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Unit-5

Machine Tools: types and classification; NC, CNC etc., static,


dynamic and thermal consideration in machine tools.

CNC MACHINES: Introduction to CNC Systems, Fundamental


aspects of machine control, types of CNC machines,
Constructional Features of CNC Machines: Structure, Drive
Mechanism, gearbox, Main drive, feed drive, Spindle Motors,
Axes motors. Timing belts and pulleys, Spindle bearing, Slide
ways, Re-circulating ball screws Backlash measurement and
compensation, linear motion guide ways, Tool magazines, ATC,
APC, Chip conveyors. Retrofitting of Conventional Machine
Tools, Retrofitting of conventional machines with CNC.
HISTORY
US Air Force commissioned MIT to develop
the first "numerically controlled" machine
in 1949. It was demonstrated in 1952.
At 1970-1972 first Computer Numeric
Control machines were developed.
Today, computer numerical control (CNC)
machines are found almost everywhere,
from small job shops in rural communities
to companies in large urban areas.

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Conventional machines section
Some of the machines in this section are :
Bandsaw - The bandsaw is useful for cutting stock to size and roughing
out shapes. It cuts curved shapes very well.
Belt sander A belt sander is used to remove rough edges. It makes use
of an abrasive riding belt. Effective on wood, plastic and most metals.

Drilling machine
The drill press is mostly
used for drilling holes,
reaming, boring,
countersinking etc.
Power hacksaw A
type of hacksaw powered
either by its own electric
motor or connected to an
engine.
Power hacksaw Drilling machine
Surface grinder It is a machine tool used to
provide high precision surface finish. The
grinding wheel rotates in the spindle head, its
height adjustable. The workpiece is fed by a
horizontal table positioned below the grinding
wheel.

Surface grinder
Slotting machine - Similar to
a vertical shaper. The most
common use is to machine
straight, flat surfaces.
Slotting machine

And several other machines for sheet metal work, electroplating etc. , as
well as callipers, micrometers etc. for measurement and testing.
The 2 principal conventional machines on which we are focusing are the
lathe and milling machines.

Lathe Machine
Lathes are designed for precisely machining relatively hard materials. With
their inherent versatility, they are used in a wide range of applications, and can
machine a broad range of
materials.

These lathe machine


removes material from a
rotating work piece via
the linear movements of
various cutting tools,
such as tool bits and drill
bits.
Operations performed on a lathe
Turning The diameter of a part can be reduced to desired dimension.

Facing - A lathe can be used to create a smooth, flat, face very


accurately
perpendicular to the axis of a cylindrical part.

Parting - Deeper and narrower than a turning tool. It is designed for


making narrow grooves and for cutting off parts.

Drilling - A lathe can also be used to drill holes accurately concentric


with the centerline of a cylindrical part.

Boring - Boring is an operation in which a hole is enlarged with a single


point cutting tool.

Threading - External threads can be cut with a die and internal threads
can be cut with a tap.
Types of lathe
Centre lathe / bench lathe / engine lathe - The most basic type of lathe.

Toolroom Lathe - Lathe optimized for toolroom work. It has all of the
best optional features that may be omitted from less expensive models, such
as a collet closer, taper attachment, and others.

Turret lathes and capstan lathes - Used for repetitive production of


duplicate parts.

Multispindle lathe - Multispindle lathes have more than one spindle and
automated control.

CNC lathe - CNC lathes are rapidly replacing the older production lathes
due to their ease of setting and operation. The part may be designed by the
Computer-aided manufacturing (CAM) process, the resulting file uploaded
to the machine, and once set and trialled the machine will continue to turn
out parts under the occasional supervision of an operator.
Types of milling cutters
In vertical mills, milling cutters
with solid shafts are usually used.

End mills are designed for cutting


slots, keyways and pockets.

Two fluted end mills can be used


to plunge into work like a drill.
Ball end mills can produce a
fillet.
Operations done on Milling machines

Roughing
Finishing
Drilling
Boring (a) Rough (b) Finish (c) Counter boring
Slotting
Key way cutting
Gear cutting
Spur
Bevel
Worm
Helical
Computer and Numerically Controlled
Machines
Numerically Controlled (NC)
NC is the operation of M/c tool by a series of coded instructions consisting of
numbers, letters of the alphabets and symbols, which the MCU (Machine Control
Unit) can understand.

Computer numerically controlled (CNC)

When numerical control is performed under computer supervision, it is called


computer numerical control (CNC). Computers are the control units of CNC
machines. A programmer enters some information in the program, but the computer
calculates all necessary data to get the job done.

For both NC and CNC systems, working principles are the same. Only the way in
which the execution is controlled is different. Normally, new systems are faster,
more powerful, and more versatile.
Comparison between NC, CNC and DNC machine tools

NC Machine CNC Machine Tool SystemDNC Machine Tool


Tool System System
1. The part program is fed to 1. In CNC machine tool system, 1. The part program is fed to
the machine through the the program is fed to the the machine through the
machine through the Main computer
tapes or other such media.
computer.
2. In order to modify the 2. In order to modify the
2. The programs can be easily
program, the tapes have to program, single computer
modified with the help of is used
be changed. computer.
3. In NC machine tool 3. The microprocessor or 3. Large memory of DNC
system, tape reader is a minicomputer forms the allows it to store a large
part of machine control machine control unit. The amount of part program.
unit. CNC machine does not need
tape reader. 4. Same part program can
4. System has no memory be run on different
4. It has memory storage
storage and each time it is machines at the same
ability, in which part program time.
run using the tape. can be stored.
5. It can not import CAD files. 5. System can import CAD 5. The data can be
6. It can not use feedback files and convert it to part processed using the MIS
program. software so as to
system.
6. The system can use effectively carry out the
7. They are not software Production planning and
feedback system.
driven. scheduling.
7. The system is software
driven.
CNC TURNING

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CNC MILLING

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CNC LASER CUTTING

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CNC PLASMA CUTTING

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CNC PRESS

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CNC RAPID PROTOTYPING

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INDUSTRIES MOST AFFECTED
by CNC
Aerospace
Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mold making

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Various popular CNC control systems

1. ECS
2. LECS
3. NUM
4. SELCA
5. MARPOSS
6. Z-16
7. FANUC
8. FAGOR
9. FIDIA
10. DECKEL
11. SINUMERIC
12. HINUMERIC
13. HEIDENHAIN A CNC Milling center by DECKEL
14. GILDEMEISTER
The construction of CNC machines
1. Elements of motion transmission

Ball-screws and nut assembly


In a CNC machine, the connection between the screw and the nut is through
an endless stream of re-circulating steel balls, replacing sliding friction
threads with rolling friction. Advantages are higher efficiency, reversibility
and reduction in wear and tear.
Hydrostatic slideways
In the hydrostatic slideways air or oil is pumped into small pockets
machined into slides which are in contact with the slideway.
2. Computers
CNC machines use an on-board computer that allows the operator to read,
analyze, and edit programmed information. In CNC machine, computer
works on a binary principle, 0 for information and 1 for processing. Special
built-in software compiles the user entered program (in code language) into
machine language and the machine moves the tool by its servomotors.
3. Control systems

There are two types of control systems on CNC machines:


Open loop (less accurate)
Closed loop (more accurate)
The open loop control system does not provide positioning feedback to the control
unit. Since this control system only counts tool movement pulses and cannot
identify discrepancies in positioning, it is slightly inaccurate.
In closed loop control system, the electronic movement pulses are sent from the
control to the servomotor, enabling the motor movement. Movements are detected
by a feedback device (transducer), which can send a signal to the control for
checking after each step.
4. Drive motors

The drive motors control machine slide movement on CNC equipment. Types used :
1. Stepper motors (convert a digital pulse into a small rotation, mostly used in
applications where low torque is required )
2. DC servo motors (rotate in response to the applied voltage, used to drive lead
screw and gear mechanisms, provide higher-torque output)
3. AC servo motors (controlled by varying the voltage frequency to control speed,
more power than a DC servo, used to drive a lead screw and gear mechanism )
4. Fluid servo motors (variable speed motors, produce more power, in the case of
pneumatic motors, than electric servomotors)

5. Tool changers

Several different cutting tools are used to produce a part. The tools must be replaced
quickly for the next machining operation. For this reason, the majority of NC/CNC
machine tools are equipped with automatic tool changers. They allow tool changing
without the intervention of the operator.
An automatic tool changer grips the tool in the spindle, pulls it out, and replaces it
with another tool. Tool changers are equipped for either random or sequential
selection.
In random tool selection there is no specific pattern of tool selection.
In sequential tool selection, the tools must be loaded in the exact order in which
they are called for in the program.
CNC PROGRAMMING

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INFORMATION NEEDED by a
CNC
1. Preparatory Information: units, incremental or
absolute positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle
speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of
rotation, stops for part movement
This information is conveyed to the machine
through a set
of instructions arranged in a desired sequence
Program.
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BLOCK FORMAT

Sample Block

N135 G01 X1.0 Y1.0 Z0.125 F5

Restrictions on CNC blocks


Each may contain only one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feedrate
Each may contain only one specified tool or spindle
speed
The block numbers should be sequential
Both the program start flag and the program number
must be independent of all other commands (on
separate lines)
The data within a block should follow the sequence
shown in the above sample block

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WORD-ADDRESS CODING
Example CNC Program
Each instruction to the machine
N5 G90 G20
N10 M06 T3 consists of a letter followed by a
N15 M03 S1250 number.
N20 G00 X1 Y1
N25 Z0.1 Each letter is associated with a
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 specific type of action or piece of
N40 G00 Z1 information needed by the
N45 X0 Y0 machine.
Letters used in Codes
N50 M05
N55 M30 N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M

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G & M Codes
Example CNC Program
G-codes: Preparatory
N5 G90 G20
N10 M06 T3 Functions involve actual tool
N15 M03 S1250 moves.
N20 G00 X1 Y1
N25 Z0.1 M-codes: Miscellaneous
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 Functions involve actions
N40 G00 Z1 necessary for machining (i.e.
N45 X0 Y0 spindle on/off, coolant on/off).
N50 M05
N55 M30

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G Codes
G00 Rapid traverse G40 Cutter compensation
G01 Linear interpolation cancel
G41 Cutter compensation
G02 Circular interpolation, left
CW
G42 Cutter compensation-
G03 Circular interpolation, right
CCW
G70 Inch format
G04 Dwell
G71 Metric format
G08 Acceleration
G74 Full-circle programming
G09 Deceleration off
G17 X-Y Plane G75 Full-circle programming
G18 Z-X Plane on
G19 Y-Z Plane G80 Fixed-cycle cancel
G20 Inch Units (G70) G81-G89 Fixed cycles
G21 Metric Units (G71) G90 Absolute dimensions
G91 Incremental dimensions

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Modal G-Codes

Most G-codes set the machine in a


mode which stays in effect until it
is changed or cancelled by another
G-code. These commands are called
modal.

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Modal G-Code List
G43 Tool length
G00Rapid Transverse compensation (plus)
G01Linear Interpolation G44 Tool length
G02Circular Interpolation, CW
G03Circular Interpolation,
compensation (minus)
CCW G49 Tool length
G17XY Plane compensation cancel
G18XZ Plane
G19YZ Plane G80 Cancel canned
G20/G70 Inch units cycles
G21/G71 Metric Units G81 Drilling cycle
G40 Cutter compensation
cancel G82 Counter boring
G41 Cutter compensation cycle
left

G83 Deep hole drilling


G42 Cutter compensation
right cycle
G43 Tool length G90 Absolute
compensation (plus)
positioning
G91 Incremental
positioning
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M Codes
M00 Program stop
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps on
M11 Clamps off
M30 Program stop, reset to start

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N Codes
Gives an identifying number for each
block of information.

It is generally good practice to


increment each block number by 5 or
10 to allow additional blocks to be
inserted if future changes are
required.

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X,Y, and Z Codes
X, Y, and Z codes are used to
specify the coordinate axis.
Number following the code defines
the coordinate at the end of the
move relative to an incremental or
absolute reference point.

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I,J, and K Codes
I, J, and K codes are used to specify
the coordinate axis when defining
the center of a circle.

Number following the code defines


the respective coordinate for the
center of the circle.

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F,S, and T Codes
F-code: used to specify the feed rate

S-code: used to specify the spindle


speed

T-code: used to specify the tool


identification number associated with
the tool to be used in subsequent
operations.
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Application of Some Codes
G01 Linear Interpolation
Format: N_ G01 X_ Y_ Z_ F_

Linear Interpolation results in a


straight line feed move.

Unless tool compensation is used,


the coordinates are associated with
the centerline of the tool.

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