CNC TECHNOLOGY

INTRODUCTION TO CNC

History of NC/DNC/CNC:
First NC milling machine was demonstrated in 1952 at the Massachusetts Institute of Technology, USA. In 1960s the technology of Direct Numerical Control (DNC) was developed.

The major difference between NC and CNC:

NC and CNC machine lies in the improved flexibility and reliability of the CNC systems. In case of NC machine the entire data input and data handling sequence including control functions are determined only by the fixed circuit interconnections of decision elements and storage devices. Hence it required change in circuitry for any additional features. Also the machine control data are read in time to time from tape. Where as CNC machine incorporates a micro processor based control system that accepts a set of program instructions and sends out put control information to the machine tool based on the feed back information received from machine interface elements.

Functioning of a CNC machine:

Hardware: It includes the microprocessors that effect control system functions and peripheral devices for data communication, machine tool interfacing and machine tool status monitoring. Software: It includes the programs that are executed by the system microprocessors. These programs process input and output instructions and control information, make all necessary computations for machine functions, coordinate the functions of the machines and accessories and provide the necessary communication links. Information: CNC operation requires data regarding the geometry of the work piece and data regarding machining parameters in a specific format, which is compatible to the CNC control system concerned. The above data can be either directly input in the control system or feed through the floppy or transmitted through RS 232-C interface cable from a PC (CAM programming system)

CNC MACHINE TOOL HARDWARE

The sequence of activities done in CNC machines is as follows:

Salient features of CNC Machines:

Machine structure Slide ways Feed drive Spindle drive Feed-back system

Classification of NC system:
Open Loop Closed Loop

Open Loop

Closed Loop

Based on control system features, the NC system is classified as follows:

Point to Point system Straight cut or straight line system Continuous path or contouring system

Point to Point system

Straight cut or straight line system

Continuous path or contouring system

Tool and tool materials used in CNC machine tools

Cutting tool materials and properties: The material must withstand excessive wear even though the relative hardness of the tool materials changes. Ability to retain hardness under severe working condition. Ability to withstand cutting forces. The frictional coefficient must remain low for minimum wear and good surface finish. Cost and easiness of fabrication should have within reasonable limits.

Type of tool material

Carbon steels High-speed steel Stellite Carbides Coated carbides Coated cemented carbides Diamond Cermets

CNC MILLING CUTTERS & COLLETS

CNC MILLING CUTTERS

CNC MILLING CUTTERS

CNC TURNING CARBIDE TOOLS

SHAPE AND FORM OF CNC TURNING TOOLS

AUTOMATIC TOOL CHANGER USED IN CNC TURNING

Advantages of CNC machines

Automatic and rapid positioning of the slides. Increased material removal rates by employing increased spindle speed and feed rates. Reducing the tool change time by using ATC and reducing job setting time by using APC. Higher positional accuracy and repeatability of the machined parts because of the machine construction and the closed loop control system elements. Higher flexibility for meeting frequent design changes with lesser cost. Reduced inspection requirements and reduced scrap there by reducing inspection and material cost. Reduced labour cost, as CNC machine does not require highly skilled man power. Reduced inventory cost as the usage of CNC machines reduces the lead time of production. Reduced tooling cost, as the CNC machine does not require jigs, fixtures or templates.

Disadvantages of CNC machines

Higher investment cost. Higher maintenance cost. Need of trained personnel

Applications of CNC machines

Metal Cutting machines: CNC milling, CNC turning, CNC drilling/jig boring, gear cutting, CNC grinding etc. Metal forming machines: Press tools, Injection/Blow moulding/Diecasting machines, Tube bending, etc Non conventional machining processes such as EDM die sinking and EDM wire cut machines. Plasma arc cutting machines. Electron Beam machining. Laser Beam machining. Ion Beam machining. Ultra sonic machining, etc. Welding machines: TIG, MIG, submerged arc welding, etc. Inspection and quality control systems: CMM, LMM. Assembly, testing and dispatch equipments and Tool and work handling systems.

INTRODUCTION TO CNC PROGRAMMING

NOMENCLATURE OF THE CNC MACHINE AXIS: The axis of CNC machine can be identified using the conventional right hand thumb rule.
The linear motions The rotary motions

DESIGNATING THE LINEAR MOTIONS

DESIGNATING THE ROTARY MOTIONS

CO-ORDINATE SYSTEM
There are two types of co-ordinate systems used in CNC Programming.
Absolute co-ordinate system Incremental co-ordinate system

ABSOLUTE CO-ORDINATE SYSTEM

INCREMENTAL CO-ORDINATE SYSTEM

PART PROGRAMMING
METHODS OF PROGRAMMING: Cad/cam based part programming. Computer assisted part programming. Manual CNC programming.

ISO G-codes

ISO M-codes

CNC MILLING MACHINE

CNC MILLING MACHINE

TWIN CNC MILLING MACHINE

CNC TURNING MACHINE

CNC TURNING MACHINE

CNC TURNING MACHINE