Development of control programs for a CNC machine. Programs for CNC machines - a complete set to get started

You can write control programs on a computer in a notepad, especially if you are good at mathematics and have a lot of free time. Or you can do it right on the machine, and let the whole workshop wait, and you don’t mind the extra workpiece. There is a third way of writing - a better one has not yet been invented.

A CNC machine processes a workpiece according to a G-code program. G code is a set standard commands, which support CNC machines. These commands contain information about where and at what speed to move the cutting tool to machine the part. The movement of the cutting tool is called a trajectory. The tool path in the control program consists of segments. These segments can be straight lines, circular arcs, or curves. The intersection points of such segments are called reference points. In the text control program The coordinates of the reference points are displayed.

Example program in G codes

There are three methods for programming CNC machines:

1. Manually.
2. On a machine, on a CNC rack.
3. In a CAM system.

Manually

For manual programming, the coordinates of reference points are calculated and the sequence of movement from one point to another is described. This can describe the machining of simple geometries, mainly for turning: bushings, rings, smooth stepped shafts.

Problems

Here are the problems encountered when a program is written on a machine manually:

- For a long time. How more lines code in the program, the higher the complexity of manufacturing a part, the higher the cost of this part. If the program contains more than 70 lines of code, then it is better to choose another programming method.

- Marriage. We need an extra blank for implementation to debug the control program and check for overcuts or undercuts.

- Equipment or tool failure. Errors in the text of the control program, in addition to defects, can also lead to breakdown of the machine spindle or tool.

Parts for which programs are written manually have a very high cost.

Rack-mounted CNC machine

On the CNC rack, the processing of the part is programmed online. The machine operator fills out a table with processing conditions. Indicates which geometry to process, width and depth of cut, approaches and departures, safe plane, cutting modes and other parameters that are individual for each type of processing. Based on this data, the CNC rack generates G commands for the tool path. This way you can program simple housing parts. To test the program, the machine operator starts the simulation mode on the CNC rack.

Problems

Here are the problems encountered when a program is written on a rack:

- Time. The machine does not work while the operator writes a program to process the part. Machine downtime means lost money. If the program contains more than 130 lines of code, then it is better to choose another programming method. Although, of course, it’s faster to write a program on a CNC machine than by hand.

- Marriage. The CNC machine does not compare the machining result to the 3D model of the part, so the CNC machine simulation does not show gouges or positive allowance. To debug the program, you need to lay down an extra workpiece.

- Not suitable for complex profile parts. It is not possible to program the processing of complex-profile parts on a CNC rack. Sometimes, for specific parts and standard sizes, manufacturers of CNC racks make special operations to order.

While the program is being created on the rack, the machine does not bring money to production.

In SprutCAM

SprutCAM is a CAM system. CAM is short for Computer-Aided Manufacturing. This is translated as “computer-assisted manufacturing.” A 3D model of a part or a 2D contour is loaded into SprutCAM, then the sequence for manufacturing the part is selected. SprutCAM calculates the trajectory of the cutting tool and displays it in G-codes for transmission to the machine. A post-processor is used to output the trajectory into G-code. Postprocessor translates internal teams SprutCAM for G-code commands for a CNC machine. It looks like
for translation from a foreign language.

The principle of operation in SprutCAM is presented in this video:

Advantages

Here are the advantages of working with SprutCAM:

- Fast. Reduces the time to create programs for CNC machines by 70%.

- Implementation without unnecessary workpieces. The program is checked before running on the machine.

- Rules out marriage. According to reviews from our users, SprutCAM reduces the occurrence of defects by 60%.

- Collision control. SprutCAM controls collisions with the part or working units of the machine, and incisions at rapid feed.

- Processing of complex-profile parts. In SprutCAM, for multi-axis operations, 13 strategies for moving the tool along the surface of the part and 9 strategies for controlling the tool axis are used. SprutCAM automatically controls the angle of inclination and calculates a safe processing path so that there is no collision of the holder or cutting tool with the workpiece.

Drawing up a control program for your CNC machine is possible in the full-featured version of SprutCAM. It needs to be downloaded and launched. After installation you will need to register. Immediately after registration, SprutCAM will start working.

For those who have just started trying, we provide a 30-day fully functional free version of the program!

SprutCAM has 15 configurations, including two special versions: SprutCAM Practitioner and SprutCAM Robot. To find out which configuration is suitable for your equipment and how much it costs, call 8-800-302-96-90 or write to info@site.

The control program for a CNC machine is a component of machine tools with numerical control. With its help, autonomous or semi-autonomous processing of workpieces is ensured. This component allows for high-quality and precise production of parts with complex shapes. Developing a control program requires special skills.

Purpose

The control program provides control over numerically controlled machines. without the need for constant monitoring. It is a set of commands that are sent to working equipment.

Using the commands:

• tools are moved;
• workpieces are moved;
• processing speed is controlled.

The program is written for specific workpieces. To create it you need to install it on your computer special program. The presence of such software will allow you to create control methods yourself if you have basic skills.

Software control can be discrete or contour. The first option is used for processing workpieces with simple forms. It allows you to perform basic functions. UE of the second type is designed for complex processing. It is most often used on turning and . Processing is carried out depending on the characteristics of a particular device. On their basis, specified functions are performed.

To create a process operation, you need to obtain information about:

• part surfaces;
• working tools;
• the amount of allowance;
• number of passes for each surface;
• cutting mode.

It is also necessary to remember in what position the tools were initially, and along what trajectory they will move. The trajectory definition is calculated based on the coordinates of the control points.

Using the control program you can perform:

• turning works;
• milling;
• grinding work.

The software can be used for several tasks at once.

You can download it on the Internet for free, or use paid applications. Paid applications may differ in the presence of additional features.

Creation

The methodology for creating a UE includes several stages. At the first stage of creating a control program, digital model products. After this, program analysis is carried out. With it, the model can be divided into points to develop a coordinate system. Tools and workpieces will move along it during work.

It is impossible to create a program without a three-dimensional model of the product. This task is performed by a specialist. Also, ready-made models can be downloaded on the Internet, but there is no guarantee that they will be suitable for the required job.

When producing programs for CNC machines, you can use automated programming systems, the most popular of which are:

• AutoCAD;
• NanoCAD;
• T-FlexCAD;
• ArtCam;
• SolidWorks.

Using software, you can change the characteristics of a future product. The more there will be collected information, the more accurate the processing will be. At the final stage, control commands are developed that will be combined into a file.

The file will be processed by the processor. Information from the file is read sequentially. Therefore, the commands are executed one after another. The program is easy to write on regular computer and connect it using a flash drive. Then it will be recorded in the memory of the computer that controls the machine, and will not need to be used. With the program itself, it will be possible to carry out serial development of parts.

The main component of control programs is G-code. It consists of numeric characters. Number system symbols can be different commands:

• technological;
• geometric;
• preparatory;
• auxiliary.

The first type is responsible for determining the working tool, processing speed, turning the device on and off. The second type determines and controls given coordinates. The third type allows the program to control the machine and also sets production modes. The latter type turns individual mechanisms on and off. A software engineer can understand the code.

When purchasing equipment, you should follow instructions that indicate how to correctly create numerical control and use Various types commands

Types of programs

When creating a program for machine tools, it is necessary to take into account a whole range of issues:

• at what speed the spindle can operate;
• at what speeds it can operate;
• what productivity is the machine capable of working with;
• how much the working tool can move;
• how many tools the machine can use.

Most questions are related to the characteristics of the machine. To determine the necessary data, it is enough to use the instructions that come with the equipment when purchasing it. Some controlled machines may have additional functions. They also need to be taken into account when programming, otherwise processing may not be carried out accurately. List additional functions also included in the instructions.

There are no universal programs for transmitting commands to the machine. The list of the most popular consists of programs for:

• development of three-dimensional models;
• quick viewing and editing of three-dimensional models;
• converting files from one format to another;
• creation and preview UP;
• performing tasks on the machine.

Control programs allow machine tools to produce complex products. Parts with complex shapes can be made of wood, metal, stone. Less commonly used materials can be processed on special machines.

Advantages

The control program helps to simplify manufacturing process several times. CNC machines do not require more than one, and work using a simple technique. UEs save time and increase processing accuracy.

They are used for:

• production of advertising banners;
• design of the premises;
• cutting and cutting sheet material;
• production of souvenirs.

With help modern applications A control program can be written by a person who has no education in programming. Thanks to the support of various operating systems, you can run the software on almost any computer device connected to a machine with a numerical control system. Flaw software applications consists of periodic occurrence of errors.

Types of errors

Errors occur most often when developing NC programs for processing parts with complex shapes. Most common cause is insufficient training of the operator-programmer. Therefore, management programs must be developed by trained employees.

There are three types of errors:

• hermetic;
• technological;
• perforation

The first type of errors occurs at the calculation stage. In most cases, they are associated with violation of the workpiece parameters, calculation of the coordinates of reference points, and determination of the position of the working tools of the machine tool.

Technological errors occur when the machine is being set up. Their reason lies in incorrectly set speed, processing parameters, and other commands specified for CNC equipment. The third type of error occurs in the perforated tape or punch.

Information about the order of processing of the product on the machine is entered frame by frame. FRAME is a part of a control program, entered and processed as a whole and containing at least one command.

In each block, only that part of the program is recorded that changes in relation to the previous block.

A frame consists of words that define the purpose of the data that follows them.

For example:

N3 - serial number frame

G02 - preparation function

(G01 - move in a straight line to the point

G02,G03 - circular interpolation clockwise or counterclockwise)

X - Coordinates of the end point of movement along the axes, Y - (for example, X+037540 (375.4mm)

Coordinates of the center of the arc during circular interpolation

F4 - feed code (for example, F0060 (60mm/min)) S2 - spindle speed code T2 - tool number

M2- auxiliary function(tool change, table change, cooling on, workpiece clamping...).

L3 - enter and cancel correction of geometric information.

LF - end of frame.

To create a program for moving the working parts of the machine, you need to associate a certain coordinate system with it. The Z axis is selected parallel to the axis of the main spindle of the machine, the X axis is always horizontal. When compiling a program, they use the concept of zero, starting and fixed points.

Preparation of the control program includes:

1.Analysis of the part drawing and selection of the workpiece.

Selecting a machine based on its technological capabilities (dimensions, interpolation capabilities, number of tools, etc.).

Development of a technological process for manufacturing a part, selection of cutting tools and cutting modes.

4.Selection of the coordinate system of the part and the starting point for the tool.

5.Choice of the method of fastening the workpiece on the machine.

Placement of reference points, construction and calculation of tool movement.

Encoding information

Recording a program on software, editing and debugging.

The use of CNC machines has significantly aggravated the problem of using humans in production environments. Doing all

actions to manufacture a part with a machine in automatic mode left the person with the most difficult and uncreative work of installing and removing workpieces. Therefore, simultaneously with the development of CNC machine tools, work was carried out to create systems capable of replacing a person when performing specific actions that require the use of “MANUAL” labor.

Milling machine and multi-operation machine (machining center) with numerical control

3.3 Industrial robots

An industrial robot (IR) is a mechanical manipulator with program control.

Manipulator - mechanical device, imitating or replacing the actions of human hands on an object of production.

Industrial robots are divided into technological (variable)

properties of the object) and transport.

The technological robot performs welding, the transport robot moves the workpieces to the processing area.

According to their carrying capacity they are divided into:

Object weight ultra-light up to 1 kg light 1 - 10 kg medium 10 -100 kg heavy 100-1000 kg super-heavy more than 1000 kg

Ultra-light robots assemble the device, while a heavy robot moves large workpieces.

PRs are also divided according to the number of degrees of freedom of the working body, according to the CNC system (closed and open, contour and positional, CNC, DNC, HNC).

Transport robot service area and workpiece movement path

Currently, transport robots are widely used to load technological equipment, deliver workpieces from the warehouse and transport parts to the warehouse. During stamping operations, transport robots feed blanks to the stamp and remove them.

Robots that weld car bodies and paint them are widely used. Robots are used in the assembly of electronic equipment, watches and other devices.

Together with technological equipment with CNC systems, industrial robots form the basis for comprehensive production automation.

Robots weld car bodies and install wooden panels on a machine for processing (examples of robot application)

Control questions:

1.Which CNC systems allow processing spherical surfaces on lathes?

2.Which CNC systems are advisable to use on drilling machines?

3.How many coordinates are interpolation possible when processing workpieces on lathes? - on milling machines?

4. How do cyclic program control systems differ from CNC systems?

5.What functions do industrial robots perform?

Sample test control card questions.

In what operations is it advisable to use CNC systems with contour control?

A). When turning stepped rollers.

B) . When milling double curvature surfaces.

IN). When machining holes in printed circuit boards.

What types of robots are used when painting complex-profile parts? A). Technological with contour control.

B). Large-sized with position control.

IN). Transport with contour control.

Any owner of a CNC machine faces the question of choosing software. Software used for this technological equipment, should be multifunctional and easy to use. It is advisable to purchase licensed software products. In this case, programs for CNC machines will not freeze, which will increase the efficiency of production processes.

Set of software for CNC machines

The choice of software largely depends on the type of equipment and the tasks that the user intends to solve. However, there are universal programs that can be used for almost all types of CNC machines. The most widely used products are:

1. . This software package was developed for the modeling and design of products manufactured on machine tools. It is equipped with the function of automatically generating models from flat drawings. The ArtCAM software package contains everything necessary tools for the design of creative products and the creation of complex spatial reliefs.
It is worth noting that this software allows you to use three-dimensional templates to create designs for future products from simple elements. In addition, the program allows the user to insert one relief into another, as in a two-dimensional drawing.

2. Universal program LinuxCNC control. Functional purpose This software is used to control the operation of a CNC machine, debug a part processing program, and much more.
A similar software package can be used for machining centers, milling and lathes, as well as thermal or laser cutting machines.
What makes this product different from others software packages is that its developers partially combined it with the operating system. Thanks to this, the LinuxCNC program has advanced functionality. You can download this product completely free of charge on the developer’s website. It is available both as an installation package and as a LifeCD.
The user interface of this software is intuitive and accessible. For the smooth functioning of the software, the computer’s hard drive must have at least 4 gigabytes. free memory. Detailed description LinuxCNC programs can be found freely available on the Internet.

3. . This software has a huge army of fans all over the world. The software is used to control milling, turning, engraving and other types of CNC machines. This software package can be installed on any computer with an operating system Windows system. The advantage of using this software is its affordable cost, regular updates, as well as the presence of a Russified version, which facilitates the use of the product by an operator who does not speak English.

4. Mach4. This latest development Artsoft company. Mach4 is considered the successor popular program Mach3. The program is considered one of the fastest. Her fundamental difference from previous versions is to have an interface that interacts with electronics. This is new software can work with large files at any time operating system. The user has access to a manual for using the Mach4 program in Russian.

5. MeshCAM. This is a package for creating control programs for CNC machines based on three-dimensional models and vector graphics. It is noteworthy that the user does not need to have extensive CNC programming experience to master this software. It is enough to have basic computer skills, as well as accurately set the parameters by which products will be processed on the machine.
MeshCAM is ideal for designing two-sided processing of any 3D models. In this mode, the user will be able to quickly process objects of any complexity on the machine.

6. SimplyCam. This is a compact and multifunctional system for creating, editing, saving drawings in DXF format. This software generates control programs and G-codes for CNC machines. They are created using mortar patterns. The user can create an image in one of graphics programs your computer and then upload it to SimplyCam. The program will optimize this drawing and convert it into a vector drawing. The user can also use a feature such as manual vectorization. In this case, the image is outlined standard tools, which are used in AutoCAD. SimplyCam creates toolpaths for CNC machining.

7. CutViewer. This program simulates material removal processing on two-axis CNC machines. With its help, the user can obtain visualization of processed workpieces and parts. The use of this software allows you to increase the productivity of the technological process, eliminate existing programming errors, and also reduce the time spent on debugging work. CutViewer is compatible with a wide range of modern machine tools. Its powerful tools allow you to detect serious errors in technological process and eliminate them in a timely manner.

8. CadStd. It's easy to use drawing program. It is used to create projects, diagrams and graphics of any complexity. Using the advanced toolset of this program, the user can create any vector drawings that can be used to design milling or plasma processing on CNC machines. The generated DXF files can then be loaded into CAM programs to generate correct part paths.

CAM (English) Computer-aided manufacturing) - preparation of the technological process for the production of products, focused on the use of computers. The term refers to both the process of computerized production preparation itself and the software and computing systems used by process engineers.

The Russian analogue of the term is ASTPP - an automated system for technological preparation of production. In fact, technological preparation comes down to automation of programming equipment with numerical control (2-axis laser machines), (3- and 5-axis milling machines with CNC; lathes, machining centers; automatic machines for longitudinal turning and turning and milling; jewelry and volumetric engraving).

CAM systems are very widespread. Examples of such systems are NX CAM, SprutCAM, ADEM.

NX CAM is a system for automated development of control programs for CNC (computer numerical control) machines from Siemens PLM Software.

Depending on the complexity of the part, turning, milling on machines with three to five controlled axes, turning and milling, and wire EDM are used. The system has all the capabilities to generate tool paths for the corresponding types of processing.

In addition, the system has a wide range of built-in automation tools - from wizards and templates to programming capabilities for processing standard structural elements.

The CNC program generator includes machining strategies designed to create programs with minimal engineer intervention.

The master model concept is the basis on which the distribution of data between the design module and other NX modules, including CAM modules, is built. The associative relationship between the original parametric model and the generated toolpath makes the process of updating the toolpath quick and easy.

In order for a program to be run on a specific machine, it must be converted into machine codes for that machine. This is done using a post processor. The NX system has a special module for setting up a postprocessor for any control racks and CNC machines. Basic settings are performed without the use of programming, however, it is possible to connect special procedures in the Tcl language, which opens up ample opportunities for making any necessary unique changes to the postprocessor.

NX CAM includes the following elements:

Turning;

3-axis milling;

High speed milling;

5-axis milling;

Programming multifunctional machines;

Electrical discharge machining;

Visualization of the processing process;

Automation of programming;

Expandable library of postprocessors;

Management of data related to processing;

Development of technological processes;

Creation of shop documentation;

Resource management;

Data exchange tools;

Simulation tools in the CAM environment.

The NX CAM program interface is shown in Figure 2.1

Figure 2.1 – NX CAM program interface

NX CAM provides enormous flexibility in machining methods and the broadest programming capabilities for CNC machines. The system has become widespread in industrial enterprises around the world.

Another example of CAM systems is SprutCAM.

SprutCAM - software for developing control programs for CNC equipment. The system supports the development of CP for multi-axis, electrical erosion and turning-milling equipment, taking into account a complete kinematic 3D model of all components as well.

The program allows you to create 3D diagrams of machines and all its components and perform preliminary virtual processing with kinematics control and 100% accuracy, which allows you to visually program complex multi-axis equipment. Currently, more than 45 schemes of various types of machine tools are available for free use.

SprutCAM is used in the metal, wood, and manufacturing industries; for electrical discharge, milling, turning, turning-milling, laser, plasma and gas processing; in the production of original products, stamps, molds, prototypes of products, machine parts, templates, as well as engraving of inscriptions and images.