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METAL CUTTING MACHINES
Relative motion between cutting tool and work piece by forcing a sharp cutting edge into the work-piece. Problems: Metals are very hard. Motion between tool and work-piece should be at sufficiently high rate Temporary solution: Power driven machines (machine tools) are capable of generating high forces required, but to use a machine tool, we need to Determine the location on the work-piece where machining is to be done. Controlling the path followed during the motion of the tool or work-piece Controlling the rate at which the path is traversed Controlling the rate at which the path is traversed Further: A highly skilled operator is required even for a simple job Inconsistency in results Much longer time, depend on knowledge and skill of operator.\ Very difficult to manufacture complex products Low productivity
Numerically Controlled Machines

Same technological capabilities as of conventional machines
in terms of machining, but differ in control of machine functions. Elements of NC system

Part program Machine control unit (MCU) The machine tool
Capabilities of Machine control unit (MCU) of a NC machine: Positioning the tool Turning the spindle ON/OFF Setting cutting speeds/feed rates Turning coolant ON/OFF Direction and rate of slide motion, spindle rotation, etc.
Computer Numerical Control (CNC)

A CNC machine is an NC machine with the added feature of an on-board computer.
CNC Machines
Machining Centers, equipped with automatic tool changers, are capable of changing 90 or more tools. Can perform milling, drilling, tapping, boring on many faces.
Ken Youssefi
Mechanical Engineering Department
CNC Machines
Turning Centers are capable of executing many different types of lathe cutting operations simultaneously on a rotating part.
CNC Controllers
The NC controller is the brain of the NC system, it controls all functions of the machine. Motion control deals with the tool position, orientation and speed.
Auxiliary control deals with spindle rpm, tool change, fixture clamping and coolant.
Many different types of controllers are available in the market (GE, Fanuc, Allen-Bradley, Okuma, Bendix, ). There are two basic types of control systems: point-to-point and continuous path.
Point-to-Point Tool Movements

Point-to-point control systems cause the tool to move to a point on the part and execute an operation at that point only. The tool is not in continuous contact with the part while it is moving. Drilling, reaming, punching, boring and tapping are examples of point-topoint operations.
Continuous-Path Tool Movements

Continuous-path controllers cause the tool to maintain continuous contact with the part as the tool cuts a contour shape. These operations include milling along any lines at any angle, milling arcs and lathe turning.
Loop Systems for Controlling Tool Movement

Open Loop System
Uses stepping motor to create movement. Motors rotate a fixed amount for each pulse received from the MCU. The motor sends a signal back indicating that the movement is completed. No feedback to check how close the actual machine movement comes to the exact movement programmed.
Types of NC control systems

Open-loop Control Stepper motor is used, having a predefined amount of revolution. Current pulses are send from MCU to individual motors. Movement/rotation depends on number of pulses send. Advantages:
Position is maintained just by keeping track of number of revolutions. Can produce a movement of 1/1000th of an inch, for a single pulse. Cheap and less complex. Easy to maintain.
Drawback: Assumption: Motor movement is precise, i.e. motor is moving the exact
amount depending on the number of pulses. No way to correct errors, because no feedback. This control is not suitable for large machines requiring greater power because of limitation of stepper motor to generate high torque.
Loop Systems for Controlling Tool Movement

Closed Loop System
AC, DC, and hydraulic servo-motors are used. The speed of these motors are variable and controlled by the amount of current or fluid. The motors are connect to the spindle and the table. A position sensor continuously monitors the movement and sends back a single to Comparator to make adjustments.
Closed-loop Control
Direct current (DC) motors are used. Can generate high levels of torque. Can be reversed. Unlike stepper motors, it cannot achieve very precise movement. Separate positions sensors are required. Position information is fed back as a signal to the controller.
Major advantage: because of feed back and servo motors reversible feature, errors can be corrected, by comparing with target position. Thus formed a closed loop. Higher accuracy than open loop systems because of feed back. Applications: Larger NC machines because of higher loads. For greater accuracy, any kind of load. Expensive and complex.
Flow of Computer-Aided CNC Processing

Develop or obtain the 3D geometric model of the part,
using CAD. Decide which machining operations and cutter-path directions are required (computer assisted). Choose the tooling required (computer assisted). Run CAM software to generate the CNC part program. Verify and edit program. Download the part program to the appropriate machine. Verify the program on the actual machine and edit if necessary. Run the program and produce the part.
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CNC Machine Tool Positioning Modes
Within a given machine axes coordinate system, CNC can be programmed to locate tool positions in the following modes; incremental, absolute, or mixed.
Mechanical Engineering Department
Machines
Conventional
Computer Numerical Control
Milling Machines
WORK HOLDING DEVICES FOR CNC MACHINES

In the CNC machines, fixtures are still required to
locate and hold the work pieces while machining. Automatic pallet change over systems are used in modern CNC machines. These pallets simply move for interchanging their positions on the machine table. While machining is being done on a job kept on one pallet, the other pallets are accessible to the operator for clamping and unclamping raw material or finished product. This saves a lot of material handling and set up time, resulting in higher productivity.
Work holding Devices for CNC Milling Machines

Vise Chucks Special fixtures Modular fixturing systems Clamp work to table
Workholding Devices
Workholding on a Lathe
Between centers Live-tailstock Dead-headstock Face plate Drive dog
Chuck 3,4, or 6 jaw Soft jaws
Others Face driver system Sub-spindle system
Tool Holding Devices- Drilling

Drill chucks Key type or keyless Drill Sleeves
Collet
CNC Machines
CNC: Horizontal, Vertical, and Planner (up to 5 axis)
CNC Machines
Laser Machining and Cutting
The machine utilizes an intense beam of focused laser light to cut the part. Material under the beam experiences a rapid rise in temp. and is vaporized. Laser cuts with a minimum of distortion, no mechanical . cutting forces.
Gas is blown into the cut to clear away molten metals, or other materials in the cutting zone. In some cases, the gas jet can be chosen to react chemically with the work piece to produce heat and accelerate the cutting speed

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METAL CUTTING MACHINES

Numerically Controlled Machines

in terms of machining, but differ in control of machine functions. Elements of NC system

Computer Numerical Control (CNC)

Mechanical Engineering Department

Point-to-Point Tool Movements

Continuous-Path Tool Movements

Loop Systems for Controlling Tool Movement

Types of NC control systems

Loop Systems for Controlling Tool Movement

Flow of Computer-Aided CNC Processing

CNC Machine Tool Positioning Modes

Mechanical Engineering Department

Computer Numerical Control

WORK HOLDING DEVICES FOR CNC MACHINES

Work holding Devices for CNC Milling Machines

Tool Holding Devices- Drilling

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