CNC MACHINES

S.C. PATRA Chief Instructor(Mech)

Conventional Machine and CNC Machine

Why CNC ?
  

Greater Automation Productivity.. Improved quality & accuracy of manufactured parts.. Repeatability Flexibility to manufacture complex jobs... Reduced scrap rate ..

  

 Cost Effective ....

 Reduced manpower

 Shorter cycle time .  Increased Operational Safety ..

Types of CNC Machines



CNC Turning Centre CNC Milling Machine CNC Horizontal Machining Centre (HMC) CNC Grinder CNC Drilling Machine CNC Gear Cutting Machine CNC Turret Punch Press

CNC MACHINING CENTRE:

1. Vertical Machining Centre (VMC): Vertical spindle configuration comprising of three basic servo axes (X - axis, Y-axis & Z - axis ): Two for the table movement and one for the spindle head.

2. Turret Machining Centre (TMC):

Same configuration as VMC but vertical spindle head replaced by an indexable tool turret. Automatic selection of tool by indexing turret. Facilitates machining on sides of cubical components.

Note : TMC eliminated manual tool change. It also introduced a large tool magazine and Auto Tool Changer (ATC) for automatic transfer of tools from the magazine to the spindle and vice-versa.

ATC & Tool Magazine

ATC is a device which can automatically change the tool from the tool magazine to the machine spindle as per the CNC programme. Tool Magazine is a device which holds number of tools and can automatically index to enable ATC to pick the right tool and to replace the used tool.

Turret Machining Centre

Horizontal Machining Centre (HMC):



It can perform machining on different faces of a cubical or prismatic component. Both VMC and HMC introduces a Automatic Pallet Changer (APC) to set the job on the machine table. Next piece of work could be loaded or set on the additional APC while the machine is busy in cutting the previous work piece. After the machining , the pallet with the finished work piece and the pallet on APC having a raw component could be exchanged automatically.

Aut

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(AP ) i ut ti ll

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Automatic Pallet Changer

ll t t /fr ll t t P ll t i t t l i l . tr f r

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Automatic Pallet Changer

Pallet is held on the machine table by locating pins and clamping mechanism to ensure repeatability and accuracy. Pallet stand with 4 x 900 manual indexing facility to approach on all sides of pallet/fixture. Provision of air cleaning system for locating pins and reference surfaces during pallet change.

Horizontal Machining Centre with Auto Pallet Changer

Value wise contents of mechanical and electronic software and hardware in different manufacturing facilities

CNC SYSTEMS

Computer Numerical Control (CNC) is computer based system to store and

process data for control of slide motions and auxiliary motions of machine tools. CNC Systems are constructed with NC nit integrated with Programmable Logic Controller (PLC) with a Feed Back Device. PLC controls the ON/OFF functions of the machine tool. It sets the output based on the input conditions & corresponding logic.

PLC Functions:  Coolant ON/OFF.

 Spindle ON/OFF.  Selection of a tool.  Change of workpiece (Pallet Changing).  Workpiece clamping etc.

Electrical/ Control Features:

    

CNC System (Controller) Drives. Servo Motors Actuators Sensors/ Feedback devices.

CNC MACHINE : The Heart..

MACHINED PART

CNC SYSTEM

DRIVES & ELECTRICALS

MACHINE TOOL

HOW A CNC SYSTEM WORKS

CNC SYSTEM
RS 232 INTERFACE DISPLAY UNIT PERIPHERAL INTERFACE (MMI OR HMI)
COMMANDS

DRIVES & ELECTRICALS

MACHINE TOOL

SYSTEM KEYBOARD

AXES OR SERVO CONTROLLER

POS. F/Bs FROM M/C TOOL COMMAND

AXES DRIVES

AXES MOTORS WITH POSITION & VELOCITY FEEDBACK SPINDLE MOTOR WITH POSITION & VELOCITY FFEDBACK

TAPE READER/ PUNCH

SPINDLE CONTROLLER

F/B FROM M/C TOOL OUTPUTS INPUTS

SPINDLE DRIVE

I/O CONTROLLER (PLC)

OUTPUTS INPUTS

SWITCHING ELEMENTS

ACTUATORS, MISCELLANEOUS MOTORS SENSORS / FEEDBACK DEVICE

CLASSIC SERVO LOOP

POSITION LOOP D/A Converter changes following Accumulator holds error to analog following error voltage

VELOCITY LOOP Amplifier

Slide Servo Motor

Interpolator issues position commands

Position feedback is subtracted from position command to provide following error

Speed feedback is subtracted from speed command Tacho

Position Transducer Monitors Position

Analog Servo Loop in CNC System

Following error signal Accumulated Command

Velocity Error Velocity Signal Amplifier

Slide Current Amplifier

DAC

M
Lead screw

Accumulated feedback

Counter
VELOCITY FEEDBACK

Encoder Tacho generator

POSITION FEEDBACK

CNC SYSTEM

DRIVES

Special Features of CNC M/c



Mechanical Features:
Ball Lead Screws. Linear Bearings. Improved Guide ways. Timing Belts. Curvic Coupling.

    

 Smooth Linear Motion. Low starting friction. Wear resistant. Very Low Backlash.

Ball Lead Screws

Linear Bearings on guide-ways

Smooth Linear Motion. Low starting friction. Wear resistant. Very Low Backlash.

Toothed Belt, Steel-wires. Slip-Proof Drive.

Timing Belt

 Used in Turret Indexing of CNC m/c.

Curvic Coupling

Fanuc Series 0i System

CNC Controller Fanuc Serial Servo bus (FSSB) Drive amplifier Servo motor

Spindle Interface (Serial)

Spindle motor Fanuc I/o Link Connection Panel I/O Modules

MOP

I/O devices

Special Features of CNC M/c

Centralized Lubrication System Diagnostic Features Turret/ Pallet Changers Auto Tool Changer

Centralised Lubrication System

Online Machine Diagnosis System

Technically defining a CNC System:

(i) MACHINE FUNCTIONS CONTROLLED BY CNC SYSTEM


AXIS FUNCTIONS
y y y

ON / OFF CONTROL POSITION CONTROL VELOCITY CONTROL

 SPINDLE FUNCTIONS
y y y

ON / OFF CONTROL DIRECTION CONTROL SPEED CONTROL

 TOOL SELECTION / TURRET INDEXING  WORKPIECE CLAMPING / PALLET CHANGING  COOLANT ON / OFF  LUBRICATION ON / OFF  MACHINE TOOL SAFETY INTERLOCK

Technically defining a CNC System:

(ii) CNC SYSTEM TYPES

 CNC SYSTEMS FOR

o o o o o

LATHES MACHINING CENTER MILLING CENTER GRINDING PUNCH PRESS

SYSTEM TYPES
o o o

T - TURNING M - MILLING, MACHINING CENTER G - GRINDING

CNC SYSTEMS
MAN FACT RER MAN FACT RER CO NTRY CO NTRY MODEL MODEL

ROCKWELL A TOMATION ROCKWELL A TOMATION

. .S. A S. A

ALLEN BRADLEY ALLEN BRADLEY 8610, 8650, 9/PC 8610, 8650, 9/PC

CINCINNATI MILACRON CINCINNATI MILACRON FAGOR

S. A . .S. A SPAIN

ACRAMATIC 950, 2100

ACRAMATIC 950, 2100

FAGOR 800, 8025, 8050

FAGOR
FAN C FAN C FAN C INDIA HEIDENHAIN

SPAIN
JAPAN INDIA JAPAN GERMANY FRANCE

FAGOR 800, 8025, 8050

FAN C 15i/150i, 16i/160i, 18i/180i, 21i/210i FAN C 0 , 0i FAN C 18i/180i, 21i/210i, 30i/31i/32i, 300i/310i/320i TNC 155, 426, 430 N M 1040, 1050, 1060

FAN C INDIA
SIEMENS

N M

INDIA

FAN C 0 , 0i

GERMANY

SIN MERIK 810, 820, 840, 880

HEIDENHAIN MITS BISHI ELECTRIC A TOMATION INC.

GERMANY JAPAN

TNC 155, 426, 430 M64 CNC, F SION 640, MPL S, TPL S AND 600 SERIES. GSK980TDa., GSK983M

GSK CNC EQUIPMENT

CHINA

SIEMENS

GERMANY

SINUMERIK 802, 840, 880

MITSUBISHI ELECTRIC AUTOMATION INC.

JAPAN

70/700 SERIES, C6/C64 SERIES, 60S/E60/E68 SERIES

CNC SYSTEM FEATURES


Axis, Spindle and I/O control features Operating features Programming features Keyboard and display features Communication features Compensation features Safety and diagnostic features

     

Axis, Spindle And I/O Control Features



AXIS CONTROL


Number Of Axis Controllable.

 Feed rates.


SPINDLE CONTROL
 Maximum Spindle Speed.

 Auto Gear Selection.

 Spindle Speed Direction

Operating Features
Basic Operating Modes:


JOG Mode MDI MODE AUTO MODE

JOG MODE
   

Manual movement of axes Manually select the tool. Manually move the axes Find the tool offset

MDI MODE
 

Program phase Manually feed the program

AUTO MODE
  

Create a Program Store the Program Execute the program

Part Programming Features

    

Inch / Metric Programming Absolute / Incremental Programming Linear / Circular / Helical / Spiral Interpolation Full Circle Programming Canned Cycles

Keyboard And Display Features


KEYBOARD FUNCTIONS


System Keyboard - Feed & Edit a Programme. Machine Control Panel - For controlling the machine parameters.

DISPLAY FEATURES Display of various screens like:

   

Position Part Program Offsets Alarms And Messages

Communication Features


Upload / Download Of Programs

Machine Status Monitoring

Compensation Features


Tool Offset Tool Length Compensation

Diameter Compensation

Safety And Diagnostic Features

Emergency Stop

Axis Overtravel

Power Up Diagnostics

Configuration of CNC System: A CNC system basically consists of the following: Central Processing Unit (CPU) Servo-control Unit (NC) Operator Control Panel Machine Control Panel Programmable Logic Controller (PLC)

Spectrum of production alternatives

CNC PROGRAMMING
Basic steps in CNC machining: i) First, prepare the program from part drawing (ii) Read the part program to the CNC system (iii) Mount the workpiece & tool on the machine (iv) Execute the program

PROGRAMMING CODES: G Preparatory code (Tool movement related function.) F Feed function T Tool No. D Tool offset. M Misc. code (for ON/OFF Function) S Spindle rpm (for spindle rotation)

G - CODES
G-codes are used to move the tool or axes by Program.
G 00 Rapid travel. G 01 Linear interpolation. G 02 Circular interpolation clock-wise. G 03 - Circular interpolation anti-clockwise. G 04 Dwell time. G 20 Inch data input G 21 Metric data input. G 22 Stored stroke check on. G 23 - Stored stroke check off.
G 27 Reference point return check.

G 28 Reference position return.

G 29 Return from reference point

G 30 Return to second reference point. G 31 Skip function. G 32 Thread function. G 36 Automatic tool compensation X G 37 - Automatic tool compensation Z
G 40 Tool nose radius compensation cancel

G 90 Absolute dimensioning. G 91 Incremental dimensioning. G 98 Feed rate in mm/min. G 99 - Feed rate in mm/rev.

M- CODES ( Miscellaneous Codes )

ON/OFF Codes. Controlled by PLC . M 00 Optional stop. M 01 Programmable stop. M 02 Main program end. M 03 Spindle clock-wise. M 04 Spindle counter clock-wise. M 05 Spindle stop. M 06 Tool change.

M 07 Coolant b on. M 08 - Coolant a on.

M 10 Chuck open. M 11 Chuck close. M 13 Spindle forward M 14 - Spindle reverse M 16 Special tool call. coolant on. coolant on.

M 17 Sub-program end. M 19 Spindle orientation. M 30 Main program end & rewind.

Tool movement along a straight Line

Tool movement along a tapper Line

Tool movement along an Arc

Thread Cutting(straight)

Tapper thread cutting

Feed Function

Reference position (Machine specific position)

Coordinate system

Co-ordinate system specified by CNC

Setting of coordinate system : When coordinate zero point is set at chuck face

Setting of coordinate system : When coordinate zero point is set at work end face

Absolute Command

Incremental Command

Diameter Programming

Cordinate values of points A and B = A(30,80), B(40,60)

Radius Programming

Cutting speed

spindle speed function

FEED:

FEED-FUNCTION = The function of

deciding the feed rate is called feed function.

Selection of tool and tool function

Miscellaneous function

Program configuration

Block configuration

Program configuration

Tool Length compensation(Tool offset)

PROGRAMMING CODES: G Preparatory code (Tool movement related function.) F Feed function T Tool No. D Tool offset. M Misc. code (for ON/OFF Function) S Spindle rpm (for spindle rotation)

G - CODES
G-codes are used to move the tool or axes by Program.
G 00 Rapid travel. G 01 Linear interpolation. G 02 Circular interpolation clock-wise. G 03 - Circular interpolation anti-clockwise. G 04 Dwell time. G 20 Inch data input G 21 Metric data input. G 22 Stored stroke check on. G 23 - Stored stroke check off.
G 27 Reference point return check.

.G 28 Reference position return.

G 29 Return from reference point

G 30 Return to second reference point. G 31 Skip function. G 32 Thread function. G 36 Automatic tool compensation X G 37 - Automatic tool compensation Z
G 40 Tool nose radius compensation cancel

G 90 Absolute dimensioning. G 91 Incremental dimensioning. G 98 Feed rate in mm/min. G 99 - Feed rate in mm/rev.

M- CODES ( Miscellaneous Codes )

ON/OFF Codes. Controlled by PLC . M 00 Optional stop. M 01 Programmable stop. M 02 Main program end. M 03 Spindle clock-wise. M 04 Spindle counter clock-wise. M 05 Spindle stop. M 06 Tool change.

M 07 Coolant b on. M 08 - Coolant a on.

M 10 Chuck open. M 11 Chuck close. M 13 Spindle forward M 14 - Spindle reverse M 16 Special tool call. coolant on. coolant on.

M 17 Sub-program end. M 19 Spindle orientation. M 30 Main program end & rewind M98 Subprogram call M99 Subprogram end

7. A raw

material of size: 40 and 60 mm. length is supplied to you . Make a CNC part program for step turning of the given job as shown in the diagram.

38 36

20

10

Step Turning: O 0001; N10 G21 G99 ; ; N30 T01 D01 M06 ; N40 S1000 M03 ; N50 G00 X41.0 ; N60 G00 Z0.0 ; N70 G01 X0.0 F1.0 ;

       

N80 G00 Z5.0 ; N90 G00 X41.0 ; N100 G00 Z0.0 ; N110 G01 X38.0 F1.0 ; N120 G01 Z-30.0 ; G130 G01 X41.0 F1.0 ; G140 G00 Z0.0 ; G150 G01 X36.0 F1.0 ; N160 G01 Z-10.0 F1.0 ; N170 G01 X41.0 F1.0 ; N180 G00 Z0.0 ; N190 G28 U0 W0 ; N200 M05 ; N219 M30 .

THANK YOU