Xyz Moving Drill Machine with 90*

7/29/2019 Xyz Moving Drill Machine with 90*

1/23

PROJECT TOPIC

Xyz moving drill machine

PERSONAL TRANSPORTER

SHRI RAM COLLEGE OF ENGINEERING AND MANAGEMENT

(AFFILIATED TO MAHARSHI DAYANAND UNIVERSITY, ROHTAK)

NH2, AURANGABAD (PALWAL), HARYANA.


2/23

CANDIDATE DECLARATION

We the students of Bachelor Of Technology in Mechanical discipline, Session: 200812, Facultyof Engineering and Technology(SRCEM); hereby declare that the work presented in this

dissertation entitled Segway- a Personal Transporter is the outcome of ourwork, is bonafide

and correct to the best of our knowledge and this work has been carried out taking care of

engineering ethics. The work presented does not infringe any patented work and has not been

submitted to any other university or anywhere else for the award of any degree or any

professional diploma.

Chirag Gupta (83009)

Mohit Chaudhary (83026)

Pawan Malik (83033)

Sachin Sharma (83041)

Vinod Chauhan (83053)


3/23

CERTIFICATE

This is to certify that Mr. Vinod Chauhan student of B.Tech (Mechanical) from SHRI RAM

COLLEGE OF ENGINEERING AND MANAGEMENT, Maharishi Dayanand University,

Rohtak, have completed his project as per partial fulfillment of the requirement for the award of

the Degree of Bachelor Of Engineering (ME) of M.D. University in a record of bonafied work

carried out under the guidance of Mr. Surender Kumar.

The project work entitled SEGWAY- A PERSONAL TRANSPORTER embodies the original

work done by him during his final year. He have successfully completed the project work up to

our full satisfaction. We wish him success in his future life.

Mr. Surender Kumar Dr. D.S. Sharma

Professor & Head of Department (Dean, Mech.)Mech. Department


4/23

ACKNOWLEDGMENT

I would like to express my gratitude to Mr. Surender Kumar (Professor & HOD), Department

Mechanical who was instrumental in the formulation of the project. I am very grateful to him for

his encouragement and dedication in making this project a successful one.

I express my sincere regards to other staff of the college for their constant support and

suggestions during the making of this project and for all the facilities provided.

I extend my thanks to all my friends and well wishers for their instant and efficient co-operation

whose efforts resulted in the timely development of the project. I also thank the technical staff of

the computer labs who provided the facilities required during development.

Finally I am indebted to my parents who have constantly provided us the opportunity and

support to rise to higher levels in life.

Vinod Chauhan (83053)

SemesterVIII

B.Tech. (Mechanical)

SRCEM,AURANGABAD(PALWAL)

Introduction


5/23

Congratulations! Your XYZ Bed Mill with the ProtoTRAK SMX CNC is an

excellent tool room machine. It features an easy-to-use interface and dozens of

features that maximize machinists productivity for any kind of toolroom job.

Manual machining is always available and made easier with features like power

feed, rapid positioning, tool offsets and all the best features of sophisticated

DROs. Two-axis machining is available at the touch of a button for prototyping

and moderately complex, low volume work.

Three-axis machining is programmed and run with unprecedented flexibility.

Programs may be entered at the control or imported from CAD/CAM files.

Advanced color graphics show program features.

The ProtoTRAK SMX CNC allows you to chose the CNC configuration that is

right for you. The base system is a powerful CNC for toolroom work. You may

add options for additional features and capabilities.

This manual will describe the operation of all basic and optional features in the

appropriate context. Where optional features are discussed, a note will explain in

which option the particular feature is found.

1.1 Manual Organization

Section 2 of this manual provides important safety information. It is highly

recommended that all operators of this product review this safety information.

Section 3 provides a description of the XYZ Bed Mill and the ProtoTRAK SMX

CNC.

Machine Control Options are described in this section.

Section 4 describes the operation of the milling machine and some basic operations

of

the ProtoTRAK SMX CNC.

Section 5 defines some terms and concepts useful in learning to program and

operate


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the ProtoTRAK SMX CNC.

The ProtoTRAK SMX CNC is organized into six Modes of operation that are

described in the following sections.

Section 6 DRO: Digital Readout, jog, and powerfeed operations.

Section 7 Programming, Part 1: covers some general programming information and

instructions on starting new programs.

Section 8 Programming, Part 2: Program Events - instructions for the canned

cycles, or events, used to program the ProtoTRAK SMX CNC.

Section 9 Programming, Part 3: the A.G.E., or Auto Geometry Engine, so powerful

it

gets its own section. Section 10 Edit: for routines to make large-scale changes to

programs in current

memory, including the powerful Spreadsheet Editing

Section 11 Set-Up: Tool information, part graphics and special codes.

Section 12 Run: Instructions on running a program to machine your part.

Section 13 and 14 Program In/Out: Storing and managing your programs.

Section 15: Sample programs for practice.

EVENT 1 Bolt Hole NOTEScenter drill

DRILL O R BORE

# OF HOLES

X CENTER

Y CENTER

Z RAPID

Z END

RADIUS

ANGLE

# OF PECKS FOR DRILL


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Z FEEDRATE

TOOL #

1

5 ABS SET

0 ABS SET

0 ABS SET

3 ABS SET

-3 ABS SET

33 SET

45 SET

1 SET

125 SET

1 SET

Drill Function

Known print value

Use the center as the reference

Sets the rapid to 3mm above the part

Sets the drill depth to -1

The radius of the bolt hole circle

Angle of first hole from zero (0) degrees

Sets 1 peck

Sets Z plunge rate to 125 mmpm

Selects Tool # 1 as the Center drill

145

XYZ Machine Tools Ltd.

XYZ Bed Mills and ProtoTRAK SMX CNC Safety, Programming, Operating &

Care Manual


8/23

EVENT 2 Bolt Hole NOTESdrill to final size

DRILL OR BORE

# OF HOLES

X CENTER

Y CENTER

Z RAPID

Z END

RADIUS

ANGLE

# OF PECKS FOR DRILL

Z FEEDRATE

TOOL #

1 SET

5 ABS SET

0 ABS SET

0 ABS SET

3 ABS SET

-9 ABS SET

33 SET

45 SET

3 SET

125 SET

2 SET

Drill Function

Known print value

Use the center as the reference

Sets the rapid to 3mm above the part


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Sets the drill depth to9 (through)

The radius of the bolt hole circle

Angle of first hole from zero (0) degrees

Sets 3 peck

Sets Z plunge rate to 125 mmpm

Selects Tool # 2 as the M7 drill

EVENT 3 CIRC PCKT NOTES

X CENTER

Y CENTER

Z RAPID

Z END

RADIUS

DIRECTION

# OF PASSES

ENTRY MODE

FIN CUT

Z FEEDRATE

XYZ FEEDRATE

FIN FEEDRATE

TOOL #

0 ABS SET

0 ABS SET

3 ABS SET

-5 ABS SET

19 SET

2 SET

2 SET


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1 SET

.25 SET

100 SET

250 SET

200 S ET

3 SET

Sets the pocket center to X zero

Sets the pocket center to Y zero

Sets the Rapid

Sets the pocket depth

Sets radius of pocket

Makes the cut direction CCW

Cuts the pocket using two (2) depths

Selects tool ramp into the material

Sets finish cut for the wall of the pocket

Sets the ramp feedrate in mmpm

Sets the pocket cutting feedrate

Sets the finish pocket feedrate.

Sets mill tool #

EVENT 4 RECTANGULAR

PROFILE

NOTESselect PROFILE and then

IRREG PROFILE

X1

Y1

X3

Y3


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Z RAPID

Z END

CONRAD

DIRECTION

TOOL OFFSET

# PASSES

FIN CUT

Z FEEDRATE

XYZ FEEDRATE

FIN FEEDRATE

TOOL #

-50 ABS SET

-50 ABS SET

50 ABS SET

50 ABS SET

3 ABS SET

-7.5 ABS SET

0 SET

1 SET

2 SET

2 SET

.25 SET

100 SET

250 SET

INC SET

3 SET

Start at lower left corner


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Through the p late

Sets tool offset LEFT

Machined at 2 depths

No change of federate

Intro to CNC Machining

CNC stands for computer numeric controlled. It refers to any machine tool

(i.e. mill, lathe, drill press, etc.) which uses a computer to electronically control the

motion of one or more axes on the machine.


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The development of NC machine tools started from a task supported by the

US Air Force in the early 1950s, involving MIT and several machine-tool

manufacturing companies. The need was recognized for machines to be able to

manufacture complex jet aircraft parts.

As computer technology evolved, computers replaced the more inflexible

controllers found on the NC machines; hence the dawn of the CNC era.

CNC machine tools use software programs to provide the instructions

necessary to control the axis motions, spindle speeds, tool changes and so on.

CNC machine tools allow multiple axes of motion simultaneously, resulting

in 2D and 3D contouring ability.

CNC technology also increases productivity and quality control by allowing

multiple parts to be produced using the same program and tooling.


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Basics of CNC Programming

There are two ways to program modern CNC machine tools.

1. Conversational Programming. This is the simpler of the two methods. In effect,this is a macro programming language used to instruct the machine to perform

pre-programmed cycles (i.e. facing, drilling holes in arrays, etc.). When writing

a conversational program, you simply enter the appropriate parameters

associated with each machining cycle. This is analogous to using the polar array

function in SolidWorks or Pro/E; you dont have to do the layout or trig to find

the location of the features; you just specify the essential parameters and the

software does the rest for you.

1. CAM Programming. This is the more powerful of the two methods. Using thismethod, you import your part model into a CAM (computer aided

manufacturing) program and define the parameters associated with each and

every machined feature on the part. These parameters include tool diameter and

length, depth of cut, tool path geometry, etc.


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Conversational CNC Programming

The following cycles are typical of the machining operations available when

programming a 3-axis CNC milling machine.

Position. Used to move the XYZ coordinates at rapid feedrate.

Drill_one. Used to position the tool at a specific XYZ coordinate position in order

to automatically drill a hole. The automatic drill cycles allow for simple drilling,

peck drilling, spot-facing and bore cycles.

Drill_pattern. Used to define polar or rectangular hole arrays for automatic drilling.

Line. Used to cut straight lines along an axis or a diagonal at the desired feedrate.

Arc. Used to cut a circle or partial circle that is part of a series of cuts that usually

includes lines as well.

Face. Used to define a rectangular zig-zag pattern used to clean off a part surface.

Pocket. Used to clear the material out of a rectangle, circle or polygon.

Frame. Used to cut the inside or outside outline of a rectangle, circle or polygon.

Tool. Used to enter tool parameters, machine function parameters and program

pause/stop codes.

Scale/mirror. Used to scale and/or mirror other part features.

Rotate. Used to repeat other part features around a specific center of rotation.


16/23

Conversational CNC Programming Example #1

Drill Pattern Bolt Circle Variables (G121):

X = X center

Y = Y center

R = Radius

A = Start angle (absolute)

N = # of holes

H = # of holes to drill


17/23

Conversational CNC Programming Example #2

Arcs and Lines (dashed line is tool path for 1/8 diameter endmill)


18/23

Conversational CNC Programming Example #2 (cont)


19/23

Below is the actual tool path code for the previous example. After the user enters

the basic parameters, this is the program that is generated by the conversational

interface to run on the CNC.

An analogy to software programming is that conversational programming is

similar to programming using a compiler (ie C, Fortran, VB, etc.) and the actual

tool path code generated is equivalent to the final compiled machine code or

instructions.

G90 G0 X0 Y-0.75 Z1 F5 [G90=absolute; G0=rapid; F=XY feed]

Z0 M3 [M3=spindle on, CW]

G1 Z-0.1 E2 [G1=linear motion; E=Z feedrate]

Y-0.5625

G2 J0.5625 X0 Y0.5625 [G2=CW circular motion]

G1 X0.6507 [G1=linear motion]

X1.5625 Y0.03608

Y-0.3

G2 I-0.2625 X1.3 Y-0.5625 [G2=CW circular motion]

G1 X0 [G1=linear motion]

G0 Y-0.75 Z1 [G0=rapid]

M30 [M30=end of program/rewind]


20/23

CNC CAM Programming

Once the part has been designed using conventional mechanical design methods

(structural analysis, FEA, fatigue study, etc.), the part is manufactured using the

following method.

1. Create a solid 3D model of the part to be produced. Any standard CAD formatis acceptable.

1. Import the solid model into the CAM (computer aided manufacturing)software. (this demonstration uses MasterCAM)

1. Input the raw material stock size and set theparts coordinate origin.

1. Input the necessary information for each tool used in machining the partfeatures. Typically, a tool library will exist, which is simply a database of tools

and their related parameters.

1. For each part feature, select the appropriate tool from the library and set theparameters necessary for machining that feature. Typical parameters include

spindle speed, depth of cut, feedrate, number of passes, tool path pattern, etc.

1. Verify the programmed tool path(s) by running the CAM softwares virtualmachining cycle.


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22/23

Final Facts about CNC Machining

CNC manufacturing offers advantages on two types of parts: (1) simple parts

that are mass produced and/or (2) complex parts with features requiring multiple

axes of simultaneous motion. For simple parts in low quantity, it is often quicker to

produce the parts on manual machines (as in lab).

CNC does not inherently imply increased part accuracy. An old CNC with a

lot of hours of use will produce less accurate features than a new quality manual

machine and vise-versa; so dont automatically associate higher accuracy with

CNC machines. (Accuracy has more to do with machine design, component

selection and mechanical wear.)


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Modern CNC machines offer increased productivity due to stiffer machineand spindle designs, more powerful motors, high pressure coolant (up to 1000 psi)

that floods the cutting zone, automatic tool changers, digital workpiece and tool

probing, and/or horizontally mounted spindles.

Downsides to CNC machines are higher initial cost, larger space and

electrical requirements, increased maintenance cost, required programming skillset

and their inherent complexity means theres a higher probably of component

failure during the useful lifespan.

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Xyz Moving Drill Machine with 90*