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Computer Aided Manufacturing (CAM): The Complete Introduction for the Beginner'southward Listen
In a world full of physical stuff – whether that's products, parts, or places – Computer Aided Manufacturing (CAM) makes it all possible. Nosotros're the ones that give the power of flight to airplanes or the rumble of horsepower to automobiles. When y'all need something made, non just designed, CAM is your answer. What happens behind the scenes? Keep reading, and you'll detect out.
What is CAM? Calculator Aided Manufacturing (CAM) is the use of software and computer-controlled mechanism to automate a manufacturing process.
Based on that definition, you need three components for a CAM system to function:
- Software that tells a machine how to make a production by generating toolpaths.
- Mechanism that can turn raw textile into a finished product.
- Post Processing converts toolpaths into a language machines can empathise.
These three components are glued together with tons of man labor and skill. As an industry, we've spent years building and refining the all-time manufacturing machinery around. Today, there's no design as well tough for any capable machinist shop to handle.
CAD to CAM Procedure
Without CAM, there is no CAD. CAD focuses on the blueprint of a product or part. How it looks, how it functions. CAM focuses on how to go far. You can blueprint the most elegant part in your CAD tool, but if you can't efficiently make it with a CAM system, so you're meliorate off kicking rocks.
The start of every technology process begins in the world of CAD. Engineers will make either a second or 3D drawing, whether that'southward a crankshaft for an auto, the inner skeleton of a kitchen faucet, or the subconscious electronics in a excursion board. In CAD, any pattern is chosen a model and contains a set of physical properties that volition exist used by a CAM system.
When a blueprint is complete in CAD, it can then be loaded into CAM. This is traditionally done by exporting a CAD file and then importing information technology into CAM software. If you're using a tool like Fusion 360, both CAD and CAM be in the same world, so there's no import/export required.
Once your CAD model is imported into CAM, the software starts preparing the model for machining. Machining is the controlled procedure of transforming raw fabric into a defined shape through actions like cut, drilling, or boring.
Computer Aided Manfacturing software prepares a model for machining by working through several actions, including:
- Checking if the model has whatever geometry errors that will impact the manufacturing process.
- Creating a toolpath for the model, a set of coordinates the machine will follow during the machining process.
- Setting whatever required machine parameters, including cutting speed, voltage, cutting/pierce tiptop, etc.
- Configuring nesting where the CAM system will decide the best orientation for a part to maximize machining efficiency.
In one case the model is prepared for machining, all data gets sent to a machine to produce the part physically. However, we can't only give a auto a bunch of instructions in English. Nosotros need to speak the car's linguistic communication. To do this, we convert all of our machining information to a language called G-code. This is the set of instructions that controls a machine's actions, including speed, feed rate, coolants, etc.
Chiliad-code is easy to read in one case y'all understand the format. An instance looks similar this:
G01 X1 Y1 F20 T01 S500
This breaks down from left to right as:
- G01 indicates a linear move based on coordinates X1 and Y1.
- F20 sets a feed rate, which is the distance the machine travels in i spindle revolution.
- T01 tells the motorcar to utilize Tool 1, and S500 sets the spindle speed.
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- A more than visual way to understand Grand-lawmaking coordinates. Image courtesy of Make:.
Once the G-code is loaded into the machine, and an operator hits outset, our job is done. Now it's fourth dimension to let the auto do the task of executing G-code to transform a raw material block into a finished production.
CNC Machines at a Glance
Upwardly until this point, nosotros've talked about the mechanism in a CAM system equally simply machines, but that really doesn't exercise them justice. Watching a Haas milling machine slide through a block of metal similar it'due south butter puts a smile on my confront every time. Without these machines, my job would exist incommunicable.
All mod manufacturing centers volition be running diverse Figurer Numerical Control (CNC) machines to produce engineered parts. The process of programming a CNC machine to perform specific actions is called CNC machining.
Before CNC machines came to be, manufacturing centers were operated manually by Machinist veterans. Of course, like all things that computers touch, automation presently followed. These days the simply homo intervention required for running a CNC car is loading a program, inserting raw textile, and so unloading a finished product.
Over at the Autodesk Pier ix workshop, nosotros accept a decent sample of CNC machines, including:
CNC Routers
These machines cut parts and carve out a variety of shapes with high-speed spinning components. For case, a CNC router used for woodworking can make easy piece of work of cutting plywood into cabinet parts. It tin also easily tackle complex decorative engraving on a door console. CNC routers have 3-axis cutting capabilities, which allows them to motility along the Ten, Y, and Z axes.
Water, Plasma & Laser Cutters
These machines employ precise lasers, high-pressure level h2o, or a plasma torch to perform a controlled cut or engraved cease. Manual engraving techniques can take months to consummate by manus, only 1 of these machines tin can complete the aforementioned piece of work in hours or days. Plasma cutters are handy for cutting through electrically conductive materials similar metals.
Milling Machines
These machines scrap away at a variety of materials like metal, wood, composites, etc. Milling machines accept enormous versatility with a variety of tools that can accomplish specific material and shape requirements. A milling machine'south overall goal is to remove mass from a raw block of material as efficiently as possible.
Lathes
These machines also chip away at raw materials like a milling motorcar. They do it differently. A milling machine has a spinning tool and stationary fabric, where a lathe spins the textile and cuts with a stationary tool.
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- Image courtesy of Halsey Manufacturing.
Electrical Discharge Machines (EDM)
These machines cut the desired shape out of raw textile through an electrical discharge. An electrical spark is created betwixt an electrode and raw textile, with the spark's temperature reaching eight,000 to 12,000 degrees Celsius. This allows an EDM to melt through nearly anything in a controlled and ultra-precise procedure.
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- Image courtesy of Absolute Wire EDM.
The Human being Chemical element of Reckoner Aided Manufacturing (CAM)
The homo element has e'er been a touchy subject since CAM arrived on the scene in the 1990s. In the 1950s, when John T. Parsons first introduced CNC machining, skillfully operating machines required an enormous amount of training and practice. The video below from NYC CNC shows a groovy case of how unlike manual machines are from today'south CNC machines:
In transmission machining days, being a Machinist was a bluecoat of honour that took years of training to perfect. A Machinist had to do it all — read blueprints, know which tools to apply, ascertain feeds and speeds for specific materials, and carefully cutting a part by hand. It wasn't just about precise transmission dexterity. Being a Machinist was, and withal is, both an art and a scientific discipline.
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- Image courtesy of ITABC.CA
These days, the Modern Machinist is alive and well as human, automobile, and software combine to movement our industry forward. Skills that used to take twoscore years to master can now be conquered in a fraction of the time. New machines and CAM software have given us more than control than ever to pattern and make better and more innovative products than our forefathers, which they'll admit…begrudgingly.
What does all this hateful for the human chemical element of manufacturing? The role of a Traditional Machinist is shifting. Today we're seeing an environment of Mod Machinists played out with three typical roles:
- The Operator. This individual loads raw materials into a CNC auto and runs completed parts through the final packaging process.
- The Setup Operator. This individual performs the initial configuration for a CNC auto, including loading a G-code program and setting up tools.
- The Developer. This individual takes the drawing for a CAD model and decides how to make it with their available CNC machines. Their job is to define the toolpaths, tools, speeds and feeds in the G-lawmaking to get the task done.
In a typical workflow, the Developer will manus off his program to the Setup Operator, who will and so load the G-code into the car. In one case the auto is set up to gyre, the Operator will and then brand the function. In some shops, these roles might combine and overlap into the responsibilities of one or two people.
Outside of day-to-day machine operations, there is also the Manufacturing Engineer on staff. In a new shop setup, this private typically establishes systems and determines an platonic manufacturing process. For existing setups, a Manufacturing Engineer will monitor equipment and product quality while treatment other managerial tasks.
The Bear upon of CAM
We have John T. Parsons to give thanks for introducing a punch card method to program and automate mechanism. In 1949 the The states Air Forcefulness funded Parsons to build an automated motorcar that could outperform manual NC machines. With some help from MIT, Parsons was able to develop the first NC prototype.
From there, the world of CNC machining started to take off. In the 1950s, the United States Army bought NC machines and loaned them out to manufacturers. The idea was to incentivize companies to adopt the new engineering science into their manufacturing process. During this time, nosotros also saw MIT develop the first universal programming language for CNC machines: G-code.
The 1990s brought CAD and CAM's introduction to the PC and has completely revolutionized how nosotros approach manufacturing today. The earliest CAD and CAM jobs were reserved for expensive automotive and aerospace applications, but today software like Fusion 360 is available for manufacturing shops of any shape and size.
Since its inception, CAM has delivered a ton of improvements to the manufacturing process, including:
- Improved auto capabilities. CAM systems can take reward of advanced 5-axis machinery to deliver more sophisticated and higher quality parts.
- Improved machine efficiency. Today's CAM software provides loftier-speed machine tool paths that assist usa manufacture parts faster than e'er.
- Improved fabric usage. With condiment machinery and CAM systems, we can produce circuitous geometries with minimal waste product, which means lower costs.
Of grade, these benefits take some trade-offs. Computer Aided Manufacturing systems and machinery require a massive upfront price. For example, a Haas VF-1 costs about $45k out the door; now imagine an entire shop floor of those. There'due south also the problem of turnover. With car operation becoming less of a skilled trade, it's tough to attract and retain good talent.
CAM is the Human being
CAM isn't simply well-nigh controlling machines on a shop flooring. It's nigh bringing together software, machines, processes, and people to build really great parts. If this is your first fourth dimension diving into the globe of CAM, I highly encourage you to reach out to a local store to become an inside tour. Feel the hum of the CNC machines in your feet, or slide your manus across a office fresh out of the car. It's an incredible experience that I hope future generations get to enjoy. CAM is all virtually the human affect.
Are you yet dinking effectually with a split CAD and CAM tool? Fusion 360 has both. Try Fusion 360 today.
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Source: https://www.autodesk.com/products/fusion-360/blog/computer-aided-manufacturing-beginners/