CAD/CAM Principles and Applications 10 CNC Hardware Basics 10-1/10-20

by P.N.Rao

10. CNC Hardware Basics

10.1 Structure of CNC machine tools

Table 10.1 Some design criteria for CNC machine tool design
[Rogers]

Machine Response Component Operating and cost

characteristics considerations
Type of command signal Undamped Reliability
Input configuration natural frequency Maintainability
Maximum feed rate Power Cost of operation
Static accuracy requirement Capital investment
Dynamic accuracy Friction Installation
Magnitude of load characteristics requirements
Range of travel Inertia
Weight of moving Stiffness
members Amount of
Power source backlash
Speed range
Bandwidth
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Fig. 10.1 Heavy machine tool structure of a CNC machining centre

(Courtesy Makino Milling Machines Co. Ltd., Tokyo,
Japan)
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Fig. 10.2 Schematic of a concrete bed of a CNC Turning centre

Fig. 10.3 Concrete bed of CNC Turning centre GF NDM-16 with

slant bed (Courtesy George Fischer, Switzerland)

10.2 Spindle design

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Fig. 10.4 Spindle design for a CNC turning centre

Fig. 10.5 Spindle design with an integral spindle motor and

cooling system for a CNC Machining centre (courtesy of
Hüller Hille GMBH, Germany)
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Fig. 10.6 Spindle assembly with the slideways of CNC vertical

axis machining centre

Fig. 10.7 Bifurcated column structure for CNC Machining centre to

improve torsional rigidity (see also Fig. 10.1)

10.3 Drives

The various drives used in CNC machines are:

x Spindle drives to provide the main spindle power for cutting.
x Feed drives to drive the axis as per the programme.
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Fig. 10.8 Typical torque speed characteristic of a 50 kW AC

spindle motor used for CNC Machine

Feed drives: The feed drives that are used in CNC machine tools
are

x DC Servo motors
x AC Servo motors
x Stepper motors
x Linear motors

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Fig. 10.9 —Typical step motor system. Precise step systems have
feedback loop (dotted line) using encoders or resolvers.
 CNC hardware basics, 10-7

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Fig. 10.10 — Step motor with permanent magnet rotor.

Stepper motors have a number of benefits, which call for their

use in motion control applications.
• Low cost
• Ruggedness
• Simplicity in construction
• High reliability
• No maintenance

Table 10.2: Comparison of Ball Screws vs Linear Motors

Characteristi Ball Screw Linear Motor

cs
Max speed 30 m/min (lead 120 m/min typical (180-
dependent) 240 m/min possible)
Max 0.5-1g 2-10g
acceleration
Static 9-18 kgf/Pm 7-27 kgf/Pm
stiffness
Dynamic 9-18 kgf/Pm 16-21 kgf/Pm
stiffness
Settling time 100 ms 10-20 ms
Max force 26.7 kN 9.0 kN/coil
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Reliability 6000-10 000 50 000 hours

hours

10.4 Actuation systems

Lead screws:

Table 10.3 Lead screw efficiencies

Efficiency (%)
Type High Median Low
Recirculating Ball 95 90 85
screw - nut
Acme with metal 55 40 35
nut*

* Since metallic nuts usually require a viscous lubricant, the

coefficient of friction is both speed and temperature dependent.

Fig. 10.11 Lead screw with Acme nut

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Fig. 10.12 — A recirculating ball screw and nut arrangement

(Courtesy THK Co. Ltd., Japan).

Fig. 10.13 — A recirculating ball screw and nut arrangement

with external return tube (Courtesy THK Co. Ltd.,
Japan).
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Fig. 10.14 — Pre-loading of the recirculating ball screw and nut

arrangement

The recirculating ball screws have a number of advantages

compared to the conventional type of screws.

Fig. 10.15 — Conventional slide way systems used in

machine tools

Linear Motion systems

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Fig. 10.16 — Antifriction guideways used in CNC machine tools

(Courtesy THK Co. Ltd., Japan).

Fig. 10.17 — Ball bush used for linear movement in CNC

machine tools (Courtesy THK Co. Ltd., Japan).
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Fig. 10.18 Use of recirculating ball screw and the LM device for axis
movement in the bed of a CNC machine tool (Courtesy
Makino Milling Machines Co. Ltd., Tokyo, Japan)

10.5 Feedback devices

x Encoders
x Linear scales
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Fig. 10.19 — The closed loop control system used for the control
in a CNC machine tool

Optical rotary encoder

Fig. 10.20 — The encoder disc for rotary position measurement.

Absolute encoder
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Incremental encoder

Fig. 10.21 — The absolute encoder disc for rotary position

measurement.

Fig. 10.22 — Operation of a digital rotary encoder for position

measurement
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Fig. 10.23 — The encoder disc for rotary position measurement.

Linear scale

Fig. 10.24 — The linear scale fixed to the machine tool structure
for direct position measurement.
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Fig. 10.25 — Principle of optical grating for position

measurement in linear scales.

10.6 Axes - Standards

Co-ordinate system

Fig. 10.26 Right hand co-ordinate systems

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Fig. 10.27 Finding directions in a Right Hand Co-ordinate System

and also the positive directions for rotary motions

Designating the Axes

First axis to be identified is the Z-axis. This is followed by the X

and Y axes respectively.

Z-Axis and Motion

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Fig. 10.28 Vertical axis Milling Machine or Machining centre

X-Axis

Y-Axis

Rotary Motions
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<
% :

Fig. 10.29 Axes designation for CNC turning centre with twin turrets
and driven tooling.

Fig. 10.30 CNC Horizontal axis boring mills in 3 and 4 axes versions
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Fig. 10.31 5 axes CNC Vertical axis machining centre configuration.