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2nd Unit

The document discusses machine structures and their components, as well as methods to improve rigidity and reduce errors. It covers the main structure, which consists of a bed and column. Forces acting on the structure include static and inertia forces. Steps taken to correct deformation include improved design, increased stiffness, heat removal surfaces, and alignment checks. Slideways require rigidity, accuracy, and friction reduction. Methods to overcome slip-stick friction include hydrostatic, air bearing, and anti-friction slideways using balls or rollers. Linear motion bearings minimize wear through rolling components. Feedback devices include transducers that convert physical values like speed or displacement to electrical signals for closed loop control.

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Pradeepvenugopal
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© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
88 views

2nd Unit

The document discusses machine structures and their components, as well as methods to improve rigidity and reduce errors. It covers the main structure, which consists of a bed and column. Forces acting on the structure include static and inertia forces. Steps taken to correct deformation include improved design, increased stiffness, heat removal surfaces, and alignment checks. Slideways require rigidity, accuracy, and friction reduction. Methods to overcome slip-stick friction include hydrostatic, air bearing, and anti-friction slideways using balls or rollers. Linear motion bearings minimize wear through rolling components. Feedback devices include transducers that convert physical values like speed or displacement to electrical signals for closed loop control.

Uploaded by

Pradeepvenugopal
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Machine structure

Drawbacks of conventional machines


Lack of stiffness
Backlash errors
Stick-slip characteristics
Machine tool resonance
Machine tool chatter

Two areas of consideration


1. Main structure of machine tool
2. Slides and slideways

Machine structure
Main structure has
1. Bed
2. Column rigidly connected
Forces acting on the main structure
1. Static forces
-wt. of machine tool , pressure of cutting tool on wk. Pc
2.
Inertia forces
- bending an deformation due to rapid acceleration and
deceleration or heat effect
In vertical columns: due to mounting driving motors on the cutting
arm

Machine structure
Steps taken to correct deformation in Main structure

1. Improved design of mild steel structure with


higher stiffness
2. Increase stiffness with ribs, braces
and angle plates in main structure
3. Normal weight distribution over
entire frame of machine
4. Ribs in the hollow cross sections
of beds
5. Bases of CI for damping

Machine structure
Steps taken to correct deformation in Main structure
(contd.)
6. Thermo symmetrical design of parts
7. Provide heat removing surfaces
8. Coolants
9. Avoiding external sources of direct heat sun, electrical
motors, oil pumps, etc.
10. Reduction of ambient temperature A/C
11. Periodical checks on alignment of machine elements

Slide and Slideways


Requirements of
slideways
Rigid, accurate design,
durable
Overcome frictional
resistances :stick-slip
-to overcome this, sliding
friction is replaced with
rolling friction

Slide and Slideways


3 Methods to overcome slip-stick friction
1. Hydrostatic type slide ways
1. Oil lubricated
2. Air bearing slideways

2. Anti-friction type slideways


1. Ball bearing guideways
2. Roller bearing guideways

3. Wear resistant slideways

Hydrostatic Type Slideways


For horizontal beds, where
the cutting forces are borne
by the sliding surfaces e.g.
Lathe
Requires a constant film of
some fluid pumped under
pressure through pockets oil
or compressed air
Pressure is automatically
varied based on the surface
load
Oil lubricated slideways best
suited for CNC milling m/c

Hydrostatic Type Slideways


Advantages of oil lubricated slideways

Drawbacks
Difficulty in fixing the moving member in a desired position
Extremely high cost of an elaborate lubricating system

Hydrostatic Type Slideways

Air bearing slideways

Compressed air used


During actual displacement of slides, the table and saddle
are raised on a cushion of compressed air
Suitable only for positioning work e.g. drilling
Drawback : possible misalignment due to uneven
distribution of load on worktable

Air bearing slideways

Anti-friction type slideways


Conventional slides
Highest fiction at lowest velocity: slip-stick movement
Point or line contact is used instead of surface contact, so
sliding friction is converted to rolling friction
Excellent control obtained with both ball and roller designs

Ball bearing guideways


Ball bearings are carried in chain cages
Hardened metal inserts with flat surface contact on the ball
track
Return groove for ball bearings to recirculate with the help of
deflector plates

Anti-friction type slideways


Roller bearing guideways
Improves load bearing properties
Rollers minimise friction and require small starting effort
Roll between V grooves

Anti-friction type slideways

Wear resistant slideways


Machines differ in their ability to withstand wear and tear
Lathe, planning machine :heavy wear
while grinding m/c : less wear
CI is used for the body of both but bearing surfaces differ
Methods for this
1.
2.
3.
4.

Flame hardening
Induction hardening
Fastening hardening surfaces
Surface coatings

Wear resistant slideways

Flame hardening and induction hardening : applied to


conventional machines

Fastening hardening surfaces: Saddle or bed is scrapped


first and fitted with pre measured hardened steel strips

Surface coatings : Low friction plastic material PTFE


Poly Tetra Floro Ethyline or Trucite liners are pasted as
anti-stick liners

Linear Motion Bearings


To minimize wear due to long, continuous hours
of production, rolling components replace sliding
components

Linear Motion Bearings

Linear Motion Bearings - Constructional features


1.
2.
3.

Bearing block
Rails
Raceways

4.
5.

Retainers
Endplates

Linear Motion Bearings

Linear Motion Bearings

Linear
Motion
Bearings

Linear Motion Bearings


Advantages
1. Very less difference between static and dynamic
friction results in reduction of drive power
- results in reduction of machine size and
weight, overall and maintenance cost.
2. Stick slip is completely eliminated
3. Requires very less lubrication, lasts long as it wears
out less
4. Smooth motion is obtained even when internal
clearance is reduced to zero

Linear Motion Bearings

Linear Motion Bearings


Life of the bearing
-total travelling distance from time of start to the
time when the first flaking appears on either track
or rolling elements
Nominal life under applied load L = (C/P) 3 * 50
Where
L = Nominal life in km
C = Basic dynamic rating kgf
P = Load kgf

Linear Motion Bearings


Nominal life in working hours
Ln = L * 10
2* ls*n*60
Where
ls = stroke length
n = cycles per minute
Travelling distance per minute = S
= 2* ls* n m/min

Recirculating balls in
leadscrew and nut assembly

Recirculating balls in
leadscrew and nut assembly

Recirculating balls in
leadscrew and nut assembly
Two thread forms are available
1. Gothic arc profile
2. Circular arc profile

Recirculating balls in
leadscrew and nut assembly
Two types of recirculating ball screws
1. The balls are returned using an external tube.
2. In the other arrangement the balls are returned to the start of the
thread in the nut through a channel inside the nut.

Recirculating balls in
leadscrew and nut assembly
Required as conventional machines have backlash and
less power transmission
Conditions
Diameter of ball bearings used must be 60 -70% of the
lead of the screw done to facilitate return to the start
Advantages
Very high efficiency 90%
Reversibility in operation
Lesser wear and tear
Longer working life
Use of rolling motion instead of sliding motion
eliminates stick-slip and reduces friction to almost zero

Drives Spindle and feed


Basic function of a CNC machine is to provide automatic
and precise motion control to its elements such work table,
tool spindle etc.
Drives are used to provide such kinds of controlled motion
to the elements of a CNC machine tool.

How?
A drive system consists of drive motors and ball leadscrews.
The control unit sends the amplified control signals to
actuate drive motors which in turn rotate the ball leadscrews to position the machine table or cause rotation of the
spindle.

Drives
A.

Spindle drives to provide the main spindle power for cutting action

Provide angular motion to the work piece or a cutting tool.


Essentially required to maintain the speed accurately within a power band
which will enable machining of a variety of materials with variations in
material hardness.
The speed ranges can be from 10 to 20,000 rpm.
AC drives are preferred to DC drives due to the advent of microprocessorbased AC frequency inverter.
High overload capacity is also needed for unintended overloads on the spindle
due to an inappropriate feed.
A compact drive is desirous with highly smooth operation.

Drives
B. Feed drives to drive the axis

Feed Drives
The feed motor needs to operate with constant torque characteristics
to overcome friction and working forces.
The drive speed should be extremely variable with a speed range of
about 1: 20000, which means it should have a maximum speed of
around 2000 rpm and at a minimum speed of 0.1 rpm.
The feed motor must run smoothly.
The drive should have extremely small positioning resolution.
High torque to weight ratio
Low rotor inertia
Quick response in case of contouring operation where several feed
drives have to work simultaneously.
Variable speed DC drives are used as feed drives in CNC machine
tools. AC feed drives are being used now-a-days

Drives Spindle and feed


Power drives
Electrical, hydraulic or pneumatic.
Electrical drives
These are direct current (DC) or alternating current (AC) servo motors or
stepper motors
They are small in size and are easy to control.

Hydraulic drives
These drives have large power to size ratio and provide stepless motion
with great accuracy.
But difficult to maintain and are bulky.
Generally they employ petroleum based hydraulic oil which may have
fire hazards at upper level of working temperatures.
Need special treatment to protect them against corrosion.

Drives Spindle and feed


Pneumatic drives
This drives use air as working medium which
is available in abundant and is fire proof.
They are simple in construction and are
cheaper.
These drives generate low power, have less
positioning accuracy and are noisy.

Drives
Pneumatic drives
Uses air as working medium
Abundant availability
Fire proof
Simple in construction
Cheaper
Generate low power
Have less positioning accuracy
Noisy.

Drives Spindle and feed


Electrical drives
direct current (DC) or alternating current (AC) servo motors.
Small in size and are easy to control

Drives Spindle and feed


Hydraulic drives
Large power to size ratio and
Provide stepless motion with great accuracy.
Are difficult to maintain and are bulky
Employ petroleum based hydraulic oil which may
have fire hazards at higher working temperatures.
Hydraulic elements need special treatment to
protect them against corrosion.

Feedback Devices

Feedback Devices
Transducer: A electronic or electric hardware device that
converts one physical quantity (speed, displacement)
into an electrical signal
Types of Feedback Devices ( for a closed loop)
1. Velocity feedback (used in contouring applications)
2. Position feedback

Feedback Devices
Types (depends on the output signal generated)
1. Analog Generates a continuous signal
voltage and current in millivolts
E.g. Tacho generator fitted on a servomotor shaft the
voltage is directly proportional to the speed of the shaft
2. Digital - Generates signal in the form of electrical pulses
or a combination of parallel bits (binary digits)
- the number of electrical pulses per minute are directly
proportional to the speed of the shaft (rpm)

Digital Velocity Feedback Devices


DC Tachometer
Contact
Breaker
Comparator

Digital Velocity Feedback Devices


DC Tachometer

Analog Feedback Devices


Analog Tachometer

Analog Feedback Devices


Analog Tachometer

Positioning Feedback Devices


LINEAR TRANSDUCERS
Glass scales with line grating
Ferranti System
Binary coded scale
Inductosyn
Transducers
Encoders/ Rotary transducers

Resolvers
Rotary encoder

Positioning Feedback Devices - Principle

Positioning Feedback Devices


Glass Scale with line grating

Positioning Feedback Devices: Ferranti System


- least count is improved

Binary Coded Scale

Binary Coded Scale

Inductosyn

Rotary Transduccers
-Measure angular displacement
- Uses photoelectric principle

Two types
1. Resolvers
2. Encoders

Optical Encoder

Resolver
an analog position sensor
Has a rotating shaft with primary winding
Stationary housing two secondary windings
offset by 90degrees

Working:
When the primary is excited with an AC signal, AC
voltages are induced in the secondary coils which
are proportional to the sine and cosine of the shaft
angle

Resolver

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