CNC MACHINES AND AUTOMATION

PROBLEMS IN CNC MACHINE

IIMT Greater Noida, UP

Vishnu Kumar Singh

Mechanical Department
Unit - 5
➢Introduction
➢Different Types of Machine Maintenance
➢System and Subsystems of CNC Machine
➢Functions of Mechanical systems
➢Best Maintenance Practices
➢Causes For The Failure Of Electronics Systems In The Machine Tools
➢Precautions to be Observed
➢Problems in Mechanical components
➢Possible defects in Guideways
➢Hydraulic systems during troubleshooting
➢Checking of Pneumatic system
➢Common Faults and Remedies
Introduction
➢A CNC machine consist of a no of electrical, mechanical ,pneumatic, hydraulic and electronic
components.
➢The person operating a CNC machine should know the common problems in these
components.

Different types of Machine Maintenance

A CNC machine consist of a no of electrical, mechanical ,pneumatic, hydraulic and electronic
components.
The person operating a CNC machine should know the common problems in these components.
1 .CORRECTIVE MAINTENANCE:-
Maintenance performed, after the occurrence of a failure, to restore the machine tool to its
original condition, to the extent possible.
2. PREVENTIVE MAINTENANCE:-
Maintenance preformed to retain the machine in its original condition, to the extent possible, by
providing systematic inspection, periodical checking servicing, detection and prevention of
failure likely to occur.
3. BACKLOG MAINTENANCE:-
Maintenance that is necessary to prevent the deterioration in the performance or functioning of
the machine by which has not been carried out. Accordingly, backlog maintenance has a higher
priority than deferred maintenance. The maintenance practices to be deferred and which
comes under backlog list will have be reviewed annually and documented.

4. DEFERRED MAINTENANCE:-
Maintenance that is due to be carried out in the current financial year but which could not be
carried out due to shortage of funds or unavailability of spare parts. Such maintenance should
be added to the backlog Maintenance programme awaiting attention.

5. TPM (TOTAL PRODUCTIVE MAINTENANCE):-

Maintenance method integrates production function of the equipment and the maintenance
function required. The maintenance of the machine and its schedule is considered and integral
part of the production schedule and the machine tools is maintained with the least disturbance
to the production activity. Such maintenance schedules are well planned and leads to overall
productivity of the plant and the equipment.
System And Sub Systems Of CNC Machines
Various functions of CNC machines are executed with the help of the following systems and sub
systems.
1. Mechanical systems.
2. Electronic Systems (CNC and drives)
3. Work holding systems.
4. Tool clamping systems.
5. Lubrication systems.
6. Coolant systems.
7. Hydraulic systems.
8. Pneumatic systems
Functions Of Mechanical Systems.
Primary function of the mechanical systems in CNC machines are similar to conventional
machines.
CNC Lathe machine consists of the following sub systems.
1. Headstock.
2. Axis assembly
3. Tool post
4. Tailstock
Best Maintenance Practices
Following are some of the best maintenance practices to be adhered to while carrying out maintenance of
CNC machines.
1. Execution of maintenance activities as per TPM (Total Productive Maintenance) Chart.
2. “Solving” the “Cause” of the problem and not the “Symptom”
3. Use of “Right” tools, fixtures, equipment and spares.
4. Understanding the accuracy class of bearing, grade of oil and their correct specifications.
5. Understanding the working of the machine tools by studying the manuals, and circle diagram supplied by
the machine manufacturers.
6. Use of flow chart/cause and defect diagrams and the breakdown history for quick repair and maintenance
/trouble shooting.
7. As far as possible carryout reassembly in a clean room.
8. When the electrical cabinet is in open position do not allow the machine in the running condition.
9. Follow proper procedure and communication protocols when reporting service/maintenance problems to
the service staff of the CNC machine tool manufacturing company.
Causes For The Failure Of Electronics Systems
In The Machine Tools.
1. Dust failing on the electronic components.
2. Corrosive fumes (coming from coolant interacting with
the hot chips)
3. Oil/Coolant dripping through cables.
4. Condensation of moisture.
5. Insects.
6. Poor Ventilation.
7. Improper power supply.
8. Improper earthing.
9. Loose connections and bare control wirings.
Precaution To Be Observed
1. Ensure secure panel and pendant sealing.
2. Maintain gasket in the good condition. (A gasket is a mechanical seal which fills the space
between two or more mating surfaces, generally to prevent leakage from or into the joined
objects)
3. Ensure proper orientation and direction of the exhaust fans.
4. Ensure proper sealing at the entry of the cables.
5. Maintain right temperature of the A/C systems.
6. Ensure that no insects and pests come near the machine tool.
7. Ensure periodic cleaning of the filters of A/C Systems.
8. Ensure periodic tightening of cable connections and avoiding bare wires.
9. Ensure Proper Power Supply.
10. Ensure proper rating/cross section of cables as per the recommendation by the manufacturer.
11. Do not mix, neutral and earth lines/wires.
12. Ensure Proper Earthing Of Points indicated by machine tool manufacturer.
(a) Do not loop earth wire between the electronic components.
(b) Ensure proper cross section of the earth wire at all the points.
(c) Ensure the earth resistance at the incoming terminals as less 1 Ohm.
(d) Do not loop earthing between different machine.
Problems In Mechanical Components

The mechanical component of CNC consist of:

(a) BED- As CNC operate on higher rpm forces
develop due to rapid acceleration tend to bend or
deform the bed leading to error. This can also be
due to heating effect.
To avoid these-
1. Thermally symmetrical designs are made
2. air conditioning of room is done
(b) TAIL / HEAD STOCK
(c) MACHINE STRUCTURE
Load carrying and supporting member of the
machine
Subjected to static and dynamic loads.
Structure should not deform or vibrate under load
beyond limit.

(d) GUIDEWAYS
Control the direction of carriage or table on which
work piece is held.
Possible Defects In Guideways
1. Improper flow of lubrication oil.
2. Wipers damaged.
3. Chips or dust entry into guideways.
4. Wearing out of jibs.
5. Wrong selection of lubrication oil.
6. Bellows with cracked openings.
The wear and tear of guideways causes misalignment and
consequently error in finish and accuracy.
CNC machine uses anti friction guideways to
(i) Reduce friction
(ii) Improve smoothness of movement
(iii) Reduce amount of wear
(iv) Reduce heat generated
(e) BALL SCREWS
A ball screw is a mechanical linear actuator that translates rotational motion to linear motion
with little friction. As well as being able to apply or withstand high thrust loads, they can do so
with minimum internal friction. They are made to close tolerances and are therefore suitable
for use in situations in which high precision is necessary. The ball assembly acts as the nut
while the threaded shaft is the screw.
(f) COUPLING/ PULLEY
Coupling are used for transmitting torque between two shafts even when
they are misaligned. For hobbyist CNCs they are used to connect the Stepper
Motor axis and the leadscrew/ball screw.
(g) AUTOMATIC TOOL CHANGER
An Automatic tool changer or ATC is used in computerized numerical control(CNC) machine
tools to improve the production and tool carrying capacity of the machine. ATC changes the tool
very quickly, reducing the non-productive time. Generally, it is used to improve the capacity of the
machine to work with a number of tools. It is also used to change worn out or broken tools. It is
one more step towards complete automation.
(h) AUTOMATIC PALLET CHANGER
A pallet is a movable & interchangeable part of a machine tool which helps to transport raw or
finished parts from the machine in order reduce downtime for part loading/unloading.

NOISE DURING SPINDLE RUNNING

Causes are:-
1. Misalignment of spindle belt.
2. Belt rubbing with the mounting bracket of the motor
3. Failure or seizure of spindle bearing.
4. Bolts of motors mounting and bolts of brackets are loose.
5. Bell crank lever screw rubbing with spindle.
Hydraulic Systems Trouble Shooting
1. Pump not Delivering -

2. System not developing pressure -

3. Pump making noise -

Checking Of Pneumatic System

1. Check for the proper air pressure in the regulator.
2. Check for proper air blast during tool changing.
3. Check for the moisture in pneumatic line (moisture in pneumatic lines should be avoided)
4. Air leakage (this may be due to clogging of filters)
Common Faults and Remedies
1. Sensors
If there are faults in a measurement system then the sensor might be at fault. A simple test is to
substitute the sensor with new one and to check the results. It is also possible to check the
voltage and current.

2. Switches and Relays

Dirt and particles of waste material between switch contacts is a common source of incorrect
functioning of mechanical switches.
3. Motor
Maintenance of both D.C and A.C. motors involve correct lubrication. With D.C. motors, the brushes
wear and can require changing.
Setting of new bushes need to be in accordance with the manufacturer’s specification.
4. Hydraulic and pneumatic systems
A common cause of faults with Hydraulic and pneumatic systems is dirt. Small particles of dirt can
damage seals, block orifices cause valve spools to jam.
Thus filter should be regularly checked and cleaned. Leaks in hoses, pipes and fittings are common
faults.

Video for Reference -

https://www.youtube.com/watch?v=ZpzQTDyEU4M