Comp ter Numerical

Computer
N merical Control

Introduction

Machining Centers
A machine tool capable of:
Multiple operation and processes in a single set-up utilizing multiple axes
Typically has an automatic mechanism to change tools

Three Axis Machining Center

The most basic type of machining
center, and they start at about $30,000.
Typically,
T i ll in
i the
th vertical
ti l configuration
fi
ti
How many surfaces of a cubic
workpiece can be machined?

Vertical
Machining Centers
VMC
C-Frame Style

C-frame style

Bed

C-frame style

Y axis Ways
Bed

C-frame style

Column

C-frame style

Column
Z axis ways

C-frame style

Headstock

C-frame style

Headstock
Spindle

C-frame style

C-frame style

C-frame style

Saddle

C-frame style

X axis ways

Saddle

C-frame style

Table

C-frame style

Splash Guard

C-frame style

Automatic
tool changer

This style of machine may

have certain accessories

P ll t Ch
Pallet
Changer

C-frame style

Indexer

C-frame style

Indexer

C-frame style

Indexer

C-frame style

Indexer

C-frame style

Indexer

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

C-frame style

Rotary table

Vertical
Machining Centers
Gantry Style

Gantry Style

Gantry Style

10 - 100 feet or more

(3 - 33 meters)

Gantry Style

Horizontal Three Axis Machine

Notice any difference in axes
orientation compared to
Vertical Machining Centre?
This type of machine starts at
about $90,000.
How many surfaces of a cubic
workpiece can be machined?

Horizontal
Machining Centers
HMC

Horizontal Machining Center

Bed

Horizontal Machining Center

Z axis ways

Bed

Horizontal Machining Center

Column

Horizontal Machining Center

Column

Y axis ways

Horizontal Machining Center

Headstock

Horizontal Machining Center

Spindle
Headstock

Horizontal Machining Center

S ddl
Saddle

Horizontal Machining Center

X axis ways

S ddl
Saddle

Horizontal Machining Center

Table

Horizontal Machining Center

Automatic
tool changer

Four Axis Machining Center

Four axis machining
g centers
are generally horizontal, and
the table rotates to create the
forth axis.
True four axis machines start
around $100,000
The fourth axis can also be
i l
implemented
t db
by adding
ddi a CNC
controlled rotary table to a
three axis vertical machine,

How many surfaces of a cubic

workpiece
k i
can be
b machined?
hi d?

Five Axis Machining Center

What is the difference between
4 and 5 axis machine?
Starting from around $250,000
Application:
complex parts and molds in the
aerospace and automotive
industries.
industries
How many surfaces of a cubic
workpiece can be machined?
Can often machine a part in one
setup
Why is this important?

Machining Center with Pallet Changer

With a pallet changer, the
operator unloads and reloads
one p
pallet while the machine
works on the other.

What are the main benefits

of the pallet changers?

Other Applications of CNC Technology

Electrical wire wrap machines

Component insertion machines
C
di t measuring
i machines
hi
Coordinate
Tape or filament winding machines
Laser cutting,
Wi EDM.
Wire
EDM

Advantages of CNC
Greater accuracy and repeatability (+/- 0.0003 Typical)
Resolution Or Smallest Movement Possible is Typically 0.0001
Tooling costs are reduced

How?

More operations can be performed with each setup

Less lead time
Design changes are facilitated
Programs can be prepared rapidly and can be recalled at any
time utilizing microprocessors.
Required operator skill is less than that for a qualified machinist,
and the operator has more time to attend to other tasks in the
work area.

Limitations of CNC

Relatively high initial cost of the equipment.

The need and cost for programming and computer
time.
Higher maintenance effort;
Special maintenance with trained personnel
personnel.
High preventative maintenance since breakdowns
are costly.

How CNC Machines Work

There are three basic components
p
in an CNC system:
y
program of instruction
machine control unit (MCU)
the processing
p
g equipment
q p

Three Basic Categories of Motion Systems

Point to Point
No contouring capability
Used For Drilling, Punching And Straight Milling
Straight cut control
one axis motion at a time is controlled for machining
Contouringg
multiple axiss controlled simultaneously
Used For Lathes, Milling, Grinding, Welding And
Machiningg Centers.

Motion Control Systems

1)) Open-loop
usingg a stepper
p
p system
y
pp motor

A motion command is sent as an electrical pulse train

Each pulse causes the motor to rotate a fraction of one revolution
Leadscrew translates the rotary motion to a linear table motion.
Why is this system called open-loop?

Recirculating Ball Screws

R
i b
ll screws?
?
Reasons ffor using
ball

Backlash could be a problem.

Recirculating Ball Screws are generally preloaded to give zero
backlash.
b kl h

More on Recirculating Ball Screws

Recirculating Ball Screws

(Rotational to Linear Velocity Conversion)

Recirculating Ball Screws

(Positioning Resolution)

/ 360

/ 360

l / 360

Example
A ball screw has a lead of 0.125 in/rev.What is the distance that
the nut will travel if the screw is turned 15 degrees?

Stepping Motors
provides
p ov des open-loop,
ope oop, digital
d g ta control
co t o of
o the
t e
position of a workpiece in a numerical control
machine.
For each ppulse it receives,, the drive unit
manipulates the motor voltage and current,
causing the motor shaft to rotate by a fixed
angle (one step).

Stepping Motors
(Full Step Operation)

200 step hybrid motor cross

section
The 1.8 degree stepping motor is the
predominant standard for industrial
automation.

Recirculating Ball Screws

(Lead
( e d Screw
Sc ew Resolution)
eso u o )
The positioning resolution of a ball screw is directly
proportional to the smallest angle that the motor can turn.

Stepping Motors
(Lead Screw Positioning Resolution)
Example

How can you improve the Lead Screw

Positioning Resolution ?

Stepping Motors
(Microstepping Operation)
The rotor can be positioned in partial steps by simultaneously
controlling the currents supplied to the stator phase windings.
Microstep sizes of 1/10,
1/10 1/16,
1/16 1/32,
1/32 and 1/125 of a full step are
most commonly used.

Example

Open-loop system Table Speed

The speed of travel depends on the frequency of the pulse train, fp (Hz,
pulse/sec)
The table feed speed,
p , vf (in/min)
(
) depends
p
on the pitch
p
and the rotational
speed (rev/min).

: rotational speed of lead screw ,

screw pitch (l) ,

table velocity (vf)

N: steps/rev

Review Question 1
Prove the previous equations.
Step angle (degrees/pulse)
Total angle (degrees) traveled assuming one-to-one gear ratio
between the motor and lead screw:

n p

l
Movement of table (in) for l pitch of lead screw (in) u
360
By combining the above two the number of pulses required to take
the table to position u could be obtained from:
360u
np
l
Rotational speed of leadscrew (rev/min) n
will depend on pulse train frequency (pulses/sec) f p
60 f p
and will be
n

Therefore travel speed v f (in/min) will be v f nl

The required pulse train to run the table at a specified feed rate will
be obtained by combining two previous equations:
vf N
fp
60l
N

Review Question 2
A CNC mill has 0.125 inch lead recirculating ball screws that
are driven by a 200 step hybrid step motor with 125 microsteps
per step. What is the position resolution of the machine? How
many microsteps will the motor have to undergo in order to
move the
th mill
ill table
t bl attached
tt h d to
t the
th ball
b ll screw 0.1
0 1 in?
i ?

l = 0.125 in/rev, N = 200 steps, m = 125 microsteps/step

l
0.125
u

0.000005 in/microstep
N .m 200 125
0.1
number of microsteps required
20,000 microsteps
0.000005