Manual Numerical Control Programming (3 hours)-Prerequisites: ENTC 1110 &/or 2170 & ENTC 2200. A study of the capabilities, programming procedures, advantages, and disadvantages of numerical control (N/C) and computerized numerical control (CNC) metalworking machine tools. Manual methods for generating, debugging, and running point-to-point and continuous path programs including linear and circular interpolation, canned cycles, loops, and subroutines to produce work pieces of increasing complexity. Lecture and laboratory.

Overview

The primary focus of this course is on manual programming of numerical control (N/C) machine tools. Students learn what N/C machines are, what they can do, and how they do it. Beginning with the basic concepts of program structure, students learn how to write, edit, and debug N/C programs and use the programs on a N/C machine to produce a part. Programs become more complex as the semester progresses and require more sophisticated programming techniques. With the purchase of the AXYZ CNC Router, we now have CAM capability and will incorporate CADD-CAM program development into the curriculum.

As an outcome of successful completion of the course, the student should:

• Understand the nature, applications, advantages, and disadvantages of numerical control machine tools.
• Understand and follow safety-related procedures for part design and machine operation.
• Manually write, edit, debug, and use N/C programs to produce a piece part.
• Utilize canned cycles, loops, and subroutines.
• Set up, communicate with, and safely operate N/C machines.
• Select cutters, cutting and spindle speeds, and feedrates for both N/C mill and N/C lathe programs.
• Understand basic tooling and part holding requirements.

Required Texts:

• Stanton, George C. Numerical Control Programming. (Under construction)
  Available URL: http://faculty.etsu.edu/hemphill/entc3710/nc-prog/index.htm
• Stanton, George C. Bridgeport Heidenhain CNC Mill: Programming & Operating Instructions. (Available URL: http://faculty.etsu.edu/hemphill/entc3710/heid-op/heid.htm)
• Stanton, George C. Bridgeport Anilam Crusader II CNC Mill: Programming & Operating Instructions. (Available URL: http://faculty.etsu.edu/hemphill/entc3710/ani-mill/index.htm)
• Hemphill, W.K. & Stanton G.C (Ed.) (1997). Language Skills Handbook, (1^st On-line Ed), Johnson City, TN: East Tennessee State University.
  Available URL: http://www.etsu.edu/scitech/langskil

Recommended Texts:

• Valentino, J.V. & Goldenberg, J. (2003). Introduction to computer numerical control (CNC) (3rd Ed.). Upper Saddle River, NJ: Prentice Hall. ISBN: 0-13-094424-6 (Hardback)

Materials & Supplies:

• Access to a PC with:
  1. AutoCAD 2005 or equalivent CADD software application. (the AutoCAD 2005 student version is one option for at-home use. Other suitable and affordable CADD applications include TurboCAD, or Visual CADD.) Check for on-line downloads of limited-use (i.e., 30 day) evaluation versions.
  2. a Windows-based ASCII text editor—other than MS Notepad. Look for one that supports user-specified tab width setings. There are numerous text editors available through the Internet (e.g., JG Soft's Edit Pad Lite (free) or Edit Pad Pro ($40); TextPad ($31), etc.). Other inexensive text editors are available on-line through searchable shareware/freeware depositories such as Winfiles.com or CNet.
• Calculator with sine, cosine, tangent, reciprocal, and square root functions
  (Texas Instruments TI-35-II or equivalent).
• A pair of safety goggles or glasses (plastic lens) with side shields.
• Ear protection (e.g., plugs or earphones)
• A couple of PC-formatted 3½” floppies or a USB flash/jump/thumb drive (program backups).
• A package of inexpensive pointed felt-tip writing pens (assorted colors) for pen plots (available through Big Lots, WalMart, K-mart, etc.)

Attendance will be taken at some time during each class meeting. Your presence and participation is important. In-class writing assignments and/or group meeting days will not necessarily be announced prior to those class meeting(s). All major exams and term project assignments will be announced at least three calendar days prior to the test/due date.

Three or more unexcused absences may result in reducing your grade; i.e., an A becomes a A-, a A- becomes a B+, and so on. If you know you are going to be absent from class for an authorized University activity, please let the instructor know before hand. When unexpected problems arise, contact the instructor by phone or E-mail as soon as possible.

Students are responsible for the material covered in
all class sessions as well as all assignments.

ETSU Policy No. 3.13, October 1, 1979: Also Faculty Handbook Policy 5.7 - Full Text

"All students in attendance at East Tennessee State University are expected to be honorable.

"Academic misconduct will be subject to disciplinary action. Any act of dishonesty in academic work constitutes academic misconduct. This includes plagiarism, the changing or falsifying of any academic documents or materials, cheating, and the giving or receiving of unauthorized aid in tests, examinations, or other assigned school work. Penalties for academic misconduct will vary with the seriousness of the offense and may include, but are not limited to: a grade of F on the work in question, a grade of F for the course, reprimand, probation, suspension, and expulsion. For a second academic offense, the penalty is permanent expulsion."

Lab Work:

N/C programs either do what they are supposed to do or they don't. Only programs that do what they are supposed to do are acceptable. The lab grade will be based on (a) how well the lab assignment(s) are programmed and (b) the quality of the work submitted.

Each lab project MUST include:

• Setup instructions including

1. the names(s) of the programmer(s), filename, and date
2. a list of the cutting tools (description, dia., feed rates) in their order of use,
3. a graphic description of all tooling and fixturing required,
4. information regarding the material(s) to be machines (type, spec, & cutting speed)
5. Coordinate information (part origin, tool change and work piece change points)

• A commented source program explaining what each line of code is supposed to do.
• A pen plot and/or sample work piece.
• CADD drawing(s) of the part and tool path(s) (center line) if appropriate.

It is the student's responsibility to verify during the last week of the course that all lab work has been recorded in the instructor's record sheet.
Omissions discovered after the course ends will not be corrected.

Minimum Percentage Score for Grades

A test, exercise, or paper may be given (or submitted) early for a University sponsored absence (please provide suitable notice, if possible). Make-up tests may be given at the discretion of the instructor and only if a student presents suitable documentation (evidence) explaining the (emergency) absence to the instructor.

Quizzes and exams may include any material covered in the lectures,
assigned readings, videos, classroom discussions or exercises.

Students with documented needs for note taking, test taking, or other classroom accommodations should make arrangements with the instructor early in the term. Contact the ETSU Disability Services, Lower Level D.P. Culp Center (Seahorn Rd. entrance)
Voice: (423) 439-8346; Fax: (423) 439-8489; TDD: (423) 439-8370

Access to the Technology department's computer resources for CADD is extremely limited.  For generating the CNC code, it is suggested that you use the CIM computer lab in Wilson-Wallis Room 109 and transmit CNC files to the Machine Tool lab PCs using "sneaker net" (a.k.a floppy diskettes).

Communication with the CNC mill controllers uses an RS-232 serial interface currently connected to DOS-based machines. Accordingly, you should remember to limit file names to the old 8.3 filename.ext standard to ensure compatibility with newer operating systems (e.g., Windows 95, 98, NT, or 2000).

Special written permission must be secured if you desire to work in any of the Technology Department's computer labs. See your instructor for information.

For information on location and operating hours of other University computer labs, contact the Office of Information Technology at 439-4OIT (that's 439-4648) or their web site

Hours of operation of the University's library are posted at the library and in various handouts. For more information contact the Sherrod Library at 439-4337.

Food and drinks are never permitted in any of the University labs.  In certain lecture-type classrooms, food and beverages may be permitted by the instructor as long as the facilities are appropriately policed after use (i.e., clean up after yourselves). If you can afford the $55,000 cash replacement cost, feel free to place beverages on CNC equipment; otherwise, keep them the heck away.

The use of tobacco products (of any type) is completely prohibited in all University buildings including doorways.  Realizing that the solution to pollution is dilution, smoking is permitted in the great outdoors; however the University doesn't want you to litter, so park your butts in the cans, not in the grass.  To accomodate the addicted, ETSU has set up a designated smokers' "Level 4 Hot Zone" in the D. P. Culp Center for indoor consumption of fuming tobacco products.  For the orally inclined, leave your cups and bottles in your cars. It is recommended that you quit using all forms of tobacco products as soon as you can (i.e., before they kill you). You've been warned; don't play cute.