INTRODUCTION OF CNC MACHINE

INTRODUCTION

In order to meet the increasing demand to manufacture complicated

components of high accuracy in large quantities, sophisticated technological
equipment and machinery have been developed. Production of these
components calls for machine tools which can be set up fairly rapidly
without much attention.
The design and construction of Computer Numerically Controlled
(CNC) machines differs greatly from that of conventional machine tools.
This difference arises from the requirements of higher performance levels.
The CNC machines often employ the various mechatronics elements that
have been developed over the years. However, the quality and reliability of
these machines depends on the various machine elements and subsystems of
the machines. There are some of the important constituents parts and aspects
of CNC machines to be considered in their designing, for example Machine
structure, Guideways, Feed drives, Spindle and Spindle bearings, Measuring
systems, Controls, Software and Operator interface, Gauging, Tool
monitoring.
The control of a machine tool by means of stored information through
the computer is known as Computer Numerically Controlled. The
information stored in the computer can be read by automatic means and
converted into electrical signals, which operate the electrically controlled
servo systems. Electrically controlled servo systems permits the slides of a
machine tool to be driven simultaneously and at the apporopriate feeds and
direction so that complex shapes can be cut, often with a single operation
and without the need to reorient the workpiece.
Computer Numerically Control can be applied to milling machines,
Lathe machines, Grinding machines, Boring machines, Flame cutters,
Drilling machines etc.

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HISTORICAL DEVELOPMENTS IN CNC MACHINES

• A relatively short time ago, machines were operated by craftsmen who

determined the many variables such as speeds, feeds, depth of cut etc.
Now much of this work is being assigned to computer and machines
that are numerically controlled.
• Numerical control as applied to machine tools, had it’s beginning in
1949, when the United States Air Force combined with Parsons
Corporation to produce contoured surface from instructions in the form
of punched tape.
• Numerical control equipment was substituted for the tracer controls on
a three axis Cininnati Hydrotel Vertical Planer Mill.
• A successful feasibility demonstration of continuous contour milling
was held in March 1952 followed by a final report; both the Air Force
and Private Industry began further work to extend the Numerical
Control technology developed at Massachusetts, Institute of
Technology, U.S.A.
• Between 1955 and 1960 only 500 Numerically Controlled Machine
were installed in U.S.A.
• During 1960 and 1964 approximately 4000 more were added.
• Till the middle of 60’s Russia, West Germany, Japan, and U.K. were
for behind U.S.A., in the production of Numerical Control Machine
Tools.
• Japan entered the Numerical Control commercial scene during mid
60’s and by 1971 surpassed the U.S.A. in NC ratio.
NC ratio = Production of NC machines tools (units)
Total production of machine tools

• U.S.S.R. is also one of the largest producers of nc machine tools

mainly for industrial use.

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FEATURES OF CNC MACHINES

• Rigid machine structure is provided, in order to bear the static load,
Dynamic load , Thermal load , Vibration.
• Guideways are used in machine tools to control the direction or line of
action of the carriage or the table on which a tool or workpiece is
held , To absorb all the static and dynamic forces.
• On a CNC machine the function of feed rate drive is to provide motion
to the slide as per the motion commands. Since the degree of accuracy
requirements are high, the feed drive should having high efficiency
and response.
• Hydrodynamic bearings, Hydrostatic Bearings, Antifriction Bearings
are provided to the CNC machine. In order to achieve the accuracy and
the quality of the work produced depends directly on the geometrical
accuracy, running accuracy and the stiffness of the spindle assembly.
• On all CNC machines, an electronic measuring system is employed on
each controlled axis to monitor the movement and to compare the
position of the slide and the spindle with the desired position.
• CNC controls are the heart of the CNC machines. The early CNC
controls were developed for simple applications in turning, machining
centres and grinding. But with increased capabilities on modern
machine tools such as higher spindle speeds, higher rapid traverses and
more number of axes, CNC systems have been developed to meet
these needs.
• Better work piece quality is one of the most important advantages in
using a hi-tech CNC machine. To maintain quality the effect of
parameters like tool wear and thermal growth can be eliminated by
automatic gauging system.
• Presently, established tool monitoring sensors and systems are
available commercially for integrating and systems are available
commercially for integrating with CNC machines. Tool monitoring
systems enable the introduction of adaptive controls on machines for
optimizing the cutting parameters.
• Feedback is taken from various devices, e.g. Ecoders, Transducers.

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MACHINE STRUCTURE

The machine structure is the load carrying and supporting member of

the machine tool. All the motors, drive mechanisms and other functional
assemblies of machine tools are aligned to each other and rigidity fixed to
the machine structure. The machine structure is subjected to static and
dynamic forces and it is, therefore , essential that the structure does not
deform or vibrate beyond the permissible limits under the action of these
forces. All components of the machine must remain in correct relative
positions to maintain the geometric accuracy, regardless of the magnitude
and direction of these forces. The machine structure configuration is also
influenced by the consideration of manufacture, assembly and operation.
The basic design factors involved in the design of machine structure
are as follows,
1. Static load
2. Dynamic load
3. Thermal load
4. Guideways
5. Feed drive: - 1)Servo motor, 2)Mechanical Transmission System
6. Spindle / spindle bearings 1)Hydrodynamic 2)Hydrostatic
3)Antifriction
7. Measuring Systems: - 1)Direct 2)Indirect
8. Controls, Software and user interface
9. Gauging
10.Tool monitoring systems: - 1)Direct 2)Indirect

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CONFIGURATION OF CNC SYSTEM

Fig shows a schematic diagram of the working principle of an NC
axis of a CNC machine and the interface of a CNC control.
A CNC system basically consists of the following:-
• Central processing unit (CPU).
• Servo control unit
• Operator control panel
• Machine control panel
• Other peripheral devices
• Programmable logic controller
Figure gives the typical control configuration of Hinumerik 3100 CNC
system.

1. Central Processing Unit (CPU) :-

The CPU is the heart of a CNC system. It accepts the
information stored in the memory as part program. This data is
decoded and transformed into specific position control and velocity
signals. It also oversees the movement of the control axis or spindle
and whenever this does not match with the programmed values, a
corrective action as taken.
All the compensation required for machine accuries (like lead
screw pitch error, tool wear out, backlashes.) are calculated by CPU
depending upon the corresponding inputs made available to the system. The
same will be taken care of during the generation of control signals for the
axis movement. Also, some basic safety checks are built into the system
through this unit and continuous necessary corrective actions will be
provided by CPU unit. Whenever the situation goes beyond control of the
CPU, it takes the final action of shutting down the system and in turn the
machine.

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2. Servo control unit :-

The decoded position and velocity control signals, generated
by the CPU for the axis movement forms the input to the servo control
unit. This unit in turn generates suitable signals as command values.
The command values are converted by the servo drive units which are
interfaced with the axes and the spindle motors.
The servo control unit receives the position feedback signals
for the actual movement of the machine tool axes from the feedback
devices (like linear scales, rotary encoders, revolvers, etc.)

3. Operator Control Panel :-

The Operator Control Panel provides control panel provides
the user interface to facilitate a two way communication between the
user, CNC system and the machine tool. This consists of two parts;
• Video display unit
• Keyboard

4. Machine Control Panel :-

It is the direct interface between the operator and the NC system,
enabling the operation of the machine through the CNC system.
During program execution, the CNC controls the axis the motion, spindle
function or tool function on a machine tool, depending upon the part
program stored in the memory. Prior to the starting of the machining process,
machine should first be prepared with some specific takes like,
• Establishing a correct reference point
• Loading the system memory with the required part program
• Loading and checking of tool offsets, zero offsets, etc.

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5. Other peripheral devices :-

These include sensor interface, provision for
communication equipment, programming units, printer, tape reader
interface, etc.

6. Programmable logic Controller:-

A PLC matches the NC to the machine. PLC’s were
basically as replacement for hard wired relay control panels. They were
basically introduced as replacement for hard wired relay panels. They
developed to be re-programmed without hardware changes when
requirements were altered and thus are re-usable. PLC’s are now
available with increased functions, more memory and larger
input/output capabilities.
In the CPU, all the decisions are made relative to
controlling a machine or a process. The CPU receives input data,
performs logical decisions based upon stored programs and drives the
output s. connection to a computer for hierarchical control are done via
the CPU.

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PROGRAMMING FOR CNC MACHINES

A program is a set of encoded information giving coordinate values
and other details to indicate how a tool should be moved in relation to a
work piece in order to achieve a desired machining form. A part program
contains all the information for the machining of a component which is input
to CNC system. The CNC system provides signals at the correct time and in
the correct sequence to the various drive units of the machine.

PROCEDURE OF PART PROGRAMMING

1) Study the relevant component drawing thoroughly.
2) Identify the type of material to be machined.
3) Determine the specifications and functions of machine to be used.
4) Decide the dimension and mode i.e. Metric or inch.
5) Decide the co ordinate system i.e. Absolute or incremental
6) Identify the plane of cutting.
7) Determine the cutting parameters for the job / tool combination.
8) Decide the feed rate programming.
9) Check the tooling required.
10) Establish the sequence of machining operations.
11) Identify whether use of special features like subroutines, mirror
imaging etc. is required or not.
12) Decide the mode of storing the part program once it is completed.

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STRUCTURE OF A PART PROGRAMMING

Part program defines a sequence of NC machining operations. The

information contained in the program can be dimensional or non dimensional
like speed, feed, auxiliary functions, etc.. The basic unit of a part program
input to the control is called a block. Each block contains adequate
information for the machine to perform a movement and or functions. Block
in turn are made up of words and each word consists of a number of
characters. All blocks are terminated by the block end character. The
maximum block length for each CNC is fixed.
A block may contain any or all the following :-

• Optional block skip ( / ).

• Sequence or block number (N).
• Preparatory functions (G).
• Dimensional information ( X,Y,Z etc. )
• Decimal point (.).
• Feed rate (F).
• Spindle speed (S).
• Tool number (T).
• Tool offset function (D).
• Miscellaneous functions (M,H, etc. )
• End of block (EOB / *)

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BLOCK EXAMPLE
N – 1234 G…..X..…Y…..S..…M…..F…..T…..D…..EOB.

Where ,
N ……...= Address of block number.
1234…. = Block number.
G ……..= Preparatory function.
X…Y…= Transcient information.
S…...= Spindle speed function.
M….= Miscellaneous function.
F…..=Feed function.
T…..=Tool function.
D…..= Compensation function.
EOB =End of Block.

Designation of some letters for certain addresses had been

standardized, for e.g. The letter N always designates block number,
other letters in standardized list are
P,G,M,X,Y,Z,I,J,K,L,U,V,W,A,B,C,F,S,T,EOB. A CNC manufacturer
may use some letters which are not standardized for special words, e.g.
R and H used in controls manufactured by Fanuc or Siemens.

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CONTROL SYSTEMS FOR CNC MACHINES

Following are the two types of control systems used in the CNC
machines

1. Open loop control system.

2. Closed loop control system.

1. Open loop control system:-

In an open loop system the machine slides are displaced
according to the information loaded from the part program into the
control system. Hence there is no measurement of slide position and no
feedback signals for comparison with the input signal. The correct
movement of slide entirely depends upon the ability of the drive
systems to move the slide through the required exact distance.
The most common method of driving the lead screw is by a stepper
motor. The stepper motors are the simplest way for converting detail
electrical signals into proportional movement. As there is no check on
the slide position, the system accuracy depends upon the motors ability
to step through the exact number of steps provided at the input as
shown in fig.

2. Closed loop control system:-

A closed loop system is as shown in fig. sends back a signal to the
control unit from a measuring device called as transducer. The
transducer is attached to the slide ways. The signal indicates the actual
movement and position of the slides.
The control unit continues to adjust the position of the slide until
it arrives it’s destination, this system has feedback. Although more
costly and complex than open loop system, these system gives more
accurate positioning. For this type of system, servomotors are used.

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TYPES OF CNC MACHINES

Following are the some important types of CNC machines,

1. Machining centre.
a) Vertical machining centre.
b) Turret machining centre.
c) Horizontal machining centre.
2. CNC Lathe Machine.
3. CNC Turning Machine.
4. CNC Drilling Machine.
5. CNC Milling Machine.
6. CNC Special Purpose Machine.

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ADVANTAGES AND DISADVANTAGES OF CNC

MACHINES

ADVANTAGES

• Higher flexibility.
• Increased productivity.
• Consistent quality.
• Reduced scrap rate.
• Reliable operation.
• Reduced non-productive time.
• Reduced manpower.
• Shorter cycle time.
• Just in time manufacture.
• An automatic material handling.
• Lesser floor space.
• Increased operational safety.
• Machining of advanced materials.

DISADVANTAGES

• CNC machines are more expensive than manually operated

machines.
• Investment in CNC machines can lead to unemployment.
• Higher maintenance cost.
• Costlier CNC personnel.
• Air conditioned place are required for installation of the
machines.
• Unsuitable for long run applications.
• Training of part programmer is required.

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CNC SYSTEMS AVAILABLE IN INDIA

Various companies are as follows,

• FANUC INDIA.
• HINDUSTAN MACHINE TOOL COMPANY.
• KIRLOSKAR MACHINE TOOL COMPANY.
• LAKSHMI ELECTRIC CONTROLS.
• ELEPRO ENGINEERING.
• ELECTRONICA.
• INDIAN PRECISION MACHINE TOOL.
• SARATHI ENGINEERING WORKS.
• N.D. AUTO CORPORATION.
• SIX SIGMA ENGINEERING.
• BHAGYALAXMI INDUSTRIAL CORPORATION.
• JEO INTERPRISES.
• BHATS TOOLING EQUIPMENTS.
• CHATURVEDI TOOLS AND EQUIPMENTS PVT LTD.
• CREATIVE CARBON COMPANY LTD.
• SUPER CUT INDUSTRIES.
• VEDA TOOLING SYSTEMS PVT. LTD.
• PRESS TOOLS INDIA LTD.

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CONCLUSION

Development of Computer Numerically Controlled

machines (CNC) is an outstanding contribution to the
manufacturing industries. It has made possible the automation of
the machining processes with flexibility to handle small to
medium batch quantities in part production.
At present Indian industries needs CNC machines, which
facing competition in global market, due to day by day
uncertainties in customer demand requirements in term of huge
variety of products with better quality and at lesser time. CNC
machines are best suitable for better accuracy and less man
power.

REFERENCES
1. ADVANCED MANUFACTURING TECHNOLOGY
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By. Prof. K. Varaprasad Rao.

2. CAD/CAM/CIM
By. Prof. P. Radhakrishnan.
3. PRODUCTION TECHNOLOGY
By. Prof. R. K. Jain.
4. CNC MACHINES
By. Prof. R. K. Mehta.
5. MECHATRONICS
By. Prof. N. Ramanuja.

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