O tli – CNC El

Outline Elements
t CNC Machining Center

• CNC Machine Tools • A machine tool capable of:

– Machining
g Centers – Multiple
p operation
p and p
processes in a single
g set-up
p
– Turning Centers utilizing multiple axis,
• Elements of Machine Tools – Typically has an automatic mechanism to change
– M i St
Main Structure
t
tools,
– Transmission Elements
– Power Generation Systems – Machine motion is programmable,
– Measurement Systems – Servo motors drive feed mechanisms for tool axis’s,
– Auxillary Systems
– Control Systems
y – Positioning feedback is provided by sensors to the
control system,

Chapter 2 ME 440 2 Chapter 2 ME 440 3

Types of Machining Centers Vertical Machine Centers*

Centers
Tool Magazine Vertical Spindle
p
• Vertical Machining Centers
– 3-Axis (X, Y, Z)
CNC Pendent
– 4-Axis (X, Y, Z, Rotary table)
– 5-Axis (X, Y, Z, Rotary table,
Rotary spindle)
• Horizontal Machining Centers
– 3-Axis (X, Y, Z)
– 4-Axis (X, Y, Z, Rotary table)
– 5-Axis (X, Y, Z, Rotary table,
Rotary spindle) [*] Haas Automation.

Chapter 2 ME 440 4 Chapter 2 ME 440 5

 3 Axis VMC
3-Axis 5-Axis
5 Axis VMC
• Programmable X and Y
axes in the plane of the
table.
table
• Z-axis in the spindle’s
direction.
direction
• Cost is about $30,000.
• One can machine:
– One surface of a cube with
the cutter-end,
– Four additional surfaces with
the side of the cutter.

Chapter 2 ME 440 6 Chapter 2 ME 440 7

Horizontal Machining
g Center* 3 Axis HMC
3-Axis
Tool Changer
• Note the designations of
Horizontal Spindle the X, Y, and Z axes.
CNC Pendent • Cost is about $90,000.
$90 000
• Used in mass-production:
Rotary Table
– Easy access to table!
• One can machine:
– One surface of a cube with
the cutter-end,
– Three additional surfaces
[*] Haas Automation.
with the side of the cutter.

Chapter 2 ME 440 8 Chapter 2 ME 440 9

 4 Axis HMC
4-Axis 5 Axis HMC
5-Axis
• Similar to the 4-axis
4 axis HMC
• Generally
G ll hhorizontal
i t l except the spindle rotates
– Table rotates to create around an axis.
the forth axis.
axis • Cost
C t is
i about
b t $250,000.
$250 000
• True four-axis machines • Used to machine complex
start around $100,000.
$100 000 parts and molds.
molds
• One can machine: • One can machine:
– Five sides of a cube with the
– Four surfaces of a cube cutter-end
with cutter-end – Six sides with the side of the
– Three additional surfaces cutte
cutter.
with the side of the • Part can be machined with
cutter. only one setup:
– Leads to more accurate part.
Chapter 2 ME 440 10 Chapter 2 ME 440 11

HMC vs. VMC CNC Turning

g Center*
CNC Panel
• Some advantages of HMC: Chuck

– Structurally more rigid

• Higher
g machining
g accuracy
y is usually
y attainable
– Accomodates larger workpieces Tool
– Allows easy access to workspace Tool
Turret

• Suitable for Automatic Pallet Changers Turret

• Well-suited
Well suited for mass production
– Gravity helps chip removal
• Disadvantage of HMC:
– Expensive [[*]] Spinner WZM

Chapter 2 ME 440 12 Chapter 2 ME 440 13

 Elements of CNC Machine Tools Main Structure
• Stationary Elements
• Main Structure – Columns, portals, beds, guideways
• T
Transmission
i i El Elements
t • Moving Elements
• Power Generation Systems
y – Translational: carriages,
carriages tables
tables, saddles
saddles, etc.
etc
• Measurement Systems – Rotational: spindle, chuck, capstan, etc.
• A ill
Auxillary S
Systems
t • Support
S t Elements
El t
• Control
Co o Sys
Systems
e s – Bearings:
g Ball bearing,
g jjournal bearings
g
– Couplings

Chapter 2 ME 440 14 Chapter 2 ME 440 15

Mechanical Structure of VMC Mechanical Structure of TC

Tool Turret
Carrier Headstock
Spindle
Assembly
Ball Screw Shaft Chuck
Hydraulic
Tailstock
Clamp
Column Assembly
T bl
Table

Slide
Carriage
Bed

Saddle
Slanted Bed

Chapter 2 ME 440 16 Chapter 2 ME 440 17

 Transmission Systems Ball Screw Drives
• Common mechanisms in
• Ball screw feed drives.
• Lead Screw • High efficiency.
• Rack and Pinion
Rack-and-Pinion • Capability of backlash
backlash-free
free
• Worm-and-Rack operation.
• B lt Drives
Belt Di • Stroke length is limited upto
4 [m].
• Gear Trains

Chapter 2 ME 440 18 Chapter 2 ME 440 19

Kinematic Relationships for

Rack and Pinion Drive
Rack-and-Pinion
Ball Screw Drive
u • Used for a travel span
ds
of 3 [m] upto 20 [m].
F hs
• Backlash-free
Ball Screw Shaft versions are also
θ T
available
– an extra-preloading
extra preloading
h hs 1 pinion is employed.
u= s θ T = F ηs =
2π 2πηs ds – quite expensive!
1 + 0.02
hs

Chapter 2 ME 440 20 Chapter 2 ME 440 21

 Preloaded Rack-and-Pinion Kinematic Relationships for
Mechanism Rack-and-Pinion Drives

u
u = r0 θ
Pinion θ
T
r0
F r0
T= F
η
Rack

Chapter 2 ME 440 22 Chapter 2 ME 440 23

Feed Drive Power Generation Systems

y
• Actuators (Electromagnetic
ds
or Hydraulic)
H d li )
hs
– Linear Motors
B ll Screw
Ball S Shaft
Sh ft T bl
Table P t
Part – Rotary Motors
• Drive Systems
Motor – Power Converters
Ball Screw Shaft Nut

• An arrangenment in machine tools to “feed”

the workpiece to the cutting tool
tool.
• Sometimes called “axis drive system.”

Chapter 2 ME 440 24 Chapter 2 ME 440 25

 Measurement Systems
y Auxillary Systems
• Can be classified in many different ways:
– Analog or Digital • Tool Loading Systems
– Linear/Translational or Rotational – Tool Turret
– Absolute or Relative – Tool Magazine and ATC
– Optical, Electromagnetic, etc.
• C
Coolant/Lubricant
l t/L b i tS
Supply
l SSystems
t
– Direct vs. indirect measurement
• Gear Changers
g ((Spindle)
p ) and Tool
Alignment Systems
• Automatic Clamps and Brakes

Chapter 2 ME 440 26 Chapter 2 ME 440 27

Automatic Tool Changers

g CNC Control Systems

• Motion Control System

– IInterpolators
l
– Axis Position Controllers
• Programmable Logic Controllers
• Electronic Device Interfaces
• Graphical User Interfaces

Chapter 2 ME 440 28 Chapter 2 ME 440 29

 Open loop Control
Open-loop Open loop Control (Cont’d)
Open-loop (Cont d)
Part
• Control unit “assumes” desired position is
as pullse stream
Program

mmand
poosition Part
tool
location
feeds
com
Table
achieved.
Interpolator
Motor
Drive
Stepper
Motor
– No positioning compensation
Ball Screw Shaft Nut
CNC System – Most stepper motor develops low torque
• Stepper
pp motor system
y is utilized. • Advantages:
– Current pulses sent from control unit to motor – Simple
– Each
ac pulse
pu se results
esu ts in a finite
te a
amount
ou t o
of revolution
e o ut o oof – Inexpensive
the motor.
– Low maintenance costs

Chapter 2 ME 440 30 Chapter 2 ME 440 31

Closed-loop
p Control Accesories
Part CNC System
Program Tool Setter (TC): Rotary Table (VMC):
Table
bl P t
Part
command
command

tool feeds
position

torque

location

Motion Motor
Interpolator Controller Drive
Ball Screw Shaft
Nut
position feedback Servo-motor

• Uses position feedback concept.

– The servo motor has a feedback loop to check the machine’s
actual
ac ua pos
position.
o
– Servo-motors have the ability to reverse instantly to adjust for
position error
– Error compensation allows for greater positional accuracy
– Modern servo-motors (AC or DC) have higher torque ranges vs.
stepper motors.

Chapter 2 ME 440 32 Chapter 2 ME 440 33

 Optional
p Axis
Complex Machined Parts

Chapter 2 ME 440 34 Chapter 2 ME 440 35