Milling Machines - Lect. 1 Introduction

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11/29/2020

Computer Numerical Control (CNC)


DR. ABDALLAH ABDELKAWY
ASSISTANT PROFESSOR
MECHANICAL DESIGN AND PRODUCTION DEPARTMENT,
FACULTY OF ENGINEERING, CAIRO UNIVERSITY

Numerical control (NC)

❖ NC has been used in industry for more than 40 years.


❖ NC is a method of automatically operating a manufacturing machine based
on a code of letters, numbers, and special characters.
❖ Program is complete set of coded instructions for executing an operation, It
is translated into corresponding electrical signals for input to motors that run
the machine.
❖ NC systems offer some advantages over manual production methods:
▪ Better control of tool motions under optimum cutting conditions.
▪ Improved part quality and repeatability.
▪ Reduced tooling costs, tool wear, and job setup time.
▪ Reduced time to manufacture parts.
▪ Reduced scrap.
▪ Better production planning

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Numerical control (NC)

❖ NC systems have been composed of the following components:


▪ Tape punch: converts written instructions into a corresponding hole pattern. The
hole pattern is punched into tape which is passed through the tape punch.
▪ Tape reader: reads the hole pattern on the tape and converts the pattern to a
corresponding electrical signal code.
▪ Controller: receives the electrical signal code from the tape reader and
subsequently causes the NC machine to respond.
▪ NC machine: responds to programmed signals from the controller and executes
the required motions to manufacture a part

Numerical control (NC)

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Components found in CNC systems

❖ Machine control unit: generates, stores, and processes CNC programs,


contains the motion controller in the form of software program.
❖ NC machine: responds to programmed signals from the MCU and
manufactures the part

CNC input and storage media

❖ A CNC machine is
a NC machine
with the added
feature of an
onboard computer
or the Machine
Control Unit
(MCU).
❖ They can be
played back,
edited, and
processed.

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Advantages of CNC compared with NC

❖ Reduction in the hardware necessary to add a machine function.


❖ CNC program can be written, stored, and executed directly.
❖ Any portion of an entered CNC program can be played back and edited.
❖ Many different CNC programs can be stored in the MCU.
❖ Several CNC machines can be linked together to a main computer. Programs
written via the main computer can be downloaded to any CNC machine in the
network (Direct Numerical Control or DNC).
❖ Several DNC systems can also be networked to form a large distributive
numerical control system.
❖ The CNC program can be input from flash or floppy disks or downloaded
from local area networks.

Advantages of CNC compared with NC

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Financial rewards of CNC investment

❖ Savings in direct labor.


❖ Savings in operator training expenses.
❖ Savings in shop supervisory costs.
❖ Savings due to tighter, more predictable production scheduling.
❖ Savings in real estate, since fewer CNC machines are needed.
❖ Savings in power consumption, due to production with a min motor idle time.
❖ Savings from improved cost estimation and pricing.
❖ Elimination of construction of precision jigs and special fixtures.
❖ Reduced inspection time due to the CNC machine’s ability to produce parts
with superior accuracy and repeatability.

MACHINING CENTERS

❖ Machining centers are the latest development in CNC technology. They are
equipped with:
▪ automatic tool changers capable of
changing 90 or more tools.
▪ Many are also fitted with movable
rectangular worktables called pallets
which are automatically load and unload
workpieces.
❖ At a single setup, machining centers can
perform such operations as milling,
drilling, tapping, boring, counterboring,
and so on.

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The Positional Control Modes

❖ Point-to-Point Controlled Machines


▪ Used in processes: drill and tap.
▪ The tool moves to a point to execute the
process without continuous contact
▪ Controller is Less sophisticated, fast response,
▪ Motion is produced through needle roller, linear
bearing types, or indeed using air bearings.
❖ Continuous Path Control
▪ Used for processes: milling turning where the
tool is contacted continuously with the
workpiece.
▪ The control path must have an interpolator, so
that it can calculate continuous path positions
until the target point is reached.

Tool location via cartesian coordination

❖ The CNC tool location is controlled by XYZ coordinates, the point of intersection
is the origin. Y
❖ Indicate the location of points
▪ A (3,-2)
▪ B (1.4)
▪ C (-2,-3)
▪ D(-3,4)
X

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Machine Tool Control Systems: Open-loop System

❖ Open-loop systems do not use any form of feedback control for the slide
movement or velocity.
❖ The motor will simply drive the slideway to the desired position by means of a
pulse count electrically generated.
❖ A command signal is sent to the stepper motor and it assumes that when the
required count of pulses has occurred, the machine slide has moved a
certain distance.
❖ This method of control is relatively cheap to
construct; however its errors are accumulated.
❖ This system uses lead screw which generate
friction and backslash which can cause
positioning error.

Closed loop systems

❖ Servo motors are used in this system, motors types are AC, DC and hydraulic
❖ In servo motors, the speed is variable depends on the amount of input AC or
DC current or amount of fluid in hydraulic
❖ Tachometer is mounted on the backside to measure and feed back the angular
velocity.
❖ This feedback is sent to the Motor Derive Unit which compares the motion with
and tachometer feedback and correct the error.
❖ Ball lead screw are used to reduce the friction and backlash
❖ A device called encoder (resolver) monitors the distance by the table and
spindle and sends information to MCU, which adjust its signal to the table or
spindle

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The Designation of Machine Tool Axes

❖ CNC machine axes are X, Y and Z


using upper case letters. The direction
of movement along each axis is
denoted by a plus (+) or minus (-) sign
❖ Rotational notation around each linear
axis and this is specified by A, B and C
in upper case.
❖ The figure shows the standard CNC
axis and directions according to the
right hand rule

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The Designation of Machine Tool Axes

❖ The spindle primary


movement in Z-axis,
movement into the
workpiece is the negative
(-Z) and movement away
from the workpiece is the
positive (+Z)
❖ In most of milling machine,
movement in X-axis is the
largest and in Y-axis is the
smallest

Tool position modes

❖ Incremental: is the operating mode in which the new tool position is defined
relative to the last tool position
❖ Absolute: the machine determines the new tool position from fixed home or
specified origin (0,0)
❖ Both incremental and absolute can be used in the same program by using
the code for changing
Tool Incremental Absolute
position X Y X Y
A 0.5 0.5 0.5 0.5
B 0.5 0 1 0.5
C 0.75 0.25 1.75 0.75

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Feed direction for milling operation

❖ Climb (down) milling: the tool makes the maximum thickness at the start of
the cut and the minimum at the end.
▪ The tool pushes down the workpiece so less clamping needed.
▪ Chips are pushed behind and away from the cutter which reduce the tool wear.
▪ It is recommended for machining thin parts that hard to clamp
▪ High impact loads causes excessive tool wear
❖ conventional (up) milling: no chip
thickness at start and max at the end
▪ Chips are pushed up in front of the cutting
tool
▪ More fixture are required to hold-down the
workpiece
▪ Is recommended for finishing operations

Feed direction for milling operation

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Thank you

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