CNC

LECTURE-9
amr.ahmed@eng.asu.edu.eg
ABOUT THE TUTOR

•B.Sc in mechanical engineering, design and production engineering

department, faculty of engineering, Ain Shams University (year 2007).
•M.sc in the CAD/CAM/CNC field /design and production engineering
department, Faculty of Engineering, Ain Shams University (Oct2007-
Oct2010).
•PhD in the virtual simulation field/design and production
engineering department, Faculty of Engineering, Ain Shams University
(May2011-May2015).
•Course instructor for many courses at various course centers and
academic institutions.
•Currently, Assistant Professor in ASU.
•Email: amr.ahmed@eng.asu.edu.eg.

2 Dr.Amr Shaaban-Introductory session 12/22/2017

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HOW THE PART PROGRAM IS EXECUTED?

Actuators & Drives

MCU
CNC
Guideways
MACHINE
TOOL Tool magazines
Sensors
Mechanical Structure

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CNC MECHANICAL STRUCTURE FE Model

CAD Model
Analysis

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 Note:
Overall evaluation of a CNC
machine tool should not ignore
the behavior of the mechanical
structure. But it should also
include the performance of the
control system.

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Machine Control Unit

•Read the coded instructions.

•Decode the coded instructions.
•Implement interpolation.
•Feed the motion commands to the amplifier
circuits for driving the axis mechanism.
•Receive the feedback signal.
•Implement auxiliary control functions.

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 TOOL MAGAZINE

INDEXING TURRET
The required turret station is specified on the program; hence the turret
indexes from one tool station to the next desired station in accordance with the
input data.
The accuracy claimed for indexing (at the spindle nose) is 0.005 mm. Indexing
accuracy is achieved by means of a hydrostatic location bolt which also acts as
the plunger of an oil pump; the plunger is surrounded by a film of oil under
pressure which effectively centralizes and eliminates wear.

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 TOOL MAGAZINE

DRUM TYPE Two types of drum magazine are used in CNC machines:
The first is without a tool catcher. In this case as soon as a tool is required and been
programmed , orders are given by the controller to rotate the drum and move it to spindle
nose to receive the used tool and fix the new one.
Second type a special mechanism (tool catcher), is employed to select the correct tool and
transfer it to the machine spindle, where it is automatically clamped in position..

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 TOOL MAGAZINE

BOX TYPE The cutting tools are stored in the magazine in a regular rectangular pattern. The
position of each tool is known by the rectangular co-ordinates of its location. To
select a tool, the program is compiled to position the spindle opposite and co-
axial with the required tool. The spindle moves forward and engages with the
shank of the tool and the shank is then gripped by a drawbar or collets. The
spindle is retracted to remove the tool from the magazine, and the slides are
actuated to move the tool to its machining position.

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 TOOL MAGAZINE

CHAIN TYPE Tools are exchanged between the chain magazine, and the spindle by means
of an automatic tool transfer unit. An advantage is that machining can
continue uninterrupted, using the tool in one spindle while tool changing is
taking place between the magazine and the spindle in the rear position. The
table may be traversed in X and Y directions under rapid or feed rates without
interfering with the exchange. On completion of a machining cycle with one
tool, the spindles index through 180° and machining can immediately starts
with the new selected tool.

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 ACTUATORS
MOTOR TYPE FUNCTION SPECIFICATIONS
Input voltage
•Provide the cutting power to the main Max power
DC MOTOR
spindle. Max Torque
Speed range
Input voltage
STEPPER •Provide the feed motion to the slides in Max power
MOTOR open loop control system. Max Torque
Resolution Deg/pulse
Input voltage
•Position and velocity encoder integrated.
DC SERVO Max power
•Provide the feed motion to the slides in
MOTOR closed loop control system. Max Torque
Resolution Deg/pulse
•Operates the chip conveyor, coolant Input voltage
AC MOTOR
pump, ATC equipments, and m/c door. Max power
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DRIVERS

12 Dr.Amr Shaaban-Introductory session 12/22/2017

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HOW THE PART PROGRAM IS EXECUTED?
•The MCU outputs signals to the spindle motor (Z-motor) and the slide motors (X&Y-motors)
analogs to the required cutting speed and feed rates (in X&Y) respectively.
•The amount and the rate of pulses sent by the MCU to the slide motors control the position
of the slide and the feed rate in both X&Y directions respectively.
•If the slide is intended to move in X-direction only (G01 X30), the MCU sends pulses to X-
motor only; and the same occurs for Y-direction (G01 Y40) only.
•If the slide is intended to move in both X&Y directions (G01 X30 Y40), the MCU sends pulse
rates to both X&Y motors to synchronize the inclined path.
•If the slide is intended to move in a circular path (G02 X20 Y40 I10 J10), the MCU sends pulse
rates to both X&Y motors according to the circular interpolation method used to obtain the
circular path.
•Each single pulse sent by the MCU to any of the slide motors will drive it with the smallest
angle that can be rotated by that motor. This angle will be converted to a displacement for the
slide via gear unit and lead screw; and consequently, this is the smallest displacement can be
moved by the slide; this is called the resolution. In the shop floor, we call this the m/c jogging.

13 Dr.Amr Shaaban-Introductory session 12/22/2017

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HOW THE PART PROGRAM IS EXECUTED?
•The relation between this angle and the displacement of the slide depends on: the gear ratio of
the gear unit attached to motor, and the pitch of the lead screw that drives the slide.
•.For example, if the gear ratio is 4 , the pitch of the lead screw is 10mm, and the resolution of
the motor is 6 degree/pulse. This leads to a travel feed resolution equal to (6/360)*(1/4)*10=
0.04mm/pulse.

•.Other example, if the gear ratio is 4 , the pitch of

the lead screw is 6mm, and the encoder attached to
the lead screw generates 200 pulses/rev. This leads
to a travel feed resolution equal to 6/200=
0.03mm/pulse. (Note: gear ratio has no effect as the
encoder is directly attached to the slide).

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 ENCODERS
1 INDUCTION TYPE ENCODER

•Inductosyn is the trade name of transducer used for measuring and monitoring
linear and rotary displacement.
•Both linear and rotary type consists of two parts: the scale and the slider with
0.2mm gab.
•The windings are bonded first to an insulating material and then to a suitable
backing material which provides the necessary strength and rigidity.
•On the slider, there are two separate short sections of the copper winding of the
same form and size as that on the scale.
•The two sections are displaced axially to each other by a quarter of the pitch of
the copper winding.
•When an alternating electric current flows through the copper winding on the
scale, induced voltage is generated in the copper windings of the slider.
•The quarter pitch shift will result in a phase between the induced voltage
generated in each slider winding. This phase can then be used to detect the
motion direction.

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 •The relation between the induced voltage Va in one winding of the
slider and the displacement X is:
Va= kV cos (2ЛX/P)
While for the other winding of the slider, the relation is:
Vb=kV sin (2ЛX/P)
where k is the coupling ratio between scale and slider,
V is the voltage input to the scale windings,
X is the linear displacement of the slider from the zero datum, and
P is the spacing (pitch) of the poles (typically 2 mm).

•When the machine tool is ordered to move into a certain position, the machine tool is
equipped with a voltage equal to that of the corresponding position but with inverse
polarity. The slider will keep moving due to the given voltage until the MCU reads zero;
which indicates that the slider reaches the desired position.

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 ENCODERS
2 OPTICAL TYPE ENCODER

•Pulse generating encoder (sometimes referred to as a incremental encoder or

digitizer) is a rotary device that outputs digital pulses in response to incremental
angular motion.
•The encoder is mounted to the end of the lead screw.
•The encoder consists of a slotted disc rotates between a LED and a
phototransistor.
•The radial slots distribute uniformly taking a ring form in an alternate pattern of
an opaque and transparent segments.
•The resolution of the encoder is determined by the screw lead and the No of
slots.
•The frequency of the generated signals of the phototransistor is the pulse rate.

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LOST OF MOTION

•The term lost of motion is used to indicate a condition in which the

consumed position is not reached.
•Sources of lost of motion:
Flexibility of the machine mechanical structure.
Backlash of screws or rack and pinions.
Friction on machine slide.
Wind up.
•Elimination of lost of motion:
Stiffening the mechanical structure.
Backlash eliminators.
Anti-friction guide ways.

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GUIDEWAYS
The main function of the guide way is to make sure that the cutting tool or machine
tool operative element moves along predetermined path.
Requirements of guide ways are :
(a) Guide way should have high rigidity.
(b) The surface of guide ways must have greater accuracy and surface finish.
(c) Guide ways should have high accuracy of travel. It is possible only when the
deviation of the actual path of travel of the operative element from the
predetermined normal path is minimum.
(d) Guide ways should be durable. The durability depends upon the ability of
guide ways to retain the initial accuracy of manufacturing and travel.
(e) The frictional forces acting on the surface must be low to avoid wear.
(f) Guide ways should have good damping properties.

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 GUIDEWAYS
Famous types of guide ways:
•Flat
•V-Type
•Dovetail
•Round Flat

Dovetail

Round

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 GUIDEWAYS
Antifriction roller type: Antifriction hydrostatic type:
Intermediate balls/rollers are inserted between In hydrostatic guide-ways, the surface of the slide
the slide and the guide-way. This is changing is separated from the guide-way by thin film of
the nature of friction from sliding to rolling. fluid supplied at pressures as high as 300 bar. The
pressure is high enough to raise the slide and
Roller types
precludes metal to metal contact.
•ball Type
•Roller type (more rigid)

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GUIDEWAYS

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TOOL HOLDERS

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TOOL HOLDERS
Gripping-3points type Shrink type

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 Design Online Academy

Design Online Academy

amr.ahmed@eng.asu.edu.eg
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