CAM - Unit II

Prof.K.Manikanda Subramanian
Mechatronics Engineering Department
CIET
Design considerations of CNC machines
to improve machining accuracy
• General requirement of CNC amchine tool design
– Productivity
– Accuracy
– Simplicity of design
– Machine response
– Safety and easy control
– Appearance
– Cost
– Operating characteristics
– Component characteristics
Design process in respect of machine
tools
Spindle design
 Steps involved in the design process
• Requirement
• Technical specification
• Selection of proper kinematic solution and
layout
• Design Calculations
• Drawing of components, parts and assemblies
 Design of machine tool structure
• Bed
• Base
• Column
• Box type housing
• Over arms
• Carriages
• Tables
 Design of machine structure
• The mating structure of the structure should
be machined with high degree of accuracy
• Geometrical accuracy of structure has to be
maintained through out the design and
service
• Structure should ensure the working stress
• Deformation does not exceed the limits of
load acting on a machine tool structure
 Design for improving machining
accuracy
• Machine tool structure
• Guide way
• Power screws
• Spindle and spindle support
• Bearing
• power unit
• Transmission element
• Work holding device
 Design of structures
• High static stiffness with optimum stiffness to
weight ratio
• Very small deflection of structural elements
under operating load of machine tools such as
cutting forces, weight of the job
• Better dynamic response
• Cast iron based heavy ribbing is used to
provide high stiffness and low weight
 Slide ways
• Precision positioning and repeatability of
machine tool slides are the major functional
requirements of CNC machine
• Inaccuracies are caused mainly due to the
stick-slip motion
 Requirement of slideway system
• High accuracy
• Good surface finish on slideway surface
• Less amount of friction forces are acting on the slideway surface to
ensure low wear
• High accuracy of travel
• High stiffness at the sliding joints
• Low co-efficient of friction at varying slide velocities
• High rigidity and rugged construction
• Good damping properties
• Minimum difference between static and dynamic friction co-
efficient
• Positive slope for friction-velocity characteristics
Design Process in respect Machine tools
System control of CNC machine tool slide
displacement
Optical gating for Monitoring the
displacement of slides
Plastic inserts for slideways
Flat Slideways
V-Slideways
Single V-Slideway
Dovetail Slideways
Round Slideways
Rolling Element Slideway
Linear Motion Guides
Relation of coefficient of friction and slide
velocity for friction guideways
 ANTI FRICTION LINEAR MOTION GUIDE WAYS

1) Reduce the amount of wear

2) Improve the smoothness of the movement.
3) Reduce the friction
4) Reduce the heat generation
 Advantages
1) Low frictional resistance
2) No stick-slip
3) Ease of assembly
4) Commercially available in ready to fit
condition
5) High load carrying capacity
6) Heavier pre loading possibility
7) High traverse speeds.
• The main disadvantage of these guide ways
compared to friction guide ways is its lower
damping capacity.

1) Re circulating ball bushing

2) Linear bearings with balls and rollers such as
re circulating LM guides
3) Re circulating roller bearings
Closed type ball bushing Open type ball bushing

Bushing mounting for linear as well as rotary

movements
Ball and Bush used for Linear Movement
in CNC Machine tools
Antifriction Guideways
Lead Screw
Recirculating Ball Screw and Nut
arrangement
 Recirculating Ball Screw and Nut
arrangement with External Return Tube
Preloading of a Recirculating Ball Screw
and Nut arrangement
Recirculation of balls in ball screw
Profiles of ball screw
Preloading Methods
Drive in a Metal cutting machine
Electric Drives
Spindle speed control system
DC Motor
Two-Pole elementary DC Machine
Servomechanism in a machine tool
control
Using strap clamps and to Hold flange plate
on NC drilling machine
Strap-Clamp assembly for holding
work on NC m/c
Workpiece locators and supports for
use on NC m/c
Grid plate used for location of
workpiece on NC m/c
Auxiliary fixture to be mounted on Master grid plate
Sub plate system
T-Slot base plate
Dowel-Pin base plate
Pallets in NC m/c
Types of tool holders
Octagonal lathe turret – Typical View
Quick change tooling
Machining center tools
Machining center tools
 Optical encoder for measurement of
position and speed of the rotary systems
Cross-Section of Rotary Encoder
Rotary Encoder Disk
Incremental Linear Transducer
Absolute Encoder Disk for rotary position
measurements
Binary and Gray Code
Digital Rotary Encoder position
measurements
Encoder Disk mounted on the lead screw
for Rotary position measurements
Synchro Resolver
Mounting positions of Linear scale
assembly
Mounting the scale unit
Mounting the scanning head
Connection of the Encoder shaft via
diaphragm coupling – Fixing Holes
Connection of the Encoder shaft via metal
bellows coupling - Clamps
Double-Gripping system of tool changing
Typical Tool Turret used in a Turning Centre
Turning Centre Operations
Linear Tooling
Spindle Assembly