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16. CNC Machine Control Systems

The document provides an overview of CNC machines, including types such as CNC Turning Centres, Milling Machines, and Machining Centres. It details the components of CNC systems, their operating features, and programming codes (G-codes and M-codes) used for various machining operations. Additionally, it outlines the steps to execute a CNC program and includes examples of programs for facing and drilling operations.

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sajal malhotra
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0% found this document useful (0 votes)
20 views43 pages

16. CNC Machine Control Systems

The document provides an overview of CNC machines, including types such as CNC Turning Centres, Milling Machines, and Machining Centres. It details the components of CNC systems, their operating features, and programming codes (G-codes and M-codes) used for various machining operations. Additionally, it outlines the steps to execute a CNC program and includes examples of programs for facing and drilling operations.

Uploaded by

sajal malhotra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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CNC MACHINES

Conventional Machine
Turret

Headstock
X-axis
assembly

Bed

Tailstock assembly
Z-axis
5/26/2021
Basic Progression to a CNC M/c
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


2-Axes Turning Centre

Figure 1.3 : Coordinate System (Turning Operations)


3-Axes Machining Centre (Milling and Drilling Operations)

Figure 1.2 : Coordinate System (Milling and Drilling Operations)


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. Horizontal Machining Centre (HMC):

• It can perform machining on different faces of a cubical or prismatic component.


• Both VMC and HMC uses Auto Tool Changer (ATC ) & Automatic Pallet Changer
(APC)
Auto Tool Changer (ATC ) & Automatic Pallet Changer (APC)

• ATC ( Auto Tool Changer ) 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.

• Automatic Pallet Changer (APC) is a device which can automatically change


the pallet to/from machine to pallet stand.

• By this Mechanism ( i .e. APC ) the pallet with the finished component and
the pallet with a raw component could be exchanged automatically.
ATC & Tool Magazine
Automatic Pallet Changer (APC)

Pallet is a transferable work table


having `T’ slots or tapped holes for
component/fixture clamping.

Used to avoid the machine waiting


time during loading & unloading of
component.

Pallet is held on the machine table by


locating pins and clamping
mechanism to ensure repeatability
and accuracy.
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 Unit integrated with HMI,


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.
Components of a CNC Machine

» CNC System (Controller)

» Drives.

» Servo Motors

» Actuators

» Sensors/ Feedback devices.


HOW A CNC SYSTEM WORKS ?

CNC SYSTEM

DISPLAY PERIPHERAL
UNIT INTERFACE
(MMI OR HMI)
DRIVES & ELECTRICALS DRIVE MOTORS

SYSTEM AXES MOTORS


KEYBOARD AXES WITH
AXES OR COMMANDS
DRIVES POSITION
SERVO & VELOCITY M
POS. F/Bs FEEDBACK
CONTROLLER FROM M/C A
TOOL C
H
COMMAND
SPINDLE MOTOR I
TAPE SPINDLE
SPINDLE F/B FROM WITH POSITION N
READER/ DRIVE
CONTROLLER M/C TOOL & VELOCITY E
PUNCH
FFEDBACK
ELEMENTS T
INPUTS
I/O O
CONTROLLER SWITCH- O
MISCELLANEOUS
(PLC) OUTPUTS
ING L
MOTORS
OUTPUTS

SENSORS /
FEEDBACK
FEEDBACK DEVICE
CLASSIC SERVO LOOP
POSITION LOOP
D/A Converter
changes following
Accumulator holds error to analog Slide
VELOCITY LOOP
following error voltage Servo Motor
Amplifier

Speed feedback is
Interpolator issues
Position feedback is subtracted from
position commands
subtracted from speed command
position command
Tacho
to provide
following error

Position Transducer
Monitors Position
Analog Servo Loop in CNC System

Following
error signal Velocity Error Velocity Slide
Accumulated Signal Amplifier
Command
Current
+
-
DAC +
- Amplifier M
Lead screw
Accumulated
feedback

Encoder
Counter Tacho
generator
VELOCITY FEEDBACK

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.
• 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 Drive amplifier


Servo motor

Fanuc Serial Servo


bus (FSSB)

• Spindle Interface (Serial)

Spindle
motor

Fanuc I/o Link


Connection Panel
I/O Modules

MOP
I/O devices
Centralised Lubrication System
Online Machine Diagnosis System
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
CNC SYSTEMS
MANUFACTURER COUNTRY MODEL
MANUFACTURER COUNTRY MODEL

ROCKWELL AUTOMATION
ROCKWELL AUTOMATION U.
U.S.
S.AA ALLEN
ALLEN BRADLEY
BRADLEY
8610,
8610, 8650,
8650, 9/PC
9/PC

CINCINNATI
CINCINNATI MILACRON
MILACRON U.S.
U. S.AA ACRAMATIC
ACRAMATIC950, 2100
950, 2100

FAGOR SPAIN FAGOR 800, 8025, 8050


FAGOR SPAIN FAGOR 800, 8025, 8050
FANUC JAPAN FANUC 15i/150i, 16i/160i, 18i/180i, 21i/210i

FANUC INDIA
FANUC INDIA
JAPAN FANUC21i/210i,
FANUC 18i/180i, 0 , 0i 30i/31i/32i,
300i/310i/320i
HEIDENHAIN GERMANY TNC 155, 426, 430

NUM FRANCE NUM 1040, 1050, 1060


FANUC INDIA INDIA FANUC 0 , 0i
SIEMENS GERMANY SINUMERIK 810, 820, 840, 880

HEIDENHAIN
MITSUBISHI ELECTRIC AUTOMATION INC. GERMANY
JAPAN TNC
M64 CNC, FUSION 155,
640, 426, TPLUS
MPLUS, 430 AND 600
SERIES.

GSK CNC EQUIPMENT CHINA GSK980TDa., GSK983M

SIEMENS GERMANY SINUMERIK 802, 840, 880

MITSUBISHI ELECTRIC AUTOMATION INC. JAPAN 70/700 SERIES, C6/C64 SERIES, 60S/E60/E68
SERIES
Program configuration
Block configuration
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 & coolant on.
M 14 - Spindle reverse & coolant on.
M 16 – Special tool call.
M 17 – Sub-program end.
M 19 – Spindle orientation.
M 30 – Main program end & rewind.
Steps to Execute a CNC Program

1.How to start the CNC Machine:


 Main Supply ON
 Stabilizer ON
 Machine Switch ON
 CNC System ON
 Releasing Emergency Button

2.JOGGING – Manual movement of tool in X, Y, and Z-axis directions in off-line mode

3. REFERENCING/HOMING – Sending the tool to Home position with X= 0, Y = 0, & Z


= 0 co-ordinates position i.e. MCS position.

4. OFF-SETTING of Tool and Workpiece – WCS & MCS – Shifting of MCS to WCS i.e.
selecting a Job ‘0’ position

5. TOOL SELECTION & INDEXING – With the help of ATC

6. SELECTING the Program to be executed


7. SIMULATION of the program – Do Simulation using the appropriate Button
to confirm that you have made the correct CNC program.
8. EXECUTION of the Program – Perform Execution of the program using
Execution Button.

9. After Execution, how to make ‘OFF‘ the CNC Machine:

 Emergency Button off

 CNC OFF

 Machine Switch OFF

 Stabilizer OFF

 Main Supply OFF

---xxx---
PROGRAM FOR FACING OPERATION

Data input in metric units (mm)

Feedrate in mm/ min

G21 G98

Reference position return


For X
For Z
G28 U0W0
Tool Change or Tool call

Tool no 2

Offset file for tool no 02

M06T02 02
Spindle rotation CW

Spindle rotation 1500 rpm

M03 S1500
Rapid travel of tool

Tool position in X-direction

Tool position in Z-axis

G00 X25.4 Z5.0


Facing cycle code

Tool position in X-direction

Tool position in Z-direction

Feed rate value

G94 X-1.0 Z0.0 F80


Z-0.2 Tool position in Z-direction

Z-0.4 Tool position in Z-direction

Z-0.6 Tool position in Z-direction

Z-0.8

Z-1.0

Z-1.2

Z-1.4

Z-1.6

Z-1.8
Z-2.0

G28
Reference position return
U0W
Spindle Stop
0
Program stop
M05

M30

----xxxx----
PROGRAM FOR DRILLING OPERATION

Data input in metric units (mm)

Feedrate in mm/ min

G71G94
Referencing code

Z-axis referencing

G75Z0
Referencing code

X & Y-axis referencing

G75X0Y0
Tool Change or Tool call

Tool no 1

M06T1
Spindle rotation CW

Spindle rortation 1000 rpm

M03S1000
Rapid travel of tool
Drilling cycle code

Offset file

Position of X,Y & Z axes

G00G90G54X0Y0Z10
Linear movement of tool Feed rate 60 mm/min

G01F60

X25Y20 position of X & Y axes

X-25Y20 position of X & Y axes

X-25Y2-20
position of X & Y axes
X25Y-20
position of X & Y axes
G00Z5
position of Z-axis
G75Z0X0Y0
X, Y & Z axes referencing
M05
Spindle stop
M30
Program stop

---xxx--
-
THANK YOU

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