CONSTRUCTIONAL DETAILS OF CNC MACHINES

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Machine tool

The main function of a machine tool is to control the workpiececutting tool positional relationship in such a way as to achieve a desired geometric shape of the workpiece with sufficient dimensional accuracy.
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Machine tool provides: work holding tool holding relative motion between tool and workpiece primary motion secondary motion

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Primary motion

Relative motion between tool and workpiece

Cutting motion

Secondary motion

Feed motion
Feed rate
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Cutting speed
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m a c h i n e p o s i t i o n t r a n s d u c e r s

c o n t r o l

u n i t

w o r k

h o l d i n g

d e v i c e

t o o l

h o l d i n g

d e v i c e

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CLASSIFICATION OF THE CHIP REMOVING METHODS ACCORDING TO THE RELATIVE MOTION

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CLASSIFICATION OF MACHINE TOOLS

THOSE USING SINGLE POINT TOOLS
lathes shapers planers boring m/cs etc.

THOSE USING MULTIPOINT TOOLS

drilling m/cs milling m/cs broaching m/cs hobbing m/cs etc.

THOSE USING ABRASIVE TOOLS

grinding m/cs honing m/cs etc.

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NUMERICALLY CONTROLLED M/C TOOLS:

An NC machine tool is functionally the same as a conventional machine tool. The technological capabilities NC machine tools in terms of machining are no different from those of conventional ones. The difference is in the way in which the various machine functions and slide movements are controlled.

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The functions and motions such as;

turning the spindle on and off setting cutting speeds setting feed rate turning coolant on and off moving tool with respect to workpiece
are performed by Machine Control Unit (MCU) in NC machine tools.

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CNC SYSTEM ELEMENTS

A typical CNC system consists of the following six elements Part program Program input device Machine control unit Drive system Machine tool Feedback system
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NC SYSTEM ELEMENTS

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OPERATIONAL FEATURES of CNC MACHINES

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PART PROGRAM

A part program is a series of coded instructions required to produce a part. It controls the movement of the machine tool and the on/off control of auxiliary functions such as spindle rotation and coolant. The coded instructions are composed of letters, numbers and symbols and are arranged in a format of functional blocks as in the following example N10 G01 X5.0 Y2.5 F15.0 | | | | | | | | | Feed rate (15 in/min) | | | Y-coordinate (2.5") | | X-coordinate (5.0") | Linear interpolation mode Sequence number
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PROGRAM INPUT DEVICE

The program input device is the mechanism for part programs to be entered into the CNC control. The most commonly used program input devices are keyboards, punched tape reader, diskette drivers, throgh RS 232 serial ports and networks.

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MACHINE CONTROL UNIT

The machine control unit (MCU) is the heart of a CNC system. It is used to perform the following functions:

Read coded instructions Decode coded instructions Implement interpolations (linear, circular, and helical) to generate axis motion commands Feed axis motion commands to the amplifier circuits for driving the axis mechanisms Receive the feedback signals of position and speed for each drive axis Implement auxiliary control functions such as coolant or spindle on/off, and tool change
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TYPES of CNC CONTROL SYSTEMS

Open-loop control Closed-loop control

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OPEN-LOOP CONTROL SYSTEM

In open-loop control system step motors are used Step motors are driven by electric pulses Every pulse rotates the motor spindle through a certain amount By counting the pulses, the amount of motion can be controlled No feedback signal for error correction Lower positioning accuracy
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OPEN-LOOP CONTROL SYSTEM

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CLOSED-LOOP CONTROL SYSTEMS

In closed-loop control systems DC or AC motors are used Position transducers are used to generate position feedback signals for error correction Better accuracy can be achieved More expensive Suitable for large size machine tools
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CLOSED-LOOP CONTROL SYSTEMS

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DRIVE SYSTEM

A drive system consists of amplifier circuits, stepping motors or servomotors and ball lead-screws. The MCU feeds control signals (position and speed) of each axis to the amplifier circuits. The control signals are augmented to actuate stepping motors which in turn rotate the ball lead-screws to position the machine table.
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STEPPING MOTORS

A stepping motor provides open-loop, digital control of the position of a work piece in a numerical control machine. The drive unit receives a direction input (cw or ccw) and pulse inputs. For each pulse it receives, the drive unit manipulates the motor voltage and current, causing the motor shaft to rotate by a fixed angle (one step). The lead screw converts the rotary motion of the motor shaft into linear motion of the work piece .
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STEPPING MOTORS

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RECIRCULATING BALL SCREWS

Transform rotational motion of the motor into translational motion of the nut attached to the machine table.

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RECIRCULATING BALL SCREWS

Accuracy of CNC machines depends on their rigid construction, care in manufacturing, and the use of ball screws to almost eliminate slop in the screws used to move portions of the machine.
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POSITIONING

The positioning resolution of a ball screw drive mechanism is directly proportional to the smallest angle that the motor can turn. The smallest angle is controlled by the motor step size. Microsteps can be used to decrease the motor step size. CNC machines typically have resolutions of 0.0025 mm or better.
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MACHINE TOOL

CNC controls are used to control various types of machine tools. Regardless of which type of machine tool is controlled, it always has a slide table and a spindle to control of position and speed. The machine table is controlled in the X and Y axes, while the spindle runs along the Z axis.
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FEEDBACK SYSTEM

The feedback system is also referred to as the measuring system. It uses position and speed transducers to continuously monitor the position at which the cutting tool is located at any particular time. The MCU uses the difference between reference signals and feedback signals to generate the control signals for correcting position and speed errors.
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CNC MACHINES FEEDBACK DEVICES

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POTENTIOMETERS

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POTENTIOMETERS

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ENCODERS
A device used to convert linear or rotational position information into an electrical output signal.

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ENCODERS

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INDUSTRIAL APPLICATIONS of ENCODERS

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RESOLVERS

A resolver is a rotary transformer that produces an output signal that is a function of the rotor position.

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SERVOMOTOR with RESOLVER

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VELOCITY FEEDBACK

Tachometers: Electrical output is proportional to rate of angular rotation. Encoders, Resolvers, Potentiometers: Number of pulses per time is proportional to rate change of position.

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Safety Considerations:
In order to take care of safety, there are special arrangements to avoid any accidents and ensure the safety that are given bellows: 1.Guarding and safety: Since the CNC machine are under continuous automatic operation where is a need to protect the machine guide ways and to ensure the safety of the operator since the machine run at high speed with automatic auxiliary operation

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2.Protection of the machine Guideways:

The protection of the machine guideways drive screw and transducer etc. is very important for efficient working and long life of the machine various types of collapsible guards and cover are use to protect those element. Using telescopic cover normally protects all the sliding elements are fitted with wiper and dry screw. Jets of the cutting fluid are used to wash away swarf and clear the tool work area

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3.Safety of the operator:

The safety of the operator is very important aspect that cannot be overlooked. To answer safe working condition CNC machine tools are provided with metallic or plastic guard. Where it is not possible to provide effective guards, proximity protection is provided by pressure mat or light barrier.

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4.Perimeter guard:
The overall guard or perimetery guard serves as an enclosure for the machine tools.
The perimetery guard protects the operator against flying swarf and from many accidents by hitting against the moving component when the machine is working. The access to the machine is provided to through large sliding door for setting up the machine and for loading/unloading of the work piece.

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4.Perimeter guard:
The doors have various types of interlock switches fitted on them. If the door is opened when the machine is working, the control unit will flash a warning signal or activate an auditory signal like buzzer. On some machine the power to the machine may be cut off if the doors are kept open beyond a certain period of time.

During set up period, the operator can cancel the warning signal. The guards are fitted with transparent window so that machining area is visible from the operator side.

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5.Pressure mat:
The pressure mats are used on milling, grinding, machine where the machine table can move to the either side of machine. Since the table moves at the rapid rate it may cause some accident if the operator is standing too close to the machine. The pressure mats are placed around the machine and if someone crosses the mat, a warning signal is generated.

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6.Light barrier:
Light barriers are also provided on milling, drilling or grinding machine. The light barrier consists of a light source, usually infrared, sending a beam to the light sensitive cell. If anything obstruct light beam, a warning signal is generated the light barrier are placed around the machine. The operator if required can make them in active.

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