29-12-2020

Work Shop Practices (ME110)

L-T-P (0-0-3)

Lab 6: Demonstration of Assembling and disassembling of CNC machines

Dr. Sajan Kapil

Assistant Professor
Department of Mechanical Engineering
IIT Guwahati, Guwahati-781039

Presentation Layout

• Introduction of CNC Shop

• Advantages and Limitations of CNC Machines
• NC and CNC Machines
• CNC Machines Components

1
 29-12-2020

What will you learn in this section?

• What are CNC Machines.

• Advantages and Limitations of CNC Machines.
•Assembly and Disassembly of CNC Machines.

Introduction to CNC Shop

• Machining is one of the processes of manufacturing in which the specified shape to the
work piece is imparted by removing surplus material. Conventionally, this surplus
material from the workpiece is removed in the form of chips through interaction of the
workpiece with an appropriate tool. This mechanical generation of chips can be carried
out by single point or multi point tools.

• Modern precision manufacturing demands extreme dimensional accuracy and surface

finish. Such performance is very difficult to achieve manually, if not impossible, even
with expert operators. CNC machining is capable of meeting the tightest tolerances, and
producing the most accurate, precise products over and over again.

2
 29-12-2020

Advantages of CNC Machines

• Continuous Use: Unlike manual labor, CNC machinery (barring any malfunction or maintenance issue) can
work continuously over any period of time without a break. This greatly increases productivity and efficiency.
• Consistency, Precision and Redundancy: With computer software, the design of any given product only
needs to be programmed once. The CNC machine can then perfectly replicate that design, for any order
quantity.
• Low Skill Requirement: CNC machine operators require little training and skill when compared to manual
machine operators.
• Fewer Personnel: Because computer software controls the machinery, fewer technicians are needed for
operation and oversight, cutting overall expenses.
• Flexibility: The software can be reprogrammed quickly and easily to produce different parts, allowing
operations to keep up with shifting customer demands.
• Capability: This technology uses computer precision to go beyond the limitations of manual capabilities. More
complex and intricate operations are possible with CNC machining.

Limitations of CNC Machines

• Cost: CNC machines are more expensive and require a greater initial investment than
machines that can be operated manually. However, as this technology becomes the standard,
supply is increasing resulting in costs gradually decreasing. There is also a cost associated
with training of the employees. As these machines heavily rely on softwares, often with every
new version of the software, new training sessions are needed to updates the employees on
new features and changes to old ones. Also softwares have licensing cost associated with
them which make the overall cost even higher.
• Skills Loss: Automation decreases the need for manpower, and fewer laborers are
hired. This could eventually lead to the complete loss of long-preserved skills.

3
 29-12-2020

NC and CNC Machines

• NC (Numeric Control) systems use fixed logical functions to handle a machine tool or the
machining process. NC specifies the control of the machine movements and various
different functions with the help of instructions represented as a sequence on punch cards.
The electronic control systems drive these NC’s. We cannot change the functions in the NC,
meaning it is not programmable, due to the rigid wiring of the control logic and it is
considered as hardwired.
• The CNC stands for Computer Numerical Control, it is generated by merging the computer
with the Numerical control. It uses internal microprocessors (computers) which are
comprised of memory registers. The memory registers stores various routines that can
successfully manipulate logical functions.

CNC Machines Components

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 on/off control of auxiliary functions such as spindle
rotation and coolant. The coded instructions are composed of letters, numbers and symbols.
Machine Control Unit
The machine control unit (MCU) is the heart of a CNC system. It is used to perform the
following functions:
• To read the coded instructions.
• To decode the coded instructions.
• To implement interpolations (linear, circular, and helical) to generate axis motion commands.
• To feed the axis motion commands to the amplifier circuits for driving the axis mechanisms.
• To receive the feedback signals of position and speed for each drive axis.
• To implement auxiliary control functions such as coolant or spindle on/off and tool change

4
 29-12-2020

CNC Machines Components (…Cont.)

Program input device
• The program input device is the means for part program to be entered into the CNC control
Drive System
• A drive system consists of amplifier circuits, drive motors, and ball lead-screws. The MCU
feeds the control signals (position and speed) of each axis to the amplifier circuits. The
control signals are augmented to actuate drive motors which in turn rotate the ball lead-
screws to position the machine table.
Machine Tool:
• CNC controls are used to control various types of machine tools. Regardless of which type
of machine tool is controlled, it always has a slide table and a spindle to control the position
and speed.

CNC Milling Machine

• The basic composition of the most universally

favored CNC milling machine is the Knee type
milling machine. On this equipment, the work
piece travels on the X and Y axes and the tool
on the Z axis.

• Increasingly CNC machining centers with 5-

axis controls are being utilized. They are
equipped with three linear axes (X, Y and Z)
and two rotating axes (A, B, and/or C).

5
 29-12-2020

CNC Milling Machine: Part List

Optional
Steel Vice 164 090

CNC Turning Machine

• CNC turning machines are in general turning
machines (lathe) with axes (slide X,Z and the
headstock spindle C) that are moved by a
servo or stepper motors and controlled via
storable programs.

• In production mainly multi-spindle turning

machines are used (lathes with powered tools
and powered tailstock). As tool holder, a
turret tool post, movable in X- and Y
direction, is used. The powered tools allow
for the complete finishing of a work piece in
one go.

6
 29-12-2020

CNC Lathe Machine: Part List

Optional
Steel Vice 164 090

References
Texts:

[1] Department of Mechanical Engineering, IIT Guwahati, Workshop Practice Manual, Vidya Mandir, Guwahati, 2018.

References:

[1] S. K. H. Choudhury, A. K. H. Choudhury and N. Roy, Elements of Workshop Technology, Volume I: Manufacturing
Processes, Media Promotors, 2008

7
 29-12-2020

Thank you