BY G.SHARATH CHANDR SRIKAR SOOGOOR VINEETH POSHALA P.
JITHENDER
(097Y1A0315) (097Y1A0344) (097Y1A0325) (097Y1A0337)
INTRODUCTION
Bharat Heavy Electricals Limited is the largest engineering
and manufacturing enterprise in India in the energy related / infrastructure sector today and ranks among the top twelve manufacturers of power equipment in the world.
Today BHEL has 14 Manufacturing Divisions, 4 Power
Sector regional Centers, 8 Service Centers 18 regional offices and large number of Project Sites spread all over India and abroad enables the Company to promptly serve its customers and provide them with suitable products , systems and services efficiently and at competitive prices.
Manufacturing Process
The benefits of civilization which we enjoy today are
essentially due to the improved quality of products available to us The improvement in the quality of the goods can be achieved with proper design that takes into consideration the functional requirement as well as its manufacturing aspects. This would ensure a better product being made available at an economical cost. Manufacturing involves turning raw material to finished products to be used for various purposes. In the present age there have been increasing demands on the product performance by way of desirable exotic properties
Manufacturing Processes are classified into four categorie: Casting Processes : Ex: Sand casting, die casting, centrifugal casting,
precision investment casting etc metal operations etc
Forming Processes : Ex: Rolling, press forging, wire drawing, sheet Fabrication Processes : It is a secondary manufacturing process. Ex:
Electric arc welding, gas welding, soldering, brazing etc
Material removal processes: It is also the secondary manufacturing
process. It is the expensive process. This process delivers good dimensional accuracy and surface finish. Ex : Turning, milling, drilling, grinding etc
Material removing process like
milling,turning,grinding,drilling etc are carried on cnc machines cnc machines are preffered for accurate job work with accurate dimensions Material is removed faster when compared with other machines Material removal rate is more when compared with other machines
DEVELOPMENT OF MACHINE TOOLS
GENERAL PURPOSE MACHINES (GPM) (CONVENTIONAL MACHINES)
SPECIAL PURPOSE MACHINES (AUTOMATICS)
(SPM)
NUMERICAL CONTROL MACHINES
COMPUTER NUMERICAL CNTROL MACHINES
Comparison of GPM / SPM / CNC : GPM - Completely manual
SPM - Built in automatic cycles / For mass
production / Changes are difficult CNC - Highly flexible / Suitable for batch production / Job production as Per production
COMPUTER NUMERICAL CONTROL OF MACHINE TOOLS
By controlling the relative movements between the tool
and the work piece geometrical shapes are machined. Control of these relative movements through coded letters numbers is known as Numerical Control of machine tools. In conventional machine operator directly controlling the machine functions. Where as in NC machine a separate media which is in between machine and operator is controlling the machine functions. These NC machines do not have any memory of their own and hence capable of only executing a simple block of information fed to it at a time.
BASIC COMPONENTS OF NC
Program of instructions
MCU
Machine tool
Program of instructions: The program instructions is the detailed step by step of directions which tell the machine tool, what to do.
Machine control unit: This consists of the electronics and hardware that read and interpret the program and convert it into mechanical actions of the machine tool.
Machine tool: It is the part of the NC system which performs the useful work.
OPERATING PRINCIPLE :
Conventional machine tool machine tool Operators brain = NC
NC controller
Hands
Eyes
=
=
DC servo drives
Feed back system
Special purpose machine tools :
Because of the CNC technology new types of machines are being made like machining centers which are predominantly made for prismatic components. Turning centers are being made for machining components which have more of turning operations but also having operations which call for milling, drilling and tapping. These machines are also called CNC lathes with driven tools or live tools. These machines have turret which has independent drive, programmable through CNC system and some of the tool positions can have tools which will rotate. Using these machines, the operations like slotting, key way milling, drilling and tapping can be completed after completing the turning operations. Similarly, the machining centers are equipped with CNC controlled facing and turning attachments to complete the turning operations in the prismatic components.
Adaptive controls
For machining operations, the term adaptive control denotes a control
system that measures certain output process variables and uses them to control the process. Some of the process variables that have been used in adoptive control are spindle deflection, torque, cutting temperature, Vibration, amplitude and horse power. The motivation for developing an adaptive machining system lies in trying to operate the process more efficiently. The typical measure of performance in machining have been removal rate cost per volume of metal removed. Benefits of adaptive control machining: 1. Increased production rates 2. Increased tool life 3. Greater part protection 4. Less operator intervention 5. Easier part programming
RESPONSIBILITIES OF CNC MACHINE OPERATOR WHILE EXECUTING THE JOB :
Job loading and setting as per the job layout Program entering manually/ through punched tape / through DNC
/ calling from memory Loading the required cutting tools into the turret / tool magazine as per the tools layout and entering the tool data into the memory Fixing the work zero with reference to the machine zero Verification of correctness of the program from graphic simulation if the system allows Machining the job in single mode as per the program. Dimensional inspection while machining and correction of tool offset if necessary. Replacement of inserts, cutting tools whenever required. Optimization of the program i.e. correction of feeds, speeds, idle movements etc
CNC machines offer the following advantages in manufacturing.
Higher flexibility. Increased machine utilization Reduced scrap rate. Reduced man power. Shorter cycle time. Higher accuracy. Automatic material handling. Lesser floor space. Increased operational safety. Machining of advanced material. Savings in jigs and fixtures
THANK YOU
