CLASSIFICATION OF CNC MACHINE TOOLS ( 1) Based on the motion type ' Point-to-point & Contouring systems There are

two main types of machine tools and the control systems required for use with them differ because of the basic differences in the functions of the machines to be controlled. They are known as point-to-point and contouring controls. ( 1.1) Point-to-point systems Some machine tools for example drilling, boring and tapping machines etc, require the cutter and the work piece to be placed at a certain fixed relative positions at which they must remain while the cutter does its work. These machines are known as point-to-point machines as shown in figure 22.1 (a) and the control equipment for use with them are known as point-topoint control equipment. Feed rates need not to be programmed. In theses machine tools, each axis is driven separately. In a point-to-point control system, the dimensional information that must be given to the machine tool will be a series of required position of the two slides. Servo systems can be used to move the slides and no attempt is made to move the slide until the cutter has been retracted back. ( 1.2) Contouring systems (Continuous path systems) Other type of machine tools involves motion of work piece with respect to the cutter while cutting operation is taking place. These machine tools include milling, routing machines etc. and are known as contouring machines as shown in figure 22.1 (b) and the controls required for their control are known as contouring control. Contouring machines can also be used as point-to-point machines, but it will be uneconomical to use them unless the work piece also requires having a contouring operation to be performed on it. These machines require simultaneous control of axes. In contouring machines, relative positions of the work piece and the tool should be continuously controlled. The control system must be able to accept information regarding velocities and positions of the machines slides. Feed rates should be programmed.

Figure 22.1 (a) Point-to-point system

Figure 22.1 (b) Contouring system

Figure 22.1 (c) Contouring systems

22.2 Based on the control loops ' Open loop & Closed loop systems 22.2.1 Open loop systems: Programmed instructions are fed into the c ontroller through an input device. These instructions are then converted to electrical pulses (signals) by the controller and sent to the servo amplifier to energize the servo motors. The primary drawback of the open-loop system is that there is no feedback system to check whether the program position and velocity has been achieved. If the system performance is affected by load, temperature, humidity, or lubrication then the actual output could deviate from the desired output. For these reasons the open -loop system is generally used in point-to-point systems where the accuracy requirements are not critical. Very few continuous-path systems utilize open-loop control.

Figure 22.2 (a) Open loop control system Figure 22.2 (b) Closed loop control system
Courtesy: http://jjjtrain.kanabco.com/vms/Media/glossary_o/cnc_opencloseloop.gif Courtesy: http://jjjtrain.kanabco.com/vms/Media/glossary_o/cnc_opencloseloop.gif

Figure 22.2 (c) Open loop system 22.2.1 Closed loop systems: The closed-loop system has a feedback subsystem to monitor the actual output and correct any discrepancy from the programmed input. These systems use position and velocity feed back. The feedback system could be either analog or digital. The analog systems measure the variation of physical variables such as position and velocity in terms of voltage levels. Digital systems monitor output variations by means of electrical pulses. To control the dynamic behavior and the final position of the machine slides, a variety of position transducers are employed. Majority of CNC systems operate on servo mechanism, a closed loop principle. If a discrepancy is revealed between where the machine element should be and where it actually is, the sensing device signals the driving unit to make an adjustment, bringing the movable component to the required location. Closed-loop systems are very powerful and accurate because they are capable of monitoring operating conditions through feedback subsystems and automatically compensating for any variations in real-time.

Figure 22.2 (d) Closed loop system

(3 ) Based on the number of axes ' 2, 3, 4 & 5 axes CNC machines. ( 3.1) 2& 3 axes CNC machines: CNC lathes will be coming under 2 axes machines. There will be two axes along which motion takes place. The saddle will be moving longitudinally on the bed (Zaxis) and the cross slide moves transversely on the saddle (along X-axis). In 3-axes machines, there will be one more axis, perpendicular to the above two axes. By the simultaneous control of all the 3 axes, complex surfaces can be machined. ( 3.2 ) 4 & 5 axes CNC machines: 4 and 5 axes CNC machines provide multi-axis machining capabilities beyond the standard 3-axis CNC tool path movements. A 5-axis milling centre includes the three X, Y, Z axes, the A axis which is rotary tilting of the spindle and the B-axis, which can be a rotary index table.

Figure 22.3 Five axes CNC machine Importance of higher axes machining : Reduced cycle time by machining complex components using a single setup. In addition to time savings, improved accuracy can also be achieved as positioning errors between setups are eliminated.

Improved surface finish and tool life by tilting the tool to maintain optimum tool to part contact all the times. Improved access to under cuts and deep pockets. By tilting the tool, the tool can be made normal to the work surface and the errors may be reduced as the major component of cutting force will be along the tool axis. Higher axes machining has been widely used for machining sculptures surfaces in aerospace and automobile industry.

(3.3) Turning centre: Traditional centre lathes have horizontal beds. The saddle moves longitudinally and the cross slide moves transversely. Although the tools can be clearly seen, the operator must lean over the tool post to position them accurately. Concentration of chips may be creating a heat source and there may be temperature gradients in the machine tool. Keeping the above points in view, developments in the structure of the turning centres lead to the positioning the saddle and the cross slide behind the spindle on a slant bed as shown in the figure 22.4. Chips fall freely because of slant bed configuration which is more ergonomically acceptable from operator's point of view.

Figure 22.4 Slant bed turning centre

22.4 Based on the power supply ' Electric, Hydraulic & Pneumatic systems Mechanical power unit refers to a device which transforms some form of energy to mechanical power which may be used for driving slides, saddles or gantries forming a part of machine tool. The input power may be of electrical, hydraulic or pneumatic.

22.4.1 Electric systems: Electric motors may be used for controlling both positioning and contouring machines. They may be either a.c. or d.c. motor and the torque and direction of rotation need to be controlled.

The speed of a d.c. motor can be controlled by varying either the field or the armature supply. The clutch-controlled motor can either be an a.c. or d.c. motor. They are generally used for small machine tools because of heat losses in the clutches. Split field motors are the simplest form of motors and can be controlled in a manner according to the machine tool. These are small and generally run at high maximum speeds and so require reduction gears of high ratio. Separately excited motors are used with control systems for driving the slides of large machine tools. 22.4.2 Hydraulic systems: These hydraulic systems may be used with positioning and contouring machine tools of all sizes. These systems may be either in the form of rams or motors. Hydraulic motors are smaller than electric motors of equivalent power. There are several types of hydraulic motors. The advantage of using hydraulic motors is that they can be very small and have considerable torque. This means that they may be incorporated in servosystems which require having a rapid response.