CNC SYSTEMS - MECHANICAL COMPONENTS

The drive units of the carriages in NC machine tools are generally the
screw & the nut mechanism. There are different types of screws and
nuts used on NC machine tools which provide low wear, higher
efficiency, low friction and better reliability.

(1) Recirculating ball screw

The recirculating ball screw assembly shown in figure 25.1 has the
flanged nut attached to the moving chamber and the screw to the fixed
casting. Thus the moving member will move during rotational
movement of the screw. These recirculating ball screw designs can have
ball gages of internal or external return, but all of them are based upon
the "Ogival" or "Gothic arc".

In these types of screws, balls rotate between the screw and nut and
convert the sliding friction (as in conventional nut & screw) to the
rolling friction. As a consequence wear will be reduced and reliability of
the system will be increased. The traditional ACME thread used in
conventional machine tool has efficiency ranging from 20% to 30%
whereas the efficiency of ball screws may reach up to 90%.

Figure 25.1: Recirculating ball screw assembly

 Figure 25.2: Preloaded recirculating ball screw

There are two types of ball screws. In the first type, balls are returned
through an external tube after few threads. In another type, the balls are
returned to the start through a channel inside the nut after only one
thread. To make the carriage movement bidirectional, backlash between
the screw and nut should be minimum. One of the methods to achieve
zero backlash is by fitting two nuts. The nuts are preloaded by an
amount which exceeds the maximum operating load. These nuts are
either forced apart or squeezed together, so that the balls in one of the
nuts contact the opposite side of the threads.

These ball screws have the problem that minimum diameter of the ball
(60 to 70% of the lead screw) must be used, limiting the rate of
movement of the screw.

(2) Roller screw

Figure 25.3: Roller screw

These types of screws provide backlash-free movement and their
efficiency is same as that of ball screws. These are capable of providing
more accurate position control. Cost of the roller screws are more
compared to ball screws. The thread form is triangular with an included
angle of 90 degrees. There are two types of roller screws: planetary and
recirculating screws.

Planetary roller screws:

Planetary roller screws are shown in figure 25.3. The rollers are
threaded with a single start thread. Teeth are cut at the ends of the roller,
which meshes with the internal tooth cut inside the nut. The rollers are
equally spaced around and are retained in their positions by spigots or
spacer rings. There is no axial movement of the rollers relative to the nut
and they are capable of transmitting high load at fast speed.

Recirculating roller screws:

The rollers in this case are not threaded and are provided with a circular
groove and are positioned circumferentially by a cage. There is some
axial movement of the rollers relative to the nut. Each roller moves by a
distance equal to the pitch of the screw for each rotation of the screw or
nut and moves into an axial recess cut inside the nut and disengage from
the threads on the screw and the nut and the other roller provides the
driving power. Rollers in the recess are moved back by an edge cam in
the nut. Recirculating roller screws are slower in operation, but are
capable of transmitting high loads with greater accuracy.

28. CNC WORK HOLDING DEVICES

With the advent of CNC technology, machining cycle times were
drastically reduced and the desire to combine greater accuracy with
higher productivity has led to the reappraisal of work holding
technology. Loading or unloading of the work will be the non-
productive time which needs to be minimized. So the work is usually
loaded on a special work holder away from the machine and then
transferred it to the machine table. The work should be located precisely
and secured properly and should be well supported.

28.1 Turning center work holding methods:

Machining operations on turning centers or CNC lathes are carried out
mostly for axi-symmetrical components. Surfaces are generated by the
simultaneous motions of X and Z axes. For any work holding device
used on a turning centre there is a direct "trade off" between part
accuracy and the flexibility of work holding device used.

Work holding
Advantages Disadvantages
methods
 High cost of jaw/chuck changing
Automatic Jaw & Adaptable for a range of work-
automation. Resulting in a more
chuck changing piece shapes and sizes
complex & higher cost machine tool

Very quick loading and

Expensive optional equipment. Bar-
unloading of the workpiece can
Indexing chucks feeders cannot be incorporated.
be achieved. Reasonable range
Figure 28.1 Short/medium length parts only can
of work piece sizes can be
be incorporated. Heavy chucks.
loaded automatically

Limited to a range of flat parts with

Simple in design and relatively
Pneumatic/Magnetic little overhang. Bar-feeders cannot be
inexpensive. Part automation is
chucks incorporated. Parts on magnetic
possible. No part distortion is
Figure 28.3 chucks must be ferrous. Heavy cuts
caused due to clamping force
must be avoided.

Adaptable to automation.
Jaws must be changed manually &
Automatic Chucks Heavy cuts can be taken.
bared, so slow part change-overs. A
with soft jaws Individual parts can be small
range of jaw blanks required.
or large in diameter

Long & short parts of

reasonably large size
Expanding mandrels
accommodated. Automation Limitation on part shape. Heavy cuts
& collets
can be incorporated. Clamping should be avoided.
Figure 28.2
forces do not distort part.
Simple in design
Expensive & can only be financially
Excellent restraint & location justified with either large runs or
of a wide range of individual & when extremely complex & accurate
Dedicated Chucks
irregular -shaped parts can be parts are required. Tool making
obtained. facilities required. Large storage
space.

( 2) Work holding for Machining Centres:

Workholding methods Advantages Disadvantages
Highly adaptable. Can be purchased in
stages to increase its sophistication. Costly for a complete
Modular Fixtures Reasonable accuracy. Speedily assembled. system. Difficult to
Figure 28.6 Small stores area is required. Can be set-up automate. Skills required in
to a machine more than one part. Proven kit assembly
technology
Relatively inexpensive. Can be operated by
mechanical, pneumatic, or by hydraulic Work holding limitations.
control. Quick to operate with ease of set- Clamping force limitations.
Automatic Vices up. Reasonable accuracy. Easily automated. Jaws can become strained.
Simplicity of design. Using multi-vices Work location problems.
allows many parts to be machined. Proven Limitations on part size.
Technology
Relatively inexpensive. Reasonable Large surface area is
accuracy. Can machine large areas of the required. Swarf can be a
Pneumatic/Magnetic
work piece. Quick setups. Easily problem. Nonferrous
Work holding devices
automated. Simplicity of design. Many material limitation on
parts can be machined at one set up. magnetic devices.
Costly & limited part
geometry clamping. Part
Allows complex geometric shapes to be
4/5 axis CNC work size limitations. Usually
machined. High accuracy. Opportunity for
holding devices only one part can be
"one hit" machining. Easily automated.
machined. Cannot be fitted
to all machines.
Dedicated Fixturing Large & small parts are easily Large storage space
accommodated. High accuracy of part required. No part flexibility.
location. Easily automated. Simplicity of
design. Proven technology. Many parts can Heavy fixtures. Tool
be machine at one setup good vibration making facilities required.
damping capacity

Figure 28.1: Indexing chucks

Figure 28.2: Mandrels

Figure 28.3: Magnetic chucks

 Figure 28.4: Vise

Figure 28.5(a): Pallets

Figure 28.5(b) Figure 28.5(c)

Figure 28.6 : Modular fixture

Figure 28.7 : Chucks