CAM Notes 1
CAM Notes 1
CAM Notes 1
EMG 4104
Lecture Notes
Table of contents
1. Coordinate Systems
2. CNC Programming Language
3. CNC Tools
4. CNC Operation
5. 2D Milling Toolpaths
6. CNC Turning
The general workflow to go from CAD model to machined CNC part is:
1. Begin with CAD model.
2. Establish Job parameters including CNC coordinate system and stock shape/size.
3. Select CNC process.
4. Select cutting tool and machining parameters.
5. Select driving CAD geometry.
6. Verify toolpath.
7. Post Process.
8. Transfer G-‐code program to CNC machine.
9. Set up and operate CNC machine to make part.
CNC machine has many advantages, but there are also disadvantages.
1. Expensive Machines; The cost of the machine is expensive, and the maintenance cost is
also high.
2. Limited Materials: The material selection is limited for certain CNC machine, mainly
metal materials can be processed by CNC machine, but the material selection for CNC
machinery is not as wide as that for conventional machining tools.
3. Machining Precision: The precision performance of CNC machines is relatively low in
some situations: when the surface roughness of the workpiece surface is too high, the cutting
accuracy of CNC machines will be greatly reduced; when there are too many holes in a
workpiece or when there are many corners on a workpiece, it will be difficult to process
with CNC machines; when cutting thin materials such as sheet metal or aluminum plate, it
is easy to have deformation issue.
4. Need skilled workers: Workers who operate the CNC machine will not be able to learn new
skills if they want to change their job in the future because their skills are very specific for
one type of work only, which is operating CNC machines or machining parts with CNC
machines, so they will have difficulties finding another job that suits them well in this field.
5. Low production speed: CNC machining is only suitable for small to middle volume
production, but not suitable for high volume batch manufacturing production because its
cost is higher than other machining like casting, injection molding, stamping etc.
Features of CNC Machine
1. Machine Control Unit
The machine control unit is where the device takes instructions to perform its functions. This is like
the CPU of the CNC machine. The instructions include decoding instructions and generating axis
motion commands. Consequently, the machine control unit makes the CNC machine more accurate
than humans.
2. CNC Tools
3. Feedback System
The feedback system has the machine’s sensors. Which provide data to the operator on the
condition of the machine as well as the errors that might occur during machining.
4. CNC Input Devices
The CNC needs commands to give the correct output. The input devices include a computer and a
tape reader that users utilize to issue commands.
5. CNC Driving Systems
These parts of the CNC machine ensure the movements of the various sections. The parts include
motors, circuits, and ball lead screws.
6. CNC Display Unit
This is the part of the machine where you can see the programs, commands, and other useful data.
CNC Tools
A wide range of tool types and configurations are available for CNC milling machines. However,
in this chapter, we only introduce the most commonly used tools for prototype and short run
production machining.
• End mills (Flat, Ball, Bull and Chamfer) Face mill
• Corner Rounding tools
• Slot Tools
• Spot-‐Center Drill
• Twist Drill
• Tap
• Reamer
• Counterbore
a. End Mill
There are many different sizes and tip angles of center, countersink, and combined drills. Be sure
the tip angle of the countersink matches the included angle of the machine screw, and that the drill
diameter is greater than the screw head diameter.
Twist Drill
Twist drills are available in many diameters and lengths. Usually made of high-speed steel, carbide,
or cobalt, they may also be coated with titanium nitride (TiN) for longer life. The tip angle of most
twist drills is 118 degrees. Other tools include taps, reaming tools and counter sinking tools.
Cutting Tool Fundamentals
All tools (except left-‐handed taps) rotate clockwise (M3) when viewed from the machine spindle
looking down at the part.
Chip Formation
Cutting tools remove metal by shearing action as illustrated in Figure 11 below. As the tool
advances into the material, it causes a small amount of the material to shear away, forming a chip.
The thickness of material sheared away by each cutting tooth is called the feed per tooth, or
chip load. As the chip is ejected from the work area it carries with it some of the heat generated
by the shearing process.
One of the best ways to validate cutting speeds and feeds is to observe the chips created
by the machining process. Chips should be curled and may change color due to heating.
Cutting Speeds and Feeds Formulas
The tool moves through the material at a specified rotational speed, defined in revolutions per
minute (RPM), and feed rate, defined in inches per minute (IPM).
CNC mills require calculating speeds and feeds in advance. These speeds and feeds can, and often
are, adjusted at the machine based on chip shape and color, cutting sound, and machine horsepower
meter readings.
Speed Formula
Milling machine cutting speeds are derived from the following formula
Where;
• Speed is the rotational frequency of the tool (Spindle Speed) in revolutions per minute
(RPM).
• SFM (Surface Feet per Minute) is the speed at which the material moves past the cutting
edge (outside diameter) of the tool in feet per minute. SFM values depend on the tool type,
tool material, and material being machined.
• Circumference is the circumference of the cutting tool in feet.
Because cutting tools are defined by their diameter in inches, the cutting speed formular can be
rewritten as:
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