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CONTENT

Content ………………………………………………………………………….......1

Abstract …………………………………………………………………………..... 2

Chapter I. CNC MACHINE OVERVIEW……………………………………….4

I. CNC machine history …………………………………………………………….4

II. CNC machine …………...……………………………………………………….8

Chapter II. CUTTING DRIVE SYSTEM DESIGN …………………………...13

A. BALL SCREW CALCULATION ...................................................................13

I. BALL SCREW CALCULATION FOR X AXIS …………………………... 13

1. Design condition………………………………………………………………..13

2. Lead selection ………………………………………………………………….13

3. Shaft and ball-bearing calculation for machine table moving along X axis …...14

4. Clusters bearing selection ……………………………………………………..19

II. BALL SCREW CALCULATION FOR Y AXIS …………………………. 22

1. Design condition ……………………………………………………………… 22

2. Lead selection ………………………………………………………………… 22

3. Shaft and ball-bearing calculation for machine table moving along Y axis ….. 23

4. Clusters bearing selection………………………………………………………28

B. LINEAR GUIDEWAYS CALCULATION ………………………………...31

Chapter III : MOTOR CALCULATION ……………………………………...38

I. MOTOR CALCULATION FOR X TABLE………………………………... 38

1. Moment of inertial ……………………………………………………………..38

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2. Driving torque ………………………………………………………………… 38

3. Motor choosing ……………………………………………………………….. 38

4. Check the time required to achieve maximum velocity……………………….. 39

5. Strain acting on the screw calculation ………………………………………….41

6. Critical load of screw shaft …………………………………………………… 41

II. MOTOR CALCULATION FOR Y TABLE ……………………………….42

1. Moment of inertial ……………………………………………………………..42

2. Driving torque ………………………………………………………………….42

3. Motor choosing ……………………………………………………………….. 43

4. Check the time required to achieve maximum velocity ………………………. 45

5. Strain acting on the screw calculation ………………………………………… 45

6. Critical load of screw shaft …………………………………………………….46

Chapter IV : CONCLUSION …………………………………………………. 47

Reference ……………………………………………………………………….. 48

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Abstract
Nowadays, the uses of modern machines to replace human physical strength,
increase performance as well as products of high quality is a necessary trend in
development of the country. The system of automatic manufaction consisting of a
variety of modern industrial machines creates very good products, in addition to high
strength as well as attractive models.
CNC (computer numerical controlled) machine machines and generates required-
complicate pieces. This terminology relates to a set of large machines using the logic
of computers to control motions as well as machine metals. In this report, we will
discuss two most common machines, there are turning and milling machine.
Advancement of computer and artificial intelligence improves CNC’s ability of
working and convenient operation. A developing idea is to generate a new CNC
machine which is designed so that its spindle is hung up by six embedded backing,
screw and ball. The accurate movements are controlled by modern computer.
This project shows procedure of calculation and design of guidance system for
machining depending on movement of three main axes.
Main tasks: Calculate and choose: ballscrew , linear guideways and motor.

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Chapter I. CNC MACHINE OVERVIEW

I. CNC machine history

What is CNC?

- CNC is the acronym for Computer Numerical Control. It is an outgrowth of the

older term "NC", which stands for just "Numerical Control". It refers to the idea of
controlling machine tools programmatically via computer. With the older "NC" term,
a computer need not be involved. The machine might be controlled using, for
example, punched tape.

- NC, and later CNC, allowed for tremendous increases in productivity for machine
tools because the machines could be run automatically without requiring constant
attention from their operator. Before the advent of such automation, there was a lesser
automation opportunity in the form of hydraulic tracer systems. Such systems used
hydraulics to cause the cutting tools of a lathe or mill to follow a template. The taper
attachments available for many manual lathes are not unlike the hydraulic tracer
capability; it's just that the tracer is capable of more elaborate templates than simple
tapers. But the advent of first NC and then later CNC radically increased the amount
of automation that was possible.

Short History of CNC

The first commercial NC machines were built in the 1950's, and ran from punched
tape. While the concept immediately proved it could save costs, it was so different
that it was very slow to catch on with manufacturers. In order to promote more rapid
adoption, the US Army bought 120 NC machines and loaned them to various
manufacturers so they could become more familiar with the idea. By the end of the
50's, NC was starting to catch on, though there were still a number of issues. For
example, g-code, the nearly universal language of CNC we have today, did not exist.
Each manufacturer was pushing its own language for defining part programs (the
programs the machine tools would execute to create a part).

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Fig 1.1: 1959 CNC Machine: Milwaukee-Matic-II was first machine with a tool
changer...

A number of key developments brought CNC rapidly along during the 1960's:

- Standard G-Code Language for Part Programs: The origin of g-code dates back to
MIT, around 1958, where it was a language used in the MIT Servomechanisms
Laboratory. The Electronic Industry Alliance standardized g-code in the early 1960's.

- CAD came into its own and started rapidly replacing paper drawings and draftsmen
during the 60's. By 1970, CAD was a decent sized industry with players like
Intergraph and Computervision, both of whom I consulted for back in my college
days.

- Minicomputers like the DEC PDP-8's and Data General Nova's became available in
the 60's and made CNC machines both cheaper and more powerful.

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By 1970, the economies of most Western countries had slowed and employment
costs were rising. With the 60's, having provided the firm technology foundation that
was needed, CNC took off and began steadily displacing older technologies such as
hydraulic tracers and manual machining.

US companies had largely launched the CNC revolution, but they had been overly
focused on the high end. The Germans were the first to see the opportunity to reduce
prices of CNC, and by 1979 the Germans were selling more CNC than the US
companies. The Japanese repeated the same formula to an even more successful
degree and had taken the leadership away from the Germans just one year later, by
1980. In 1971, the 10 largest CNC companies were all US companies, but by 1987,
only Cincinnati Milacron was left and they were in 8th place.

More recently, microprocessors have made CNC controls even cheaper,

culminating with the availability of CNC for the hobby and personal CNC market.
The Enhanced Machine Controller project, or EMC2, was a project to implement an
Open Source CNC controller that was started by NIST, the National Institute of
Standards and Technology as a demonstration. Some time in 2000, the project was
taken into the public domain and Open Source, and EMC2 appeared a short time later
in 2003.

Machine3 was developed by Artsoft founder Art Fenerty as an offshoot of early

EMC versions to run on Windows instead of Linux, making it even more accessible
to the personal CNC market. Art's company, ArtSoft, was founded in 2001.

Both the EMC2 and Mach3 CNC software programs are alive and thriving today,
as are many other CNC technologies.

What Kinds of CNC Machines Exist?

The short answer is more than we could possibly go into here, but let's try to
cover some of the major categories of CNC, which are the most common.

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CNC Machine Lathes

Some view Lathes as the only universal machine tool because a lathe can make
all of the parts needed for another lathe. A lathe spins the workpiece in a spindle while
a fixed cutting tool approaches the workpiece to slice chips off of it. Because of this
geometry, lathes are ideal for parts that have symmetry around some axis that could
be chucked up in the spindle.

CNC Lathes have at the very least the ability to drive the cutting tool under g-
code control over 2 axes, referred to as X and Z. They may have a considerable
amount of other functionality as well, and there are many variations on lathes such as
Swiss Lathes.

The act of cutting a workpiece on a lathe is called "Turning".

CNC Milling Machines

In a mill, the cutter is placed in the spindle where it rotates. The workpiece then
moves past the cutter so that chips may be sliced off. The act of cutting a workpiece
on a mill is called "Milling".

CNC Mills have at the very least the ability to drive cut in 3 dimensions (some
older machines may be limited to 2 or 2 1/2 if there are limitations on when that 3rd
dimension may be used) which are referred to as the X, Y, and Z axes.

CNC Routers

A CNC Router is actually a type of CNC Mill, typically one that uses what's
called a "gantry" configuration. Typically they're called CNC Routers instead of CNC
Gantry Mills when they're used to cut wood, but this need not exclusively be the case.
Many think of CNC machines as being focused on cutting metal, but there is a huge
market for CNC woodworking machines of which the CNC Router is the principle
example.

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There are many more types of CNC machine than just these three most common
types including CNC presses of various kinds and so on.

II. CNC machine

Computer Numerical Control (CNC) is a specialized and versatile form of Soft

Automation and its applications cover many kinds, although it was initially developed
to control the motion and operation of machine tools. Computer Numerical Control
may be considered to be a means of operating a machine through the use of discrete
numerical values fed into the machine, where the required 'input' technical
information is stored on a kind of input media such as floppy disk, hard disk, CD
ROM, DVD, USB flash drive, or RAM card etc. The machine follows a
predetermined sequence of machining operations at the predetermined speeds
necessary to produce a workpiece of the right shape and size and thus according to
completely predictable results. A different product can be produced through
reprogramming and a low-quantity production run of different products is justified.

There are some kinds of common CNC machines:

 CNC turning
 CNC milling
 Spark CNC borer
 Wire cutting of CNC machine
 Advantages of CNCs:
 Machine many complicate pieces
 Better arrangement of production

 Time of circulation is less due to higher concentration of operation and lower

extra time
 Higher flexibility
 Lower magnitude of optimization
 Lower cost of testing

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 Lower cost of waste product

 Operate mayny shifts by a continuous way
 Lower requirement of worker
 Higher performance
 Higher productive capacity
Construction of CNC
There are two main parts:
- Actuator: base plate, frame, machine table, rotary table, ball lead screw,
hybrid bearing of tool, main spindle assembly & lead rail

- Control: motor, control system and center computer. General model

of CNC machine:

1. Actuator unit

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a. Block and Base plate

Use cast –iron to manufacture

Requirement:

- High stiffness
- Vibration protector devices
- Heat stability
- Purpose
- Machining accuracy
- Base plate props for stability and balance of machine

b. Table machine

Table machine iss used to hold workpieces or holding devices

Requirement: High stiffness, stability and movement accuracy

c. Main spindle features:

Assemble tools in this place. Movement of spindle will create cutting force to cut
workpieces in machining process

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- Spindle is controlled by motors( Servo)

- Types of main spindle control: direct control, gear control and band control

d. Directive band

Direct movements of band respect to X, Y and movement of Z of mani spindle

e. Screw , nut

f. Tool hybrid bearing

Use to contain cutting tools reserving for machining process

g. Kinematic chain of machine

- Kinematic chain of shear rate

- Kinematic chain of movement of cutting tools

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2. Structure of control unit

a. Main control unit on CNC

- MCU

- Driving unit

Control unit combines funtions to control machine:

+ Datainput

+ Dataprocessing

+ Dataoutput

+ Machine I/Ointerface

Hardware control unit: CPU, RAM, ROM, BUS, PMC, SERVO, Interfacing unit

b. Kinds of motor on CNC

- DC motor
- AC motor
- Step motor
- Servo motor

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Chapter II. CUTTING DRIVE SYSTEM DESIGN

A. BALL SCREW CALCULATION

I. BALLSCREW CALCULATION FOR X AXIS
1. Design conditions :
- Type of CNC machine : Milling machine
- Normal force (z direction ) : Fmz = 900kgf = 9000N
- Mass of the work: M =300 kg
- Table mass : M x =200 kg
- Maximum speed ( no load ) : V1 =20m/min
- Maximum speed ( load ) : V2 = 10mm/min

- Maximum acceleration : a =0,5g = 5m/ s 2

- Required life : Ls = 50 ( km )
- Drive motor : N max = 2000rpm
- Position accuracy : ±0,03/1000mm
- Repeatability : ±0,005mm
- Lost motion : ±0,02mm ( no load )
- Sliding surface friction coefficient : 𝜇 =0,1
- Maximum stroke : Lx = 550𝑚𝑚

2. Lead selection :
From the maximum rotational speed of motor N max and rapid traverse speed of table
Vmax , lead l is :

𝑉𝑚𝑎𝑥 20000
𝑙≥ = = 10𝑚𝑚
𝑛𝑚𝑎𝑥 2000

 Choose l = 10mm

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3. Shaft and ball-bearing calculation for machine table moving along X axis :
3.1. Work condition and data calculated :
 Work condition :
- Sliding resistance : Fa = 𝜇g(M + M x ) = 0,1  10  ( 300 + 200) = 500N = 50 kgf
 Data calculated :
 Type of ball bearing
 Accuracy grade
3.2. Ballscrew nut selection
3.2.1. Axial force

- Preliminảy selection :

Choosing type of support for ballscrew :

Although CNC machines have rotation speed of screw or velocity of work table
not too large but to meet the requirements about high quality of products when
machining on CNC machines, the navigation system requirements high precision. So
we choose type of support for screw is fix-support :

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With this type of support, two coeciffients depending on the type fitted f and 
to receive valid: f = 15.1 and  = 3.927
 Data :
+ The main cutting force : Fm = 18000N = 1800 kgf
+ Normal force ( z direction ) : Fz = 9000N
+ Friction coefficient : μ = 0,1
+ Total mass : m= M + M x = 500 kg
+ Sliding surface friction force: f = 500 N
+ Gravitational acceleration : g= 10 m/ s 2
+ Work acceleration : a = 0.5g = 5 m/ s 2

 Axial force calculating :

- At the time acceleration (turn left):
Fa1 = μ(mg+ Fz ) + ma + f = 0,1  (500  10 + 9000)+ 500  5 + 500 = 4400 N

- Constant speed (turn left ):

Fa 2 = μ(mg + Fz ) + f = 0,1(500  10 + 9000) + 500 = 1900 N

- At the time working (turn right):

Fa 3 = Fm + μ(mg + Fz ) + f = 18000 + 0,1  (500  10 + 9000 ) + 500 = 19900N

- At the time deceleration (turn right):

Fa 4 = μ(mg + Fz ) - ma + f = 0,1  (500  10 + 9000) – 500  5 + 500 = - 600 N

Mean load :

Where:
 F1max , F1max : Maximum axial force when machining and not machining.

 N1max , N 2 max : Maximum rotation of shaft when machining and not machining.

 T1, T2: operating time with load or without load.

Axial force and percent respectively:

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Data Axial force Rotation speed Time

(kGf) l = 10mm
rpm %
Type of work
Rapid feed F1 = 440 2000 30
Cutting F2 = 1990 1 70

 Mean load :

3 4403 × 2000 × 0.3 + 19903 × 1 × 0.7

𝐹𝑚𝑥 = √ = 455.11 𝑘𝑔
2000 × 0.3 + 1 × 0.7

Mean rotation is : Nm = 2000×0.3 + 0.7 = 601 (rpm)

3.2.2. Basic rate load selection (Co, Ca)

 Static load :
Corresponding equations :
C0 = fs . Fa max

Where:
- C0 : Static load
- fs: static strenght factor, with machine tool is fs = 1,5 – 3 (chọn fs = 2)
- Fa max : maximum axial force acting on ball-scrwew
C0 = 2×19900 = 39800 N

 Dynamic load :

Ls
Ca  3  Fmx  Fw
l
Where:
 𝐹𝑚𝑥 is the mean load
 𝑓𝑤 dynamic load factor of tool machine, choose follow this table:

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Type working Velocity of cutting fw

Lighting V < 15 (m/min) 1.0 - 1.2

Normal 15 < V < 60 (m/min) 1.2 – 1.5
Heavy V > 60 (m/min) 1.5 – 3.0

Choose 𝑓𝑤= 1,3

 𝐿𝑠 : required life of ball screw (km)
 𝑙 is working length ( mm )

50
 Ca  3  455.111.3  266.03 (kgf)
550
So choosen the ballscrew have dynamic load Ca  267kgf

3.2.3. Choose type of ball :

In case stiffness is a major concern, lost motion becomes less important,
following specifications are to be selected :
+ External circulation Ballscrew
+Type : FDWC
+ Number of circuit : B× 3 hoặc B x 2

3.2.4. Diameter of screw :

L= maximum stroke + length nut + margin = 550 + 100 + 300 =950mm
Screw shaft supported method is fix-support -> f = 15.1
Select motor rotation speed for approximately 80% compared with the rotational
speed limits so we have :
n=80%. Nmax = 80%. 2000 = 1600 rpm.
 Root diameter :
𝑛 × 𝐿2 1600 × 9002
𝑑𝑟 = = = 8.6𝑚𝑚
𝑓 × 107 15.1 × 107

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3.2.5. Choose series :

From above results :
Lead : 10mm
Root diameter: 𝑑𝑟 ≥8.6
Static load : C0 = 39800𝑁
Dynamic load : Ca = 2670𝑁
Choose series :
 Type of ball screw : DFT 2510-3.5
 Shaft diameter : 25 mm
 Lead : 10mm
 dr = 20.5 mm
 Static load: C0 = 44200N
 Dynamic load: Ca = 21100N

The length of ball screw shaft :

L= maximum stroke + nut length + margin
L  550 + 147 + 300 = 997 mm

 Rough check :
- Life :
Ca 3 2110
Ls  ( ) l  ( )3  550  24947( km)
Fmx Fw 455.111.3

- Allowable velocity :
Chosse the fix-support type : f = 15.1
𝑑𝑟 7
20.5
𝑛= 𝑓× × 10 = 15.1 × × 107 = 3114 𝑟𝑝𝑚 > 2000
𝐿2 9972

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Both life expectancy and work speed are greater than the design requirements.
So the choice as above is satisfied.

3.2.6. Accuracy of length

Required accuracy of positon is : ±0,03/1000mm
Choose level of accuracy with deviation& accumulation strain:
 Accuracy grade : C3
 E = 0,029/1600mm
 E = 0,018mm
3.2.7. Shift due to temperature ( seeting 3℃ )
+ Shift due to temperature:
L = 𝜌. 𝜃. 𝐿 = 12  10  3  997 = 0,036mm.
6

+ Acting force :
L E dr 2 0.036  2.1104    20.52
F  L  K s    250.28 kgf
4L 4  997

4. Clusters bearing selection

 Choose clusters bearing
Screw shaft is fix- support so we choose the clusters bearing like following figure :

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The diameter of the screw shaft is 25mm so we choose type of ball bearing is
BL025101000+A000

Have :
- Axial force acting on each shaft : Fmx  455.11 kgf

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- Mass : m = 500 kgf

- Force acting on 4 ball-bearing are the same :
mg 500 10
Fr    1250 N
4 4
Calculate the ratio : Fmx / Co
Fmx 455.11
  0.12
Co 3840

Take this ratio to following figure to fine the corresponding of e for radial contact
groove ball bearing.

 e = 0.3
Fmx
From the ratio and compare it to the value of e:
VFr

Fmx 455.11
  3.64 >> e
VFr 1 125

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V= 1 because the inner ring is rotating.

Since the ratio is greater than e, extract the X and Y factor from above figure as X =
0.56 and Y = 1.45
 the equivalent load can be calculated :
P  XVFr  YFmx  0.56 1125  1.45  455.11  729.91 kgf

Test : Co  P  Fr1/3  729.911251/3  3650 < 3840 kgf

 the life of bearing :
3 3
Ca 1440
L   7.68 millions of revolution
P 729.91
So the bearing is accepted.

II. CALCULATING AND CHOOSING BALL SCREW FOR Y AXIS

1. Design conditions :
- Type of CNC machine : Milling machine
- Normal force ( z direction ): Fmz = 900kgf = 9000N
- Mass of the work: M =500 kg
- Table mass : M y =140 kg
- Maximum speed ( no load ) : V1 =20m/ph
- Maximum speed ( load ) : V2 = 10mm/ph

- Maximum acceleration : a =0,5g = 5m/ s 2

- Required life : Ls = 50 ( km )
- Drive motor : N max = 2000rpm
- Position accuracy : ±0,03/1000mm
- Repeatability : ±0,005mm
- Lost motion : ±0,02mm ( no load )
- Friction coefficient : 𝜇 =0,1
- Maximum stroke : Lx = 400𝑚𝑚

2. Lead selection :
From the maximum rotational speed of motor N max and rapid traverse speed of table
𝑉𝑚𝑎𝑥 20000
Vmax , lead l is :𝑙 ≥ = = 10𝑚𝑚
𝑛𝑚𝑎𝑥 2000

 Choose l = 10mm

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3. Shaft and ball-bearing calculation for machine table moving along Y axis :
3.1. Work condition and calculated data :
 Work condition :
- Sliding resistance : Fa = f = 𝜇g( M + M x ) = 0,1  10  ( 500 + 140) = 640N = 64
kgf
 Data calculated :
 Type of ball bearing
 Accuracy grade
3.2. Selecting the ballscrew nut :
3.2.1. Axial force :

With this type of support, two coeciffients depending on the type fitted f and 
to receive valid: f = 15.1 và  = 3.927
 Data :
+ The main cutting force : Fm = 18000N = 1800 kgf
+ Normal force ( z direction ) : Fz = 9000N
+ Friction coefficient of ball : μ = 0,1
+ Toatal mass : m= M + M x = 640 kg
+ Friction force of sliding : f = 640 N
+ Graviaty acceleration : g= 10 m/ s 2

+ Work acceleration: a = 0.5g = 5 m/ s 2

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 Axial force calculating :

- At the time acceleration (turn left ):
Fa1 = μ(mg+ Fz ) + ma + f = 0,1  (640  10 + 9000)+ 640  5 + 640 = 5380 N

- At the time constant speed (turn left ):

Fa 2 = μ(mg + Fz ) + f = 0,1(640  10 + 9000) + 640 = 2180 N

- At the time working (turn right ):

Fa 3 = Fm + μ(mg + Fz ) + f = 18000 + 0,1  (640  10 + 9000 ) + 640 = 20180N

- At the time decceleration (turn right):

Fa 4 = μ(mg + Fz ) - ma + f = 0,1  (640  10 + 9000) – 640  5 + 640 = - 1020 N

Mean load :

Where:
 F1max , F1max : Maximum axial force when machining and not machining.

 N1max , N 2 max : Maximum rotation of shaft when machining and not machining.

 T1, T2: operating time with load or without load.

Axial force and percent respectively:
Data Axial force Rotation speed Time
(kGf) l = 10mm
rpm %

Type of work
Rapid feed F1 = 538 2000 30
Cutting F2 = 2018 1 70

 The mean load :

3 5383 × 2000 × 0.3 + 20183 × 1 × 0.7

𝐹𝑚𝑥 = √ = 548.6 𝑘𝑔
2000 × 0.3 + 1 × 0.7

Mean rotation : Nm = 2000×0.3 + 0.7 = 601 (rpm)

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3.2.2. Calculating basic rate load (Co, Ca)

 Static load :
Corresponding equations :
C0 = fs . Fa max

Where:
- C0 : Static load
- fs: static strength factor, for machinetool is fs = 1,5 – 3 (chọn fs = 2)
- Fa max : Maximum axial force acting on ball-screw
C0 = 2×20180 = 40360 N

 Dynamic load :

Ls
Ca  3  Fmx  Fw
l
Where:
 𝐹𝑚𝑥 : mean load
 𝑓𝑤 : dynamic load factor, choose follow this table:
Type working Velocity of cutting fw

Lighting V < 15 (m/min) 1.0 - 1.2

Normal 15 < V < 60 (m/min) 1.2 – 1.5

Heavy V > 60 (m/min) 1.5 – 3.0

Choose 𝑓𝑤= 1,3

 𝐿𝑠 : require life of ball screw. (km)
 𝑙 is working length ( mm )

50
 Ca  3  548.6 1.3  356.6 (kgf)
400
So we choose the screw has dynamic load Ca  357kgf

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3.2.3. Selecting the type of nut :

In case stiffness is a major concern, lost motion becomes less important, following
specifications are to be selected :
+ External circulation Ballscrew
+ Type : FDWC
+ Number of circuit : B× 3 hoặc B x 2
3.2.4. Selecting the root diameter of shaft :
L= Maximum stroke + length nut + margin = 400 + 100 + 300 =800mm
Screw shaft supported method is fix-support -> f = 15.1
Select motor rotation speed for approximately 80% compared with the rotational
speed limits so we have : n=80%. Nmax = 80%. 2000 = 1600 rpm.
 Root diameter :
𝑛 × 𝐿2 1600 × 9002
𝑑𝑟 = = = 8.6𝑚𝑚
𝑓 × 107 15.1 × 107
3.2.5. Choose series
From above results :
Lead : 10mm
Root diameter: 𝑑𝑟 ≥8.6
Static load : C0 = 40360𝑁
Dynamic load : Ca = 3566𝑁
Choose series :
 Type of ball screw : DFT 2510-3.5
 Shaft diameter : 25 mm
 Lead : 10mm
 dr = 20.5 mm
 Static load: C0 = 44200N
 Dynamic load: Ca = 21100N

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The length of shaft :

L= Maximum stroke + nut length + margin
L  400 + 147 + 300 = 847 mm

 Rough check :
- Life working:
Ca 3 2110 3
Ls  ( ) l  ( )  400  10358( km)
Fmx Fw 548.6 1.3

- Allowable rotation :
Type of support is fixed – support so : f = 15.1
𝑑𝑟 7
20.5
𝑛= 𝑓× 2
× 10 = 15.1 × 2
× 107 = 4314 𝑟𝑝𝑚 > 2000
𝐿 847
Both life expectancy and work speed are greater than the design requirements.
So the choice as above is satisfied.

3.2.6. Accuracy of length

Required accuracy of positon is : ±0,03/1000mm
Choose level of accuracy with deviation& accumulation strain:
 Accuracy grade : C3
 E = 0,029/1600mm

27
Project 1

 E = 0,018mm
3.2.7. Shift due to temperature ( seeting 3℃ )
+ Shift due to temperature:
L = 𝜌. 𝜃. 𝐿 = 12  10  3  847 = 0,03mm.
6

+ Acting force :
L E dr 2 0.03  2.1104    20.52
F  L  K s    245.5 kgf
4L 4  847

4. Selecting the clusters bearing:

 Choose clusters bearing
Screw shaft is fix- support so we choose type of clusters bearing like following
figure:

28
Project 1

Shaft diameter of ballscrew is 25mm so we choose type of ball bearing is

BL025101000+A000

Have :
- Axial force acting on each shaft : Fmx  548.6kgf
- Mass : m = 640 kgf
- Force acting on 4 ball-bearing are the same :
mg 640 10
Fr    1600 N
4 4
Calculate the ratio : Fmx / Co
Fmx 548.6
  0.14
Co 3840

29
Project 1

Take this ratio to following figure to fine the corresponding of e for radial contact
groove ball bearing.

 e = 0.3
Fmx
From the ratio and compare it to the value of e:
VFr

Fmx 548.6
  3.43 >> e
VFr 1 160

V= 1 because the inner ring is rotating.

Since the ratio is greater than e, extract the X and Y factor from above figure as X =
0.56 and Y = 1.45
 the equivalent load can be calculated :
P  XVFr  YFmx  0.56 1160  1.45  548.6  885.07 kgf

 the life of bearing :

3 3
C 1440
L a   4.3 millions of revolution
P 885.07
So the bearing is accepted.

30
Project 1

B. LINEAR GUIDEWAYS CALCULATION :

Choose type of linear guides has series : Model NH15AN
- Dynamic load : Ca  14.2 kN

- Static load : C0  20.7 kN

- Work condition :
Data X table Y table
Mass of work (kgf) 300 500
Table mass (kgf) 200 140
Velocity when no load (m/s) 0.35 0.35
Working acceleration (m/ s 2 ) 5 5

Time table when X table move:

v 0.35
Time to reach a = 5m/ s 2 with v = 0.35m/s is : t1 = t3 =   0.7 s
a 0.5

v2 0.352
And the distance 𝑋 = = = 0,01225m = 12,25 mm.
2a 25

So the distance that X table acceleration/decceleration is 12,25 mm ⇒ the distance

that X table move uniform is : ls - (12,25x2)

Working X table Y table

ls = 550 mm ls = 400 mm
Acceleration (mm) 12.25 12.25
Constant (mm) 525.5 375.5
Decceleration (mm) 12.25 12.25

31
 Project 1

Distance psitionings:
 Y table: Distance positioning :
- If X table in the middle of Y table then there is no flip torque .So, when calculate
should set X table in the farthest position with center of Y table for operating system
working on hardest.
- When calculate data for Y table, set X table and blank is a single block has mass
equal to total mass ( mo+ mx ) = 860kg.
- Regarded center of X table, Y table, cutting tool lying on the same straight line.
Distance positioning : (mm) X table Y table

The distance between two cursors on the same 450 235

rail l1
The distance between two cursors on the 235 332
different rail l2
According to the z axis, center of blank is same 0 275
with center of table: l3
Distance from center of blank to center of table : 0 200
l4
The height fromcenter of ballscrew shaft to the 85 274
table: l5
The height from center of ballscrew shaft to the 285 474
blank: l6

32
Project 1

X table acceleration to the right or decceleration to the left.

Y table acceleration forward or decceleration downward.
The acting force when machining:
1. Calculate the load that each carriage exerts
 Uniform motion,radial load Pn

Uniform motion, radial load Pn (N) X table Y table

m1 g m1 gl3 m1 gl4 m2 g Fmz 3500 2430

P1     
4 2l1 2l2 4 4
m g m gl m gl m g F 3500 8281
P2  1  1 3  1 4  2  mz
4 2l1 2l2 4 4
m g m gl m gl mg F 3500 5270
P3  1  1 3  1 4  2  mz
4 2l1 2l2 4 4
m g m gl m gl mg F 3500 -582
P4  1  1 3  1 4  2  mz
4 2l1 2l2 4 4

 Acceleration to the left, Pnla1 :

Acceleration to the left, Pnla1 X table Y table

m1a1l6 m2 a1l5 2931 -499
1 1  P1 
Pla 
2l1 2l1
mal m al 3119 6168
P2la1  P2  1 1 6  2 1 5
2l1 2l1
mal m al 3119 3157
P3la1  P3  1 1 6  2 1 5
2l1 2l1
mal m al 2931 -3511
P4la1  P4  1 1 6  2 1 5
2l1 2l1
mal
Lateral load : Pt1la1   1 1 4 0 -1064
2l1
mal
Pt2la1  1 1 4
0 1064
2l1

Pt3la1 
m1a1l4 0 1064
2l1
mal
Pt4la1   1 1 4
0 -1064
2l1

33
Project 1

 Decceleration to the left Pnla3 :

Decceleration to the left Pnla3 X table Y table

m1a3l6 m2 a3l5 4069 5359
1 3  P1 
Pla 
2l1 2l1
mal m al 2931 5351
P2la3  P2  1 3 6  2 3 5
2l1 2l1
mal m al 2931 2341
P3la3  P3  1 3 6  2 3 5
2l1 2l1
mal m al 4069 2347
P4la3  P4  1 3 6  2 3 5
2l1 2l1
mal
Lateral load : Pt1la3  1 3 4 0 1064
2l1
mal 0 -1064
Pt2la3   1 3 4
2l1
mal 0 -1064
Pt3la3   1 3 4
2l1
mal 0 1064
Pt4la3  1 3 4
2l1

 Acceleration to the right Pn ra1 :

Acceleration to the right Pn ra1 X table Y table

m1a1l6 m2 a1l5 4069 5359
Pra
1 1  P1  
2l1 2l1
mal m al 2931 5351
P2 ra1  P2  1 1 6  2 1 5
2l1 2l1
mal m al
P3 ra1  P3  1 1 6  2 1 5
2931 2341
2l1 2l1
mal m al 4069 2347
P4 ra1  P4  1 1 6  2 1 5
2l1 2l1
mal
Lateral load : Pt1ra1  1 1 4 0 1064
2l1
mal
Pt2 ra1   1 1 4
0 -1064
2l1
mal
Pt3 ra1   1 1 4
0 -1064
2l1
mal 0 1064
Pt4 ra1  1 1 4
2l1

34
Project 1

 Decceleration to the right: Pn ra3

Decceleration to the right Pnla3 X table Y table

m1a3l6 m2 a3l5 2931 -500
Pra
1 3  P1  
2l1 2l1
mal m al 4069 11210
P2 ra3  P2  1 3 6  2 3 5
2l1 2l1
mal m al 4069 8199
P3 ra3  P3  1 3 6  2 3 5
2l1 2l1
mal m al 2931 -3512
P4la3  P4  1 3 6  2 3 5
2l1 2l1
mal
Lateral load : Pt1ra3   1 3 4 0 -1064
2l1
mal 0 1064
Pt2 ra3  1 3 4
2l1
mal 0 1064
Pt3 ra3  1 3 4
2l1
mal 0 -1064
Pt4 ra3   1 3 4
2l1

2. Equivalent load :
 In constant motion:

Constant motion X table Y table

PE1  P1 3500 2430
PE 2  P2 3500 8281
PE 3  P3 3500 5270
PE 4  P4 3500 -582

 Acceleration to the left:

Acceleration to the left X table Y table
PE1la1  Pla
1 1  Pt1la1
2931 1563
PE 2la1  P2la1  Pt2la1 3119 7232

3 1  Pla
3 1  Pt3la1
Pla 3119 4221
PE 4la1  P4la1  Pt4la1 2931 4475

35
Project 1

 Decceleration to the left :

Decceleration to the left X table Y table
PE1la3  Pla
1 3  Pt1la3
4069 6423
PE 2la3  P2la3  Pt2la3 2931 6415
PE 3la3  Pla
3 3  Pt3la3
2931 3405
PE 4la3  P4la3  Pt4la3 4069 3411

 Acceleration to the right

Acceleration to the right X table Y table
PE1ra1  Pra
1 1  Pt1ra1
4069 6423
PE 2 ra1  P2 ra1  Pt2 ra1 2931 6415
P3ra1  P3ra1  Pt3ra1 2931 3405
PE 4 ra1  P4 ra1  Pt4 ra1 4069 3411

 Decceleration to the right

Decceleration to the right X table Y table
PE1ra3  Pra
1 3  Pt1ra3
2931 1564
PE 2 ra3  P2 ra3  Pt2 ra3 4069 12274
P3ra3  P3ra3  Pt3ra3 4069 9263
PE 4 ra3  P4 ra3  Pt4 ra3 2931 4576

3. Check static factor:

C0 20700
- X table: f sx    6.64
PE 2la1 3119

- Y table :
C0 20700
f sx    2.86
PE 2la1 7232

Satisfied with safe requirement.

36
Project 1

4. Average load:
The average load ( N ) X table Y table
PE1la13 X 1  PE31 X 2  PE1la33 X 3  PE1ra13 X 1  PE31 X 2  PE1ra33 X 3 3529 2789
Pm1  3
2ls

PE 2la13 X 1  PE32 X 2  PE 2la33 X 3  PE 2 ra13 X 1  PE32 X 2  PE 2 ra33 X 3 3493 8317

Pm 2  3
2ls

PE 3la13 X 1  PE33 X 2  PE 3la33 X 3  PE 3ra13 X 1  PE33 X 2  PE 3ra33 X 3 3943 5336

Pm 3  3
2ls

PE 4la13 X 1  PE34 X 2  PE 4la33 X 3  PE 4 ra13 X 1  PE34 X 2  PE 4 ra33 X 3 3529 1570

Pm 4  3
2ls

5. Nominal life: Ln

Choose f w = 1,2:

Nominal life : Ln (km) X table Y table

3
 C  1885 3819
L1  50   
 f w Pm1 
3
 C  1944 144
L2  50   
 f w Pm 2 
3
 C  1351 545
L3  50   
 f w Pm3 
3
 C  1885 21408
L4  50   
 f w Pm 4 

=> So the linear guides are satisfied.

37
 Project 1

Chapter 3 : MOTOR CALCULATION

I. MOTOR CALCULATION FOR X TABLE

- Maximum rotational speed : 2000 vòng/phút
- Time to reach maximum speed : 0,7s

1. Moment of inertial :
- Screw shaft :

   7.8 103
JB  D L 
4
 2.54  99.7  11.93(kgf .cm2 )
8 8
- Moving part :
2 2
 l   1 
 W   
2
JW  500   12.67( kgf .cm )
 2   2 
- Coupling :
  l '  D '4 7.8  103    (3D)  (1.7 D) 4
JC  
32 32
7.8  103    (3  2.5)  (1.7  2.5) 4
  1.87(kgf .cm 2 )
32
'
D is diameter of screw shaft, l is the connecting shaft length.
So the moment of inertial of the ballscrew is :

J L  J B  J W  JC  11.93  12.67  1.87  26.47(kgf .cm2 )

2. Driving torque :
In this case, the time sharing of machine working at acceleration condition is limited.
Assuming the machine works at constant speed, the torque caused
by angular acceleration is then neglected.
- Preloading force :
Fa 0  l 663.3 1
Tp  k   0.3   31.7(kgf .cm)
2 2
- The friction torque :

38
Project 1

Fa  l 440 1
+ Rapid feed : Ta    77.8(kgf .cm)
2  2  0.9

1990 1
+ Cutting : Tc   351.9(kgf .cm)
2  0.9
The maximum require driving torque is preloading torque plus friction torque of
heavy cutting: TL  Tp  Tc  383.6(kgf .cm)

3. Motor choosing :
Select servo motors to control the axis motion trajectory Ox

Input data

+ Ball screw lead : l =10mm

+ Sliding friction coefficient between the steel and iron we choose 𝜇=0,1

+ Gravitational acceleration g = 10m/s2

+ The weight of the head is moving m = 500kg

+ The tilt angle of the shaft α= 0 ̊.

+ Deceleration gear ratio i = 1. (Due to choose the motor directly connected to the
vit-me without over gear)

+ The performance of the machine 𝜼 =0,9.

+ Maximum cutting force Fm = 1990kgf

+ Maximum speed of motor 2000rpm

a) Friction moment
m.g..l.cos  500 10  0.1 0.01 cos 0
M fric    0.9 Nm
2 .i. 2 1 0.9
b) Anti-gravity torque of texture

Due to horizontal structure 𝛼 = 0 so Mwz = 0

c) Linear velocity

39
Project 1

With screw diameter is selected as 25mm so:

 Dn   25  2000
vmax    2.6m / s
60 1000 60000
d) Moment of machine
l  Fm 0.01 19900
M machine    13.5 Nm
2  i   vmax 2  1 0.9  2.6
e) Static moment

M sta  M fric  M wz  M machine  0.9  0  13.5  14.4Nm

f) Speed of motor
vmax  i 2.6 1
nnoml    260rpm
l 0.01
Based on the static moment of the engine and the motor speed, we choose its engine
1FT6086 – 8AC7 moment is 22.5 Nm boots and a maximum rotational speed
2000rpm as shown below:
Requirement : nmotor ≥ nnoml
Mmotor ≥Mstat

4. Check the time required to achieve maximum velocity :

40
 Project 1

The time required to reach maximum velocity is:

Where :
- J is the total moment of inertia. (Torque + torque calculations for by
motor - Rotor Inertia J)
- TM'  2TM
- TL is the torque
- f is the factor of safety. f = 1.2
Re-arrangement:
(26.47  66.5) 104 2  2000
ta   1.2  0.35s  0.7 s
2  22.5  383.6 10 102 60
 satisfied.
5. Calculation of strain acting on the screw :
F F 19900  4 N
   max2   60.3N / mm2  60.3 106 2
A  dr   20.52
m
4
Tmax  TL  383.6kgf .cm  3836kgf .mm
 dr 4   20.54
J   17338.6mm4
32 32
T  r 3836 12.5 N 6 N
   2.8  2.8  10
J 17338.6 mm 2 m2
N
 max   2   2  60.4 106 2
m
Selecting the material of shaft is 50CrMo4 has :
- Yield strength is 5.5 108 N / m2 >  max
- Tensile strength is 8 108 N / m 2 >  max
 the choosen screw shaft is satisfied.
6. Critical load of screw shaft :
 2 NEI dr 4 20.54
P  2
 m 2
 10 3
 500  2
103  97845kgf  19900kgf
L L 950

Therefore the shaft of ball screw is safe.

41
 Project 1

II. MOTOR CALCULATION FOR Y TABLE :

- Maximum rotation speed : 2000 rpm

- Time to reach maximum speed : 0,7s
1. Moment of inertial:
- Screw shaft :

   7.8 103
JB   D4  L   2.54  84.7  10.13(kgf .cm 2 )
8 8
- Moving part :
2 2
 l   1 
J W  W    640     16.21(kgf .cm )
2

 2   2 
- Coupling :

  l '  D '4
7.8 103    (3D)  (1.7 D) 4
JC  
32 32
7.8  103    (3  2.5)  (1.7  2.5) 4
  1.87(kgf .cm 2 )
32
'
D is diameter of screw shaft, l is the connecting shaft length.
- So the moment of inertial of the ballscrew is :

J L  J B  J W  JC  10.13  16.21  1.87  28.21(kgf .cm2 )

2. Driving torque :
In this case, the time sharing of machine working at acceleration condition is limited.
Assuming the machine works at constant speed, the torque caused
by angular acceleration is then neglected.
- Preloading torque :
Fa 0  l 672.7 1
Tp  k   0.3   32.1(kgf .cm)
2 2
- Friction torque :

42
 Project 1

Fa  l 538 1
+ Rapid feed : Ta    95.1(kgf .cm)
2  2  0.9

2018  1
+ Cutting : Tc   356.9(kgf .cm)
2  0.9
The maximum require driving torque is preloading torque plus friction torque of
heavy cutting: TL  Tp  Tc  389(kgf .cm)

3. Choose motor :
Select servo motors to control the axis motion trajectory Ox
Input data

+ Screw pitch l =10mm

+ Sliding friction coefficient between the steel and iron we choose 𝜇=0,1

+ Gravitational acceleration g = 10m/s2

+ The weight of the head is moving m = 640kg

+ The tilt angle of the shaft α= 0 ̊.

+ Deceleration gear ratio i = 1. (Due to choose the motor directly connected

to the vit-me without over gear)
+ The performance of the machine 𝜼 =0,9.

+ Maximum cutting force Fm = 2018kgf

+ Maximum speed of motor 2000rpm
b) Friction moment

m.g..l.cos  640 10  0.1 0.01 cos 0

M fric    1.1Nm
2 .i. 2 1 0.9
b) Anti-gravity torque of texture

Due to horizontal structure 𝛼 = 0 so Mwz = 0

43
Project 1

c) Linear velocity

With screw diameter is selected as 25mm so:

 Dn   25  2000
vmax    2.6m / s
60 1000 60000
d) Moment of machine
l  Fm 0.01 20180
M machine    13.7 Nm
2  i   vmax 2  1 0.9  2.6
e) Static moment

M sta  M fric  M wz  M machine  1.1  0  13.7  14.8Nm

f) Speed of motor
vmax  i 2.6  1
nnoml    260rpm
l 0.01

Based on the static moment of the engine and the motor speed, we choose its engine
1FT6 086 – 8AC7 moment is 22.5 Nm boots and a maximum rotational speed
2000rpm as shown below:

Requirement : nmotor ≥ nnoml

Mmotor ≥Mstat

44
 Project 1

4. Check the time required to achieve maximum velocity :

The time required to reach maximum velocity is:

Where :
- J is the total moment of inertia. (Torque + torque calculations for by
motor - Rotor Inertia J)

- TM'  2TM
- TL is the torque

- f is the factor of safety. f = 1.2

Re-arrangement:
(28.21  66.5) 104 2  2000
ta  2
 1.2  0.39s  0.7 s
2  22.5  389 10 10 60
 satisfied.
5. Calculation of strain acting on the screw :
F F 20180  4 6 N
   max2   61.3 N / mm 2
 61.3  10
A  dr   20.52 m2
4
Tmax  TL  389kgf .cm  3890kgf .mm
 dr 4   20.54
J   17338.6mm4
32 32
T  r 3890 12.5 N 6 N
   2.8  2.8  10
J 17338.6 mm 2 m2
N
 max   2   2  61.4 106 2
m
Selecting the material of shaft is 50CrMo4 has :

- Yield strength is 5.5 108 N / m2 >  max

- Tensile strength is 8 108 N / m 2 >  max
 the choosen screw shaft is satisfied.

45
Project 1

6. Critical load of screw shaft :

 2 NEI dr 4 20.54
P   m 2 10  500 
3
103  97845kgf  20180kgf
L2 L 950 2

Therefore the shaft of ball screw is safe.

46
Project 1

Chapter IV : CONCLUSION

Problem : Design the guidance system for 3 -axis CNC milling machine .

Based on the problem of selecting the details , parts used in CNC machines, we can
calculate :
1. Ball screw shaft X and Y. With a given length of working, we determined the
allowable diameter matching the requirements speed of the machine and dynamic
load factor response to the requirements load.
2. Determined the type of ball bearing needed for 2 shaft.
3. The motor has capacity, torque and starting torque suitable for acceleration ,
deceleration and phases work of the machine.
4. Selected the guide rails.

No Name Parameter Note

1
Ballscrew shaft X DFT 2510-3.5 NSK Co.
2
Ballscrew shaft Y DFT 2510-3.5 NSK Co.
3
Ball bearing shaft X BL025101000+A000 PMI Co.
4
Ball bearing shaft Y BL025101000+A000 PMI Co.
5
Linear guide shaft X NH15AN NSK Co.
6
Linear guide shaft Y NH15AN NSK Co.
7
Motor shaft X 1FT6086 – 8AC7 SIEMENS Co.
8
Motor shaft Y 1FT6 086 – 8AC7 SIEMENS Co.

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Project 1

Reference
- NSK ball screw, NSK linear guide way catalog.
- PMI ball bearing catalog
- Hệ thống truyền động và dẫn hướng máy CNC 01-2014 – Bộ môn GCVL và
DCCN
- Giáo trình dung sai lắp ghép và kỹ thuật đo lường – Giáo sư Ninh Đức Tốn

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