2.

CNC SYSTEM
The advantages derived from CNC machines are due to their salient constructional features listed
below.
2.1 MACHINE STRUCTURE
High rigidity
High stiffness to weight ratio
Thermal stability
Good damping characteristics
2.1.1SLIDE WAYS
Antifriction bearing elements like re-circulating ball packs, re-circulating ball bushings.
Hydrostatic or Aerostatic slide ways.
Plastic or non-metallic liners like PTFE (Poly Tetra Fluro Ethylene), Turcite B, etc.
2.1.2 SPINDLE DRIVE
Wide spindle speed range to meet cutting parameters
DC motors with silicon controlled rectifier drive or AC motors with variable frequency.
Spindle orientation for Automatic Tool change and fine boring applications.
2.1.3FEED DRIVE
Slides are actuated by precision re-circulating ball screw mechanism driven by servo motors.
DC motors with silicon controlled rectifier drive or AC motors with variable frequency.
2.1.3 FEED-BACK SYSTEMS
The accuracy of positioning in any CNC machine achieved by measuring the position or
displacement of the slide and comparing it with the commanded 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 commanded position, is brought to zero. That is why CNC is called Error
driven systems. The position measuring devices could be direct or indirect depending upon
whether the device is fitted directly in the slides or at the end of the ball screw.
Some of the measuring devices are linear inductosyns, Optical scales with gratings, rotary
encoders, rotary inductosyns, brush less synchro resolvers, etc.
2.1.4 AUTOMATIC TOOL CHANGER (ATC)
Automatic Tool Changer (ATC) is an important element of machining centers responsible for
increase in productivity by reduction of idle time during tool change. Present day CNC machines
are equipped with ATC units capable of performing tool changes within 3 to 7 seconds.
In act ATC unit, the tool magazine can be drum type with capacity up to 40 tools or chain type
with capacity up to 132 tools.
The tool change arm can be of single gripper type or of double gripper type.
The tool selection can be of Sequential type (applicable for less no, of tools and consuming
more time) or of Random type (applicable for more no. of tools and consuming less time).

2.1.5 AUTOMATIC PALLET CHANGER (APC)

Similar to ATC the Automatic pallet changer (APC) aids in increase of productivity by reducing
the job setup time considerably. The function of the pallet changer is to interchange the pallet on
the machine that one pallet has the finished component and the other pallet with newly loaded
component. The pallet when transferred from the Pallet changer on the machine gets located and
clamped with heavy clamping force either hydraulically or mechanically.
APC could be of dual pallet type or multiple pallet pool type.
2.1.6 SOME OF THE OTHER SALIENT FEATURES
Thermal stabilization of headstock, feed drive elements and machine structural elements by recirculating refrigerated oil.
Axial calibration for all fixed mechanical elements.
Lost motion compensation for backlash, axial and torsional deflections.
Usage of Touch trigger probes for post process metrology purpose, tool condition monitoring.
Tool measurement and setting of tool offsets and thermal error compensation.
Centralized lubrication of slides, etc, controlled by timer or soft ware.
Coolant systems of either flood type or mist type.
Chip conveyors for collection and disposal of chips.
Auto diagnostic facilities to aid for maintenance and service personnel.
2.2 SLIDE ACTUATION IN CNC MACHINES:
In a conventional machine hand wheels actuate slides. Occasionally when automatic feed is
needed the slides are power driven from the machine spindle.

SLIDE

PULSES
AMPLIFIER

MOTOR
LEAD
SCREW

MCU (Machine control unit)

BASIC ELEMENTS OF SLIDE MECHANISM IN CNC

But in a CNC machine the story is quite different. Here the hand wheels are replaced by motors
and each slide has its won independent motor. The motor speed can be infinitely varied to get the
desired feed rate.
A schematic diagram of the slide actuation mechanism of a CNC machine is shown. This
diagram is rather an oversimplified one and is given only to understand the fundamental principle
of slide actuation. The following description will help understand its working.
MCU reads the program as soon as it receives the start signal from the operator.
It processes the instruction and sends out low-level electrical pulses. (voltage)
An amplifier magnifies these low voltage pulses high enough to drive the motor.
The motor rotates and drives the lead screw and this in turn causes the slide to move.
The number of pulses sent by the MCU would depend on the following facts.
M/c. resolution
Feed rate
Distance to be traveled
2.3 MACHINE RESOLUTION:
Every single pulse sent out by the MCU causes the slide to move a specific distance and
machine resolution is the distance moved by the slide for a single pulse. Thus a resolution of
0.001 would mean that the slide would move 0.001mm for every pulse. In other words for a travel
of 1mm the MCU will send out 1000 pulses.

2.3.1 PULSE FREQUENCY:

The number of pulses sent out by the MCU every second is called pulse frequency and the
input voltage to motor depends directly on this factor. The pulse frequency is not a constant value.
It depends on the required feed rate and the machine resolution.
Pulse frequency = Feed rate in mm/min / M/c resolution x 60. pulse / second.
As the resolution is constant for a given machine the pulse frequency may be taken as directly
proportional to the feed rate.
It may thus be concluded that as the MCU read the instruction it sends out pulses at
frequencies corresponding to the desired feed rates. Since the input voltage to the motor is
proportional to the pulse frequency, the motor speed is automatically adjusted to achieve the
desired feed rate.
Example1.
Determine the pulse frequency for a feed rate of 30mm/min if the M/c resolution is 0,001 mm.
Solution:
Pulse frequency = Feed rate in mm/min
----------------------------M/c resolution x 60
= 30 / 0.001 x 60
= 500 pulses/sec.
Example2.
Determine the number of pulses in the above example for a travel of 40mm.

Solution:

No. of pulses = Distance to travel

------------------------Resolution
= 40 / 0.001
= 40,000 pulses.

2.4 FEED BACK CONTROL SYSTEM

Based on feedback control NC system is classified as follows:
2.4.1 OPEN LOOP SYSTEM:
In an open loop control system hsa no provisions for detecting or comparing the cutting tool
movement with the commanded value.These systems are not used where extremely accurate
positioning is required.

OPEN LOOP SYSTEM

MACHINE
CONTROL
UNIT

MACHINE SLIDE
DISPLACEMENT

DRIVE
MOTOR

2.4.2 CLOSED LOOP CONTROL:

In closed loop control system has provisions for detecting or comparing the cutting tool movement
with the commanded value.

CONTROL
COMPUTER

CLOSED LOOP SYSTEM

DRIVE MOTOR

PROGRAM
INPUT

SLIDE

TRAVERESE
MEASUREMENT

COMPARATOR
COMMAND VALUE
ENCODER

ACTUAL VALUE

FEED BACK SIGNALS

A
closed loop control has a device called encoder and this can continuously ascertain the distance
actually travelled by the tool and then monitor the same by feedback signals to the control. The
control takes corrective action in case any error is detected .