UNIT V

CNC MACHINING

Numerical Control System

Numerical

control machine tools are the machine

tools which controls the various operations
during machining by some specified letters,
numbers & symbols.
The NC machine tool runs on the given program
to it without human operator.
The NC program consists a set of instructions for
controlling the motion of the drives in the
machine tool as well as the motion of the cutting
tool.

Types of NC System
Traditional

numerical control (NC)

Computer numerical control (CNC)
Distributed numerical control (DNC)

Elements of NC machine tool

system

Components of NC machine tool

system

Controlled axes in NC systems

Basic components of NC system

Software
Machine

control unit (MCU)

Machine tool

Capabilities of MCU
Machine

tool spindle start and stop

Varying the spindle speed
Changing the direction of rotation of the spindle
Start and stop coolant supply
Changing the desired tool
Changing the desired work piece
Lock and unlock fixtures and work pieces.
Guiding the cutting tool tip along the desired
path
Controlling the feed rate of movement of the tip

Problems with conventional NC

machines
Punched

tape
Tape reader
Controller
Management information
Part programming mistakes
Non optimal speed and feed

Classification of NC machines
based on control system
Open

loop control system

Closed loop control system

Open loop control system

Closed loop control system

Classification of NC machines based

on numerical control system
Point

to point NC system
Straight cut NC system
Contouring NC system

Point to point NC system

Straight cut NC system

Contouring NC system

Important elements used in NC

machines 1. Linear ball bearing

2. Ball screw

Driving systems of NC machines

AC

drives
Direct current motors
Stepping motors
Hydraulic motors
Pneumatic drives

Hydraulic systems

Pneumatic drives

Advantages
It

provides greater accuracy

Improved product quality
High production rates
Less scrap
Less operator skill is required
Tooling cost is less

disadvantages
High

cost
Long preparation time

Computer Numerical Control

(CNC)

Now that we have seenwhat the NC machine isand its

various parts, it is easier to understand what theCNC
machineis. CNC is theshort formfor Computer Numerical
control. We have seen that the NC machine works as per
the program of instructions fed into the controller unit of
the machine. TheCNC machinecomprises of the mini
computer or the microcomputer that acts as the controller
unit of the machine. While in the NC machine the program
is fed into the punch cards, inCNC machinesthe program of
instructions is fed directly into the computer via a small
board similar to the traditional keyboard.

InCNC machinethe program is stored in the memory of the

computer. The programmer can easily write the codes, and
edit the programs as per the requirements. These programs
can be used for different parts, and they dont have to be
repeated again and again.

Compared to the NC machine, theCNC machineoffers

greater additional flexibility and computational capability.
New systems can be incorporated into the CNC controller

Block diagram of CNC machine

Types of CNC
There

are two types of CNC are used according

to machine control design.

Hybrid CNC
Straight CNC

Hybrid CNC
Hard

wired logic circuits for functions like feed

rate generation, circular interpolation etc., in
addition to computer mass production of circuits
and less expensive computer.

Straight CNC
Computer

to perform all NC functions.

Special features of CNC machines

Cutting Spindles
Requirements

of

spindles

for

machines:
High stiffness both static and dynamic
Running accuracy
Axial load carrying capacity
Thermal stability
Axis freedom for thermal expansion
High speeds of operation

CNC

Special features of CNC machines

Cutting Spindles
Requirements

of

spindle

tool

machines:
Drill chuck operators
Collet chucks
Morse nose adaptors
Shell mill adaptors
Face mill adaptors
Screwed shank end mill adaptor
Boring bars
Boring heads

for

CNC

Special features of CNC machines

Spindle Heads
Inclinable

head
Robot head
Horizontal spindle head
Vertical spindle head
Universal head

Special features of CNC machines

Feed Drive
Requirements

of feed drive:
Constant torque for overcoming frictional and
working force
Maximum speed up to 3000 rpm
Possibility of small position increments such
as 1 2 um.
Permanent magnet construction
Low armature or rotor inertia
Integral mounting feedback devices

Special features of CNC machines

Feed Drive
Different

types of feed drives:

DC servomotor
Brushless DC servomotor
AC servomotor
Stepper motor
Linear motors

Special features of CNC machines

Slide Movement Element
Requirements

of a good slideway system:

Low co efficient of friction at varying slide
velocities.
Maximum difference between static and
dynamic friction co efficient positive slope for
friction velocity characteristics
Low rate of wear
High stiffness at the sliding joints
Sufficient damping

Hydrostatic Slide ways

Swarf and Coolant control

In

CNC machining process, metal chips are

formed in the form of micro particles. These

particles are known as swarf.
The

coolant and swarf should be separated which

may be known as swarf and coolant control.

Automatic Tool Changer (ATC)

Tool

turret

Tool

magazines

Disc or drum type

Chain type
Rake type
Automatic

tool changer

Tool Turret

Tool Magazine Drum type

Tool Magazine Chain type

Tool Magazine Rake type

Automatic Tool Changer (ATC)

Automatic Tool Changer (ATC)

The spindle stops at the correct orientation for the

tool change arm to pick the tool from the spindle.
Tool change arm moves to the spindle.
Tool change arm picks the tool from the spindle.
Tool change arm indexes to reach the tool magazine.
Tool magazine indexes so that the tool from the
spindle can be placed.
The tool is placed in the tool magazine.
The tool magazine indexes to bring the required tool
to the tool change position.
Tool change arm picks the tool from the tool
magazine.
Tool change arm indexes to reach the spindle.
New tool is placed in the spindle.
Tool change arm moves back to its parking position.

Automatic Tool Changer (ATC)

Advantages:

Increase in operator safety by changing tools

automatically
Changes the tools in seconds for maintenance
and repair
Increases flexibility
Heavy and large multi-tools can easily be
handled
Decreases total production time

Work holding Devices

Collet chucks
Jaw chucks
Arbors

Fixtures

Types of CNC machines

CNC machining centre

CNC turning centre
CNC lathes
CNC milling / drilling machines
CNC special purpose machines

Direct or Distributed Numerical

Control (DNC)
It

can be defined as a manufacturing system in

which a number of machines are controlled by a
computer through direct connection and in real
time. The tape reader is omitted in DNC thus
relieving the system of its least reliable
component. Instead of using tape reader the part
program is transmitted to the machine tool
directly from the computer memory. In principle,
one computer can be used to control more than
100 separate machines.
The system consists of four components.
1. Central computer
2. Bulk memory which stores the NC part
programs.
3. Telecommunication lines.
4. Machine Tools.

Direct or Distributed Numerical

Control (DNC)

Advantages of DNC

The computer can be remotely located even a

thousand miles away.
The computer can simultaneously program for many
NC machines.

Part Program

Machining involves an important aspect of relative

movement between cutting tool and work piece. In
machine tools this is accomplished by either moving
the tool with respect to work piece or vice versa. In
order to define relative motion of two objects,
reference directions are required to be defined. These
reference directions depend on type of machine tool
and

are

defined

by

considering

an

imaginary

coordinate system on the machine tool. A program

defining motion of tool / work piece in this coordinate
system is known as a part program.

Lathe and Milling machines are taken for case study

Methods of Creating Part

Programming

Manual part programming

Computer assisted part programming (CAPP)

Manual data input

Computer automated part programming

Data Required for Part

Programming

Job dimension/ Work piece

Work holding

Cutting speed, feed & depth of cut

Finished dimension with tolerance

Sequence of operation

Types of tools

Mounting of tools

Reference Points

Machine origin

Program origin

Part origin

Reference point and axis on a

lathe

Reference point and axis on a

Milling

Programming modes

Absolute programming (G90)

Incremental programming (G91)

Part Program Format and

Symbols

N00 G01 X-60 Y50 F15 S1000 M03

N Block number

G Preparatory function

X & Y Coordinates

F Feed

S Spindle speed

M Miscellaneous functions

Types of CNC Codes

Preparatory functions (G codes)

The term "preparatory" in NC means that it

"prepares" the control system to be ready for
implementing the information that follows in the
next

block

of

instructions.

Apreparatory

functionis designated in a program by the word

address G followed by two digits. Preparatory
functions are also calledG-codesand they specify
the control mode of the operation.

Miscellaneous functions (M codes)

Miscellaneous functions use the address letter M
followed by two digits. They perform a group of
instructions such as coolant on/off, spindle on/off,

Micromachining
Micromachining

refers

technique

for

the

fabrication of 3D structures on the micrometer

scale. It refers the super finishing, a metal
working process for producing very fine surface
finishes. It mainly involves the Micro Electro
Mechanical

Systems

(MEMS)

micromachining processes.

to

perform

Process involved in Micromachining

Photolithography

process

Etching
LIGA
Laser

ablation process

Mechanical

micromachining

Micromachining Photolithography

Micromachining Photolithography

Etching

Etching

LIGA LIthographite,
Galvanoformung,Abformung
It

involves

lithography,

electroplating

molding process.
The

basic five steps of LIGA:

Resist development
X ray radiation and masking
Electroforming
Resist removal
Plastic molding

and

LIGA

Types of Micromachining Process

Bulk

micromachining

Surface

micromachining

Wafer Machining