Introduction to CNC machine.txt Introduction to CNC Sanjit Chattopadhyay What is CNC? CNC means Computer Numerical Control.

. A form of programmable automation. Typical program containing coded alphanumeric data, such as G01 X120 Y200 The data represent relative positions between a cutting tool and a workpiece spindle Slide movement Drive motor signal Drive motor Feedback signal MCU Feedback device NC part program Why CNC machining? Improved automation Improve the quality and accuracy of manufactured parts Flexibility to manufacture complex or otherwise impossible jobs 2D and 3D contours Stabilize manufacturing costs Typical CNC machine Major component: -Drivers unit -Sliding system -Machine control unit (MCU) Drives of CNC machine tool Hydraulic actuator -high power machine tool Stepping motor -small machine due to limited power and torque DC motor -excellent speed regulation, high torque, most widely used Friction behavior versus velocity (a) Sliding friction, conventional screw (b) Rolling friction, ball-bearing screw Ball-bearing leadscrew Ball-bearing leadscrew Nut Nut


Control of CNC Machine Tool Interpret a CNC program Produce coordinated pulses for multiple axes of motion Activate the series of commands in sequential order Schematic illustration of the major components ofa numerical control machine tool. Open loop system Operates without verifying that the actual position is equal to the specified position Page 1

Introduction to CNC machine.txt Usually a stepping motor Closed loop control system Uses feedback measurement to verify that the actual position is equal to the specified location Servo motor with a feedback loop Two Basic Types of Control in CNC Measurement of linear displacement (a) Direct measurement of the linear displacement of a machine-tool worktable. (b) and (c) Indirect measurement methods. Direct measurement 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 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. Encoder operating principles LED light passes through a moving disc to produce an electronic output from a photodiode cell Encoders -Incremental encoder -Absolute encoder Incremental encoders The most common incremental provide a digital pulse for each resolvable position to be counted and referenced to a home position. These digital pulses are then fed into a high-speed counter module located in a drive or controller interface. Absolute encoders Every position of an absolute device is unique, and these devices do not lose position when power is removed. Incremental vs. absolute encoders Touch Probes Touch probes used in machining centers for determining workpiece andtool positions and surfaces relative tothe machine table or column. (a) Touch probe determining the X-Y(horizontal) position of a workpiece, (b) determining the height of ahorizontal surface, (c) determining theplanar position of the surface of acutter (for instance, for cutter-diameter compensation), and (d) determiningthe length of a tool for tool-lengthoffset. Source: Hitachi Seiki Co., Ltd. Machine coordinate system Workpiece coordinate system G54 Z X Y


Motion control -point to point control B Workpiece is moved to a programmed location with no regard for path taken to get to that location Once the move is completed, some A processing action is accomplished by Page 2

Introduction to CNC machine.txt Workpiece the cutting tool Examples: drilling or punching a hole Moving at maximum rate from point to point. Accuracy of the destination is important but not the path Motion control -continuous path (CP) Continuous simultaneous control of more than one axis, thus controlling path followed by tool relative to part Controls both the displacement and the velocity. Use linear and circular interpolators. Interpolator: Digital differential analyzers (DDA). A B A B Linear interpolation Circular interpolation NC machine rating NC Part Programming Techniques Accuracy Repeatability Spindle and axis motor horsepower Number of controlled axes 1. Manual part programming 2. Computer-assisted part programming 3. CAD/CAM-assisted part programming Dimension of workspace Common features: Features of the machine and the controller. Points, lines, and surfaces of the workpart must be defined relative to NC axis system Programmed position Repeatability Movement of the cutting tool must be defined relative to these part features Avg. error Test result NC Words A G-code program consists the following words: N, G, X, Y, Z, I, J, K, F, H, D, S, T, R, M N -Sequence number (Used for line identification) G -Preparatory function Page 3

X Y Z R F S H D T M

Introduction to CNC machine.txt -X axis designation -Y axis designation -Z axis designation -Radius designation -Feedrate designation -Spindle speed designation -Tool length offset designation -Tool radius offset designation -Tool Designation -Miscellaneous function (See below)

Preparatory functions: preparing MCU to perform a specific mode of operation Use G codes followed by two digits Interpolation is used, linear and circular Canned cycles NC Words G codes ExampleN10 MSG(This is my first NC program) N20 F200 S900 T1 D2 M3 N30 G0 X100 Y100 N40 G1 X150 N50 G2 X150 Y120 I=AC(45) J=AC(35) N60 X100 N70 Y100 N80 G0 X0 Y0 N90 M30


NC Words Spindle control words S word is used to specify the spindle speed M03: turn spindle on in clockwise M04 turns spindle on in counter clockwise M05 turn spindle off Dimensional words X, Y, Z for primary motion direction in X, Y, Z Feed words F Code. feed speed. mm/min (mmpm), or mmpr. Automatic tool change T word is used to tell the machine which tool station is to placed in the spindle. NC Words M Codes M Code. miscellaneous word. M0 Program stop Example M01 Optional stop N10 MSG(This is my first M02 End of main program NC program) M03 Spindle CW N20 T1 D2 M06 Page 4

Introduction to CNC machine.txt N25 F200 S900 M3 M07 M04 Spindle CCW N30 G0 X100 Y100 M05 Spindle stop N40 G1 X150 M06 Tool change N50 M07 M08 N80 Y120 Flood coolant on N60 X100 Mist coolant on N70 Y100 G0 X0 Y0 M05

M09 Coolant off N90 M30 M17 End of subprogram M30 End of program Example block command for milling operation: N10 MSG(This is my first NC program) N15 G54 N20 F200 S900 T1 D2 M3 N30 G41 G0 X100 Y100 N40 G1 X150 N50 Y120 N60 X100 N70 Y100 N80 G40 G0 X0 Y0 N90 M30 Complete part program consists of a sequence of such block commands Manual Part Programming: Example 100 100 150 120 Y X Summary


Concept of CNC machine Basic components of CNC machine CNC control CNC programming

Page 5