CNC Handbook. Helmut A. Roschiwal. Hans B. Kief. Translated by Jefferson B. Hood. Mc Graw Hill. Singapore Sydney Toronto

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1 Hans B. Kief Helmut A. Roschiwal CNC Handbook Translated by Jefferson B. Hood Mc Graw Hill New York Chicago San Francisco Lisbon London Madrid Mexico City Milan New Delhi San Juan Seoul Singapore Sydney Toronto

2 Preface ix Parti Introduction to CNCTechnology 1 1. Historical Development of Numerical Control Production Germany after World War II Rebuilding the German Machine Tool Industry Worldwide Changes Typical New NC Machines The Japanese Influence The Crisis in Germany Causes and Effects Flexible Manufacturing Systems Situation and Outlook Conclusions 8 2. Milestones in the Development of NC 9 3. What Are NC and CNC? The Path to NC Hardware Software Control Methods NC Axes PLCs Interface Section Computers and NC NC Programs and Programming Data Input Operation Important Points to Remember 27 Part 2 Functions of Numerical Control Systems 29 i. Implementation of Dimensional Data Introduction Axis Designations Closed-Loop Position Control Position Measurement Feed Drives Important Points to Remember 60

3 2. Implementation of Switching Information Tool Changing Automatic Workpiece Changing Changing the Speed Important Points to Remember Functions of Numerical Control Systems Definition Basic Functions of CNC Special Functions ofcnc CNC Displays Open-Ended Control Systems Price Considerations Advantages of the Latest Developments in CNC : 96 Important Points to Remember PLCs: Programmable Logic Controllers Definition Origins of the PLC Structure and Functions of PLCs Data Buses and Field Buses Advantages of PLCs PLC Programming and Documentation Programs Program Memory PLCs, CNC Systems, and PCs in Integrated Operation Selection Criteria for PLCs Important Points to Remember Effects of CNC on Machine Components Machine Configuration Machine Frames Guides Main Drives Machine Enclosures Coolant Supply Chip Removal Important Points to Remember 127 Part 3 Types of Numerically Controlled Machines Computer Numerical Control Machine Tools Machining Centers, Milling Machines 131

4 1.2 Turning Machines Grinding Machines Gear-Cutting Machines Drilling Machines Parallel Kinematic Machines Sawing Machines Laser Machining Systems Punching and Nibbling Machines Tube-Bending Machines Electrical-Discharge Machines Electron-Beam Machines Water-Jet Cutting Machines Development Trends in Numerically Controlled Machine Tools Measuring and Testing Important Points to Remember Additive Manufacturing Processes Introduction Definition Process Chain Classification of Additive Manufacturing Processes Introduction to the Principal-Layer Manufacturing Processes Important Points to Remember Flexible Manufacturing Systems Definition Flexible Manufacturing Islands Flexible Manufacturing Cells Technical Characteristics of Flexible Manufacturing Systems Application Criteria for Flexible Manufacturing Systems Manufacturing Principles Machine Selection and Layout Workpiece-Transport Systems CNC Systems Suitable for Flexible Manufacturing Host Computers in Flexible Manufacturing Systems Economic Advantages of Flexible Manufacturing Systems Problems and Risks in the Design of Flexible Manufacturing Systems Flexibility and Complexity Simulation of Flexible Manufacturing Systems Production Planning System (PPS) Important Points to Remember Industrial Robots and Handling Introduction 250

5 vi Contents 4.2 Definition: What Is an Industrial Robot? Structure of Industrial Robots Mechanical Elements/Kinematics Gripper or Effector Controllers Safe Robot Technology Programming Sensors Application Examples for Industrial Robots Application Criteria for Industrial Robots Comparison of Industrial Robots and CNC Machines and Outlook 266 Important Points to Remember 267 Part 4 Tooling Systems for Computer Numerical Control Machines Tooling Systems Introduction Tool Systems Tool Presetting In-House Tool Catalogs Tool Identification Tool Management Tool Measurement and Monitoring with Laser Systems Important Points to Remember Close-to-Process Production Measurement Technology in Combination with Mechatronic Tool Systems Introduction Parallel Measurement Technologies Close-to-Process Measurement in Idle Times Close to the Process with Bore Gauges Actuator-Driven Tool Systems Close the Control Circuit Mechatronic Tool Systems A Closed Process Chain Outlook Important Points to Remember 308 Part 5 Computer Numerical Control Programs and Programming 309 i. Computer Numerical Control Programs Definition Structure of NC Programs Program Structure, Syntax, and Semantics 314

6 vii 1.4 On/Off Commands (M-Functions) Dimensional Data Preparatory Functions (G-Functions) Cycles Zero Points and Reference Points Transformation Tool Compensation Important Points to Remember Programming of CNC Machines Definition ofnc Programming Programming Methods The NC Programmer Graphics to Make Work Easier Distributed Intelligence Selecting a Suitable Programming System Important Points to Remember CNC Programming Systems Introduction Machining Processes Are Undergoing Major Changes The Area of Application Sets the Priorities Input Data from Various Sources Capabilities ofmodern NC Programming Systems (CAM) Data Models with a Uniform High Standard CAM-Oriented Geometry Manipulation Only High-Performance Machining Strategies Count D Models Offer More Innovation with Feature Technology Automatic Object Detection Machining Database Tools Clamping Planning and Definition of the Sequence The Importance of Simulation Postprocessors Generated Data and Interfaces with the Machine Tools Important Points to Remember Manufacturing Simulation Introduction Qualitative Classification of Systems Components of a Simulation Scenario 364

7 viii Contents 4.4 Procedure for NC Simulations Fields of Application Important Points to Remember 373 Part 6 Integrating Computer Numerical Control Technology into In-House Information Technology Systems Direct Numerical Control or Distributed Numerical Control Definition Functions of DNC Application Criteria for DNC Systems Data Communication with CNC Systems Methods for Requesting Programs DNC Systems Currently Available Network Technology for DNC Advantages of Using Networks NC Program Management Advantages ofdnc Operation Cost-Effectiveness ofdnc Current State and Trends Important Points to Remember LANs-Local-Area Networks Introduction Local-Area Networks (LANs) What Is Information? Characteristics and Features oflans Gateways and Bridges Criteria for Selecting a Suitable LAN Interfaces Important Points to Remember Digital Product Development and Manufacturing: From CAD and CAM to PLM Introduction Terminology and History Digital Product Development Digital Manufacturing Important Points to Remember 419 Glossary 421 index 451

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