CNC TECHNOLOGY
INTRODUCTION TO CNC AND METAL CUTTING
HISTORY
US Air Force commissioned MIT to develop the first "numerically controlled" machine in 1949. It numerically controlled 1949 was demonstrated in 1952. At 1970-1972 first Computer Numeric Control 1970machines were developed. Today, computer numerical control (CNC) machines are found almost everywhere, from everywhere small job shops in rural communities to companies in large urban areas.
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DEFINITION
In CNC (Computer Numerical Control), the Control), instructions are stored as a program i a i t ti t d in micromicro-computer attached to the machine. The computer will also handle much of the control logic of the machine, making it more adaptable than earlier hard-wired hardcontrollers.
CNC APPLICATIONS
Machining 2.5D 2 5D / 3D Turning ~ Lathes, Turning Centre Milling ~ Machining Centres Forming 2D Plasma and Laser Cutting Pl dL C tti Blanking, nibbling and punching 3D Rapid Prototyping
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SAMPLE CNC MACHINES
CNC TURNING
CNC MILLING
CNC LASER CUTTING
CNC PLASMA CUTTING
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CNC PRESS
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CNC RAPID PROTOTYPING
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INDUSTRIES MOST AFFECTED by CNC
Aerospace Machinery Electrical Fabrication Automotive Instrumentation Mold making
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SAMPLE PRODUCTS OF CNC MANUFACTURING
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AUTOMOTIVE INDUSTRY Engine Block
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AUTOMOTIVE INDUSTRY(Contd) Different Products
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AEROSPACE INDUSTRY Aircraft Turbine Machined by 5-Axis CNC Milling Machine
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CNC MOLD MAKING
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ELECTRONIC INDUSTRY
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RAPID PROTOTYPING PRODUCTS
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ADVANTAGES OF CNC
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Utilization of computers in manufacturing applications has proved to be one of the most significant advantages & developments over the last couple of decades in helping to improve the productivity and efficiency of manufacturing systems.
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ADVANTAGES of CNC
Productivity Machine utilisation is increased because more time is spent cutting and less time is taken by positioning. Reduced setup time increases utilisation too too.
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PROFIT i increases as COST d decreases and as PRODUCTIVITY increases.
PRODUCTIVITY through AUTOMATION AUTOMATION
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AUTOMATION
any means of helping the workers to perform p their tasks more efficiently
transfer of the skill of the operator to the machine
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Transferred skill
muscle power manipulating skill vision skill
Results
engine driven First industrial machine tools revolution mechanization hard automation use of position transducers, cameras
cnc machines, industrial robots, soft automation, computer control of manufacturing systems
brain power
increase of accuracy, part recognition second industrial revolution
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COST = COST OF MANUFACTURING AND COST OF MATERIAL HANDLING
EFFICIENCY OF MANUFACTURING
PRODUCTIVITY = AVERAGE OUTPUT PER MAN-HOUR PROFIT = INCOME - COST
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ADVANTAGES of CNC
Quality Parts are more accurate. Parts are more repeatable. Less waste due to scrap.
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ADVANTAGES of CNC
Reduced inventory Reduced setup time permits smaller economic batch quantities. Lower lead time allows lower stock levels. Lower stock levels reduce interest charges and working capital requirements.
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ADVANTAGES of CNC
Machining Complex shapes Slide movements under computer control. Computer controller can calculate steps. First NC machine built 1951 at MIT for aircraft skin milling.
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ADVANTAGES of CNC
Management Control CNC leads to CAD Process planning Production planning
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DRAWBACKS of CNC
High capital cost Machine tools cost $30,000 - $1,500,000 Retraining and recruitment of staff g New support facilities High maintenance requirements Not cost-effective for low-level production on costlowsimple parts As geometric complexity or volume increases CNC becomes more economical Maintenance personnel must have both mechanical and electronics expertise
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FUNDAMENTAL OF METAL CUTTING
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The metal cutting operations (also called machining) is one of the most important manufacturing processes in industry today (as it was yesterday). yesterday).
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MACHINING IS THE REMOVAL OF MATERIALS IN FORMS OF CHIPS FROM THE WORKPIECE BY SHEARING WITH A SHARP TOOL. TOOL
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The main function of a machine tool is to control the workpieceworkpiececutting tool positional relationship in such a way as to achieve a desired geometric shape of the workpiece with sufficient di ith ffi i t dimensional i l accuracy.
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Machine tool provides: work holding tool holding relative motion between tool and workpiece primary motion secondary motion
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Primary motion
Relative motion between tool and b t t l d workpiece
Cutting motion
Secondary motion
Feed motion
Feed rate
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Cutting speed
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CLASSIFICATION OF THE CHIP REMOVING METHODS ACCORDING TO THE RELATIVE MOTION
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CLASSIFICATION OF MACHINE TOOLS
THOSE USING SINGLE POINT TOOLS lathes shapers planers boring m/cs etc.
THOSE USING MULTIPOIN T TOOLS drilling m/cs milling m/c s m/cs broaching m/cs hobbing m/cs etc.
THOSE USING ABRASIVE TOOLS grinding m/cs honing m/cs m/c s etc.
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BASIC COMPONENTS OF CNC SYSTEMS
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machine control unit position transducers
work holding device tool holding device
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ISO MACHINE TOOL AXIS DEFINITION
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ISO MACHINE TOOL AXES DEFINITIONS
AXIS Z MACHINE TOOL WITH SPINDLE axis of spindle, (+Z) as tool goes away from the work piece MACHINE TOOL WITH NO SPINDLE perpendicular to work holding surface, (+Z) as tool goes away from the workpiece
MACHINE TOOL WITH ROTATING WORKPIECE
MACHINE TOOL WITH ROTATING TOOL
HORIZONT AL AXIS X radial and parallel to cross slide, (+X) when tool goes away from the axis of spindle horizontal and parallel to work holding surface, (+X) to the right when viewed from spindle towards work piece
VERTICAL AXIS horizontal and parallel to the work holding surface, (+X) to the right when viewed from spindle towards column parallel to and positive in the principal direction of cutting (primary motion)
apply right hand rules
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RIGHT HAND RULE
Vertical Machine Horizontal Machine
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STANDARD LATHE COORDINATE SYSTEM
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STANDARD MILLING MACHINE COORDINATE SYSTEM
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NUMERICALLY CONTROLLED MACHINE TOOLS: An NC machine tool is functionally the same y as a conventional machine tool. The technological capabilities NC machine tools in terms of machining are no different from those of conventional ones. The difference is in the way in which the various machine functions and slide movements are controlled.
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The functions and motions such as; turning the spindle on and off setting cutting speeds setting feed rate turning coolant on and off moving tool with respect to workpiece are performed by M hi C t l U it f d b Machine Control Unit (MCU) in NC machine tools.
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MACHINE TOOL AUTOMATION
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CNC SYSTEM ELEMENTS
A typical CNC system consists of the the following six elements Part program Program input device Machine control unit Drive system y Machine tool Feedback system
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NC SYSTEM ELEMENTS
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OPERATIONAL FEATURES of CNC MACHINES
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PART PROGRAM
A part program is a series of coded instructions required to produce a part. It controls the movement of the machine tool and the on/off control of auxiliary functions such as spindle rotation and coolant. Th coded h i dl t ti d l t The d d instructions are composed of letters, numbers and symbols and are arranged in a format of functional blocks as in the following example N10 G01 X5.0 Y2.5 F15.0 | | | | | | | | | Feed rate (15 in/min) | | | Y-coordinate (2.5") | | X-coordinate (5.0") | Linear interpolation mode Sequence number
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PROGRAM INPUT DEVICE
The program input device is the mechanism f part programs to be h i for t t b entered into the CNC control. The most The commonly used program input devices are keyboards, keyboards, punched tape reader, diskette drivers, throgh RS 232 serial ports and networks. networks.
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MACHINE CONTROL UNIT
The machine control unit (MCU) is the heart of a CNC system. It is used to perform the following functions: Read coded instructions Decode coded instructions Implement interpolations (linear, circular, and helical) to generate axis motion commands Feed axis motion commands to the amplifier circuits for driving the axis mechanisms Receive the feedback signals of position and speed for each drive axis Implement auxiliary control functions such as coolant or spindle on/off, and tool change
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TYPES of CNC CONTROL SYSTEMS
OpenOpen-loop control ClosedClosed-loop control
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OPENOPEN-LOOP CONTROL SYSTEM
In open-loop control system step motors are openused Step motors are driven by electric pulses Every pulse rotates the motor spindle through a certain amount By counting the pulses, the amount of motion can be controlled No feedback signal for error correction Lower positioning accuracy
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CLOSEDCLOSED-LOOP CONTROL SYSTEMS
In closed-loop control systems DC or AC closedmotors are used Position transducers are used to generate position feedback signals for error correction Better accuracy can be achieved More expensive Suitable for large size machine tools
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CONTROL
Desired path (p, v, a) p (p, , a)
3-axis position control (encoder feedback) Velocity control (tachometer feedback) Torque control (current feedback)
Path generator
Linear interpolation Circular interpolation Complex path interpolation (contouring)
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DRIVE SYSTEM
A drive system consists of amplifier circuits, circuits stepping motors or servomotors and ball lead-screws. The MCU feeds leadcontrol signals (position and speed) of each axis to the amplifier circuits. The control signals are augmented to actuate stepping motors which in turn rotate the ball lead-screws to position the machine leadtable.
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STEPPING MOTORS
A stepping motor provides 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 bya fixed angle (one step) The lead screw converts the rotary step). motion of the motor shaft into linear motion of the workpiece .
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STEPPING MOTORS
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RECIRCULATING BALL SCREWS
Transform rotational motion of the motor into translational motion of the nut attached to the machine table.
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RECIRCULATING BALL SCREWS
Accuracy of CNC machines depends on their rigid construction, care in manufacturing, and the use of ball screws to almost eliminate slop in the screws used to move portions of the machine.
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COMPONENTS OF RECIRCULATING BALL SCREWS
Ball screw Ball nut (anti-backlash) (antiWays Linear bearings
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POSITIONING
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. Microsteps can be used to decrease the motor step size. CNC machines typically have resolutions of 0.0025 mm or better.
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MACHINE TOOL
CNC controls are used to control various types of machine t l Regardless of t f hi tools. R dl f which type of machine tool is controlled, it always has a slide table and a spindle to control of position and speed. The machine table is controlled in the X and Y axes, while the spindle runs along the Z axis.
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FEEDBACK SYSTEM
The feedback system is also referred to as the measuring system. It uses position and system speed transducers to continuously monitor the position at which the cutting tool is located at any particular time. The MCU uses the difference between reference signals and feedback signals to generate the control signals for correcting position and speed errors.
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CNC MACHINES FEEDBACK DEVICES
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ENCODERS
A device used to convert linear or rotational position information into an electrical output signal.
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ENCODERS
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INDUSTRIAL APPLICATIONS of ENCODERS
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RESOLVERS
A resolver is a rotary y transformer that produces an output signal that is a function of the rotor position.
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SERVOMOTOR with RESOLVER
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DRIVE MOTORS
DC servo motors AC servo motors t Stepper motors Hydraulic motors
POSITION FEEDBACK
Incremental encoder Quadrature Q d t Absolute encoder Resolver Tachometer No feedback ( p (open loop)
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POTENTIOMETERS
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POTENTIOMETERS
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VELOCITY FEEDBACK
Tachometers: Electrical output is proportional to rate of angular rotation. Encoders, Resolvers, Potentiometers: Number of pulses per time is proportional to rate change of position. g p
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CNC MACHINES CUTTING TOOLS (CUTTERS)
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CNC CUTTERS
Turning center cutters Machining center cutters
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TURNING CENTER CUTTERS
Types of cutters used on CNC turning centers t Carbides (and other hard materials) insert turning and boring tools Ceramics High Speed Steel (HSS) drills and taps
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STANDART INSERT SHAPES
V used for profiling, weakest insert, 2 edges per side. D somewhat stronger, used for profiling when the angle allows it, 2 edges per side. T commonly used for turning because it has 3 edges per side. C popular insert because the same holder can be used for turning and facing. 2 edges per side. W newest shape Can turn and shape. face like the C, but 3 edges per side. S Very strong, but mostly used for chamfering because it wont cut a square shoulder. 4 edges per side. R strongest insert but least commonly used.
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TYPICAL TURNING, THREADING and PARTING TOOLS
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MACHINING CENTER CUTTING TOOLS
Most machining centers use some form of HSS or carbide insert endmill as the basic cutting tool. Insert endmills cut many times faster than HSS, but the HSS endmills leave a better finish when side cutting.
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MACHINING CENTER CUTTING TOOLS (contd)
Facemills flatten large surfaces quickly and with an excellent finish. Notice the engine block being finished in one pass with a large cutter. g
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MACHINING CENTER CUTTING TOOLS (contd)
Ball endmills (both HSS and insert) are used for a variety of profiling operations such as the mold shown in the picture. Slitting and side cutters are used when deep, narrow slots must be cut.
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MACHINING CENTER CUTTING TOOLS (contd)
Drills, Taps, and Reamers Common HSS tools such as drills, taps, and reamers are commonly used on CNC machining centers. Note that a spot drill is used instead of a centerdrill. Also, spiral point or gun taps are used for through holes and spiral flute for blind holes. Rarely are hand taps used on a machining center center.
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TOOL HOLDERS
All cutting tools must be held in a holder that fits in the spindle. These include end mill holders (shown), collet holders face (shown) holders, mill adapters, etc. Most machines in the USA use a CAT taper which is a modified NST 30, 40, or 50 taper that uses a pull stud and a groove in the flange. The machine pulls on the pull stud to hold the holder in the spindle, and the groove in the flange gives the automatic tool changer something to hold onto. HSK tool g g holders were designed a number of years ago as an improvement to CAT tapers, but they are gaining acceptance slowly.
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