CNC TECHNOLOGY

CP 04 02 08

CHAPTER - 2

D.JUSTIN BABU

INTRODUCTION TO CNC MACHINES

HISTORY OF NC / CNC / DNC

INTRODUCTION TO CNC MACHINES

WHAT IS NUMERICAL CONTOL MACHINES

The machine tool in which the relative movements of the cutting tool and the work piece and other relevant functions are controlled by the input of numerical commands and data is called NUMERICAL CONTROL MACHINES

INTRODUCTION TO CNC MACHINES

WHAT IS NUMERICAL CONTOL MACHINES
First NC Milling was demonstrated in 1952 at the MASSACHUSETTS Institute of Technology, USA. In 1960 the Technology of Direct Numerical Control (DNC) was developed. The earlier steps were to send the NC data directly to machine control by passing the TAPE READER. This way it was possible to control the NC machine tool directly by the computer, hence the name DIRECT NUMERICAL CONTROL(DNC). DNC systems not only eliminated the less reliable TAPE READER but also represented an important step towards total manufacturing automation.

Components of Numerical Control

Machine Part Program Machine Control Unit (MCU)

Engineering design of a part

Develop manufacturing plan for the part

The basic NC Process From Bedworth et al. 1991

Program numerical control instructions to allow the part to be manufactured according to the plan Process the program to develop cutter location data set

Post Process for a specific machine tool

TECHNOLOGY OF NC:

TECHNOLOGY OF DNC:
Direct Numerical Control It is defined as a manufacturing system in which a number of machines are controlled by a computer through direct connections

The main parts of a DNC system

Central Computer

Shop Computer

CNC Machine

CNC Machine

CNC Machine

CNC Machine

CNC-MILLING MACHINE

TWIN CNC MILLING MACHINE

What Is CNC?

CNC stands for Computer Numerical Control.

Prior to this, it was called NC, for Numerical Control. In the early 1970's computers were introduced to these controls, hence the name change

CNC
In CNC machine tools, a dedicated computer is used to perform all the basic functions of NC machine.

Additional features available in CNC compared to NC is

Part program can be directly typed using keyboard. Part program can be edited which is stored in the memory. Sub programming can be done. Cutting tool path can be generated. We can obtain information regarding machine utilization.

WHAT IS NUMERICAL CONTOL MACHINES

The present generations of CNC machines are designed to meet the requirements of HIGH PRODUCTIVITY, FLEXIBILITY and HIGH RELIABLITY to produce components of HIGH QUALITY and ACCURACY levels combined with REDUCTION IN MANUFACTURING COST.

TECHNOLOGY OF CNC:

NC Programme CNC CONTROLLER

Actuating devices (spindle motor, servo motor and controller)

Machine tool

Feed back transducer (Resolver,Encoder, Linear Scale or Tachogenerator)

Basic Elements of a CNC System

COMPUTER

MACHINE CONTROL UNIT

MACHINE TOOL

ADVANTAGES OF CNC:
Reduced non-productive time: * Work piece set up time is less. * Tool set up & tool changing time is less. Elimination of operator errors: * Machine is controlled by the computer. * The program is tested before machining. Improved quality control: * Greater accuracy. * Reduced scrap. * Reduced inspection. Reduced floor space: * one machine can do so many operations. Results in reduced floor space
Easier to program Easy storage of existing programs Easy to change a program Avoids human errors NC machines are safer to operate Complex geometry is produced as cheaply as simple ones

Usually generates closer

tolerances than manual machines

DISADVANTAGES CNC MACHINE

Higher investment cost (CNC machine is more sophisticated and complex technology). Higher maintenance cost (CNC is more complex and more accurate). Need of trained personnel (Certain aspects of these machine operations require higher-level skill than a conventional machine).
Planned support facility: Most of the preparatory work for CNC is done away from the machine. Hence to reduce machine idle time proper planning is required.

COMPARISON BETWEEN NC AND CNC NC 1. Hand Wired hence functions are limited. CNC 1.Software control, hence function are many

2.Cannot be use for complex contour machining

3.Reliability is poor.
4.Memory is limited 5.Program editing was difficult. 6.Cheaper

2.Can be use for complex contour machining

3.Reliability is high.
4.Memory considerably large 5.Program editing is easier. 6.Comparetively costlier

7.No diagnostic was available.

7.Diagnostic was available

Any movement under control of NC input is called an axis. (ie) 2 axis machine: X,Y control (usually lathe) 3 axis machine: X,Y,Z control 4 axis machine: X,Y,Z, one rotational control 5 axis machine: X,Y,Z, two rotational control
*often called machining centers and include tool changes Toshiba 9 axis mill for sub propellers

Typical Programming Procedure

NC SYSTEM
Classification of NC system

Based on feed back system NC system is classified

Open loop system

Closed loop system

Based on Motion control system features, the NC system as follows

Point to point system. Straight cut or straight line system Continuous path or conturing system

Classification of NC system

OPEN LOOP SYSTEM

A control system in which the output value is not checked against the desired value is known as Open loop control system Machine tool controls having slide displacements, which do not make any provision for a feedback signal to be compared with the input, to enable the feed drive to correct the slide position, are classified as open loop controlled machines Less accuracy A stepper motor is the best example for open loop system

NC SYSTEM
Classification of NC system
OPEN LOOP SYSTEM
INPUT

TAPE READER

MCU - AMPLIFIER

DRIVE MOTOR

MACHINE TOOL SLIDE DISPLACEMENT

GEAR BOX

Open Loop System

The open loop system are usually of digital type Example
A stepping motor rotated, through a fixed angle in response to an input signal, i.e., digital electrical signals converts into proportional movement

Applications of Open Loop Control System

Light duty machines Less investment No need of much accuracy

Disadvantages
Backlash error in lead screw Less accurate
Note SLO-SYN stepper motor used to avoid the drawbacks in open loop control system

NC SYSTEM
Classification of NC system
CLOSED LOOP SYSTEM
A control system in which movement of the machine slide is checked and corrected with respect to input signals and mainly by the signals from the feedback device The feed back from the monitoring device is then compared with the input information and the slide position is regulated by the servo system until it agrees with the desired position The use of closed loop control system enable the displacement or position of a slide to be achieved to a very high degree of accuracy by using a measuring or monitoring device to determine the slide displacement

Data Process in CNC Closed Loop Control

Program

Computer / MCU

Comp arator

Servo motor

Techo Gen

Gear box

Machine slide

AM P

Velocity Feed back

VFL Positional Transducer (or) Encoder

Displacement Feed back

NC SYSTEM
Classification of NC system
CLOSED LOOP SYSTEM
TAPE READER
Command Signal Say a distance of 100 mm Converted command Converted Command (100-99.85)

COMPARATOR UNIT

PROCESSING UNIT
Deviation in processed From Eg: 0.15 Converted into Hydraulic form

Signal Representing Actual Position Eg; 99.85 mm

MESAURING DEVICE
MACHINE TOOL SLIDE DISPLACEMENT

CONTROLLING UNIT
Eg: Hydraulic Ram

NC SYSTEM
Classification of NC system
Based on Motion control system features, the NC system as follows

Point-to-Point system Straight cut or Straight line system Continuous path or Contouring system

NC SYSTEM
Classification of NC system
POINT-TO-POINT SYSTEM Positioning System Point-to-Point system the machine performs machining operations at specific positions and does not affect the work piece while moving from one point to the next. In PTP, the importance is given to move the work piece/tool to a predefined location with respect to other, when the location reached, the operation performed Tool/Table movements are rapid traverse Path of movement is irregular

Example: In a drilling machine where co-ordinates are positioned by the system

NC SYSTEM
Classification of NC system
POINT-TO-POINT SYSTEM

Point to Point type) Point to Point (P (P type)

Y
The PTP machines are
best suited for Drilling Tapping Punch press Boring Spot welding

P2 P1 P3 X

P0

Jig boring machines

NC SYSTEM
Classification of NC system
STRAIGHT CUT OR STRAIGHT LINE SYSTEM In this system, the cutting tool moves parallel to X axis (or) Y axis during the machining operations at a controlled rate This is an extension of Point-to-Point control system when the provision of straight cut milling capability. Example Face Milling. Pocket milling Stepped Turning on Lathe Boring, etc..,

NC SYSTEM
Classification of NC system
STRAIGHT CUT OR STRAIGHT LINE SYSTEM

Straight Cut (L-type)

Y

P1

P2

P4

P3 X

P0

NC SYSTEM
Classification of NC system
CONTINUOUS PATH OR CONTOURING SYSTEM

This calls for continuous, simultaneous and co-coordinated or in other words interrelated motion of the tool and work piece along different coordinate axes. This enables profiles, contours and curved surfaces to be machined. This means that the position of several slides must be controlled on the machine tool so that their relative position and velocities must be established at every point and continuously, throughout the entire operation.

NC SYSTEM
Classification of NC system
CONTINUOUS PATH OR CONTOURING SYSTEM

Contouring System

Contouring or Continuous
The contouring systems are suitable for Curved paths Conical shapes Parabola Hyperbola Fusion welding Flame cutting

Y P1 P2

P4 P0

P3 X

Three types of Interpolatation

Linear Interpolation Circular Interpolation Parabolic Interpolation

APPLICATION OF CNC MACHINES

1. METAL CUTTING MACHINES

CNC Milling CNC Turning CNC Drilling / Boring

CNC Gear Cutting

CNC Grinding

APPLICATION OF CNC MACHINES

2. METAL FORMING MACHINE

Press Tools Injection / Blow Moulding Machines Die Casting Machines Tube Bending

APPLICATION OF CNC MACHINES

3. NON CONVENTIONAL MACHINING PROCESS
EDM Sinking and EDM Wire-cut machines. Plasma Arc cutting machines. Electron Beam machining. Laser Beam machining.

Ion Beam machining.

Ultrasonic machining etc.

APPLICATION OF CNC MACHINES

4. Welding machines (TIG, MIG, Submerged Arc welding etc.)

5. Inspection and Quality Control systems (CMM,LMM).

6. Assembly, Testing and Despatch equipments.

7. Tool and work handling systems

SERVO CONTROLLERS

The function of a servo can be described as follows. A command signal which is issued from the user's interface panel comes into servos POSITIONING CONTROLLER. The positioning controller is the device which stores information about various jobs or tasks. It has been programmed to activate the motor/load,. Change speed/position. The signal then passes into the servo control or amplifier section. The servo control takes this low power level signal and increases, or , amplifies, the power up to appropriate levels to actually result in movements of servo motor/load.

 These low power level signals must be amplified: Higher voltage levels are needed to rotate the servo motor at appropriate higher speeds and high current levels are required to provide torque to move heavier loads. This power is supplied to servo control (amplifier) from the power supply which simply converts AC power into the required DC level. It also supplies any low level voltage required for operation of integrated circuits. As the power is applied onto the servo motor ,the load begins to moveSpeed and position changes. As the load moves, so does some other device move.

This other device is either a tachometer,resolver or encoder (providing the signal which is sent back to the controller). This feedback signal is informing the positioning controller whether the motor is doing the proper job.

The positioning controller looks at this feed back signal and determines if the load is being moved properly by the servo motor; and, if not , then the controller makes appropriate corrections. For example Assume the command signal has to drive the load of 1000 rpm For some reason it is actually rotating at 900 rpm. The feed back signal will inform the controller that the speed is 900 rpm. The controller then compares the commanded signal (desired ) of 1000rpm and the feed back signals (actual speed) of 900rpm and notes an error. The controller then outputs a signal equals the command signal, i.e there is no error. Servo system is defined that it consists of several devices which control or regulate speed/position of a load

Encoder
The transducer that is connected directly to the rotor or the lead screw is the simplest arrangement requiring no additional gearing (many servomotors come with integral rotary encoders). Optical Rotary Encoder An optical rotary encoder converts the rotary motion into a sequence of digital pulses. The pulses are counted to convert u-absolute or incremental position measurement. The encoder generally come in two forms, absolute encoder and incremental encoder. The absolute encoder provides the exact rotational position of the shaft whereas the incremental encoder gives the relative position of the shaft in terms of digital pulses. The optical encoder consists of a disc (as shown in Fig) with a number of accurately etched equidistant lines or slots along the periphery.

The encoder disc is attached to the shaft of the machine whose rotary position needs to be measured.

Reference Slot

Sensor Position

Slotted Hole
Sensor

 The disc is placed between a light source (generally infra red LED) and a light measuring device (photo diode). When the disc rotates the lines are interrupted and the light measuring device counts the number of times the light is interrupted. By a careful counting and necessary calculations it is possible to know the position traversed by the shaft.

Retrofitting
Replacing the conventional leadscrews with ball-bearing screws. Adding stepper motors ( for open loop control), or dc servomotors and feedback devices (for closed-lop control); the drive is added to each controlled axis. If control is applied three are more axes, the total expense becomes considerable and the project is not always cost effective.

SALIENT FEATURES OF CNC MACHINES

1. MACHINE STRUCTURE

High rigidity. High stiffness to weight ratio. Thermal stability. Good clamping characteristics.

Working Principle of CNC

SALIENT FEATURES OF CNC MACHINES

2.FEED DRIVE

Slides are actuated by precision pre-loaded re-circulating ball screw and nut mechanism driven by servomotors and an electronic controller Speed motor have a constant Torque Non-moving slides are held by powerful servo locks and are not mechanically clamped.

Requirements of CNC Feed drive

The CNC feed drive should have constant torque to overcome frictional and working forces Should provide variable speed with a speed range of 0.1 rpm to 2000 rpm without waviness Able to position the tools with the smallest increment of 1-2 micrometer Low electrical and mechanical time constants High torque to weight ratio High torque for quick response Totally enclosed design-safe & maintenance conditions

Commonly used Feed drives/Drive motors

DC Silicon Controlled Rectifier (SCR) Pulse Width Modulated (PWM) drive DC servo motor
High performance motor Start and stop must be made quickly and accurately Light weight Low inertia armatures of DC servo motor respond quickly to the excitation voltage changes

Brush less DC Servo motor AC servo motor Stepper Motor Variable frequency AV drive or Linear motors

Linear Motor
Most of the CNC Machine tools use linear motor It consists of a series of magnets attached to a machine base and a set of electrical coils plotted around a steel laminated core attached to the moving slide A linear motor is an electric motor that has had its stator and rotor "unrolled" so that instead of producing a torque (rotation) it produces a linear force along its length

SALIENT FEATURES OF CNC MACHINES

2. SLIDE WAYS

In conventional machines, there is direct metal to metal contact between the slide way and the moving slides which results in very slow movements and machine utilization. The conventional type of arrangement does not meet the requirement of CNC Machines

The demand on slide ways is much more in CNC machines because of the rapid movements and higher machine utilization.

Conventional Slide Way Systems used in Machine Tools

SLIDE WAYS

The design of slide way in a CNC machine should, Reduce friction.

Reduce wear.
Satisfy the requirements of the movement of the slides. Improve smoothness of the drive To meet this requirements CNC machine slide ways, the techniques used include hydrostatic, linear bearings with balls, rollers or needles and surface coatings

SLIDE WAYS HYDROSTATIC SLIDE WAYS

In this slide ways air or oil is pumped into small pockets or cavities machined into the carriage or slides which are in contact with the slide way. The pressure of the fluid gradually reduces to atmospheric pressure as it seeps out from the pockets, through the gap between the slide and slide ways.

The hydrostatic slide way provides almost a frictionless condition for the movement of the slide.

SLIDE WAYS HYDROSTATIC SLIDE WAYS

For efficient operation it is very important that the fluid and slide ways are kept clean.

The hydraulic slide ways need a very large surface area to provide adequate support.

SLIDE WAYS

HYDROSTATIC SLIDE WAYS

SLIDE WAYS

LINEAR BEARING WITH BALLS & ROLLERS

The sliding friction due to direct metal contact between the slide and slide ways is replaced with rolling friction by the use of antifriction ball or roller bearing. These are designed to run along precision ground shafts and offer frictionless movement over varying strock of length with high linear precision.

SLIDE WAYS

LINEAR BEARING WITH BALLS & ROLLERS

For movement along a flat plane, re-circulating linear roller bearings are used. The main characteristic of the linear roller bearing is that there is a continuous roller circulation, which allows unlimited linear movement.

A linear bearing (also called TYCHOWAY), consists of hardened & precision ground supporting elements and a number of cylindrical rollers

SLIDE WAYS
LINEAR BEARING WITH BALLS & ROLLERS
The rollers are guided between the shoulders of the supporting elements with very close tolerances.
The guiding element prevents the rollers from falling out and sliding against each other. The guiding elements assist in smooth return of the rollers to the loading zone.

SLIDE WAYS

LINEAR BEARING WITH BALLS & ROLLERS

SLIDE WAYS
LINEAR BEARING WITH BALLS & ROLLERS

Linearslide with Balls

SLIDE WAYS
LINEAR BEARING WITH BALLS & ROLLERS
The rollers are in contact with guide ways machined on the bed of the machine.
This provides smooth and easy movement. The machine bed surfaces coming in contact with rollers have to be hardened . To reduce the problem of accurate machining of bed, hardened steel guides with special guide forms may be attached to the machine bed and rollers can move on the rail.

LINEAR BEARING WITH BALLS & ROLLERS

LINEAR BEARING WITH BALLS & ROLLERS The linear roller bearing can be mounted horizontally for load carrying applications such as machine tool table. They can be mounted vertically to provide support, guidance and motion for vertical elements of the machine tool.

Vee and flat roller arrangement can also be used to provide frictionless linear movement.

SURFACE COATINGS The guiding surfaces of the machines are coated with low friction materials such as POLYTETRAFLUROETHYLENE (PTFE), or replaceable strips of low friction material are used. When the strips wear to such an extent that the alignment is in error, these can be replaced.

ELEMENTS OF MOTION TRANSMISSION RE CIRCULATING BALL SCREW & NUT

The rotary motion from the drive motor needs to be converted into linear motion to move the various axes of the machine. In conventional machine square thread is used. The conventional machines use lead screw for motion transmission purpose. Due to high friction between the lead screw & nut results in poor transmission efficiency and back lash. In CNC machines with use of re-circulating ball screw and nut arrangement these problems have been overcome. Here again, the approach is to replace sliding friction by rolling friction.

NC MACHINE TOOLS
DRIVE UNITS
ELEMENTS OF MOTION TRANSMISSION
RE CIRCULATING BALL SCREW & NUT

ELEMENTS OF MOTION TRANSMISSION RE CIRCULATING BALL SCREW & NUT

The connection between the screw and the nut is through an endless stream of re-circulating steel balls.
The screw thread is a hardened and ground ball race in which the steel balls, in the nut, circulate. The balls rotate between the screw and the nut and at the same point the balls are returned to start of the thread in the nut.

The rigidity of the drive system & positioning accuracy can be further improved by pre-loading the nut assembly.

ELEMENTS OF MOTION TRANSMISSION RE CIRCULATING BALL SCREW & NUT ADVANTAGES

HIGH EFFICIENCY: As compared to conventional lead screw the efficiency of ball screw & nut assembly is very high (over 90%).The power requirement is also less due to reduce friction.

ELEMENTS OF MOTION TRANSMISSION RE CIRCULATING BALL SCREW & NUT ADVANTAGES

REVERSIBILITY: The ball screw & nut assembly is reversible which makes it possible to back drive the unit . i.e. by applying axial force to either nut or screw, the unconstrained member can be made to rotate.

ELEMENTS OF MOTION TRANSMISSION

RE CIRCULATING BALL SCREW & NUT ADVANTAGES

WEAR & LIFE: The re-circulating rollers reduce wear to a minimum and the ball screw. Hence longer life with out loss of accuracy.

ELEMENTS OF MOTION TRANSMISSION

RE CIRCULATING BALL SCREW & NUT ADVANTAGES

NO STICK SLIP: Stick slip is a phenomenon, which occurs when small movement between two lubricated elements are required. The lubricating medium tries to cause the mating elements to stick to each other to resist motion and results in a jerky motion as the mating elements try to stick and then slip during their relative movement. Since the sliding metal-to-metal contact is substituted by rolling contact, the stick-up phenomenon is eliminated in the ball screw and nut assembly.

Ball Lead-Screw

SALIENT FEATURES OF CNC MACHINES

3.FEED-BACK SYSTEM

The accuracy of positioning in CNC is achieved by measuring the position or displacement of the slide and comparing it with the command position as per the part program. The servo system then actuates the slide such that the error, which is the difference between actual position and the command position, is brought to zero (is called ERROR DRIVEN SYSTEM). The position measuring devices could be direct or indirect depending upon whether the device is directly fitted in the slide or at the end of the ball screw. Some of the measuring devices are Linear inductosyns, Optical scales with grating, Rotary encoders, Rotary inductosyns, Brush less synchroresolvers, etc.

FEED BACK DEVICES

FEEDBACK DEVICES

VELOCITY FEEDBACK DEVICE

POSITION FEEDBACK DEVICE

FEED BACK DEVICES:

Two types of feed back is required. 1) Velocity feed back 2) Positional feed back

Velocity feed back:

It will measure the spindle rpm. Tachogenerator is used.

It will generate voltage in proportional to the speed.

The tachogenerator is normally built in the servomotor cases and is directly fitted on the servomotor shaft. The o/p voltage is compared & monitored the spindle speed. Rotary encoders are also used to provide feedback for velocity control.

FEED BACK DEVICES

POSITION FEED BACK DEVICE

Measurements from cutting edge are not possible due to the presence of chips, coolant, holding devices and in some case, due to the component geometry itself The positional feed back is provided by measuring the slide movements with measuring devices The position measuring devices are either rotary or linear measuring transducers.

POSITION FEED BACK DEVICE

ROTARY OR ANGULAR POSITION MEASURING TRANSDUCERS Angular position measuring transducers operates by measuring the angular speed of a rotating element, normally of a lead screw, from the known value of the lead screw, movement of the work table or machine slide is calculated by control system Angular position measuring transducers operate on the photo electric principle The transducer consists of a disc fitted on the axis of lead screw The disc is made up of uniform alternate transparent and opaque areas A light source is fitted on one side of the disc and photocell on the other side When the disc rotates with rotation of the lead screw, the photocell will sense the light and dark areas alternatively As the dark area of the disc is gradually uncovered the light intensity falling on the photocell goes on increasing until it reaches the maximum when the transparent part of the disc comes in from the light source

POSITION FEED BACK DEVICE

ROTARY OR ANGULAR POSITION MEASURING TRANSDUCERS

As the disc continuous to rotate the dark area starts to reduce the light intensity falling on the photocell which will gradually reduces to zero when the dark area comes between the photocell and light source The photocell gives output voltage based on the intensity of light falling on it and the out put from photocell resembles a sine-wave, which is converted in to square shaped pulses to make it useful for control purposes The number of output pulses is then counted As the output from the photo cell is related to the rate at which the transparent areas of the disc comes in front of the light source, the speed of the lead screw is calculated from the known number of lines engraved on the rotating disc The displacement of the slide is then calculated from the lead of the lead screw

FEED BACK DEVICES

POSITION FEED BACK DEVICE
ROTARY OR ANGULAR POSITION MEASURING TRANSDUCERS The direction of the rotation of lead screw is sensed by putting a second photocell in the circuit The second photocell is positioned in such a way that the output from the two photo cell will be out of phase This phase difference is used to determine the direction of rotation of lead screw Position measurement by angular position measuring transducer is indirect as the output of the transducer as to be converted into table displacement

FEED BACK DEVICES

POSITION FEED BACK DEVICE
LINEAR POSITION MEASURING TRANSDUCERS
Linear position measuring transducer also operate on the photoelectric principle. The linear measuring system measures the displacement of the machine lied from a fixed datum.

POSITION FEED BACK DEVICE

LINEAR POSITION MEASURING TRANSDUCERS

FEED BACK DEVICES

POSITION FEED BACK DEVICE
LINEAR POSITION MEASURING TRANSDUCERS A linear measuring system consists of a precision linear scale engraved with closed space alternate transparent and opaque parallel lines as one unit and a photocell and light source as the second unit. One of the units is fixed on the stationary element of the machine tool and the other unit is fixed to the moving worktable. A pulse is generated by the photocell as it is exposed to light source through the transparent areas of the linear scale.

FEED BACK DEVICES

POSITION FEED BACK DEVICE
LINEAR POSITION MEASURING TRANSDUCERS

A pulse is generated by the photocell as it is exposed to light source through the transparent areas of the linear scale. From the known number of the engraved lines per unit length on the linear scale and by counting the pulses, the displacement of the work table can be established.

FEED BACK DEVICES

POSITION FEED BACK DEVICE
LINEAR POSITION MEASURING TRANSDUCERS

As in the case of rotary transducers, a second photocell is used to detect the direction of movement.
The linear system may have either a glass cell in which case light passes through the transparent area or a ss scale , the light is reflected from the transparent areas.

LINEAR POSITION MEASURING TRANSDUCERS

SALIENT FEATURES OF CNC MACHINES

4.SPINDLE DRIVE High spindle power and wide speed range with step less variation of RPM. Full power availability at all speeds.

DC motors with silicon controlled rectifier (SCR) drive or AC motors with variable frequency.
Spindle orientation for Automatic Tool Change and fine boring application.

Radial Roller Bearing

Work Holding End

Power from Spindle Motor

SALIENT FEATURES OF CNC MACHINES

5. AUTOMATIC TOOL CHANGER (ATC)
ATC is an important element of machining centers for increasing the productivity by reducing of idle time during tool change. ATC units are capable of performing tool change within 3 to 7 seconds. In an ATC unit the tool magazine could be drum type with the capacity up to 40 tools or chain type with capacity up to 132 tools. The tool change arm could be of single gripper or double gripper type. The tool selection could be of Sequential type (applicable for less no. of tools and consuming more time) or of Random type (applicable for no. of tools and consuming less time). The latter type is more commonly used.

TURRET CHAIN TYPE

DRUM TYPE

SALIENT FEATURES OF CNC MACHINES

6. AUTOMATIC PALLET CHANGER (APC)
APC aids in increase of productivity by reducing the job set up time. Function is to interchange the pallet on the machine that has finished component and the other pallet with the newly loaded component. Setting up of the work piece is done away from the machine tool. Thus improves machine utilization time.

The pallet changer gets located on the machine and clamped with heavy clamping force either hydraulically or mechanically. APCs could be of dual pallet type or multiple pallet pool type.

INTRODUCTION TO CNC MACHINES

SALIENT FEATURES OF CNC MACHINES
Some other features of CNCs Thermal stabilization of headstock, feed drive elements and machine structural elements by re-circulated refrigerated oil. Axial calibration for all fixed mechanical elements. Lost motion compensation for all fixed mechanical elements. Usage of Torch trigger probes for post process metrology purposes, Tool condition monitoring, Tool measurement and setting of tool offsets and thermal error compensation. Centralized lubrication of slides, etc., controlled by timer or software. Coolant systems of either flood type or myst type. Chip conveyors for collection and disposal of chips. Auto diagnostic to aid maintenance and service personnel.