Unit-5

Machine Tools: types and classification; NC, CNC etc., static, dynamic and thermal consideration in
machine tools.

CNC MACHINES: Introduction to CNC Systems, Fundamental aspects of machine control, types of CNC
machines, Constructional Features of CNC Machines: Structure, Drive Mechanism, gearbox, Main drive,
feed drive, Spindle Motors, Axes motors. Timing belts and pulleys, Spindle bearing, Slide ways, Re-
circulating ball screws Backlash measurement and compensation, linear motion guide ways, Tool
magazines, ATC, APC, Chip conveyors. Retrofitting of Conventional Machine Tools, Retrofitting of
conventional machines with CNC.
 HISTORY
US Air Force commissioned MIT to develop the first
"numerically controlled" machine in 1949. It was
demonstrated in 1952.
At 1970-1972 first Computer Numeric Control
machines were developed.
Today, computer numerical control (CNC) machines
are found almost everywhere, from small job shops in
rural communities to companies in large urban areas.

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 Conventional machines section
Some of the machines in this section are :
Bandsaw - The bandsaw is useful for cutting stock to size and
roughing out shapes. It cuts curved shapes very well.
Belt sander A belt sander is used to remove rough edges. It makes
use of an abrasive riding belt. Effective on wood, plastic and most
metals.
Drilling machine
The drill press is mostly
used for drilling holes,
reaming, boring,
countersinking etc.
Power hacksaw A
type of hacksaw powered
either by its own electric
motor or connected to an
engine.
Power hacksaw Drilling machine
 Surface grinder It is a machine tool used to
provide high precision surface finish. The
grinding wheel rotates in the spindle head, its
height adjustable. The workpiece is fed by a
horizontal table positioned below the grinding
wheel.

Surface grinder
Slotting machine - Similar to
a vertical shaper. The most
common use is to machine
straight, flat surfaces.
Slotting machine

And several other machines for sheet metal work, electroplating etc. , as
well as callipers, micrometers etc. for measurement and testing.
 The 2 principal conventional machines on which we are focusing are the
lathe and milling machines.

Lathe Machine
Lathes are designed for precisely machining relatively hard materials. With
their inherent versatility, they are used in a wide range of applications, and can
machine a broad range of
materials.

These lathe machine

removes material from a
rotating work piece via
the linear movements of
various cutting tools,
such as tool bits and drill
bits.
Operations performed on a lathe
Turning The diameter of a part can be reduced to desired dimension.

Facing - A lathe can be used to create a smooth, flat, face very

accurately
perpendicular to the axis of a cylindrical part.

Parting - Deeper and narrower than a turning tool. It is designed for

making narrow grooves and for cutting off parts.

Drilling - A lathe can also be used to drill holes accurately concentric

with the centerline of a cylindrical part.

Boring - Boring is an operation in which a hole is enlarged with a single

point cutting tool.

Threading - External threads can be cut with a die and internal threads
can be cut with a tap.
 Types of lathe
Centre lathe / bench lathe / engine lathe - The most basic type of lathe.

Toolroom Lathe - Lathe optimized for toolroom work. It has all of the
best optional features that may be omitted from less expensive models, such
as a collet closer, taper attachment, and others.

Turret lathes and capstan lathes - Used for repetitive production of

duplicate parts.

Multispindle lathe - Multispindle lathes have more than one spindle and
automated control.

CNC lathe - CNC lathes are rapidly replacing the older production lathes
due to their ease of setting and operation. The part may be designed by the
Computer-aided manufacturing (CAM) process, the resulting file uploaded
to the machine, and once set and trialled the machine will continue to turn
out parts under the occasional supervision of an operator.
Types of milling cutters
In vertical mills, milling cutters
with solid shafts are usually used.

End mills are designed for cutting

slots, keyways and pockets.

Two fluted end mills can be used

to plunge into work like a drill.
Ball end mills can produce a
fillet.
 Operations done on Milling machines

Roughing
Finishing
Drilling
Boring (a) Rough (b) Finish (c) Counter boring
Slotting
Key way cutting
Gear cutting
Spur
Bevel
Worm
Helical
 Computer and Numerically Controlled
Machines
Numerically Controlled (NC)
NC is the operation of M/c tool by a series of coded instructions consisting of
numbers, letters of the alphabets and symbols, which the MCU (Machine Control
Unit) can understand.

Computer numerically controlled (CNC)

When numerical control is performed under computer supervision, it is called

computer numerical control (CNC). Computers are the control units of CNC
machines. A programmer enters some information in the program, but the computer
calculates all necessary data to get the job done.

For both NC and CNC systems, working principles are the same. Only the way in
which the execution is controlled is different. Normally, new systems are faster,
more powerful, and more versatile.
 Comparison between NC, CNC and
DNC machine tools
1. The part program is fed to
the machine through the
tapes or other such media.
2. In order to modify the
program, the tapes have to
be changed.
3. In NC machine tool system,
tape reader is a part of
machine control unit.
4. System has no memory
storage and each time it is
run using the tape.
5. It can not import CAD files.
6. It can not use feedback
system.
7. They are not software
driven.
1. In CNC machine tool system, 1. The part program is fed to
the program is fed to the the machine through the
machine through the Main computer
computer.
2. The programs can be easily 2. In order to modify the
modified with the help of program, single computer is
computer. used
3. The microprocessor or
minicomputer forms the 3. Large memory of DNC
machine control unit. The allows it to store a large
CNC machine does not need amount of part program.
tape reader.
4. It has memory storage 4. Same part program can be
ability, in which part run on different machines
program can be stored. at the same time.
5. System can import CAD
files and convert it to part 5. The data can be processed
program. using the MIS software so
6. The system can use feedback as to effectively carry out
system. the Production planning
7. The system is software and scheduling.
driven.
CNC TURNING

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CNC MILLING

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CNC LASER CUTTING

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CNC PLASMA CUTTING

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CNC PRESS

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CNC RAPID PROTOTYPING

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 INDUSTRIES MOST AFFECTED by CNC
Aerospace
Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mold making

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 Various popular CNC control systems

1. ECS
2. LECS
3. NUM
4. SELCA
5. MARPOSS
6. Z-16
7. FANUC
8. FAGOR
9. FIDIA
10. DECKEL
11. SINUMERIC
12. HINUMERIC
13. HEIDENHAIN A CNC Milling center by DECKEL
14. GILDEMEISTER
 The construction of CNC machines
1. Elements of motion transmission

Ball-screws and nut assembly

In a CNC machine, the connection between the screw and the nut is through
an endless stream of re-circulating steel balls, replacing sliding friction
threads with rolling friction. Advantages are higher efficiency, reversibility
and reduction in wear and tear.
Hydrostatic slideways
In the hydrostatic slideways air or oil is pumped into small pockets
machined into slides which are in contact with the slideway.
2. Computers
CNC machines use an on-board computer that allows the operator to read,
analyze, and edit programmed information. In CNC machine, computer
works on a binary principle, 0 for information and 1 for processing. Special
built-in software compiles the user entered program (in code language) into
machine language and the machine moves the tool by its servomotors.
3. Control systems

There are two types of control systems on CNC machines:

Open loop (less accurate)
Closed loop (more accurate)
The open loop control system does not provide positioning feedback to the control
unit. Since this control system only counts tool movement pulses and cannot
identify discrepancies in positioning, it is slightly inaccurate.
In closed loop control system, the electronic movement pulses are sent from the
control to the servomotor, enabling the motor movement. Movements are detected
by a feedback device (transducer), which can send a signal to the control for
checking after each step.
4. Drive motors

The drive motors control machine slide movement on CNC equipment. Types used :
1. Stepper motors (convert a digital pulse into a small rotation, mostly used in
applications where low torque is required )
2. DC servo motors (rotate in response to the applied voltage, used to drive lead
screw and gear mechanisms, provide higher-torque output)
3. AC servo motors (controlled by varying the voltage frequency to control speed,
more power than a DC servo, used to drive a lead screw and gear mechanism )
4. Fluid servo motors (variable speed motors, produce more power, in the case of
pneumatic motors, than electric servomotors)

5. Tool changers

Several different cutting tools are used to produce a part. The tools must be replaced
quickly for the next machining operation. For this reason, the majority of NC/CNC
machine tools are equipped with automatic tool changers. They allow tool changing
without the intervention of the operator.
An automatic tool changer grips the tool in the spindle, pulls it out, and replaces it
with another tool. Tool changers are equipped for either random or sequential
selection.
In random tool selection there is no specific pattern of tool selection.
In sequential tool selection, the tools must be loaded in the exact order in which they
are called for in the program.
CNC PROGRAMMING

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 INFORMATION NEEDED by a CNC
1. Preparatory Information: units, incremental or absolute
positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of rotation,
stops for part movement
This information is conveyed to the machine through a set
of instructions arranged in a desired sequence Program.

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 BLOCK FORMAT

Sample Block
N135 G01 X1.0 Y1.0 Z0.125 F5

Restrictions on CNC blocks

Each may contain only one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feedrate
Each may contain only one specified tool or spindle speed
The block numbers should be sequential
Both the program start flag and the program number must
be independent of all other commands (on separate
lines)
The data within a block should follow the sequence shown
in the above sample block

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 WORD-ADDRESS CODING
Example CNC Program
N5 G90 G20 Each instruction to the machine consists
N10 M06 T3 of a letter followed by a number.
N15 M03 S1250
N20 G00 X1 Y1 Each letter is associated with a specific
N25 Z0.1
type of action or piece of information
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 needed by the machine.
N40 G00 Z1
N45 X0 Y0 Letters used in Codes
N50 M05
N55 M30 N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M

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 G & M Codes
Example CNC Program
N5 G90 G20 G-codes: Preparatory Functions
N10 M06 T3 involve actual tool moves.
N15 M03 S1250
N20 G00 X1 Y1 M-codes: Miscellaneous
N25 Z0.1
Functions involve actions
N30 G01 Z-0.125 F5
N35 X3 Y2 F10 necessary for machining (i.e.
N40 G00 Z1 spindle on/off, coolant on/off).
N45 X0 Y0
N50 M05
N55 M30

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 G Codes
G00 Rapid traverse G40 Cutter compensation
cancel
G01 Linear interpolation G41 Cutter compensation
G02 Circular interpolation, left
CW G42 Cutter compensation-
G03 Circular interpolation, right
CCW G70 Inch format
G04 Dwell G71 Metric format
G08 Acceleration G74 Full-circle programming
G09 Deceleration off
G17 X-Y Plane G75 Full-circle programming
on
G18 Z-X Plane
G80 Fixed-cycle cancel
G19 Y-Z Plane G81-G89 Fixed cycles
G20 Inch Units (G70) G90 Absolute dimensions
G21 Metric Units (G71) G91 Incremental dimensions

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 Modal G-Codes

Most G-codes set the achi e i a ode

which stays in effect until it is changed or
cancelled by another G-code. These
commands are called odal .

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 Modal G-Code List
G00 Rapid Transverse G43 Tool length compensation
G01 Linear Interpolation (plus)
G02 Circular Interpolation, CW
G03 Circular Interpolation, G44 Tool length compensation
CCW (minus)
G17 XY Plane
G49 Tool length compensation
G18 XZ Plane
G19 YZ Plane
cancel
G20/G70 Inch units G80 Cancel canned cycles
G21/G71 Metric Units G81 Drilling cycle
G40 Cutter compensation cancel
G41 Cutter compensation left G82 Counter boring cycle
G42 Cutter compensation right G83 Deep hole drilling cycle
G43 Tool length compensation
(plus) G90 Absolute positioning
G91 Incremental positioning

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 M Codes
M00 Program stop
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps on
M11 Clamps off
M30 Program stop, reset to start

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 N Codes
Gives an identifying number for each block of
information.

It is generally good practice to increment each

block number by 5 or 10 to allow additional
blocks to be inserted if future changes are
required.

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 X,Y, and Z Codes
X, Y, and Z codes are used to specify the
coordinate axis.
Number following the code defines the
coordinate at the end of the move relative to
an incremental or absolute reference point.

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 I,J, and K Codes
I, J, and K codes are used to specify the
coordinate axis when defining the center of a
circle.

Number following the code defines the

respective coordinate for the center of the
circle.

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 F,S, and T Codes
F-code: used to specify the feed rate

S-code: used to specify the spindle speed

T-code: used to specify the tool identification

number associated with the tool to be used in
subsequent operations.

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 Application of Some Codes
G01 Linear Interpolation
Format: N_ G01 X_ Y_ Z_ F_

Linear Interpolation results in a straight line

feed move.

Unless tool compensation is used, the

coordinates are associated with the centerline
of the tool.

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