Fundamentals of CNC

Technology

Mr. A. Panchariya
Dept. of mech. Engg.
MNIT Jaipur 1
Fundamentals of CNC
Technology

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 Session objectives
On completion of this session, the
delegates would have understood
about
The history of NC and CNC machine
The components of CNC machine
Working of a CNC machine
Application and limitations of CNC machine
Merits and demerits of adopting CNC

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 What is a machine tool?
The main function of a machine tool is to
remove metal from a piece of work to give
the required shape and size.
This is accomplished by achieving proper
relative motion between the work-piece
and the tool.

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 Conventional Machine Tool
In conventional lathe the job is fixed
between centers and made to rotate by
powering the spindle.
The tool motion is achieved by operating
the hand wheels and the feed rates are
manually controlled.
The productivity and quality of the product
depends on the operators skill and attitude.
These machines are characterized by low
speed, feed and metal removal rate.
Producing complex part will be difficult

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 Todays requirement
In, recent times, the main requirement of the
machining industry is that the machine tool must
be flexible, generally suitable for batch
production, capable of carrying out many
operations on single setting and high metal
removal rate.
The conventional machines dont meet these
requirements; hence the machine tool with new
concept was invented

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 Numerically Controlled
Machine Tools
Numerically controlled (NC) is the term to
describe the control of machine movements
and various other functions by instructions
expressed as a series of numbers, letters or
symbols and initiated in an electronic-
controlled system.
Computer numerical control
Computerized numerical control (CNC) is the
term used when the control system includes
a computer in the loop (1970s)
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 History of NC machines
1947-U.S. air force has great need for automated
machining of free from surfaces.
Late 1940s- john person devices method involving
drilling holes at locations specified on punch cards.
1951 - Servo-mechanism Lab at MIT subcontracted to
refine system.
1952 lab demonstrates modified milling machine (first NC
machine).MEEM4403 Computer Aided Design Methods.
1970-computer controlled developed (called computer
numerical control CNC
1980s- direct numerical control
developed
One mainframe
computer controls
many machines.

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Central computer

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 History of NC machine
1980s Distributed numerical
control (DNC) developed.
Mainframe computer sends programs
to PC controlling each NC machine.

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 Benefits of CNC
Improved automation
The operator invention related to producing work
piece can be reduced or eliminated.
Many CNC machine can run attached during their
entire machining cycle ,freeing operator to do other
tasks.
Reduced operator fatigue
Consistent and predictable machining time for each
work piece.
Todays CNC machines boast almost unbelievable
accuracy and repeatability specifications.
CNC machine tools are flexible. Since these machines
are run from program, running a different work piece
is almost as easy as loading a different program.

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 Any limitations of CNC?
Relatively few but
Initial cost and subsequent
installation.
Continuous working to meet cost.
Steady flow of work is must.
Operator skill and management.
Lots of preplanning and high caliber
maintenance schedule.
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 Schematic of an NC
machine tool
MCU machine control unit- controls
the motion of the NC machine tool
DPU data processing unit reads
and interprets the part program;
sends immediate commands to CLU.
CLU- control loop unit reads
position sensors and sends control
signals to motors.

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Numerical Control

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NC/CNC System Element

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Punched tape used for Transfer
of Part Program to NC Machine

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CNC machine Basic Working
Motion Control- The heart of CNC
- All forms of CNC equipment have to or
more direction of motion called axes.
- These axes can be precisely and
automatically positioned along their
length of travel
The two most common axis types are:
- Linear (driven along a straight path)
- Rotary (driven along a circular path)
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 Conventional Machine -
Working

A conventional machines slide is moved

by an operator turning the hand wheel
Accurate positioning is accomplished by
the operator accounting the number of
revolutions made on the hand wheel,
plus the graduation on the dial

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In CNC Machine

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 In CNC Machines
CNC machines allow motions to be
actuated by servomotors under control
of CNC, and guided by part program.
Generally speaking, the motion type
(rapid, linear and circular), the axes to
move, the amount of motion and notion
rate (feed rate ) are programmable with
almost CNC machine tools.

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Types of CNC Machines

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CNC Vertical milling
Machine

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CNC vertical Machining
centre

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CNC Horizontal milling
centre

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Double-column machining
center

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CNC Turning Center

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CNC Dual Turret turning
center

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Heavy duty CNC Lathe

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CNC measuring Machine

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CNC Fabrication Machine

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 Machining Centers
The latest developments in the CNC machine
tools are the versatile machining center.
This is a single machine capable of doing a
number of operations such as drilling,
reaming tapping, milling and boring.
All types of tools are mounted on a drum/
chain or egg box type magazine which are
put into the spindle by automatic tool
changer (ATC) under the control of tool
selection instruction.

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 Establishing coordinate
system
Establish coordinate systems- Tool path coordinate
system must match machine tool coordinate system
Z-direction-: same as tool spindle rotation or work-piece
rotation axis. + ve --- tool moves away from work-piece
Y- direction: chosen to give right hand coordinate system

Some machine tools have secondary slide motion labeled u, v,

and w.
Some machine tool have rotational motion about x, y,
and z axes labeled a, b, and c respectively
2- axis machine allows controlling two motion
simultaneously a 3-axis machine allows controlling three
motion simultaneously ,etc.
2-axis, 3-axis ,4-axis and 5-axis machines are most
popular; 9 axis is also available

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Establishing coordinate
system

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 Electric drives
Drive motor are required to perform
the following functions:
To drive the main spindle (spindle drive)
To drive the saddle or carriage(Axis drive)

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 Spindle drive
In CNC machines, large variation in cutting speed
is required
The cutting may vary from 10 meters per minutes
to 1000meters per minutes
The cutting speed are provided by rotation of main
spindle with the help of an electric motor through
suitable gear mechanism
To obtained optimum cutting speed and feeds, the
drive mechanism should be such as to provide
infinitely variable speed between the upper and
the lower limits.
The infinitely variable speed system used CNC
machines employ either electrical motors (AC or
DC) or fluid motors

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 Drive Motors
The drive may be direct from the motor to
machine spindle or indirect, through belt
or gear transmission
If belt drive is employed, Toothed Belts are
used and if gear drives are employed, is
constant meshing type of gear box where
gears giving various ratio are usually in
constant mesh and are operated by
remote controlled electro magnetic or
hydraulic clutches
Stepper motor drives have limited use in
CNC machines
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 Drive Motors
1. AC induction motors are used to drive main spindle directly
2. The AC induction motor are more reliable, easily
3. Maintainable and less costly compared to other electrical
motors
4. Speed variation in AC motors can be obtained by pole
change method
5. The step-less speed variation can also be obtained by
varying the frequency of the help of frequency converters
6. DC motors are being extensively used for step less speed
variation of spindle
7. The step-less variation of speed is obtained by varying the
D.C. voltage applied to the motor
8. Fluid motor are also being used for driving the spindle
9. Pressurized oil or air supplier by a pump running at constant
speed is directed on to the blades of the motor, which are
capable of giving very high rotational speed

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Grinding Processes

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 Session objectives
By the end of session ,the delegates
would have understood:
Principles of grinding
Classification of grinding processes
Grinding wheel specifications
Detail of abrasive wheel parameters
Different wheel forms
Dressing of grinding wheels

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 GRINDING
Definition: Another material removal process, in
which abrasive particles are contained in bonded
grinding wheel, that operates at very high surface
speed.
the grinding wheel is usually in disk shaped and
is precisely balanced for high rotational speeds.
Process characteristics:
Dimensional accuracy: 0.3 to 0.5 m
Surface finish: Ra = 0.15 to 1.25 m
Specific energy for grinding: 50 j/mm3 (other
processes: 2 to 5 j/mm3)
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Horizontal Grinding

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 Chip formation
In grinding, the chips are small but are formed
by the same basic mechanism of compration
and shear.
Burning chips are the sparks observed during
grinding with no cutting fluid, because the chips
have heat energy to burn or melt I the
atmosphere.
The feed and the depth of cut in grinding are
small, while the cutting speed is high.
grinding may be classified as non-precision or
precision, according to the purpose and
procedure.
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 Non-precision grinding
The common form called, snagging and off-hand
grinding. Both are done primarily to remove stock
that can not be taken of as conveniently by other
methods.
The work is pressed hard against the wheel or
vice versa.
The accuracy and surface finish are of secondary
importance.
Precision grinding
Its concern with producing good surface
finished and accurate dimension.
3 types of precision grinding exists
External cylindrical grinding
internal cylindrical grinding
surface grinding

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 Grinding wheel
A grinding wheel is made of abrasive
grins held together by bond.
These grains cut like teeth when the
wheel is revolved at high speed and is
brought to bear against a work piece.
The properties of a wheel that determine
how it acts are the kind and size of
abrasive, how closely the grains packed
together and amount of bonding
material.

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 Grinding wheel
specifications
All grinding wheel manufacturers use substantially
the same standard wheel making system.
This system uses numbers and letters to specify
abrasive type, grit size, grade structure, and
bonding material.
However, properties of the wheels are determined
to a large extent by the way the wheels are made.
The processes vary from one plant to another, and
wheels carrying the same symbols but made by
different manufacturers are not necessarily
identical.

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Grinding wheel information

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 American national standard
institute's marking system for
standard wheels
Prefix-Abrasive type-Abrasive grain size-Grade-
structure-Bond-type-Manufacture record
Ex: 51-A-36-L-5-v-23
Prefix : Manufacturer symbol indicating exact
kind of abrasive (use optional)
Abrasive type: A: aluminum oxide
C: silicon carbide
B: boron nitride
D: diamond
Grain size: coarse:8-24,medium:30-60,fine:70-
180,very fine:>220

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American national standard institute's
marking system for standard
wheels(continue.)
Grade : ranges from A-Z, where A represent
soft , Z represent hard wheel grade.
Structure : Scale is numerical. 1: very dense
and 15 very open.
Bond type : B : Resinoid
E : Shellac
R : Rubber
S : Silicate
V : Vitrified
Manufacturer record : Manufactures private
marking to identify the wheel.

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Correctly Mounted Wheel

Bench or pedestal mounted grinders

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 Abrasive materials
Different abrasive materials are
appropriate for grinding different work
material.
Abrasive are hard substances used in
various forms as tool for grinding and
other surface finishing operations.
They are also able to cut materials which
are too hard for other tools and give
better finishes and hold closer tolerances.

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Common abrasive materials
1. Aluminum oxide (Al2O3) known as Alundum
or Aloxide. Various substances may be
added to enchance hardness, toughness,
etc. plain is Al2O3 white, and used to grind
steel ferrous , high strength alloys.
2. Silicon carbide (SiC) known in trade as
Carborundum and Crystalon. Harder than
Al2O3, but not tough. Used to grind :
aluminum, brass, stainless steel, cast iron,
certain brittle ceramics
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 Common abrasive
materials(continue)
Boron Nitride in the forms of single-
crystal cubic boron nitride (CBN) and
microcrystalline cubic boron nitride
(MCBN) under trade names such as
Boraszon or Borpax . Used for hard
materials such as hardened tool steels
and aerospace alloys.
Diamond a pure form of carbon. Used
on hard materials such as ceramics
cemented carbide and glass.
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Characteristics of abrasives

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 Bonding materials
To get wide range of properties needed in
grinding wheels, abrasive materials bonded by
using organic or inorganic materials.
Inorganic bonds :
1.Vitrified bond: clay bond melted to a porcelain
or glass like consistency.
it can be made strong and rigid for heavy
grinding and not affected by water ,oil , acids.
2. Silicate bond: essentially water glass
hardened by baking. It holds grains more
loosely than a vitrified bond gives closer cut .

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Bonding materials and wheel
speeds

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 Wheel shape and sizes
The principal dimensions that
designate the size of grinding wheel
are the outside diameter, width,
hole diameter. Standard wheel
shapes are made in certain sizes
only, but variety is large.

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Surface Grinding Operations

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Surface Grinding

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Cylindrical Grinding
Operations

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Centerless Grinding

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Grind Wheel Dressing

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Grind Wheel Dressing

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 Honing Process
Honing is a low abrading which uses
bonded abrasive wheel sticks for removing
stock from metallic and non metallic
cylindrical surfaces as well as flat surface.
Performed as a final operation to correct
the errors that have occurred from the
previous machining operations.
Objective:
Correction of geometrical accuracy out of
roundness, taper, axial distortion
Dimensional accuracy

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 Session Summary
Principles of grinding
Classification of grinding processes
Grinding wheel specifications
Details of abrasive wheel parameters
Different wheel forms
Dressing of grinding wheels
A brief outline of honing process
have been discussed
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