Computer Numerical Control

Computer Numerical Control (CNC) is one in which the function and motions of a
machine tool are controlled by means of a prepared program containing coded alphanumeric
data. CNC are control the motions of the workpiece or tool, the input parameters such as
feed, depth of cut, speed, and the functions such as turning spindle on/off, turning coolant
on/off.

Application
The applications of CNC include both for machine tool as well as non-machine tool
areas. In the machine tool category, CNC is widely used for lathe, drill press, milling
machine, grinding unit, laser, sheet-metal press working machine, tube bending machine etc.
Highly automated machine tools such as turning centre and machining centre which change
the cutting tools automatically under CNC control have been developed. In the non-machine
tool category, CNC applications include welding machines (arc and resistance), coordinate
measuring machine, electronic assembly, tape laying and filament winding machine for
composites etc.

Advantages

Highly Accuracy in manufacturing

Short Production Time
Greater manufacturing flexibility
Simpler Fix Turing
Contour machining (2 to5-Axis machining)
Reduced human Error

Disadvantages

Include High Initial Cost

High Maintenance Cost
Requirement of skilled part Programmer
Complex nature of Technology

Elements of A CNC
A CNC system consists of three basic components (Figure 1):
1. Part Program
2. Machine Control Unit (MCU)
3. Machine tool (Lathe, Drill, Press, Milling Machine etc.)

Part Program
The part program is a detailed set of commands to be followed by the machine tool. Each
command specifies a position in the Cartesian coordinate system (x, y, z) or motion
(workpiece travel or cutting tool travel), machining parameters and on/off function. Part
programmers should be well versed with machine tools, machining processes, effects of
process variables, and limitations of CNC controls. The part program is written manually or
by using computer-assisted language such as APT (Automated Programming Tool)

Fig 1 A typical numerical control system for a milling machine

Machine Control Unit

The machine control unit (MCU) is a microcomputer that stores the program and executes the
commands into actions by the machine tool. The MCU consists of two main units: the data
processing unit (DPU) and the control loops unit (CLU). The DPU software includes control
system software, calculation algorithms, translation software that converts the part program
into a usable format for the MCU, interpolation algorithm to achieve smooth motion of the
cutter, editing of part program (in case of errors and changes). The DPU processes the data
from the part program and provides it to the CLU which operates the drives attached to the
machine leadscrews and receives feedback signals on the actual position and velocity of each
one of the axes. A driver (dc motor) and a feedback device are attached to the leadscrew. The
CLU consists of the circuits for position and velocity control loops, deceleration and backlash
take up, function controls such as spindle on/off.

Machine Tool
The machine tool could be one of the following: lathe, milling machine, laser, plasma,
coordinate measuring machine etc. Figure 2 shows that a right-hand coordinate system is
used to describe the motions of a machine tool. There are three linear axes (x, y, z), three
rotational axes (i, j, k), and other axes such as tilt (0) are possible. For example, a 5-axis
machine implies any combination of x, y, z, I, j, k, and 0.

Fig 2 Right-hand coordinate system used in lathe

CNC Turning Centre

A CNC turning center is one of the most popular types of metal cutting CNC machines
because it is designed to perform common, yet important, types of machining operations. It is
important to understand these machining operations in order to properly use a CNC turning
center.
Physically CNC lathe machine is a simple lathe machine with CNC controls panel equipped
with it. Internally all the functionality of CNC lathe machine it controlled through CNC
control.
CNC Computer Numerical Control Taking digitized data, a computer and CAM program
is used to control, automate, and monitor the movements of a machine. The machine can be
a milling machine, lathe, router, welder, grinder, laser or waterjet cutter, sheet metal
stamping machine, robot, or many other types of machines.

CNC Turning Centre Parts (Fig 3)

1.
2.
3.
4.
5.
6.
7.
8.

Head Stock
CNC lathe Bed
Chuck
Tail Stock
Tail Stock Quill
Foot Switch or Foot Pedal
CNC Control Panel
Tool Turret

Fig 3 CNC Lathe Machine Main Part Introduction

1. Head Stock (Fig. 4)

Headstock of a CNC lathe machine have the main motor of CNC lathe machine which drives
the main spindle. Chuck is mounted on this main spindle. Here is another CNC lathe
machine, the headstock covers are removed, so you can see the Main drive (Main Motor),
Gears. Gears can be selected with the CNC programming instructions
z

Fig 4. CNC Turning Head stock

2. CNC lathe Bed

The tool turret travel over the CNC lathe bed, which is specially hardened so any kind of
machining cant affect them.

3. Chuck (Fig 5)
CNC lathe machine chuck grips the component which are to be machined. Chuck itself has
many parts. Jaws are mounted on the chuck to grip the part, you might read more about jaws
here CNC Machine Jaws an Introduction for CNC Lathe Machinist.

Fig5. Chuck with Jaw

4. Tail Stock
Tailstock are mostly used to give an extra gripping force for component machining. For long
components machining they provide extra force on the other end so machining process can
complete smoothly. You can see in the above picture at the one end chuck is gripping the
component and on the other end tailstock is providing the extra force.

5. Tailstock Quill
Actually you move the whole tailstock forward or reverse, but in that way it is not used to
grip the part, but tailstock is travelled to a point near the component and then it is set there,
after that you actuate the tailstock quill which travel either with hydraulic pressure or
pneumatic pressure to grip the component.

6. Foot Switch or Foot Pedals (Fig. 6)

Foot switches are used to actual the chuck and tailstock quill. Through these pedals CNC
machinists open and close the chuck to grip the component, the same way tailstock quill is
taken to forward position or reversed through theses pedals.

7. CNC Control Panel (Fig. 7)

The brain of the CNC machine, all the CNC program are stored inside this panel, CNC
machinists control the whole machine through the keys on this panel. CNC machinists
stat/stop the machine move axis by pressing different keys on this panel.
They can enter new program by using this panel, programs can be transferred by using USB
port on this panel as well. So this is the main part which controls the whole CNC machine.

Fig 6 Foot Pedal

Fig 7 CNC Control Panel

8. Tool Turret
The tools are mounted on the tool turret which are used for component machining. Tool
turrets vary in shapes and number of tools that can be mounted on them.

Fig.8 Tool Turret

CNC Turning Centre Classification

The major categories of CNC turning centres are classified as under

Turn mill Centres. (X, Z, C)

Multiple-axis turning centres. (X, Z, C, Y)
Vertical turning centres.
Twin turret turning centres.
Multiple-spindle turning centres.
Integrated material handling.

Turn mill Centres (X, Z, C)

The major development in the CNC turning centre is the development of the turn mill centres.
Many turning components are not completely machined in lathes alone. After finishing the
lathe operations, it may have to go to a drilling or milling machine to carry out operations
such as drilling cross- holes, milling of flats, keyways, slots etc. to overcome such types of
problems, there was a development of combined machine tool. Such a machine tool is called
CNC turn mill centre. In order to do the milling operation in a lathe, the main spindle will not
rotate. Instead, the tool will rotate in the tool turret. For this purpose, a separate drive is
provided in the turret, so that the tools such as twist drills and end mils rotate in the tool
turret. Such tools are called driven tools. The main spindle holding the work piece can
therefore be indexed suitably to get the necessary profiles. This is called the C axis. The
driven tooling can therefore move in addition to the X & Z axes like the normal turning
centre, and can also move in the C-axis. The combination of these three axes can make the
machine tool really versatile and allows for a range of complex surfaces to be produced. A
fig. 9 of CNC turn mill centres as given bellow.

Fig. 9 CNC Turn Mill Centre

Multiple-Axis Turning Centre

There are a large number of variations to be found in this category of machine tools where a
large number of axes are provided in addition to the 2 or 3 axes machines.

Twin-turret turning centres (Fig 10)

one of the possibilities is providing two turrets in a turning centre in place of 1 in the normal
turning centre. This makes it a 4-axes turning centre with both turrets capable of moving
independently in two axes each. The main advantage to be gained in such cases is that
machining can be done by two tools as well as having a larger tool capacity. Since two tools
will be machining simultaneously, a large amount of chips would be generated which needs
to be carefully disposed of in such cases.

Fig 10 Twin-turret turning centre

Multiple Spindle Turning Centres (Fig 11)
For large volume of production of small and medium sized parts with standard tolerances, it
may be necessary to go for multi-spindle turning centre. In this the headstock is consists of
two spindles, tailstock with two quills, which are arranged parallel to each other at a fixed
distance. Two turrets are provided to provide the tools for these two spindles. These
machines, in view of capability of simultaneous machining of two parts, are capable of high
productivity, which is normally demanded in the automotive sector.

Fig 11 Multiple Spindle Turning Centre

In the above fig. a twin-spindle turning centre is shown. The twin spindle and turrets are
separately controlled in this case also, except that the spindles in this case are maintained in
line such that it is possible to carry out the machining of a component which requires two set
ups.
The machining of the first set up is completed in the left spindle. Then the workpiece is
transferred to the right spindle from the left spindle to raise automatic continuous machining
operations. Then the workpiece can be completely machined in the right spindle. As a result,
this allows higher productivity

Fig 12 Twin-spindle turning centre

It is possible to further configure turning centres by having a number of combinations with
larger number of axes by combining them in any order of the following options in a modular
manner.

Turret with turning tools

Turret with driven tools.
Turret with Y-axis movement.
Programmable tailstock.
Tool changer for the Y-axis turret.
C-axis movement.

Vertical Turning Centre (Fig 13)

For very large-diameter work-pieces, the turning with a horizontal spindle becomes very
difficult. Hence in such cases a vertical turning centre is used. A vertical turning centre
generally has the spindle in vertical direction in place like the table of a machining centre. A
heavy and large workpiece can be clamped into the chuck, which is in the horizontal plane.
The tool turret is kept in a plane above the spindle. For quick changing of the jobs, the
automatic pallet changer which replaces the chuck in a manner very similar to the shuttle type
tool changer in a machining centre.

Fig 13 Vertical Turning Centre

Another concept in vertical turning centre is to make the spindle above the tool turret
below by conventional vertical turning centre. This is generally used for smaller work-pieces
compared to the conventional vertical turning centre. The workpiece is held in the chuck and
rotated by the vertical spindle above, while the tool turret lies below.
The vertical turning centre useful for large-volume production of small automobile
components is the pick-up turning centre. This has two vertical spindles, one of which is
movable. This movable spindle acts like a tool-change arm, except in this case it is a
transferring the workpiece. A movable spindle picks up the workpiece from the conveyor and
moves into the machining area. After completing the initial machining in the movable
spindle, it directly transfers the semi-finish component to the other spindles working area.
The second set up machining will be completed in the stationary spindle. After the complete
machining, a gripper in the second turret removes the part from the spindles and places on the
conveyor belt. With such a machine design, separate loading and turnover systems are not
required. This provides a complete machining of components with two set-ups from the two
ends. Vertical turning centres can do the following operations

Turning
Drilling
Milling
Grinding
Gear cutting
Balancing
Gauging