2 Introduction To CNC Technology (CNC Course CD) 1

CNC MACHINING : TECHNOLOGY
AND ECONOMIC CONCERNS
Lecture 2 Introduction to CNC Technology
Introduction to CNC Technology

Anatomy of CNC Machines
Operational Features of a CNC Machine
Purchasing a CNC Machine
INSTRUCTOR:
DR. KUNWAR FARAZ AHMED
What is CNC?
Computer Numeric Control
The process of manufacturing machined parts using a

computerized controller to command motors which drive
each machine axis.
(2)
History of CNC
Date Institution Technology
1947 John Parsons, Developed a control system that
Parsons Corporation, directed a spindle to many points in
Michigan succession
1951 Servomechanism Added computer to Parson.s
Laboratory of MIT System
1952 Cincinnati Milicron Hydro-TelVertical Spindle Milling
Machine - First three-axis
numerically controlled, tape-fed
machine tool
(3)
History of CNC
1954 NC was announced to public
1957 First production NC machines were

delivered and installed
1960 NC machine tools commonly available
A lot of the initial funding for the development of NC

machine tools came from the United States Government
(4)
Why Use CNC Machines?
Increase production throughput
Improve the quality and accuracy of manufactured
parts
Stabilize manufacturing costs
Manufacture complex or otherwise impossible jobs -
2D and 3D contours
(5)
Advantages of CNC
Flexibility of operation is improved, as is the ability to
produce complex shapes with good dimensional accuracy,
repeatability, reduced scrap loss, and high production rates,
productivity, and product quality.
Tooling costs are reduced, since templates and other fixtures
are not required.
Machine adjustments are easy to make with microcomputers
and digital readouts.
More operations can be performed with each setup, and less
lead time for setup and machining is required compared to
conventional methods. Design changes are facilitated, and
inventory is reduced.
(6)
Advantages of CNC...(cont)
Programs can be prepared rapidly and can be recalled at
any time utilizing microprocessors. Less paperwork is
involved.
Faster prototype production is possible.
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.
(7)
Limitations of CNC
Relatively high initial cost of the equipment.
The need and cost for programming and computer time.
Special maintenance with trained personnel.
High preventative maintenance since breakdowns are costly.
(8)
Working Principles of CNC Machines
Anatomy of a CNC Machine
3- Axis Vertical Mill
(9)
Anatomy of a CNC Machine
Horizontal Drilling Machine
(10)
(11)
Recirculating Ball Screws
(12)
Purpose
Transform rotational motion of the motor into translational
motion of the nut attached to the machine table.
(13)
(14)
Rotational to Linear Velocity Conversion
(15)
Positional Resolution
(16)
Positional Resolution (Example...)
(17)
Lead Screw Resolution
(18)
Stepping Motors
Provide open-loop, digital control of the position of a workpiece in a
numerical control machine.
The drive unit receives a direction input (cw or ccw) and pulse inputs.
For each pulse it receives, the drive unit manipulates the motor voltage
and current, causing the motor shaft to rotate by a fixed angle (one step).
The lead screw converts the rotary motion of the motor shaft into linear
motion of the workpiece.
(19)
Stepping Motors
Full Step Operation
- Hybrid stepping motors have a
variable-reluctance rotor with a
permanent magnet in its magnetic
path, usually in the rotor.
- The term hybrid refers to the use
of two sources of magnetic field,
the stator windings and the
permanent magnet.
- Hybrid stepping motors are used
when small step angles are
required.
- The 1.8 degree stepping motor is
the predominant standard for
industrial automation
(20)
Angular Positioning
(21)
Stepping Motors
Lead Screw Positioning Resolution
(22)
Stepping Motors
Microstepping Operation
- Rotor can be positioned in partial steps by simultaneously
controlling the currents supplied to the stator phase windings.
- Microstep sizes of 1/10, 1/16, 1/32, and 1/125 of a full step are
most commonly used
(23)
Stepping Motors
(24)
Stepping Motors
(25)
CNC Positioning (Summary ...)
The positioning resolution of a ball screw drive mechanism
is directly proportional to the smallest angle that the motor
can turn.
The smallest angle is controlled by the motor step size.
Microstepping can be used to decrease the motor step size.
CNC machines typically have resolutions of 0.0001 in or

better.
(26)
(27)
Position Feedback Options
(28)
What are Potentiometers?
(29)
Potentiometers (Examples ...)
(30)
What are Encoders?
A device used to convert linear or rotational position
information into an electrical output signal.
(31)
How Does a Rotary Optical Encoder Work?
Outer track is used to
determine position
Middle track is used to

measure direction of rotation.
Inner track is used to indicate

a complete revolution.
Integrated counter circuits

are used to count leading or
falling edges of pulses.
(32)
Incremental Encoders
Incremental Encoder -
Produces equally spaced pulses
from one or more concentric
tracks on the code disk.
Position is determined by
counting pulses
Incremental Encoder must be

calibrated. Power loss will lead
to loss of position information
unless backup power source is
used.
(33)
Absolute Encoders
Produces a binary number
that uniquely identifies each
position on the code disk.
Absolute encoders do not

have to be recalibrated after
a power loss.
Absolute encoders are more

expensive than incremental
encoders.
(34)
How Does a Linear Optical Encoder Work?
Linear instead of rotary
scale.
Glass is used because of

low sensitivity to
temperature changes.
(35)
MTD Bridgeport
(36)
Industrial Applications
Rotary Encoders are widely

used with robotics.
Linear encoders are widely

used with machine tools.
(37)
What are Resolvers?
A resolver is a rotary transformer that produces an
output signal that is a function of the rotor position.
(38)
Servo Motor with Resolver
(39)
(40)
Velocity Feedback
Device Operational Principal
Tachometers Electrical output is
proportional to rate of angular
rotation
Encoders, Number of pulses per time is
Resolvers, proportional to rate change of
Potentiometers position
(41)
Rotary Encoder Velocity
(42)
(43)
CNC Programming Methods
(44)
Main Controller User Interfaces
(45)
Types of CNC Programming Languages
Standard Proprietary
(Conversational)
ISO 6983 Respond to prompts

Typically proprietary
EIA RS274
(46)
Who and What is EIA?
Electronic Industries Association
(US Manufacturers of Electronic Equipment)
www.eia.org/eng/published.htm
(47)
Who and What is ISO?
Worldwide International Standards Organization
(ISO - means ONE)
www.iso.ch
(48)
ISO 6983 and EIA RS274
Standards are very similar
EIA in most cases will adopt an ISO standard with only

minor changes and issue the standard under an EIA number.
CAD/CAM programs support these standards
(49)
Major Manufacturers of ISO and EIA Main Controllers
Fanuc
General Electric
Bendix
Cincinnati Milicron
Giddings and Lewis
(50)
Purchasing CNC Machines
Important Considerations on machines Avoid
Do not buy a machine below serial # 100! Or the first ones
off the line
Do not buy rotary tables or 5 axis machines unless you really
need it
Do not buy a machine with an HSK spindle and tooling
without some research
Avoid Machines that are special order
(51)
Choosing the Right Machine for the Job
Size of working envelope: table size, tool clearance, chuck
size and tool change swing clearance
Tool capacity
Type of tool holders used: CAT/BT/HSK (less cost or
availability)
Machine horsepower (for cutting force)
Type of machine control (easier on operators less collisions)
Compatibility with existing CAM software (or programs
already written)
Number of machining axes
Flexibility can you run other jobs on it if the another
machine is down?
(52)
Choosing the Right Machine for the Job
Fixtures determine length, width, height, how many parts in one cycle to
determine size of machine.
What is the cycle time if the operator is running multiple machines? You
may not need that extra second for a better fitted machine.
Considerations you may also consider on using this machine as backup
for other jobs incase you need to wait 3-4 weeks for replacement parts.
Also, consider buying 2. To have an extra machine to swap parts for
troubleshooting can save you a lot of money.
Automation/integrations -How easy is it to get this done, either through
the dealer or integrator. Can vary big time in actual costs for this. It may
also be cheaper to ship machine to integrator to automate, so ask if this is
an option for you.
(53)
Questions to Ask The Salesman
What machines do you sell the most of? These will have the bugs worked
out and therefore, the least amount of problems and most parts
available.
Can I get a time study? Only ask for an approximate cycle time for this. If
you are more serious ask for a real time study that is more accurate.
They will less likely help you out in the future if they think they are doing
this most likely for nothing.
Can I have a part run to determine actual cycle time or get a turn key?
Many times they will run an actual part as long as you agree to purchase
the machine if the cycle time is below an agreed upon time.
(54)
Questions to Ask The Salesman
Can I see this machine at another customer? There is nothing like looking
at something before you buy. Look at the machine, pretend you are the
operator and see how easy it is to perform everyday tasks. If you can
look to see what they are cutting, look for chip build up that can cause
problems. Check if they are using large face mills, which cause the most
problems.
Penalty clauses- If a salesmen lies to you about delivery to get the sale, or
promises a certain cycle time that can't be achieved, that is going to hurt
your business and possibly cause you to lose the contract. Think about a
penalty clause, only after you agree on a price and a guaranteed date of
delivery, present a penalty clause to the salesmen and tell them this will
be required to get the sale. Make sure you present them with your
reasons for proposing this clause they should understand, ask them if
they were the owner, would you do the same thing
(55)
Inexpensive Machines: What Do You Get?
Stalling of spindle (less horse power)
Narrower linear guides
Smaller ballscrew diameters
Less ballscrew bearings
Less and smaller bearings in spindle
No oil chillers on spindle
Not as rigid casting
Less general safety and types of interlocks
Components don't last as long
Less horse power
Machine leveling screws will be thinner and can teeter back and forth
especially if up to high
All of these things add up to less tolerances and greater damage if the machine
is crashed. In general, components will deteriorate much quicker. Look at the
different Manufacturer machines.
(56)
Machine Quality
Rigidity crashing a machine is the number one reason for downtime, the
cheaper the machine the more damage is not always the case, but better
finish and better tool life is the biggest benefit. Since cheaper machines
may not be as rigid they will also have more give when a crash occurs.
However if for example a spindle is not built the greatest due to quality
reasons this may also fail easily due to a crash.
Ball screws, Linear guides/box ways will not hold up
Accessing and replace machine parts Look over the different models. You
will see a huge difference.
Look at the tool changer There are many problems associated with tool
changer designs. Is it located inside the work area? How easy is it to
replace the cam followers that usually break?
(57)
Machine Quality
Spindles High quality spindles tend to have more and larger bearings,
which can handle more abuse. They also have greater horse power so you
can't stall the spindle when taking large cuts. The speed of the spindle
stays more constant, the finish is better with heavy cuts, longer tool life,
and save cycle time by taking larger cuts.
Tolerances Tighter tolerance means longer life and a smoother operation.
Less horsepower spindle stalling or unstable RPM possibly during heavy
cuts
If Spindles are usually belt drive and often can be stalled.
(58)
Services
Wait time for service tech How close is the dealer? Anything over 1.5
hours will take much longer to get your machine fixed.
Quality of service techs Sometimes outside contractors might be your best
bet for most jobs. They can be more consistent given you get the same
person every time and you can learn their quality of work very quickly.
When warranty issue is a concern, the dealer is the only way to go.
Parts Availability selecting a model that was not the first off the truck will
tend to have more replacement parts in stock.
Dealer response time for information and parts For some dealers it takes
at least a day to get parts or information from the manufacturer through
the dealer.
Find out what access they have to online manuals Some of the
manufacturers now have online parts lists, procedures and information
through satellite. With this technology you will definitely save time and
money for your repairs.
(59)

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CNC MACHINING : TECHNOLOGY

AND ECONOMIC CONCERNS

Lecture 2 Introduction to CNC Technology

Introduction to CNC Technology

Computer Numeric Control

The process of manufacturing machined parts using a

1954 NC was announced to public

1957 First production NC machines were

1960 NC machine tools commonly available

A lot of the initial funding for the development of NC

The need and cost for programming and computer time.

Special maintenance with trained personnel.

High preventative maintenance since breakdowns are costly.

The smallest angle is controlled by the motor step size.

Microstepping can be used to decrease the motor step size.

CNC machines typically have resolutions of 0.0001 in or

Middle track is used to

Inner track is used to indicate

Integrated counter circuits

Incremental Encoder must be

Absolute encoders do not

Absolute encoders are more

Glass is used because of

Rotary Encoders are widely

Linear encoders are widely

ISO 6983 Respond to prompts

EIA in most cases will adopt an ISO standard with only

CAD/CAM programs support these standards

Giddings and Lewis

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