cnc overview presentation
TRANSCRIPT
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An Overview of CNC machines
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Contents
Various types of machines Why CNC machines, applications & economics Classifications of CNC machines Elements of CNC machines: Mechanical ,
Electronics & accessories CNC features & systems Programming of CNC machines Special terminology Testing of CNC machines Leading makes of Indian & imported CNC machines HSM: High sped Machining.
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Types of machines
GPM with conventional or PLC controlGPM with CNC ControlSPM with Conventional or PLC controlSPM with CNC controlTransfer LinesFMS
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Definition of a CNC machine
A machine tool , whose movements are controlled by a micro -processor & can be programmed for part cutting.
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Applications of CNC machines
CNC machines are used when : Batch size is small Bigger product mix with lot of
variation Part access requires multiple set
ups Referencing not possible by
fixturing
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It is a myth that CNC It is a myth that CNC machines can solve all machines can solve all problems !!problems !!
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SPM’s give normally better quality , productivity & lower cost of part for mass production environment.
Many industries are doing away with M/C when volumes go higher, for volumes higher than 100 /day , SPM line is preferred.
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Advantages of CNC machines
Flexibility of part productionFlexibility of processAccurate reproduction of parts.No operator errorsMinor product changes can be
readily adapted.
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Limitations of CNC machines
Higher capital & running cost. Low productivity compared to SPM
‘sRequirement of skilled manpower
for part production & maintenanceless robust compared to SPM &
GPM. Downtime is normally higher.
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Summary Slide
Applications of CNC machines
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Applications of CNC machines
Typical examples of CNC use For turning applications as variety is high. For multi product set up. For job shops & tool rooms For die making For small size of production & more variety of
operations / parts. E.g. Crankcase set up in Nagpur, John Deere Transmission Set up in Pune etc.
For prototyping For difficult referencing e.g. Dowel hole making in
crankcase & Trans. Case. Etc.
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Classifications of CNC Machines
HMC : Horizontal Machining CentreVMC : Vertical Machining CentreCNC turning CentreCNC milling & grinding machinesDrill Tap centersFMSHexapods
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Vertical machining Centre
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VMC- Hitachi with APC
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Horizontal Machining Centre
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FMS
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Head Changer HMC
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Hexapods
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Elements of CNC machines - Mechanical
Guideways Hardened & ground type Cast guideways LM guideways Roller guideways Tercite coatings
Ball screws Precision Rolled Dual nut arrangement for backlash elimination
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Classification of Ball screws
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LM guide ways
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Elements of CNC machines - Mechanical
Spindles In-built Cartridge Motorized spindles Gear box
ATC: Automatic Tool Changer Magazine type , e.g. LMW , BFW Corrousal type , e.g. AMS Disc type , e.g. Arrow or Feeler Direct pick up , e.g. AMS HMC
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Elements of CNC machines - Mechanical
APC: Automatic pallet Changer: APC enables loading of next part while machining of first part is in progress. Linear type e.g. LMW, PAL Shuttle type , e.g. BFW TMC 630 N Rotary type , e.g. Makino , BFW Maxpro
series Manual type , e.g. UCAM
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Rotary Pallet Changers
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ATC for VMC
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ATC for VMC
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ATC for HMC
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ATC for HMC
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Elements of CNC machines - Mechanical
Table: table is mounted on bed , it receives either fixture or pallet. Table has t -Slots or tapped holes. In case of APC machine,table has pallet
locating & clamping mechanisms. Index table Rotary table : continuos NC table B axis.
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Elements of CNC machines - Mechanical
Turret : Turret is used in Turning centers for tool storing , holding & positioning. Unidirectional , Bi-directional Hurth coupling Driven tools
Tail stock Hydraulic, non programmable Programmable
Part catchers & Bar feeders
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Elements of CNC machines - Electronic
Control: controls are a combination of hardware & software that decides & monitors machine movements & other functions through program. Fanuc 0-MC , 0-MD, 0-i etc. Siemens : 810 , 840 etc. Mazatrol , Heidenhein , Mitsubishi , Fagor
Drives: Drives are communication hardware & software between machine control to motors.they are called servo drives as they work in closed loop control & monitor movements via. Sensors like encoders. AC /DC drives Analogue / Digital drives
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Elements of CNC machines - Electronic
Encoders: Encoders are feed back sensors used for communicating the machine position to the controller. Rotary encoders: they are mounted on the drive
motor shaft & feed the angular position to the controller.rotary encoders do not give feed back on the actual axis position. ( open loop)
Linear encoder : these are nothing but linear scales. They are mounted on the slide itself & give feed back of actual machine position ( closed loop)
Limit / proximity switches: these are sensor elements that give digital signal out put to confirm completion of any movement. They are normally used for axis limit detection , ATC position detection etc.
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CNC accessories
Coolant & chip disposal systems Standard coolant system : For bed
wash , Component flooding etc. High pressure coolant : 15 to 125
bars.normally used for coolant through tool feature.
Special rotary unions are required for coolant thru. Spindle : Deublin make.
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CNC accessories
Filtration systems Cartridge filtration system Drum filtration system Centrifuge filtration system Magnetic separator Paper band filtration system Oil skimmers
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CNC accessories
Chip conveyors: Scraper type Magnetic type Screw conveyor
AC for CNC panel Makes : Sunbeam , Advanced , Rittal etc.
Tool presetter: Ashwini , Optomech , Zoller etc. Used for taking tool offset offline new generation pre-setters allow direct loading of
tool offsets.
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CNC accessories
Lubrication systems Centralized auto. Intermittent type:
CENLUBE, Willy Vogal, Used for guideway lubrication
Grease lubrication: Klubber , majorly for spindle but also for guideways.
Eco pack for guidewaysMulti spindle heads , Angle Heads.
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Features & Systems
Part seat checkingProbing: Renishaw, Mitutoyo
Spindle mounted probe for work measurement Table mounted probes for tool measurement
Live hydraulicsTool monitoring : Montronix, O-mat,
In-built tool monitoring is done by spindle load &
vibration monitoring against ideal curves.
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Programming of CNC machines
Manual programming: through G, M , T codes
CAD, CAMDigitizingWork offsetTool offsetReferencing
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Tooling of CNC machines
Different types of spindle tapers ISO-BT 30/ 40 /50 HSK Modular tooling Pull studs Modular fixtures Form A/ B type tooling
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HSK taper for Spindle
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Special Terminology
MRR - Material Removal RateRS 232Linear motorsInternet connectivityGrid settingMotor specificationsTaper cleaning
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CNC specifications
Capacities : like X-Y-Z strokes , table size , motor power etc.
Dimensions : floor space , Spindle to table , floor space
Performance :Spindle taper, Rapid rates, RPM etc.
Accuracies: Positioning error, repeatability etc.
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Spindle Motor Characteristics
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Testing of CNC machines
Geometrical testing Parallelism , squareness , Spindle run out etc.
Accuracy testing Repeatability , positioning accuracy , Backlash etc. JIS standard, VDI- DGQ 3441 standard etc. LASER Calibration
Performance testing MRR, Part cutting
Other tests Spindle heating, Vibration, idle cycle running etc.
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Leading makes of CNC machines
Local : LMW, BFW, HMT, AMS ,PAL , MKL etc.
Imported European: Heller, Grob, Chiron , Huller-
hulle ,Cincinnati, Bridgepart, Warner - Swaccy etc.
Japanese : Makino, Mazac, Hitachi, Yazda , Nigata , Mitsubishi, Mori-seiki etc.
Taiwanese : supermax , Feeler , Hard ford, Tong - Tai etc.
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High Speed machining
This technology is created for getting Multi-spindle productivity from single spindled machines.
Features of HSM High rapid rates : upto 100 M/min High spindle speeds : up to 25000 RPM High acceleration >1g Reduced idle times : like tool change : 1.5 sec. ,
Pallet change : 10 secs. Etc. High cutting speeds, reduced loads &
distortions.
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High Speed machining
Change in machine elements : Ceramic ball bearings , Hydro-static bearings
for spindles. Linear motors Newer controls Ball screw cooling Spindle core cooling Rotary pallet changers Armless ATC, Direct pick up. High machine rigidity High pressure coolant through Spindle
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Demo of Heller MC-16 doing helical Interpolation