INTRODUCTION TO CNC

‫السيد أحمد الموشى‬.‫د‬

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 The main software functions associated with a CNC system
Computer Numerical Control, CNC

An idea is turned into a pencil sketch

on the back of an old envelope, and
a machinist uses that information to
produce a finished workpiece while
standing at the mill.

The original idea, for example, is an

entirely human contribution, whereas
creating the program may require
both human and computer
contributions

From a software point of view, there

are three main stages in the process:
create a design, turn the design into
data and use the data to control a
machine.
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Stages in the CAD/CAM/CNC process.

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CNC- (Vertical) Milling Machine

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 Collet

Collet Chuck

End Mill

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CNC -Turning Machine

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Tool holder
Turret Head

Carbide Inserts

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 CNC Machines Specification

• DUTY CONDITIONS :- The Machine should be designed to perform variety of

operations such as Milling, Boring, Drilling, Reaming, Tapping, Contouring, etc. on
medium sized alloy steels, forgings, castings and non ferrous alloys, etc.

• MATERIAL / CONSTRUCTION OF MACHINE :- The machine should have rigid

structure designed for reliability in accuracy and speed. The machine should be
stress relieved, vibration free and have stabilized structure for long lasting
accuracy.

• TECHNICAL DETAILS OF THE MACHINE :-

- Table Size (minimum) : 800 – 900 MM Length 450 – 550 MM Width
- T-Slot Dimensions : 4 to 5 X 18 MM X 80-100 MM ,
- Load On Table (in Kgf) : 400 kg. (Minimum)
- TABLE TRAVEL X - Axis (Longitudinal) : 600 MM (Minimum) 5.2.2) Y - Axis ( Cross )
: 400 MM (Minimum) 5.2.3) Z – Axis ( Vertical ) : 450 MM (Minimum)

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 CNC Machines Specification

- FEEDS :- Feed Rate (in X, Y, Z – Axes) : 1 – 10,000 mm/min –

- Rapid Traverse ( in X, Y, Z- Axes) : 24/24/24 m/min
- SPINDLE :- Spindle Speed : 8000 rpm (Maximum)
- Spindle Power : 5.5 to 15 KW (or) Std. Power
- Spindle Nose Taper : 7/24 No. 40 (or) BT-40 5.4.4) Height of Spindle Face from
Table top : minimum range: 100–150 mm maximum range: 600–650 mm
- AUTOMATIC TOOL CHANGER : No. of Tools : 20 - 24 Nos. 5.5.2) Max. Tool Dia. i)
All Pockets full : 80 mm ii) Alternate Pockets Empty : 125 mm iii) Max. Tool Length :
250 mm iv) Max. Tool Weight : 8 kg. v) Tool Change Time : 8 Sec.
- ACCURACIES :- Positioning Accuracy : ± 0.005 mm to ± 0.015 mm 5.6.2)
Repeatability : ± 0.003 mm to ± 0.005 mm
- CNC SYSTEM & PROGRAMMING FEATURES :- FANUC OIMD (or) SIEMENS
(SINUMERIK 840D) with colour LCD display
- Minimum increment : 0.001 mm
- Part program storage
- Part Program Editing
- RS-232C Serial Interface ( Computer Interface )
- Memory card for saving and restoring data
- Features of maintenance diagnosis.
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 CNC Machines Specification

- Tool Management : a) Tool life monitoring with time b) Tool Length Offset c) Tool
Radius Offset d) No. of Tool Offset
- Co–ordinate System : a) Auto Referencing b) Machine Co-ordinate system setting
c) Work co-ordinate system setting d) Program additive zero offset
- MACHINE LOCK : a) Auto Function Lock b) Soft approach to and exit from contour
c) Data protection key
- Programming support functions : a) Machine Cycle : Milling, Drilling, Tapping,
Boring, etc. b) Cycle sub-programming c) Extra Stop
- Graphics and Simulation,
- Maintenance and Safety : a) Emergency Stop b) Safety Interlock, etc.
- Leaser Calibration certificate should be provided for each axis.
- STANDARD FEATURES :- Complete work area enclosed
- Spindle mounted probe
- Chip Conveyor with trolley
- Air Conditioner for electrical cabinet & it should be energy efficient.
- Suitable Voltage Stabilizer & Isolation Transformer
- Electronic Edge Finder
- Coolant system (Auto & Manual)
- Set of Operator Tools, ie. Spanners, Allen Key Set, etc. 10
 CNC Machines Specification

- Machine Lighting
- Air Gun , Automatic Lubrication System
- USB Ports
- Electrical equipment with wiring suitable for standard 3 Phase, 415 V, 50
Hz, AC Supply.
- Inside Control panel all drives and cards to be fixed for easy maintenance
and removal, and control panel to be fixed at proper position for easy
maintenance of electrical service engineers.
- ESSENTIAL ACCESSORIES ( STD. / OPTIONAL) :- Swivel base,
Clamping Kit for job Holding ( ie. T-bolts & Nuts, stepped clamps, blocks,
etc.) – 1 set for each machine , Collet Set, size : 0 to 16mm – 1 set for
each machine , Tool Holding Kit (Adaptors with pull studs for holding
collets, T-Max Cutters, Endmills, The supplier has to include Manufacturer
Recommended List of Spares and Cost The supplier shall agree to provide
service support during the life of the machine.
- MANUALS : Three sets of manuals in English covering operation,
programming, maintenance, spare parts, CNC System, electrical circuit
diagrams & PLC ladder diagrams,

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 CNC Machines Specification

- Dispatch; The manufacturer shall dispatch the machine duly packed. Any
damage to the parts of the machine & spare parts shall be replaced by the
tenderer at free of cost & replacement shall accompany certificate of the
original manufacturer..
- The firm shall arrange all necessary tools, tackles consumable, welding
m/c, chain pulley blocks, necessary labour force, technical personal for
carrying out the erection, alignment and commissioning of new machine
adhering all safety and security
- TRAINING :- Training should be given by the firm at Site in the following
areas. Programming & Operation : Min. Four Persons Mechanical
Maintenance : Min. Two Persons CNC System & Electrical Maintenance :
Min. two persons The duration of such training shall not be less than two
weeks. The vendor should indicate the detailed syllabus of such training
proposal. GUARANTEE / WARRANTY for a period of 12 months
- SITE VISIT :- The firm should visit the site to ascertain the scope of work
and functional requirement before submitting quotation.

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 ◼ CAD / CAM systems

◼ CAD systems make use of vector graphics which

means that each part of the object design can be
individually viewed and altered

◼ CAM systems use the CAD designs to create a

series of instructions and data that can be used by
the computer controlled machinery to create the
product

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Computer-Integrated Manufacturing (CIM)

It is the use of integrated systems and data communications

coupled with new managerial philosophies.
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Manufacturing Manufacturing Engineering
Resource Planning Execution Systems Systems
Systems

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 The operation of a CIM system gives the user substantial
benefits:

➢ Reduction of design costs by 15-30%;

➢ Reduction of the in-shop time of a part by 30-60%;

➢ Increase of productivity by 40-70%;

➢ Better product quality, reduction of scrap 20-50%.

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 Introduction
Conventionally, an operator decides and adjusts
various machines parameters like feed , depth of cut
etc depending on type of job , and controls the slide
movements by hand.

In a CNC Machine functions and slide movements are

controlled by motors using computer programs.
The most basic function of any CNC machine is
automatic, precise, and consistent motion control.

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 Why CNC is Accurate?
Light but rigid Hollow design with ribs to have less deflection and low
construction nat. freq., Design improvement using mode shape
analysis
Low inertia Keep weight of moving elements low
Low friction and play Guide way elements, Ball lead screws, Pre-loading

Good damping Appropriate material selection

Minimization of thermal Control of ambient temperature (humidity and
effects suspended dust too), Use of thermally stable material,
Advanced electrical and Advanced drives, Accurate sensors for position,
electronics and velocity, force, vibration, temp. etc., Sophisticated
computing feedback control loops, Interpolators

Error compensations Axis calibration & pitch error compensation, Diameter

and length compensations, Adaptive control
Accurate manufacture Use of accurate manufacturing processes

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 Alloy steel Frames
For CNC Machine Tools Cast Iron Frames
For conventional Machine Tools

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Types of Manufacturing Automation
Manufacturing
Automation

Hard / Rigid / Mechanized Soft / Flexible/ Programmable

Automation Automation

Copy milling machines CNC Machines

Special purpose machines Robots

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Copy milling machines

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Special purpose machines

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 Components of
Numerical Control (NC) system

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Data Input – Punched tape

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NC

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 Numerical Control – Definitions
➢ A Technique for Automatically Controlling
Machine Tools, Equipment, or Processes by
a Series of Coded Instructions (American Society of
Tool and Manufacturing Engineers)

➢ A Form of Programmable Automation In Which the

Process is Controlled by Numbers, Letter, and
Symbols which Form the Program of Instructions for a
Particular Workplace or Job (Mikell Groover)

➢ Running a Machine Tool By Tape or Cable to Make It

Produce More for Less (Bendix Industrial Controls NC Handbook)
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 Principles of Numerical Control

Data
Processing
Unit
(DPU)
Machine
Control Unit
(MCU)

Control Loop
Unit
(CLU) CNC
System

CNC
Machine

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A DPU consists of some or all of the following parts,
• data-input device such as a paper-tape reader (as in the old says), RS-232-
C port, and so on;
• data-reading circuits
• decoding circuits for describing data among the controller axes; and
• an editor.

A CLU, on the other hand, consists of the following,

• an interpolator that supplies machine-motion commands between data
points for tool motion;
• position-control-loops hardware for all the axes of motion, where each axis
has a separate control loop;
• velocity-control loops, where feed control is required;
• auxiliary function control, such as coolant on/off, gear changes, and spindle
on/off control.
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 Numerical Control
Advantages for Design

➢ Less Expensive, More Accurate Prototypes

➢ Better Adherence to Specifications
➢ Better Assessment of Production Times/Costs
➢ “Impossible” Parts Can be Made

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 Numerical Control
Advantages for Manufacturing (1)
➢ Greater Flexibility
⚫ Shape
⚫ Part Volumes
➢ Increased Accuracy
➢ More Operations from a Single Set-Up
➢ Less Manufacturing Time Variability
➢ Better Scheduling
➢ Increased Capacity
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 Numerical Control
Advantages for Manufacturing (2)
➢ Greater Machine Utilization
➢ Reduced Tooling Costs
➢ Reduced Tool Costs
➢ Reduced Flow Time
➢ Reduced Workpiece Handling
➢ Greater Safety
➢ Improved Integration

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Disadvantages of NC Machines

Increase in electrical maintenance

High initial investment

Higher per-hour operating cost than

traditional machine tools

Retraining of existing personnel

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 NC --Applicability
➢ Long Series of Operations Where an Error in the
Sequence Would Destroy the Value of the Part

➢ Wide Variety of Parts/Sequences on the Same

Equipment

➢ Complex Sequences of Operations

➢ Human Operation Impractical Due to Health or

Psycho-Motor Requirements

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CNC -- Classification

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CNC -- Classification

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NC MACHINE CLASSIFICATIONS
1. Motion control: point to point (PTP)
and continuous (contouring) path

2. Control loops: open loop and closed loop

3. Power drives: hydraulic, electric,

or pneumatic

4. Number of controlled Axes,

5. Hardwired NC and softwired Computer

Numerical Control (CNC)
1) Motion control: point - point & Contouring systems

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Point to Point

• Moving at maximum rate from point to point.

• Accuracy of the destination is important but not the path.

• Drilling is a good application.

Continuous Path
• Controls both the displacement and the velocity.
• Machining profiles.
• Precise control.
• Use linear and circular interpolators.
(Interpolators: Control multiple axes simultaneously to move
on a line, a circle, or a curve.)

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 2) Control Loop : Open Loop and Closed Loop System

(a) The open loop control system does not provide positioning feedback to the
control unit. Since this control system only counts tool movement pulses and
cannot identify discrepancies in positioning, it is slightly inaccurate.

(b) In closed loop control system, the electronic movement pulses are sent from the
control to the servomotor, enabling the motor movement. Movements are detected
by a feedback device (transducer), which can send a signal to the control39for
checking after each step. (more accurate)
3) Axes
Three axis CNC machine:
1. The working table moves along x- and y-axis, and the tool along z-axis.
2. In machining, tool orientation is fixed, either in vertical or horizontal direction.
3. If all surfaces to be machined are accessible by the cutter in one setup,
a 3-axis CNC machine is used

Five axis CNC machine:

1• X-, Y-, and Z- Axis Motions and A- and B- axis Rotations
(Simultaneously)
2• Tool orientation can be changed simultaneously during machining.
•3 If some surface patches to be machined are not accessible by the
cutter in one setup, a 5-axis CNC machine is used

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3 & 5 Axes CNC Machines

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 Axes
➢ Part or Tool Movement
⚫ ½ Axis When Axis Movement Limited (Must

complete move Before Other Axes Can Move

(e.g., Drill – Must Move Up/Down with Table
Stopped.

➢ Number of Axes

• 2, 2 ½ , 3, 3 ½ , 4, 4 ½, 5, Axis Machines
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• Translational and Rotational Axes
4) Power Supply

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 The frequency of the stepping motor
A stepping motor is a device whose output shaft rotates through a fixed angle
in response to an input pulse. The accuracy of the system depends on the
motor‘s ability to step through the exact number.

The pulse frequency, f, in pulses/sec determines the travel speed of the tool or
the workpiece.
f = N (rpm) /60, Hz where N = number of pulses per revolution,
The travel speed, V, is then given by V = p (rpm) where p pitch in mm/rev

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 Stepping motor; distance traveled
The frequency of the stepping motor depends on the load torque. The higher the
load torque, lower would be the frequency . Excessive load torque may occur in
motors due to the cutting forces in machine tools . Hence this system is more
suitable for cases where the tool force is low ( wood cutting) or does not exist
(Example: laser cutting) .

Each pulse causes the motor to rotate a fraction of one revolution (α).

α = 360/N, degrees where N = number of pulses required for one revolution

If the motor receives "n" number of pulses then;
the total angle, αt = n (360/N), degrees or αt = n/N in terms of no. of revolutions.

If there is a 1 :1 gear ratio between the motor and the leadscrew, then the
leadscrew has (n/N) revolutions . If the pitch of leadscrew is p (mm/rev),
then the distance traveled axially, say x,

x = p(n/N)

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Example
A stepping motor has N = 150, p = 4 mm/rev ; If n = 2250
pulses, what is the distance traveled in x-direction? What should
be the pulse frequency for a travel speed of 10 m/min ? What is
the BLU ?

1) x = (4) (2250)/150 = 60 mm
2) 10 000= 4 (rpm), from which, rpm = 2500
f = (150) (2500)/60 = 6 250 Hz
3) BLU = p / N = 4/150 = 0.03 mm/pulse

Basic Length Unit (BLU)

Each BLU unit corresponds to the position resolution of the axis of motion.
For example,1 BLU = 0.001mm means that the axis will move 0.001mm for
every one electrical pulse received by the motor.
Pulse = BLU = Bit
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Example (2)

Consider a CNC worktable driven by a closed-loop control system consisting

of a servomotor, leadscrew, and optical encoder. The leadscrew has a pitch, p =
4 mm and is coupled to the motor shaft with a screw to motor gear ratio of 1 : 4.
The encoder generates 150 pulses per revolution of the leadscrew. If the
number of pulses and the pulse rate received by the control system are 3450
and 200 Hz respectively, calculate ;
a. Table speed
b. Motor speed in RPM
c. Distance traveled by the table

a) V= p(rpm) = 4(rpm)
rpm of the leadscrew = (60 f/N ) = (60) (200)/(150) = 80 f = N (rpm) /60
V = (4) 80 = 3200 mm/min =3.2 m/min
rpm of the motor = 80 * 4 = 320
c) x = p(n/N) = 4 (3450)/150 = 92 mm

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Example (3)

A dc servomotor is coupled to a leadscrew which drives the table of a CNC

machine tool. A digital encoder, mounted at the end of the screw, emits 500
pulses per revolution. If the pitch is 5 mm per rev, and the motor rotates 600
rpm (1 :1 gear ratio), calculate ;
a. Table speed
b. Frequency of pulses transmitted by the encoder

a. V= p(rpm) = 5 (600) = 3000 mm/min = 3 m/min

b. f = N (rpm) /60 = 500 (600)/60 = 5000 Hz

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CNC TECHNOLOGY

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 CNC TECHNOLOGY
• Instructions are stored as a program in micro-computer
attached to the machine.

• Refers to a computer controller that controls the

movement of every axis of the machine

• Using G and M codes instructions

• Drives the spindle or machine tool into a raw material to

fabricate or to remove the unwanted material from work
piece more accurately without human intervention.

• The computer will also handle much of the control logic of

the machine, making it more adaptable than earlier hard-
wired controllers. 50
 CNC

• A numerical control system in which

the data handling, control sequences,
and response to input is determined
by an on-board computer system at
the machine tool.

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52
CNC

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 NC, CNC and DNC

Direct numerical control (DNC):

control of multiple machine tools
by a single (mainframe) computer
through direct connection and in
real time

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Direct Numerical Control – DNC --

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 Functions of DNC
Programs must be made available for downloading to CNC machine tools

Part program can be uploaded after editing from CNC machine

Tool management

Data processing and management functions

Syntax checking and graphic proving of programs on CNC computer

CNC can be operated directly from DNC computer

Flexibility in shop floor scheduling

Machinability database for calculating speed/feed

Getting the data about health of the machine in the form of sensor signals
which can be used for preventive/predictive maintenance
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Elements of CNC Systems

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 Breakout Board
Performs a breakout of the signals present on
each of the pins on the db-25 connection.
Provide basic connectivity required for step and
direction signaling for each axis, limits, …

Drives are devices that accept and amplify the signals

rate coming from the breakout board. One drive is
required per each motor to be used.

Power Supply; All controllers will have some form of

incorporated power supply (standalone or integral to the
drives themselves) that provide the designed voltage
and amperage necessary to drive the motors.
 Elements of CNC Systems

• Control Panel
• Tool Change mechanism,
• Feed drive
• Measuring system;
Direct / Indirect
Stepping motor Power supply Emergency stop
Driver to power up stepping button
translates a pulse into a high motors and drivers
powered signal

Limit Parallel Breakout board

the interface from the
switch cable computer to the drivers
tells the computer the carries the signals
limits of the CNC from the computer to
machine the CNC electronics
 8 Relay Outputs

Wireless Control allows the

operator to conveniently and
precisely set up jobs and tools
remotely.
24 VDC logic power supply

communication between the CNC PC

and the CNC control board

Control Stepper Motors and/or Servo

Motors! Step and Direction Drive Spindle Motor Drive
Interface for Four Axes Control 0-10 vdc 3 phase output
analog out

1 or 3 phase input,

8 Inputs for switches and rotary or a linear scale encoder

sensors such as home, limit Laser control
switches, lube switch, unit

CNC touch probe

closed loop stepper system can eliminate loss of step, make real-time position error correction, and use 100%
available torque of the driven stepper motor. It can also power the driven stepper motor with reduced heating, lower
noise, low vibration 61
Schematic of typical electronic
items associated with a CNC
milling machine.

A CNC machine may integrate

sensors designed to indicate when
slides reach particular positions
(limit or home switches, for
example) or the speed of rotation
of a spindle. These sensors send
signals to the computer system, but
normally pass through an interface
first where they are turned into a
form suitable for the computer, with
appropriate voltage levels or data
formats. As with the signals to the
motor drivers, the interface
provides isolation between the
sensors and the computer.
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Stepper motors and servos may be directly connected to feed screws or they may
be connected via pulleys and toothed belts.

Neither stepper motors nor servo systems are connected directly to the computer,
because the motors require considerably more power than the computer could
supply. Instead, the computer sends low-powered logic-level signals to a driver
unit, which responds to the signals by generating pulses of much higher voltage
and current to suit the motors.
Typical voltages range from 5 to 70 volts or more, and typical currents depend on
the rating of the motors, with some powerful stepper motors requiring up to 10 amps
at 70 volts for each motor.

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Variable Frequency Drive (VFD or Inverter) that accepts 220v single or three phase.
Control VFD/Spindle via Breakout board and mach3. Control the spindle rpm:
“Output 0-10V analog voltage for inverter to control the spindle speed.

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The relay board will turn on standard electrical devices up to 12 amps and 250 volts using a standard 5v control signal
. It acts like an automatic switch to turn on and off electrical devices and applications. It can be activated by g-code
M3/M4 and M5. Common examples: Air Solenoids, Water pumps, Lube Pumps, Dust collection, Estop contactors, etc.
Outputs are controlled by M-codes, PLC and/or the operator control panel and are user configurable.

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 Control Panel

1) Display screen

2) Software controlled
keys used to select (1)
function keys
(3)

3) Input panel

(2)
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 Some key functions on display screen
1. FEED HOLD
Acts as an interrupt control to the program when pressed,
preventing any further tool movement until canceled.

2. SINGLE BLOCK
With machine running in automatic mode controlled from the
PC, this allows the operation of only a single block (line) of the
program at a time to be toggled on/off. Press CYCLE START to
proceed.

3. CYCLE START
This sets the machine in automatic mode and starts the
machining from the PC program. Also used to resume an
Automatic cycle after a FEED HOLD is canceled and to action
the next line if Single Block is active.
4. FEED SPEED CONTROL

Provides stepless control of tool feed speed in the X, Y and Z axes

from 0 to 100% in 10% increments.

5. JOG TABLE AXIS CONTROLS

These four buttons control manual movement of the table in the X

and Y axes.

Move the table in the X axis while held pressed.

Move the table in the Y-axis while held pressed.

6. JOG HEAD AXIS CONTROLS

Move the head in the Z axis while held pressed.

Pressing this button together with any of the other six axis control
buttons provides rapid movement of the axes in the indicated
direction.
7. MANUAL
When lit, machine is operated from control panel (Manual mode). Pressing
MAN puts light out and machine is controlled by computer (Automatic
mode). Press MAN again to revert to manual mode operation.

8. AIR MIST CONTROL

Switches on or off the optional air mist coolant when fitted.

9. DATUM M/C - PROGRAM ABORT

After initially powering up the machine and pressing the Power Reset button
, with the machine in Manual mode (Manual mode button lit) press to datum
the machine axes.
• With the machine in Manual mode, the machine can be re-datumed
at any point. This should always be done if a physical stall of the axes
has occurred.
•During an Automatic Cycle with a Feed Hold (1) active, pressing will
Abort the current job.
10. TOOL CHANGE
With auto tool changer fitted, press to change to next tool automatically.

11. TOOL RELEASE

Releases the tool holder from the spindle if fitted with the auto tool changer.
Guard door must be open and tool holder held.

12. WORK HOLDING UN-CLAMP

Controls un-clamping of workpiece in pneumatic work holder vice, when
fitted.

13. WORK HOLDING CLAMP

Controls clamping of workpiece in pneumatic work holder vice, when
fitted.

14. DOOR OPEN

Controls opening of the automatic doors when fitted.
15. DOOR CLOSE
Controls closing of the automatic doors when fitted.

16. SPINDLE CONTROLS

These control the speed and direction of rotation of the spindle.

Spindle Forward - Pressing this button starts the spindle rotating

forward. Holding it down increases forward speed. Pressing and holding the
'Spindle Reverse' button reduces speed in the forward direction.

Spindle Reverse - Pressing this button starts the spindle rotating in

reverse direction. Holding it down increases spindle speed in reverse
direction. Pressing and holding the 'Spindle Forward' button reduces speed in
the reverse direction.

Spindle Stop - Pressing this button stops spindle rotation.

17. EMERGENCY STOP
Pressing this pushbutton stops all machine movement and switches off
the electronics, and the button locks in the depressed position.
If the machine is in production, an appropriate message is displayed on
the PC screen.
The button must be turned to release it and the Hard Reset button (23)
pressed to enable the machine to be started. The machine must be
datumed using the Datum M/C key (9).
If the machine was performing a production cycle, the cycle must be
repeated from the beginning.
Tool Change

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Tool turrets:
An advantage of using tool turrets is that the time taken for tool changing will be
only the time taken for indexing the turret. Only limited number of tools can be
held in the turret.

Tool magazines:
Tool magazines are generally found on drilling and milling machines. When
compared to tool turrets, tool magazines can hold more number of tools and also
more problems regarding the tool management. Though a larger tool magazine
can accommodate more number of tools, but the power required to move the tool
magazine will be more.

Chain magazine:
These magazines can hold large number of tools and may hold even up to 100
tools. Tools will be identified either by their location in the tool holder or by means
of some coding on the tool holder.

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Tool Turret for Turning

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77
 Chain Magazine; Milling Center

Tool Magazine
 Elements of a feed drive axis.
Slideways
A slideway is used to control the direction, or line of action, of the translational
movements of the carriages or table on which the tools or work are held.

The alignment of the slideways to each other and to the axis of spindle is
critical. The shape and size of the work produced depends not only on the
accuracy of the amount of movement, but also on the direction of the relative
movements of the tool and the work. There are different forms of slideways
such as cylindrical, vee and flat.

Screw and Linear bearings with balls, rollers or needles:

Because of the problem of metal to metal contact the relative high amount of
friction is generated, which exits between the faces in contact, typically 0.15 for
lubricated steel sliding on steel.

A number of machines have flat (or screw) roller bearings fitted to the carriages
to provide a rolling motion rather than sliding motion. The rolling motion is
frictionless.
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Elements of a Feed drive axis
Rolling Friction slideways
Linear guide with rail and carriage

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Rolling friction slide ways (Recirculating Ball Screw)

• Balls circulate between screw and nut

• Balls are recirculated using deflector or return tube
• Preloading to reduce backlash

Advantages

1. Longer life
2. Relatively small wear. Will maintain accuracy through
entire life of the screw.
3. Rolling motion reduces friction considerably. Can be
used for carrying heavier loads at faster speeds.
4. High efficiency(85-95%)
5. Small power requirement
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Linear Guide rail. Full length or cut to order. Comes with 2 linear guide blocks for misalignment.

20mm, linear ball bearing blocks (also

called pillow blocks) for circular rails

High strength, high quality aluminum ,¾ * ¾ * 0.13 “ . This is used

with v-groove track.
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84
Ball screws are a type of screw that has a specific thread profile which will allow for a
set of balls in a ball nut to smoothly circulate. This makes for an extremely smooth,
low friction movement. The ball screw has machined ends and includes two bearing
blocks for each end. Make sure to have a coupling that has a bore of 17mm on one
end and the motor shaft diameter bore on the other end.

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Chain and sprocket Rack and pinion , and belt drive moving mechanisms

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87
 Measuring System; Feedback loop system;

• Direct measurement system

A measuring scale secured to the slide or machining table
and measuring value resolver (encoder) pick up information
optically from measuring scale and converts this into
electrical signal.

• Indirect measurement system

The slide traverse is represented by rotation and a resolver
records the rotational movement of a pulse disc. The control
system calculates the slide traverse movement from rotation
pulse.

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Optical Rotary Encoders (Indirect Position Measuring)

Produce angular position data directly in digital form,

eliminating any need for the ADC converter. A light source and
photocell arrangement are mounted so that the slots pass the
light beam as the disk rotates. The angle of the Shaft is
deduced from the output of the photocell.

A) incremental Optical Encoder:

has only one track of equally spaced

slots. Position is determined
by counting the number of
slots that pass by a photo
sensor, where each slot
represents a known angle.
b) Absolute Optical Encoders:

Using a glass disk marked off with a pattern of

concentric tracks. A separate light beam is sent
(Note: Black areas through each track to individual photo sensors.
cause a 1 output)
Each photo sensor contributes 1 bit to the output
digital word. The encoder in Figure outputs a 4-
bit word. The disk is divided into 16 sectors, so
the resolution in this case is 360°/16 = 22.5°. For
better resolution, more tracks would be required.
For example, eight tracks and 256 sectors
(providing 256 states) yield 360°/256 = 1.4°/state,
and ten tracks (providing 1024 states) yield
360°/1024 = 0.35°/state.
92
 Adaptive Control

A.C. control system that measures certain output process

variables like spindle deflection, force, torque, cutting
temperature, vibration amplitude, horse power and uses them to
control speed or feed

NC reduces non productive time in a machining operation

A.C. determines proper speeds and feeds during

machining as a function of variation in work piece, hardness,
width or depth of cut and air gaps in part geometry.

Increased metal removal rate and reduced cost per volume of

metal removed
93
Where to use adaptive control?
1. In-process time consumes significant portion of the
machining cycle time. (>40%)

2. Significant sources of variability in the job

3. Higher cost of operation of machine tool

4. Work material – steel, titanium, high strength alloys

94
Sources of variability in machining

1. Variable depth/width of cut

2. Variable workpiece hardness and variable

machinability

3. Variable workpiece rigidity

4. Tool wear

5. Air gaps during cutting

95
 Configuration of typical
Adaptive Control machining system

96
 Advantages of self adjusting cutting parameters
by adaptive control

In real cutting time the operation parameters (f, s, d) go on

automatically and constantly adjusting themselves by A C so that;

• Use maximum available spindle power

• Limit the deflection of cutter

• Limit the cutting tool temperature

• Limit the vibration amplitude of the cutter

97
98
Part Programming

99
 Program structure

- Which tool should be loaded on the machine spindle;

- What are the cutting conditions (speed, feed, coolant ON/OFF etc)

- The start point and end point of a motion segment

- how to move the tool with respect to the machine.

Sequence and format of words:

N3 G2 X+1.4 Y+1.4 Z+1.4 I1.4 J1.4 K1.4 F0.25 S1000 T4 M8

sequence no destination coordinates dist to center of circle tool

feed rate spindle speed

Cutting preparatory function

miscellaneous 100
function
101
102
103
104
105
Flow chart of a CAM System

106
 Coordinate System
CNC Axes
Axes on a CNC lathe
Axes on a CNC milling machine
Zero and reference points on CNC
Zero Point of machine on a CNC lathe
Machine Zero Point and Work part zero point on
CNC milling machine
113
End of program with reset (M30)
Stops the machine after the last program
block has been executed, including the
coolant (lubricant) supply feature and the
spindle speed;
resets the control system and/or the
machine tool to its/their initial position.
114
Absolute dimensions G90

G1 X50 Z-40 G0 Z1
Incremental dimensions G91

G1 X50 Z-40 G0 Z 41
G1 = linear interpolation
118
119
AUTO CHAMFERING “C” AND CORNER “R” (Option)

Command path Z→X :

A : Start point of instruction
G01 Z B ± K B : End point of instruction
G01 Z B ± R CC’ : Running point of
command

Z +X (+ K/R )
Z -X (- K/R )

Command path X → Z :
G01 X(u) B ± K
G01 X(u) B ± R

X +Z (+ K/R )
X -Z (- K/R )

120
N1 G01 Z30.0 R6.0 F0.2 :
N2 X100.0 K-3.0 :
N3 Z0 :

Example)

121
Circular interpolation G2 / G3
 To determine the lengths for I and K, draw an arrow from the circle starting point
A to the circle center point M.
Two cases are distinguished:
Case 1 ; M is paraxial to X or Z:
Case 2 ; M is not paraxial to X or Z:

In this case, the arrow AM must be divided into a horizontal and a vertical direction.
G01 X30.0 Z60.0 F0.3 :
Z35.0 :
G02 X40.0 Z30.0 I5.0 :

G01 X50.0 :
Z0 :
G01 X40.0 Z60.0 F0.3 :
G03 X50.0 Z55.0 K-5.0 :

127
N20 G54 M06 T0300 :
G96 S20 M03 LIMS=5000:
G00 X0 Z3.0 M06 T0303 M08 :
G01 Z0 F0.2 :
G03 X20.0 Z-10.0 R10.0 :
G01 Z-50.0 :
G02 X100.0 Z-74.385 I40.0 K20.615 : (G02 X100.0 Z-74.385 R45.0)
G01 Z-115.0 :

G00 X200.0 Z200.0 M09

M30 : 128
N20 G54 M06 T0300 :
G96 S20 M03 LIMS=5000:
G00 X35.0 Z5.0 M06 T0303 M08 :
G01 Z-20.0 F0.2 :
G02 X67.0 Z-36.0 R16.0 : (G02 X67.0 Z-36.0 I16.0 K0)
G01 X68.0 :
G03 X100.0 Z-52.0 R16.0 : (G02 X100.0 Z-52.0 I0 K-16.0)
G01 Z-82.0 :
G00 X200.0 Z200.0 M09
M30 :

129
Tool nose radius compensation (G41 / G42 - G40)
With longitudinal and face turning,
the programmed contour and the
created contour are identical.

with taper turning & radius turning,

the programmed contour and the
created contour are not identical

Programming exercise with regard to the tool nose radius compensation

The TNRC is only activated when finishing, since an allowance is used both in the
diameter and in the turning length when rough-turning.
131
N100 G42 G00 X.. Z..
N105 G01 Z-.. F..
N110 G02 X.. Z-.. R..
N115 G40 G00 X.. Z..

N100 G41 G00 X.. Z..

N105 G01 Z-.. F..
N110 G02 X.. Z-.. R..
N115 G40 G00 X.. Z..

132
Stock Removal (cycle 95)

133
134
135
136
137
Grooving (cycle 93)

138
140
141
142
143
Calculate the coordinates and complete the program for the finishing pass of the
following lathe part

144
145
Calculate the coordinates and complete the program for the finishing pass of the
following CNC lathe part (diameter 37 x length 90) of mild steel.

146
147
148
CNC Milling
Circular Milling, G2-G3
 G17
Location of Milling Surface XY
 G18
Location of Milling Surface XZ
Cutter radius compensation is
necessary to ensure that the programmed
contour will be
identical with the executed contour.

When the cutter radius compensation

(CRC) is
active, the control system will establish an
appropriate tool centre path (equidistant),
accounting for the cutter radius.
G41 /G42 ---G40
◼ N3 G18 S630 T1 M66
◼ N4 G58
◼ N5 G0 0 X-7 Y5 Z27
◼ N6 Y-5
◼ N7 Z18
◼ N8 G42
◼ N9 G01 X50 M3 S800 F100 M08
◼ N10 Z36
◼ N11 X-7
◼ N12 G40
◼ N13 G0 X-10 Y50 Z-10
◼ N14 G28 M30
158
159
160
161
162
163
164
165
166
167
168
169
170
Command Meaning

G0 Rapid Traverse
G1 Machining Traverse
G2 Circular Interpolation Clockwise
G3 Circular Interpolation Counterclockwise
G17 Working plane X-Y
G18 Working Plane X-Z

G40 Cutter Radius Compensation OFF

G41 Cutter Radius Compensation ON-Left
G42 Cutter Radius Compensation ON-Right
G54-59 Settable Part Zero Offset
G500-599

G64 Contour mode

G71 Input system metric

G90 Absolute dimensioning
G91 Incremental dimensioning
G94 Feed in mm/min
G95 Feed in mm/rev
G96 Constant cutting speed ON

M8 Coolant on
M17 Subprogram end
M3 Spindle on clockwise
CHF Insert Chamfer

Pocket2 Circular pocket

Holes 1 Row of holes with Mcall 171
172
173
174
175
176