Introduction to CNC

EM-406 : Mfg Process, Tool & Auto NUST : College of EME Mechatronics Department

What is CNC?
Computer Numerical Control
The process of manufacturing machined parts using a computerized controller to command motors which drive each machine axis.

History of CNC
1947 John Parsons, Parsons Corporation, Michigan Developed a control system that directed a spindle to many points in succession Servomechanism Laboratory of Massachusetts Institute of Technology (MIT) Added computer to Parsons system Cincinnati Milicron Hydro-Tel Vertical Spindle Milling Machine First three-axis numerically controlled, tape-fed machine tool

1951

1952

History of CNC
(Continued) 1954 1957 NC was announced to public First production NC machines were delivered and installed NC machine tools commonly available

1960

A lot of the initial funding for the development of NC machine tools came from the United States Government.

Why CNC machine tools?

Increase production throughput Improve the quality and accuracy of manufactured parts Stabilize manufacturing costs Manufacture complex or otherwise impossible jobs 2D and 3D contours.

Integration with Mathematics

x Complex curves and surfaces can be described mathematically

Integration with Mathematics

(Continued)

Vf feed rate along curve

Tangent Or Slope

Vf

x
Vx = Vy = x x 2 + y 2 x x + y
2 2

Curve to be followed Complex curves can be followed by breaking the curve into a series of small straight lines and using linear interpolation.

Vf Vf

Advantages of CNC
Flexibility of operation is improved, as is the ability to produce complex shapes with good dimensional accuracy, repeatability, reduced scrap loss, and high production rates, productivity, and product quality. Tooling costs are reduced, since templates and other fixtures are not required. Machine adjustments are easy to make with microcomputers and digital readouts. More operations can be performed with each setup, and less lead time for setup and machining is required compared to conventional methods. Design changes are facilitated, and inventory is reduced.

Advantages of CNC
(Continued) Programs can be prepared rapidly and can be recalled at any time utilizing microprocessors. Less paperwork is involved. Faster prototype production is possible. Required operator skill is less than that for a qualified machinist, and the operator has more time to attend to other tasks in the work area.

Limitations of CNC
Relatively high initial cost of the equipment. The need and cost for programming and computer time. Special maintenance with trained personnel. High preventative maintenance since breakdowns are costly.

Anatomy of a CNC Machine

(3-Axis Vertical Mill)

Chang, Figure 9.8

Anatomy of a CNC Machine

(Horzontal Drilling Machine)

Operational Features of CNC Machine A CNC control system

includes a velocity loop within an axis drive system and a position loop external to the axis drive system.

Degarmo, Figure 29-10.

Recirculating Ball Screws

A - Ball Screw B Linear Bearings

Microcomputer Controlled X-Y Table

Recirculating Ball Screws

(Purpose) Transform rotational motion of the motor into translational motion of the nut attached to the machine table. Advantages of Recirculating Ball Screws
Pneumatic Ball ACME Fluid Belt, Rack & Cam Screws Screws Power Chain Pinion Followers Cylinders

Inexpensive Low Power Use Low Maintenance High Accuracy High Repeatability High Efficiency High Load Capacity Compact Size

Recirculating Ball Screws

(Continued)

Recirculating Ball Screws are generally preloaded to give zero backlash.

Recirculating Ball Screws

(Rotational to Linear Velocity Conversion) Lead distance the nut moves parallel to the screw axis when the screw is given one revolution.

Vf Feed Velocity
Vf n= l in => min = rev min in rev
D

[ [

] [ ]

Recirculating Ball Screws

(Positioning Resolution)

1 u = l 360 u axial displacement [in] l ball screw lead [in/rev] rotation angle [degrees] 1 converts revolutions 360 to degrees rev degrees

Recirculating Ball Screws

(Positioning Resolution Example)

l = 0.125 in = 15 degrees u = l 1

( 360)

Example A ball screw has a lead of 0.125 in/rev. What is the distance that the nut will travel if the screw is turned 15 degrees?

u = (0.125 in ) (15 degrees) rev 360 degrees = 0.0052 in

Recirculating Ball Screws

(Lead Screw Resolution)

l = 0.125 in u =l 1 360

The positioning resolution of a ball screw is directly proportional to the smallest angle that the motor can turn.

u = (0.125 in/rev ) rev 360 degrees u = 0.00035 in/degree

Stepping Motors

A stepping motor provides open-loop, digital control of the position of a workpiece in a numerical control machine. The drive unit receives a direction input (cw or ccw) and pulse inputs. For each pulse it receives, the drive unit manipulates the motor voltage and current, causing the motor shaft to rotate by a fixed angle (one step). The lead screw converts the rotary motion of the motor shaft into linear motion of the workpiece. Figure 10.15

Stepping Motors
(Full Step Operation)
Hybrid stepping motors have a variable-reluctance rotor with a permanent magnet in its magnetic path, usually in the rotor. The term hybrid refers to the use of two sources of magnetic field, the stator windings and the permanent magnet. Hybrid stepping motors are used when small step angles are required. The 1.8 degree stepping motor is the predominant standard for industrial automation.
Bateson, 386.

200 step hybrid motor cross section

Figure 1.12

Stepping Motors
(Angular Positioning)

360 degrees = N steps N = 200 360 deg = = 1.8 deg/step 200 steps

Stepping Motors
(Lead Screw Positioning Resolution)

u = l 1

( 360)

360 N

Example

l u = N
Increased resolution can be obtained using a technique known as microstepping.

l = 0.125 in/rev N = 200 steps/rev 0.125 in/rev u = 200steps/rev = 0.000625 in/step

Stepping Motors
(Microstepping Operation)

The rotor can be positioned in partial steps by simultaneously controlling the currents supplied to the stator phase windings. Microstep sizes of 1/10, 1/16, 1/32, and 1/125 of a full step are most commonly used.

360 N*m

m=number of microsteps per full step

Stepping Motors
(Lead Screw Positioning Resolution)

u = l 1

( 360)

360 = N*m

Example
m = 32 microsteps/steps

l u = Nm

l = 0.125 in/rev N = 200 steps/rev 0.125 u = 200 32 = 0.0000195 in/microstep

Summary
The positioning resolution of a ball screw drive mechanism is directly proportional to the smallest angle that the motor can turn. The smallest angle is controlled by the motor step size. Microsteps can be used to decrease the motor step size. CNC machines typically have resolutions of 0.0001 in or better.

Assignment
A CNC mill has 0.125 inch lead recirculating ball screws that are driven by a 200 step hybrid step step motor with 125 microsteps per step. What is the position resolution of the machine? How many microsteps will the motor have to undergo in order to move the mill table attached to the ball screw 1.0 in?