CAD/CAM Principles and Applications by P.N.

Rao

10 CNC Hardware Basics 10-1/10-20

10. CNC Hardware Basics

10.1 Structure of CNC machine tools Table 10.1 Some design criteria for CNC machine tool design [Rogers] Machine Response Type of command signal Input configuration Maximum feed rate Static accuracy Dynamic accuracy Magnitude of load Range of travel Weight of moving members Power source Component characteristics Undamped natural frequency Power requirement Friction characteristics Inertia Stiffness Amount of backlash Speed range Bandwidth Operating and cost considerations Reliability Maintainability Cost of operation Capital investment Installation requirements

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Fig. 10.1 Heavy machine tool structure of a CNC machining centre (Courtesy Makino Milling Machines Co. Ltd., Tokyo, Japan)

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Fig. 10.2

Schematic of a concrete bed of a CNC Turning centre

Fig. 10.3

Concrete bed of CNC Turning centre GF NDM-16 with slant bed (Courtesy George Fischer, Switzerland)

10.2 Spindle design

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Fig. 10.4

Spindle design for a CNC turning centre

Fig. 10.5

Spindle design with an integral spindle motor and cooling system for a CNC Machining centre (courtesy of Hller Hille GMBH, Germany)

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Fig. 10.6

Spindle assembly with the slideways of CNC vertical axis machining centre

Fig. 10.7

Bifurcated column structure for CNC Machining centre to improve torsional rigidity (see also Fig. 10.1)

10.3 Drives The various drives used in CNC machines are: Spindle drives to provide the main spindle power for cutting. Feed drives to drive the axis as per the programme.

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Fig. 10.8

Typical torque speed characteristic of a 50 kW AC spindle motor used for CNC Machine

Feed drives: The feed drives that are used in CNC machine tools are DC Servo motors AC Servo motors Stepper motors Linear motors

Fig. 10.9 Typical step motor system. Precise step systems have feedback loop (dotted line) using encoders or resolvers.

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Fig. 10.10 Step motor with permanent magnet rotor. Stepper motors have a number of benefits, which call for their use in motion control applications. Low cost Ruggedness Simplicity in construction High reliability No maintenance

Table 10.2: Comparison of Ball Screws vs Linear Motors Characteristi Ball Screw cs Max speed 30 m/min (lead dependent) Max 0.5-1g acceleration Static 9-18 kgf/ m stiffness Dynamic 9-18 kgf/ m stiffness Settling time 100 ms Max force 26.7 kN Linear Motor 120 m/min typical (180240 m/min possible) 2-10g 7-27 kgf/ m 16-21 kgf/ m 10-20 ms 9.0 kN/coil

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Reliability

6000-10 000 hours

50 000 hours

10.4 Actuation systems Lead screws:

Table 10.3 Lead screw efficiencies Efficiency (%) High Median Low 95 90 85 55 40 35

Type Recirculating Ball screw - nut Acme with metal nut*

* Since metallic nuts usually require a viscous lubricant, the coefficient of friction is both speed and temperature dependent.

Fig. 10.11 Lead screw with Acme nut

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Fig. 10.12 A recirculating ball screw and nut arrangement (Courtesy THK Co. Ltd., Japan).

Fig. 10.13 A recirculating ball screw and nut arrangement with external return tube (Courtesy THK Co. Ltd., Japan).

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Fig. 10.14 Pre-loading of the recirculating ball screw and nut arrangement The recirculating ball screws have a number of advantages compared to the conventional type of screws.

Fig. 10.15 Conventional slide way systems used in machine tools Linear Motion systems

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Fig. 10.16 Antifriction guideways used in CNC machine tools (Courtesy THK Co. Ltd., Japan).

Fig. 10.17 Ball bush used for linear movement in CNC machine tools (Courtesy THK Co. Ltd., Japan).

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Fig. 10.18 Use of recirculating ball screw and the LM device for axis movement in the bed of a CNC machine tool (Courtesy Makino Milling Machines Co. Ltd., Tokyo, Japan)

10.5 Feedback devices Encoders Linear scales

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Fig. 10.19 The closed loop control system used for the control in a CNC machine tool

Optical rotary encoder

Fig. 10.20

The encoder disc for rotary position measurement.

Absolute encoder

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Incremental encoder

Fig. 10.21 The absolute encoder disc for rotary position measurement.

Fig. 10.22 Operation of a digital rotary encoder for position measurement

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Fig. 10.23 Linear scale

The encoder disc for rotary position measurement.

Fig. 10.24 The linear scale fixed to the machine tool structure for direct position measurement.

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Fig. 10.25 Principle of optical grating for position measurement in linear scales.

10.6 Axes - Standards

Co-ordinate system

Fig. 10.26 Right hand co-ordinate systems

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Fig. 10.27 Finding directions in a Right Hand Co-ordinate System and also the positive directions for rotary motions Designating the Axes First axis to be identified is the Z-axis. This is followed by the X and Y axes respectively. Z-Axis and Motion

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Fig. 10.28 Vertical axis Milling Machine or Machining centre X-Axis

Y-Axis

Rotary Motions

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Fig. 10.29 Axes designation for CNC turning centre with twin turrets and driven tooling.

Fig. 10.30 CNC Horizontal axis boring mills in 3 and 4 axes versions

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Fig. 10.31 5 axes CNC Vertical axis machining centre configuration.