Project On Most2d

(GOVT. OF INDIA UNDERTAKING) BOILER AUXILIARIES PLANT RANIPET

A PROJECT REPORT On

MOST2D

Submitted by RAMANAND KUMAR (staff no: 4174933) SUPERVISOR TRAINEE (OP&C)

SIGNATURE (HRDC CO-ORDINATION)

SIGNATURE (CONTROLLING OFFICER)

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CONTENTS • • • • •

introduction Nesting module Make item drawing Nesting – make nesting layouts Cutting – make tool path & CNC codes

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MOST 2D (NESTING & CUTTING MODULE)

MOST 2D :- professional offers a complete solution for generating nested layout as well as cnc codes for oxyfuel, plasma, laser and waterjet cutting machine.

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NESTING MODULE •

Automatic nesting of multiple parts and sheets, including offcut nesting.

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Manual nesting using add / delete / rotate / move / mirror / slide commands.

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Build option to combine automatic & manual nesting for progressive improvement.

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Real time error checking during manual nesting.

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Automatic as well as manual leadin – leadout generation.

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Automatic as well as editable sequencing for each cutting cycle.

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Automatic as well as editable travel direction for each cutting cycle.

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Automatic, semi – automatic as well as manual offcut generation.

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Statistical as well as graphical report generation.

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Multipurpose scrap cutting cutting contours.

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Multiple torch cutting for greater productivity.

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Common edge cutting for saving time, material and resources.

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Corner loop generation for superior finish at corners.

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Linking and chain cutting to reduce the number of piercing operation.

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Rapid motion bypass for avoiding tool collision with other parts.

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Bevel cutting.

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User defined database for storing cutting parameters for each material & thickness.

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Cnc code generation for all the popular cnc controllers / machines.

STEP1 – CAD – MAKE ITEM DRAWING

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take care of the following points while generating the drawing of an item.

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A.1.a Each item drawing must be saved in an item drawing file, having the extension MDF. A.1.b Each MDF file must contain the drawing of one item only. A.1.c Each item drawing must contain exactly one outermost profile i.e. main boundary. A.1.d An item drawing can also contain inner profiles i.e. holes. A.1.e Each profile should consist of a chain of following 3 types of entities. I.

Straight line

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Circular arc

III.

Circle

A.1.f All the entities should be connected at their endpoints to form close profiles.

A-2. specify all the default options once you have installed the software. (normally, this is a onetime activity.) A.2.a the default unit of linear measurement is MM. if you want to work with to work with INCH, please select the command tools => units and specify the unit of measurement as INCH. A.2.b specify the length of leadin / leadout as well as other default option using the command tools => options.

A-3

create an item drawing.

A.3.a If the item drawing has already been saved as a dxf / dwg / dstv / …other card / cam file, execute step B - 4. A.3.b For creating a new item drawing, launch ITEM.

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A.3.c Press F-10 key to see different types of standard shapes which can be defined using ITEM. Press up and down arrow keys on the keyboard to view their sketches in the dialog box that appears on the screen. If it is possible to define the item as a parametric shape, type the parameters (P1,P2,etc.) as per the sketch, which appears in the dialog box, select the ok button, and proceed to the next step. However, if it is not possible to define the item drawing as a standard shape, you can create the item drawing using other commands under the menus insert / draw / modify and proceed to the next step. Alternatively, you can also generate the item drawing using another cad software, save the drawing as a dxf / dwg file and jump directly to step B-4. A.3.d select the command view => zoom out to see the complete item drawing. A.3.e select the command insert => automatic leadin – leadout to add leadin / leadout. (if necessary, set the length of leadin / leadout using the command tools =>options, before executing this step.) A.3.f select the command tool => validate to check the item drawing. A.3.g select the commands file => save to save the drawing in an MDF file.(control+s)

A - 4 convert a drawing file generated from another cad / cam software into an MDF file. A.4.a launch ITEM. A.4.b select the command file => convert from another cad / cam software into an MDF file. A.4.b select the command file => convert to view the file conversion dialog box. specify the input – drawing format. Next, if the input drawing is created in INCH units, please ensure that the scale factor appears as 25.4 , instead of 1, in the file conversion dialog . specify suitable tolerance distance for joining adjacent entities.

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Select the crossover correction as well as overlap correction options, only if necessary. After specifying all the options, select the ok button in order to exit from the file conversion dialog box. A.4.c in the next dialog box that appears on the screen, select one or more input drawing files, which you would like to convert. (you can select multiple files by keeping the control key pressed, while selecting the drawing files from the dialog box.) select the ok button after selecting all the input files for conversion. A.4.d ITEM will convert all the selected drawing files to MDF files and save them in the same folder. For example, if you convert c:/abc/p1.dwg using this procedure, you will find 2 files viz. p1.dwg and p1.mdf under the folder c:/abc after conversion. A.4.e Add leadin / leadout and other details to each item drawing one by one, as shown below. •

Select the command file => open to open an MDF file in ITEM.(control + O)

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Execute steps A.3.d to A.3.g.

A-5

define process data.

A.5.a You can identify for marking, cutting and other application / process in ITEM. To do so, first select the candidate profile (or , profiles ) using the mouse. Next, select the candidate profile using the mouse. Next, select the command modify => properties. Then, specify the type and other attributes of the selected profile in the dialog box that appears on your screen. After specifying all the options, select the ok button in the dialog box. (by default, all profiles are identified as cutting profiles. You can use this command in order to identify marking profiles, in the dialog box. (by default, all profiles

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are identified as cutting profiles. You can use this command in order to identify marking profiles, open cuts and punches.) A.5.b you can also attach additional cutting data with each input profile, if necessary. For example, you can define bevel cutting data, stitches, corner loops as well as hole cutting sequence (in case the part drawing has large number of holes) using different commands under cut menu. For more information regarding their usage, please refer to the on- line help associated with ITEM.

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NESTING - MAKE NESTED LAYOUTS

B –1 specify all the default options / settings, after installing the software. B.1.a the default unit of linear measurement is MM. if you want to work with INCH, please select the command job => unit and specify the unit of measurement as INCH. B.1.b specify all the relevant global options (like, default folder locations) using the command job => options.

B – 2 define a new input job nesting. B.2.a launch MOST. B.2.b select the command file => new to start a new job in most. (control + N) B.2.c select the cutting device and then, the ok button in the new job dialog box.

B – 3 define constraints i.e. cutting parameters for the job. (this step is not required if you use material engineer.) B.3.a select the command job => constraints.(F-10) B.3.b specify tool size (kerf) as well as clearance limit (additional distance between parts, after leaving 2 * kerf distance) in the constraints dialog box. Also specify the default leadin / leadout length, ifyou may want to edit leadin / leadout after nesting. Select the ok button in the constraints dialog box after specifying all the cutting parameters.

B – 4 define the stock list i.e. the inventory of fresh and offcut stocks, which is available for nesting.

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B.4.a select the commands job => stock list .(F- 11) B.4.b if you want to add a fresh rectangular stock to the stock list, execute the following steps. •

Select add fresh stock button in the stock list dialog box.

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Type the stock dimensions and select the ok button in the dialog box that appears on the screen.

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Type stock name (say, “fresh stock 1’’) and select the ok button in the dialog box that appears on the screen.

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Type stock properties using the options shown in stock properties dialog box and select the ok button. (important properties are : general => total quantity, physical => material & physical => thickness.)

B.4.c if you want to add an offcut (remnant) stock to the stock list, execute the following steps. •

Select add used stock button in the stock list dialog box.

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Select the offcut drawing drawing file (i.e. the file in which the drawing of the offcut stock has been saved ) from the file selection dialog box and select the ok button.

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Specify the stock name and stock name and stock properties, as explained in step C.4.b.

B.4.d if you want to change the properties of an existing stock, select the stock with the mouse and click on the properties button in the stock list dialog box.id you want to remove an existing stock from the stock list, select the stock with the mouse and click on the remove button in the stock list dialog box.

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B.4.e select the close button in the stock list dialog box, after making all the modification in the stock list.

B – 5 define the shape list i.e. bill of materials, containing the list of all the parts, which have to be nested. B.5.a select the command job => shape list. (F-12) B.5.b if you want to add a new shape for nesting, execute the following steps. •

Select add shape button in the shape list dialog box.

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Select the part drawing file (typically, an MDF file generated using ITEM, as described earlier) from the file selection dialog box and select the ok button. Note, you can also select multiple part drawing files by keeping the control key pressed while selecting the part drawing files from this dialog box.

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Type the shape name and select the ok button in ghe new dialog box that appears on the screen.

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Specify shape properties using the options shown in shape properties dialog box and select the ok button.

B.5.c if you want to change the properties of an existing shape, select the shape with the mouse and click on the properties button in the shape list dialog box. If you want to remove an existing shape from the shape list, select the shape with the mouse and click on the remove button in the shape list dialog box. B.5.d select the close button in the shape list dialog box, after making all the modifications in the shape list.

B – 6 nest the job. B.6.a select the command fit => Go (F-5) to nest the job automatically. Note, you can break the automatic nesting process at any point of time by pressing the escape key on the keyboard. B.6.b select the command file => save to save the nested job in a job file. A job file is a binary file having the extension job. You can open this file for further editing in your next session with most, of necessary. B.6.c study each nested layouts manually using commands like zoom-in , zoom-out, pan, etc. under view menu.

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B.6.d Modify the layouts manually using commands like move, slide, rotate, mirror, add, remove, etc. under fit menu. B.6.e select the command fit => build, if you would like to nest the layout automatically Without moving those shapes, which have been already nested on the stock. Note, you can break the nesting process at any point of time by pressing the escape key on the on the keyboard. B.6.f Select the command file => save to save to save the modified nested job once again in a file.(control + s )

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CUTTING – MAKE TOOL PATH & CNC CODES C – 1 view the cutting plan. C.1.a view the cutting sequence using the command view => details => cutting sequence. C.1.b view the cutting direction for each cutting cycle using the command view => details => cutting sense. C.1.c simulate the cutting process using the command view => details => cutting simulation. Note, you can break the simulation at any point of time by pressing the escape key on the keyboard.

C – 2 edit leadin / leadout profiles. C.2.a to add leadin / leadout automatically to all the nested shapes, select all the shapes using the command edit => select all and then, select the command leadio => automatic leadin – out => selected shapes. Note, the software reads the size of each leadin / leadout from the constraints and style / geometry from the corresponding toolpath options specified using the command job => options => toolpath. C.2.b To shift an existing leadin / leadout to another location on the same cutting cycle (eg. To shift a leadin from a mid point to a corner point), select the command leadio => shift leadin. C.2.c To add a fresh leadin manually, select the appropriate command under the submenu leadio => add leadin. C.2.d To remove a leadin, select the appropriate command under the submenu leadio => remove leadin.

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C.2.e To add a fresh leadout manually, select the appropriate command under the submenu leadio => add leadout. C.2.f To remove a leadout, select the appropriate command under the submenu leadio => remove leadout.

C – 3 Edit the cutting plan. C.3.a If necessary, align the direction of X–Y axes in the software with the X-Y axes on your cutting machine using the command file => default parameters. ( note, in general, axes alignment is a onetime operation.) C.3.b To edit the sequence number of a cutting cycle, select the command cut => sequence => edit sequence no. to edit the sequence numbers of a group of cutting cycles, select the appropriate command under the submenu cut => sequence. C.3.c To reverse the sense of a cutting cycle, select the command cut => reverse sense. C.3.d To change the neutral (home) position of the cutting torch, select the command cut => neutral position.

C – 4 Work with advanced cutting features. C.4.a Number of advanced cutting features are supported under the cut menu. However, before using these commands, it is advisable to understand the basic nesting and cutting commands supports by the software. Once you know how to perform simple nesting and cutting operations using the software, you can learn more about advanced features like multiple torch cutting, linking, stitch cutting, chain cutting, corner loop generation, common line cutting, rapid motion bypass, etc., using the on – line help provided with the nesting module.

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C – 5 Generate offcut (remnant stock) and shortcut (user- defined cut ) contours. C.5.a to define the offcut as well as shortcuts automatically, execute the following steps. •

Select the command contour => draw => offcut.

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Please refer to the on- line help for detailed procedure regarding offcut generation.

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Save the offcut in an MDF file using the command contour => export offcut => export offcut file.

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C.5.b You can define additional cutting contours (called shortcuts) in a nested layout, using the following commands. •

Contour => draw => grid.

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Contour => draw => shortcut followed by line drawing commands under the submenu contour => draw line.

C – 6 Generate CNC code file. C.6.a Select the post – processor compatible with your cutting machine using the appropriate command under result => CNC codes submenu. C.6.b Specify the cnc code options like program name, code version number, cutting device, etc in the cnc options dialog box and select the ok button. ( please note, the software generates special codes for certain applications and customers. In such cases, you would have already received corresponding guidelines from our side, in that case, please specify these parameters exactly as specified by us, in order to generate desired codes.) C.6.c Specify the name and location of the which you would like to write the cnc codes, in file save dialog box. C.6.d You can also define cnc code generation setting for multiple machine by adding them to machine list using the command job => options => machine => machine list. In that case, you can generate separate cnc code file for each machine in the list using just one command viz. result => CNC codes => machine list.

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C– 7

Select the command file => save in order to save all the nesting as well as

cutting data in a job file. A job file is a binary file, which has the extension job. You can open this file for further editing in your next sessions with MOST, if necessary.

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