm), S = 2500 (revolution/min), F 500 (mm/min)

(mm) Materials Clamp ỉ60x60 PP Plastic Three – jaw Chock

The References of A, C axis are adjusted suitably.

No Technology step Tool type ỉ S

Table 4.13 Processing Technology of Exercise 3 d Simulation result and product

 The exercise will present about using trajectory, drilling cycles and adjusting parameters of this cycles to program manufacturing,

87 adjusting port, choosing zero points for a 5D model Besides, the exercise will be useful for holding on complex models

 The exercise meets learning outcomes which has been mention in section 1.7 a Drawing:

Figure 4.103 Drawing exercise 4, 5-axis processing b Technology Procesing

 Tool: Endmill ỉ6, t = 1 (mm), S = 1800 (revolution/min), F 600 (mm/min)

 Tool: Drilling ỉ6, t = 2 (mm), S = 2500 (revolution/min), F 500 (mm/min)

 Tool: Driling ỉ4, t = 2 (mm), S = 2500 (revolution/min), F 500 (mm/min)

 Tool: File Rotary and burr

 The Volume Rough processings, Drilling (exercise 1, 2 và 3) c Technology parameter :

(mm) Materials clamp ỉ62x55 PP plastic Three – jaw chock

The Reference A, C axis are adjusted suitably

NO Technology step Tool type ỉ S

CONCLUSION AND RECOMMENDATIONS

Tiêu đề	Compose Exercises And Operation Materials On The 5-Axis CNC Milling Machine For Teaching CAD/CAM - CNC Subject
Tác giả	Truong Xuan Thai, Le Minh Tai
Người hướng dẫn	M.E Duong Thi Van Anh
Trường học	Hcm City University Of Technology And Education
Chuyên ngành	Machinery Manufacturing Technology
Thể loại	Graduation Thesis
Năm xuất bản	2017
Thành phố	Ho Chi Minh City

Định dạng
Số trang	109
Dung lượng	8,3 MB