Tech-Design - Festo

Tech-Design®

CNC MillStudent Guide

eSeries

Edition 137674-Q0

Lab-Volt®, Tech-Design® and Mind-Sight™ logos are registered trademarks of Lab-Volt Systems, Inc. Fabricus® software is a product of Cameleon, Inc. Copyright© 2004-2005. All rights reserved.

Lab-Volt recognizes product names as trademarks or registered trademarks of their respective holders.

Video footage from: “An Overview of CAM,” Copyright 1992, Meridian Education Corporation

Certain clipart and images used within this course are used with permission from: Copyright© 2003 Microsoft Corporation, One Microsoft Way, Redmond, Washington 98052-6399, U.S.A. All rights reserved. www.ablestock.com. Copyright© 2003 Lab-Volt Systems, Inc. and its licensors. All rights reserved. www.comstock.com. All rights reserved. Copyright 2009 JUPITERIMAGES, and its licensors http://www.photos.com/en/company/terms CorelDRAW® 9. All rights reserved.

All other trademarks are the property of their respective owners. Other trademarks and trade names may be used in this document to refer to either the entity claiming the marks and names or their products. Lab-Volt Systems, Inc. disclaims any proprietary interest in trademarks and trade names other than its own.

FIRST EDITIONFirst Printing, June 2010Copyright 2010 Lab-Volt Systems, Inc.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopied, recorded, or otherwise, without prior written permission from Lab-Volt Systems, Inc.

Information in this document is subject to change without notice and does not represent a commitment on the part of Lab-Volt Systems, Inc. The Lab-Volt® software and other materials described in this document are furnished under a license agreement or a nondisclosure agreement. The software may be used or copied only in accordance with the terms of the agreement.

ISBN 978-1-60533-218-5

Lab-Volt License AgreementBy using Lab-Volt’s electronic training software whether delivered via the internet, local area network, or by means of portable data storage medium, you are agreeing to become bound by the terms of this License Agreement, Limited Warranty, and Disclaimer.

This License Agreement constitutes the complete agreement between you and Lab-Volt. If you do not agree to the terms of this agreement, do not use the software. Promptly return any physical copies of the software and all other materials that are part of Lab-Volt’s multimedia eSeries product within ten days to Lab-Volt for a full refund or credit.1. License Grant. In consideration of payment of the license fee, which is part of the one time or subscription price you paid for this Lab-Volt product, Lab-Volt, as Licensor, grants to you, the Licensee, a nonexclusive, nontransferable license to use this copy of the software with the corresponding curriculum resources for the agreed purchased period. Lab-Volt reserves all rights not expressly granted to the Licensee.

2. Ownership. As the Licensee, you own the physical media on which the software is originally or subsequently recorded or fixed, but Lab-Volt retains title to and ownership of the software programs recorded on the original media and any subsequent copies of the software, regardless of the form or media in or on which the original and other copies may exist. This license is not a sale of the original software program of Lab-Volt’s software or any portion or copy of it.

3. Copy Restrictions. The software and the accompanying materials are copyrighted and contain proprietary information and trade secrets of Lab-Volt. You may make copies of the software solely for backup purposes provided the copyright notice is reproduced in its entirety on the backup copy.

Unauthorized copying of the software even if modified, merged, or included with other software or with written materials is expressly forbidden. You may be held legally responsible for any infringement of Lab-Volt’s intellectual property rights that is caused or encouraged by your failure to abide by the terms of this agreement.

4. Permitted Uses. This software and all accompanying documentation is licensed to you, the Licensee, and may not be transferred to any third party for any length of time without the prior written consent of Lab-Volt. You may adapt, or create derivative works based on the Lab-Volt curriculum product, but may not sell your derivative or adapted course or share it with others outside of your school or department. You are expressly forbidden to modify, translate, disassemble, reverse engineer, or decompile, the Lab-Volt product without the prior written permission of Lab-Volt. Lab-Volt can not be held responsible for inaccurate, harmful, or offensive content created by the user either directly or indirectly due to content manipulation or content additions. Written materials provided to you may not be modified, adapted, translated, or used to create derivative works without the prior written consent of Lab-Volt.

5. Termination. This agreement is effective until terminated. It will terminate automatically without notice from Lab-Volt if you fail to comply with any provisions contained herein. Upon termination you shall destroy the written materials, Lab-Volt’s

software, and all copies of them, in part or in whole, including modified copies, if any.

6. Registration. Registration of your purchased software product is not a requirement. Lab-Volt may from time to time update the software. Non service impacting changes will be made at Lab-Volt’s discretion. Within the warranty period, updates to your purchased media can be made available to you upon request only if the requestor has an active subscription with Lab-Volt or can provide proof of purchase of a non subscription-based product. Return of the original product may be a requirement to receive an updated version.

7. Miscellaneous. This agreement is governed by the laws of the State of New Jersey.

Limited Warranty and DisclaimerThis software has been designed to assure correct operation when used in the manner and within the limits described in the provided product Installation & User’s Guide. As a highly advanced software product, it is quite complex; thus, it is possible that if it is used in hardware configurations with characteristics other than those specified in the provided User’s Guide or in environments with non-specified, unusual, or incompatible software products, problems may be encountered by a user. In such cases, Lab-Volt will make reasonable efforts to assist the user to properly operate the software but without guaranteeing its proper performance in any hardware or software environment other than as described in the provided User’s Guide.

This software is warranted to conform to the descriptions of its functions and performance as outlined in the courseware documentation. Upon proper notification and within a period of one year from the date of installation and/or customer acceptance, Lab-Volt, at its sole and exclusive option, will remedy any nonconformity or replace any defective software free of charge. Any substantial revisions of this product, made for purposes of correcting software deficiencies within the warranty period, will be made available, also on a licensed basis, to registered owners free of charge. Warranty support for this product is limited, in all cases, to software errors. Errors caused by hardware malfunctions or the use of non-specified hardware or other software are not covered. LICENSOR MAKES NO OTHER WARRANTIES OF ANY KIND CONCERNING THIS PRODUCT, INCLUDING WARRANTIES OR MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. LICENSOR DISCLAIMS ALL OBLIGATIONS AND LIABILITIES FOR DAMAGES, INCLUDING BUT NOT LIMITED TO SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE USE OF THE SOFTWARE PRODUCT LICENSED UNDER THIS AGREEMENT. Questions concerning this agreement and warranty and all requests for product repairs should be directed to Lab-Volt field representative in your area.

LAB-VOLT SYSTEMS, INC.P.O. Box 686Farmingdale, NJ 07727Attention: Program DevelopmentPhone: (732) 938-2000 or (800) LAB-VOLTFax: (732) 774-8573Technical Support: (800) 522-4436Technical Support E-Mail: [email protected]

CNC Mill Table of Contents

Student GuideTech-Design by Lab-Volt vii

Introduction .................................................................................................................1

Introduction to the CNC Mill ......................................................................................3To-Do List ..............................................................................................................3Study Guide ...........................................................................................................4Video Response: CNC Mill.....................................................................................7

Running the Mill ..........................................................................................................8To-Do List ..............................................................................................................8Study Guide ...........................................................................................................9CNC Mill Activity Approval Form ..........................................................................10

CAD Software ............................................................................................................11Study Guide .........................................................................................................12Video Response: Generating a PART Program ...................................................13CNC Mill Activity Approval Form ..........................................................................14

Design Modification .................................................................................................15To-Do List ............................................................................................................15Study Guide .........................................................................................................16CNC Mill Activity Approval Form ..........................................................................17Impacts Video Response: CNC Mill Impacts .......................................................18

A New Part .................................................................................................................19To-Do List ............................................................................................................19Study Guide .........................................................................................................20Data Sheet: Sketch a Part ...................................................................................21Data Sheet: PART Program ................................................................................23CNC Mill Activity Approval Form ..........................................................................24

Completing the New Part .........................................................................................25To-Do List ............................................................................................................25Study Guide .........................................................................................................26Data Sheet: Fabricus ...........................................................................................27CNC Mill Activity Approval Form ..........................................................................28

Designing and Programming ..................................................................................29To-Do List ............................................................................................................29Study Guide .........................................................................................................30Data Sheet: Program Instructions ........................................................................32

Vises and Parts .........................................................................................................33To-Do List ............................................................................................................33Study Guide .........................................................................................................34CNC Mill Activity Approval Form ..........................................................................35

Subroutines and Loops ...........................................................................................36To-Do List ............................................................................................................36Study Guide .........................................................................................................37

Table of Contents CNC Mill

Student Guide

viii Tech-Design by Lab-Volt

Manufacturing Issues...............................................................................................39To-Do List ............................................................................................................39Study Guide .........................................................................................................40CNC Mill Activity Approval Form ..........................................................................41

Complex Designs and Parts ....................................................................................42To-Do List ............................................................................................................42Study Guide .........................................................................................................43

The Final Part ............................................................................................................44To-Do List ............................................................................................................44Study Guide .........................................................................................................45CNC Mill Activity Approval Form ..........................................................................46CNC Mill Activity Approval Form ..........................................................................47

Appendices ...............................................................................................................49Independent Study

Project Proposal ...............................................................................................51Topic Outline ....................................................................................................52Bibliography .....................................................................................................53Activities ...........................................................................................................54Drawings ..........................................................................................................55

Student GuideTech-Design by Lab-Volt 1

Introduction

IntroductionThis Student Guide is organized by unit. In each unit you may find:

Unit Objectives• New Terms and Words• To-Do List• Study Guide• Data sheets (worksheets)• Video response sheets•

The Unit Objectives are a summary of what you can expect to learn in the unit.

New Terms and Words provide the definitions for words you may not be familiar with. If you come across any other words you do not understand, look them up in a dictionary, write the definitions, and add them to your Student Guide. Understanding vocabulary is the biggest key to understanding any information.

The To-Do List helps you keep track of all the work you do.

The Study Guide will help you to take notes as you read the unit. You can use this to study for the unit test. You can use all of the unit Study Guides to study for the course test.

Data sheets or worksheets provide space to record information or answer questions about activities. Some also give you a place to write down the details of your projects.

Video response sheets are worksheets that go with the videos you will watch. After you watch a video, answer the questions on the video response sheet.

You can save any other work you do for this course in this guide.

Use the Student Guide to study what you have learned. Your teacher may also ask to collect your work for a grade.

Student Guide

2 Tech-Design by Lab-Volt

Introduction


CNC Mill Unit Details

Name: Date:

Introduction to the CNC Mill

ObjectivesDuring this unit, you will:

define CNC and CAM.•examine the history and development of CNC and CAM.•identify the benefits of using CAM software.•describe the main parts of a CNC mill.•explain the concept of Program Reference Zero.•understand CNC mill safety procedures.•

To-Do List Complete the following assignments. Use this to-do list to keep track of each task.

To-Do Due Date Notes

F Study Guide

F Video Response: CNC Mill

F Timeline Activity

F Unit Test

New Terms and WordsCalibration—the checking or adjusting of the scale on a measuring instrument.PRZ—a reference point that enables the computer and the milling machine to locate the X, Y, and Z coordinates that are entered into the PART program.

????

Unit Details CNC Mill

Student Guide4 Tech-Design by Lab-Volt

Name: Date:

Study Guide

Introduction to the CNC Mill

Milling MachinesI.

A milling machine is a A. used to machine solid materials, called

.

The workpiece is positioned in a B. or a .

A milling machine can perform many operations, including: C. ,

, , ,

etc.

Numerical ControlII.

Numerical control refers to the automation of A. by

having them by numerical codes.

The earliest numerical control machines, called NC machines, were driven by B.

.

One serious problem with NC machines is that the punched tape was C.

.

Automated machines driven directly by one computer were called D.

machines.

If the computer in a DNC assembly line failed, all machines E.

.

Automated machines that have an integrated special purpose computer are called F.

machines.

The technology that incorporated computers into the manufacturing process is known as G.

.

The 5400 CNC MillIII.



The 5400 CNC mill is a A. machine, although it has many industrial

.

Mechanical ComponentsB.

The main workpiece components of the CNC mill are: 1. ,

, , and

.

Control functions are provided in the 2. .

Front PanelC.

The power to the spindle motor is controlled by the 1.

button.

The Emergency Stop button can be turned 2. only with a key.

The 3. button can switch the motor on and off.

The on and off 4. of the mill is indicated by a .

A 5. provides control menus and prompts.

Specific commands are entered through a 6. .

Program Reference ZeroD.

Manual setup and calibration is performed using the 1.

.

The X keys control 2. movements.

The Y keys control 3. movements.

The Z keys control 4. movements.

The point where the control axes intersect is called 5.

.

Generally, the PRZ is positioned on the 6. of the

workpiece.

Safe OperationsIV.

Emergency ConditionsA.



The 1. button stops the PART program, but

does not turn the mill off.

The 2. button turns off power to the mill.

Safety ProceduresB.

Never leave the key in the 1. button.

Never open the 2. during mill operations.

The tool spindle 3. if the safety doors are opened.

Always wear 4. .

Don’t allow long hair or loose clothing 5. .

Verify your setup is correct before 6. mill.

Never leave the operating mill 7. .

Don’t operate the mill if anyone is 8. spindle.



Name: Date:

Video Response: CNC Mill

How different is the training CNC mill from real industrial mills?

_____________________________________________________________________________

What type of hand cranks and handles are identified as missing?

_____________________________________________________________________________

Why are handles and hand cranks missing?

_____________________________________________________________________________

How are commands provided to the mill?

_____________________________________________________________________________

Where are tools inserted?

_____________________________________________________________________________

Where is the stock material to be milled mounted?

_____________________________________________________________________________

What is the name of the mounting slots in the XY table?

_____________________________________________________________________________What is objective of the T slots and T bolts?

_____________________________________________________________________________

Where can a vise be mounted?

_____________________________________________________________________________Where are all the mill controls located?

_____________________________________________________________________________Where is the control panel located?

_____________________________________________________________________________



Name: Date:

Running the Mill


discuss the codes and instructions used in PART programs.•use CNC Mill software to prepare a CNC PART program for execution.•execute the CNC PART program on the mill to manufacture a part.•



F Study Guide

F Activity Guide: Manufacture a Simple Part CNC Mill Activity Approval Form

F Unit Test

New Terms and WordsCompiler—a specialized computer program that converts a source program written in a specific language to another language. This is done so it can be understood by computer processors.Syntax—the grammatical rules and structure patterns required when writing computer-based code.

Additional Equipment RequiredCNC Mill CNC Mill Software

????



Name: Date:

Study Guide

Running the Mill

PART ProgramI.

The PART program contains the instructions for A. a part.

The program can be written by a B. .

The part instructions contain many C. .

Some of G&M codes are considered industry D. .

There are G&M codes that are E. to a given machine.

The program includes specific locations and movement paths specified by F.

.

CNC MillII. Software

The A. CNC Mill software processes the for the

.

The Line Editor is used to B. and a PART program.

After the program is entered, the software C. it.

The compiler can D. and syntax program

errors.

The E. simulates the actual milling process.

After a program is developed, compiled, and emulated, it is F.

into the CNC mill.

Operating the MillIII.

Before executing the program, the A. must be properly loaded into the

mill.

The correct B. must be installed.

Set the C. with precision.

Follow all D. procedures.



Name: Date:

CNC Mill Activity Approval Form

ACTIVITY NAME: Manufacture a Sample PartI have completed the following processes:

successfully compiled the required PART program with no unresolved errors.a. completed the emulation process for the required PART program. The emulation b. matches the expected results shown in the Activity Guide for this activity.reviewed the CNC Mill Safety Precautions in Appendix A of the Activity Guide.c.

I will follow all of the safety precautions as directed.

STUDENT’S SIGNATURE:__________________________________________

DATE: __________________________________

INSTRUCTOR’S APPROVAL: _______________________________________

DATE: __________________________________



Name: Date:

CAD Software


explore the history of design.•define CAD.•identify the relationship between CAD and CAM.•generate and view a PART program using an existing design in • Fabricus.compile and emulate the PART program using • CNC Mill software.download and execute the PART program on the CNC mill.•



F Study Guide

F Video Response: Generating a PART Program

F Activity Guide: CAD/CAM Teamwork CNC Mill Activity Approval Form

F Unit Test

Additional Equipment RequiredCNC Mill CNC Mill Software Fabricus Software



Name: Date:

Study Guide

CAD Software

Computer-Aided DesignI.

Computer-Aided Design is known as A. .

The main purpose of CAD is to show exact B. and

of objects.

Generally three views are drawn: C. , , and

views.

CAD allows making drawings D. and easier to .

Most CAD drawings are E. .

FabricusII.

The Views toolbar allows A. of a design, show the tool

, provide a , and display the .

The Drawing toolbar has many B. shapes, and

shapes.

The exact X, Y, and Z coordinates are entered in the C.

box.

Drawings in D. Fabricus can be to the CNC mill.

While CAD and CAM systems may use different software programs, CAD designs can be E.

to CAM forming the

teamwork.



Name: Date:

Video Response: Generating a PART Program

What opens automatically when you open the Fabricus software?

_____________________________________________________________________________

_____________________________________________________________________________

How are measurements made when you are creating a drawing?

_____________________________________________________________________________

Where is the required geometry selected?

_____________________________________________________________________________

How can a geometrical shape be re-sized?

_____________________________________________________________________________

Where is a finished geometry as part of a drawing?

_____________________________________________________________________________

How can you gain a better view of a part you may be working on?

_____________________________________________________________________________

How can you open the Geometry Properties dialog box?

_____________________________________________________________________________

_____________________________________________________________________________

What can you do using the Geometry Properties dialog box?

_____________________________________________________________________________

How can you export a drawing file to the CNC mill?

_____________________________________________________________________________



Name: Date:


ACTIVITY NAME: CAD/CAM TeamworkI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



Name: Date:

Design Modification


implement a design change using CAD software.•identify required changes to the PART program.•modify the PART program to reflect design changes.•download and execute the PART program on the CNC mill.•examine the impact of manufacturing on the environment.•



F Study Guide

F Activity Guide: Making a Change CNC Mill Activity Approval Form

F Impacts Video Response: CNC Mill Impacts

F Unit Test




Name: Date:

Study Guide

Design Modification

Design ChangesI.

Even if a design is well done and accepted, A. to a part are

possible.

Changes may be driven by B. observed

during product testing.

A product recall may C. to many parts.

Changes may be driven by new customer D. .

Some product changes may require customer E. .

Managing Design ChangeII.

When a part needs to be changed, first change A. .

After the design itself is changed, work the changes in the B. .

The design change is considered completed after the C. is tested

successfully.

When a design and the PART program are changed, D. the original files

for .

During a part change use procedures that have E. impact

on product production.

A design change may result impact F. and

.



Name: Date:


ACTIVITY NAME: Making a ChangeI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



Name: Date:

Impacts Video Response: CNC Mill Impacts

What drives companies to manufacture products?

_____________________________________________________________________________

What was the percent increase in the world population in the last 60 years?

_____________________________________________________________________________

What significant resource needed by manufacturing is identified?

_____________________________________________________________________________

What are some of the industries in the United States that are very energy intensive?

_____________________________________________________________________________

How is the world ranking of the United States aluminum industry?

_____________________________________________________________________________

How much of aluminum production costs are due to energy consumption?

_____________________________________________________________________________

How wide are the applications of chemicals?

_____________________________________________________________________________

What are some of the detrimental results of chemicals on the environment?

_____________________________________________________________________________

What is a potential impact on forests due to industrial needs?

_____________________________________________________________________________

What are some side effects caused by deforestation?

_____________________________________________________________________________

What resource is heavily used in the glass industry?

_____________________________________________________________________________

What three R’s are currently taught with regards to environmental concern?

_____________________________________________________________________________

How are products that meet energy guidelines labeled?

_____________________________________________________________________________



Name: Date:

A New Part


use the CAD software to create a design for a new part.•analyze basic instructions contained in PART programs.•prepare the new PART program for manufacturing.•



F Study Guide

F Activity Guide: Design a Coaster CNC Mill Activity Approval Form

F Data Sheet: Sketch a Part

F Data Sheet: PART Program

F Unit Test




Name: Date:

Study Guide

A New Part

Using CAD for New DesignsI.

New designs start as A. in someone’s .

Many changes are likely during B. of a new design.

One big advantage of using CAD is its C. of making changes.

Different phases of a new design are D. and

with CAD technology.

As a new design is being planned, the information may range from E.

to complete .

Exact F. and of the new

product are required for manufacturing.

PART ProgramII.

The PART program contains the A. that tells the

machine what to do.

It is important to understand the B. to help

resolve program .

Most skilled machinists are familiar with the C. .



Name: Date:

Data Sheet: Sketch a Part

Use the space on the pages that follow to sketch the three views (Top, Front, and Side) of the part that you will design using Fabricus. Be sure to label your measurements.

TOP

FRONT



SIDE



Name: Date:

Data Sheet: PART Program

Is Inch or Millimeter programming specified in the program? Identify the line of code and the 1. instruction which appears?

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

On what program line number is INCR first specified? 2.

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

On what program line is the G91 first specified?3.

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

A mix of G&M codes and conversational commands will be processed by the CNC Mill 4. correctly. Why do you think this is possible?

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

After the first MOVE instruction for the Ellipse-1 geometry, there are a number of statements 5. specifying the X, Y, and Z coordinates in which the Z coordinate does not change. How does this affect the movement of the tool in the CNC Mill?

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________



Name: Date:


ACTIVITY NAME: Design a CoasterI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



Name: Date:

Completing the New Part


download and execute the PART program on the CNC mill.•decorate and customize the completed part.•



F Study Guide

F Activity Guide: Finishing Touches CNC Mill Activity Approval Form

F Data Sheet: Fabricus

F Unit Test

New Terms and WordsPrototype—a model or the initial version of an object or living thing.Warranty—a manufacturer’s promise to stand behind a product.


????



Name: Date:

Study Guide

Completing the New Part

From Parts to ProductsI.

All finished products are made up of many A. .

Some parts are also complete B. .

Products in the MarketplaceII.

Manufacturers make products with A. customers .

A prototype is often made B. a product is

to the marketplace.

The primary motivation for making products is to C. .

A product sells well if the D. meets what customers are willing

.

Manufacturing costs include E. ,

and .

Most manufacturers offer F. for the products they sell.



Name: Date:

Data Sheet: Fabricus

Identify two different ways to open the 1. Stock properties dialog box.

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

What does the 2. Geometries list display?

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

How does the 3. Snap to Grid button assist in the creation of geometries?

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

For what purpose are container and island geometries used? 4.

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

What is the impact upon a geometry being defined as an island? 5.

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________



Name: Date:


ACTIVITY NAME: Finishing TouchesI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



Name: Date:

Designing and Programming


study design geometries and options available in CAD software.•examine G&M codes used in CNC mill programs.•analyze the usage of the X-Y-Z coordinate system in CNC Mill programs.•create a new part design and emulate the generated program code.•



F Study Guide

F Activity Guide: Design Features

F Activity Guide: Program Instructions

F Data Sheet: Program Instructions

F Unit Test

New Terms and WordsParameter—a measurement or value on which something else depends.Polyline—a curve which is formed by connecting a group of line segments which are not all contained on a single straight line.

Additional Equipment RequiredCNC Mill Software Fabricus Software

????



Name: Date:

Study Guide

Designing and Programming

Design TechnologiesI.

GeometriesA.

Designs in CAD are made using 1. shapes.

A continuous figure of connected line segments is called a 2. .

An arc is generally a portion of 3. or of .

A wedge of a circle is called a 4. drawing.

One of the most complex figures is a 5. .

The lines of geometric shapes can have 6. .

Drawing PropertiesB.

All shapes used in a drawing should have 1. to make

it easier to read.

Geometric shapes can be either 2. or .

The milling machine removes all material between the 3.

and the .

Geometric shapes can be linked and moved as a 4. .

Geometric shapes that share the same design area can be 5.

or .

Programming TechnologiesII.

G&M CodesA.

G&M codes are grouped into four sets of commands: 1. ,

, , and

.

2. codes involve tool movements.



3. codes address any pauses required when data

must be exchanged.

The group of set-up instructions is called 4. .

Instructions to stop and use subroutines are called 5.

.

Specific values provided with many G&M codes are called 6. .

Values and SpecificationsB.

Specific location values are provided by 1. on the X, Y, and

Z coordinates.

The measurement system must be specified as 2. or

.

Coordinate values can be either 3. or

.

If a coordinate value is unchanged from one command to the next, its value 4.

.

It is important to use helpful 5. throughout the

program.



Name: Date:

Data Sheet: Program Instructions

Assuming that 1. Fabricus is being used, what steps would you take to change the tool required for Polygon-4 so it is reflected in the CNC Mill Line Editor?

a. ___________________________________________________________________________

___________________________________________________________________________

b. ___________________________________________________________________________

c. ___________________________________________________________________________

d. ___________________________________________________________________________

All of the geometries are groove cuts. For the geometry Polygon-1, locate the first MOVE 2. (G01) statement. Note the sets of X-Y-Z values with this command.

Explain the need for the number of parameters for this command.a.

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________Do the X-Y-Z values identify the center of the tool or the outside edge of the tool?b.

_____________________________________________________________________________

For the geometry Polygon-2, will the tool move in a clockwise or a counter-clockwise motion? 3. [If you need to, use a piece of scrap paper to plot the first two or three X-Y parameter values on the MOVE statement.]

_____________________________________________________________________________

Which is the first polygon to use multiple passes of the tool to reach the required depth? What 4. can you say about the X-Y values on each successive pass?

_____________________________________________________________________________

_____________________________________________________________________________

Polygon-8 has a ΔZ of 0.4996 inches, but the depth of the workpiece is 0.5000 inches. Why 5. do you think the design does not have the tool go all the way to the bottom?

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________

_____________________________________________________________________________



Name: Date:

Vises and Parts


manufacture the part which was emulated before.•analyze vises.•



F Study Guide

F Activity Guide: Milling the Emulated Part CNC Mill Activity Approval Form

F Unit Test




Name: Date:

Study Guide

Vises and Parts

VisesI.

A vise is a mechanism that holds A.

in place.

Types of VisesB.

Some vises are specialized, such as 1. and

vises.

2. vises allow rapid adjustments of the workpiece.

Vises that hold the workpiece in two places are called 3. vises.

A workpiece that has curved surfaces may be held by a 4.

vise.

A workpiece that needs to be rotated should be secured with a 5.

vise.

When cuts are needed at an angle, the workpiece could be held by an 6.

vise.

Some vises can hold 7. workpieces at a time.

8. vises hold thin workpieces by suction.

High quality vises are important in order to maintain C.

in all machining operations.

A low quality vise could D. tools, parts, and

to the machinist.



Name: Date:


ACTIVITY NAME: Milling the Emulated PartI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



Name: Date:

Subroutines and Loops


explore programming subroutines and loops.•design a part in • Fabricus.analyze the generated code.•complete the • CNC Mill software processing through emulation.



F Study Guide

F Activity Guide: Design a Nameplate

F Unit Test

New Terms and WordsSubroutine—a sequence of instructions that can be inserted into a computer program wherever necessary.


????



Name: Date:

Study Guide

Subroutines and Loops

SubroutinesI.

A subroutine contains programming code that can be used in A.

of the overall program.

The use of subroutines makes programming B. since common

instructions can be written .

A subroutine is identified by the C. , which includes the name

of the subroutine as a .

The end of the subroutine is marked with the D. .

The E. CNC Mill software uses the to execute a

subroutine.

The name of the subroutine is specified as a F. of the

.

A subroutine can G. subroutines.

A subroutine shared by several programmers should be H. in its own

.

LoopsII.

Loops are used when a series of A. are used a

.

A loop starts with a B. , and ends with an

.

A DO loop within another DO loop is called a C. .

The number of times a loop should repeat is specified as a D.

of the .

Programming III.



It is good practice to add A. to a program to explain

.

A compiler checks the B. of the program, but does not guarantee it

.

An emulator C. the correct result of a PART program.

Code downloaded to a mill from a CAD program may look D.

to a code written directly for the mill.



Name: Date:

Manufacturing Issues


discuss manufacturing issues.•manufacture a part.•



F Study Guide

F Activity Guide: Manufacture the Nameplate

CNC Mill Activity Approval Forms

F Unit Test




Name: Date:

Study Guide

Manufacturing Issues

Marketing IssuesI.

A. in all aspects is important for sound business decisions.

Companies use B. to determine what products to

manufacture.

Companies need to understand the price customers are C. .

Companies also need to determine what D. and

technology to use to meet their cost targets.

Manufacturing CostsII.

There are two types of manufacturing costs: A. and .

The costs that do not vary significantly with which product to manufacture are called B.

.

Examples of fixed costs include: C. ,

,

.

Variable costs are those spent to make D. .

Examples of variable costs include: E. , ,

, , etc.

Tracking all costs is an F. function for

business.



Name: Date:


ACTIVITY NAME: Manufacture the NameplateI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



Name: Date:

Complex Designs and Parts


examine PART programming issues.•discuss problem determination and problem resolution.•use program debugging skills to resolve problems.•begin the processing for a complex part.•



F Study Guide

F Activity Guide: Debugging Complex Designs

F Unit Test




Name: Date:

Study Guide

Complex Designs and Parts

Programming for Complex DesignsI.

Use A. and as appropriate to simplify

the program.

Careful B. help identify and debug programs.

Make sure all programs are C. with current production changes.

Add D. to help read and interpret the code.

Use comments particularly to explain E. and

.

Problem ResolutionII.

Problems in production can occur during any A. .

It is important to identify the B. of the problem, how it was

, what need to be made, and

how to going forward.

The PART program may need to beC. in its various stages.

Once a problem has been resolved, the correction must be D. .

If changes are made to a program, investigate similar E. for other

parts.

F. is a good skill to have for problem

resolution.

Changes to the code must be done G. and be compiled

and emulated before the production line.



Name: Date:

The Final Part


examine Computer Integrated Manufacturing.•explore Flexible Manufacturing Systems.•complete the last manufacturing process step.•explore careers in manufacturing.•



F Study Guide

F Activity Guide: Complete the Key Chain CNC Mill Activity Approval Forms

F Unit Test

New Terms and WordsAggregate—formed by a combination of factors.Configured—put together in a specific way, often for a specific purpose.


????



Name: Date:

Study Guide

The Final Part

Computer Integrated Manufacturing (CIM)I.

CIM extends the use of computers to manage A. business

and .

With CIM, a company uses information technology to make B.

of inventory,

Current information is available to C.

functions.

CIM is a D. for manufacturing management.

Flexible Manufacturing Systems (FMS)II.

With FMS, companies can A. their operations to respond to

changes.

Automated production lines can be adjusted to make different B.

with minimal .

C. addresses the ability to define quickly

alternate ways of making products.

The ability of a long production line without intervention is called D.

.

While very advantageous, FMS has the disadvantage of requiring E.

and .



Name: Date:


ACTIVITY NAME: Key Chain A MillingI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



Name: Date:


ACTIVITY NAME: Key Chain B MillingI have completed the following processes:




DATE: __________________________________


DATE: __________________________________



CNC MillAppendices

Student GuideTech-Design by Lab-Volt 51Student GuideTech-Design by Lab-Volt 51

CNC Mill Independent Study

Project Proposal

Name:

Course:

Section:

Topic

State as specifically as possible the idea, question, and/or activity you have chosen.

Description

State why you have chosen this topic, what you expect to learn, any previous experience you had with this topic, and the type of investigation you will conduct.

Materials

State what materials, people, or activities will be involved in the completion of your project.

Due Date:

Instructor’s Approval:

Student’s Signature: Submit this proposal with your completed project.

Student Guide


Independent Study CNC Mill

Student Guide


Topic Outline

Name:

Course:

Section:

In the area provided, write the outline you will use for your independent study project.

Introduction

Discussion

Conclusion

Due Date:






Bibliography

Name:

Course:

Section:

In the area provided, supply the name, author, publisher, and publication date of the references you plan to use for your independent study project.

Texts1.

2.

Journals1.

2.

3.

Others (Examples: work experience, interviews)1.

2.

Due Date:



Student Guide



Student Guide


Activities

Name:

Course:

Section:

In the area provided, give descriptions of the activities or exercises you plan to incorporate into your independent study project. Include the materials and the time required for each of the activities or exercises.

Activities

Exercises

Due Date:






Drawings

Name:

Course:

Section:

Due Date:



In the area provided, supply rough sketches of any drawings you intend to use in your independent study project. If you need additional worksheets, you may make additional copies.

Student Guide



Student Guide


30-37674-Q0

|3037674-Q00000B~

Documents

Tech-Design - Festo