CNC Machine Tools and Control
systems
CNC machining centres
• Machining centres
• Manufacturing centres
• Categories of machining centre
CNC Machining Centers
• Vertical axis machining centre
• Horizontal axis machining centre
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Vertical-Axis Machining Centres
• Generally provided with a variety of accessories to
complete the job in a single set-up
• Mostly used in tooling industry for machining dies and
moulds
CNC Machining Centers
Present day production
vertical axis CNC
machining centre
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Vertical-Axis Machining Centres
• 5-axis VMC
• Spindle head can be
swiveled in two axes
(about X or Y axis) to
CNC Machining Centers
provide A and B axis
motion
• Used for machining
sculptured surfaces to
avoid gouging and
undercutting
• Variations of VMCs
• Travelling column
• Gantry structure
• Multiple spindle
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Vertical-Axis Machining Centres
• Travelling-column machining centre
• Tool head is positioned on a cross-rail supported by two
heavy travelling columns by the side of the table
• Can take heavy cuts with very long table travels
CNC Machining Centers
• Used for very long workpieces such as aircraft structural
components
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CNC Machining Centers Vertical-Axis Machining Centres
A 5-axis CNC travelling column machining centre for aerospace machining applications (Courtesy Jobs S.p.A., Italy)
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Vertical-Axis Machining Centres
• Gantry type CNC machining centre
CNC Machining Centers
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Vertical-Axis Machining Centres
• 4-spindle CNC
machining centre
• possible to use
either 1, 2 or 4
spindles
CNC Machining Centers
simultaneously
• provided with
special work-
holding
accessories with
rotary motions
• pallet changer
allows for the
setting up of the
workpiece when
the machining
action is carried
out
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Vertical-Axis Machining Centres
• High speed machining
centre
• Placement of the ATC
close to the spindle
CNC Machining Centers
allows for a very fast
chip-to-chip time
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Horizontal-Axis Machining Centre
• HMC is sturdier than the vertical configuration
• Used for machining heavy prismatic workpieces with
large metal-removal rates
• Big tools require high capacity tool magazines
CNC Machining Centers
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Horizontal-Axis Machining Centre
• Rotary table
• Provides a fourth axis in the form of B
• Makes it feasible for the machining of all four faces of the
component facing the tool
CNC Machining Centers
• Allows for close tolerances as large part of the component
can he finished in a single set-up
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Horizontal-Axis Machining Centre
• Spindle swiveling facility in HMC
• For machining in two different planes (XY and XZ)
• Allows for a fifth face to be machined in addition to the four
faces
CNC Machining Centers
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Horizontal-Axis Machining Centre
• HMC with a 2-axis rotary table
CNC Machining Centers
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Horizontal-Axis Machining Centre
• Various planes possible by the 2-axis rotary table with
a HMC
CNC Machining Centers
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Horizontal-Axis Machining Centre
• Pallet changer
• Small table with standardized dimensions such as 500 × 500
mm, 630 × 630 mm
• Generally available in two forms, the one with precision
CNC Machining Centers
drilled holes and the other with T-slots
• Improved machine utilization time
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Horizontal-Axis Machining Centre
• Automatic pallet changer (APC)
CNC Machining Centers
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Horizontal-Axis Machining Centre
• Rotary pallet changer
• Simple arrangement
CNC Machining Centers
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Horizontal-Axis Machining Centre
• Shuttle pallet changer
• Rotary carousal with a twin pallet shuttle for interchange
between table and carousal
• For long hours of unattended operation
CNC Machining Centers
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CNC Turning Centres
• Turn mill centres (X, Z, C)
• Multiple axis turning centres (X, Z, C, Y)
• Vertical turning centres
• Twin turret turning centres
CNC Turning Centers
• Multiple spindle turning centres
• Integrated material handling
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Slant bed of a CNC turning centre
• Slant bed allows for better view of the machining
plane and easy placement of various devices
CNC Turning Centers
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Turnmill Centre (X, Z, C)
• Reduces delays in scheduling the jobs on different
machine tools, transportation, storage
• Produces components with tight tolerances
CNC Turning Centers
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Turnmill Centre (X, Z, C)
• A separate drive is provided in the turret, so that the
tools such as twist drills and end mills rotate in the
tool turret
CNC Turning Centers
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Turnmill Centres (X, Z, C)
• In addition to the X and Z directions (like normal
turning centre), driven tooling can also move in C-axis
• Different combinations of these axes allow for the
machining of various complex shapes
CNC Turning Centers
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Multiple-Axis Turning Centres
• Twin-Turret Turning Centres
• Twin turrets make it a 4-axes turning centre with both turrets
capable of moving independently in two axes each
• Machining can be done by two tools as well as having larger
tool capacity
CNC Turning Centers
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Multiple-Axis Turning Centres
• Headstock consists of two spindles and a tailstock with
two quills, arranged in parallel to each other at a fixed
distance
• Two turrets provide the tools for these two spindles
CNC Turning Centers
• High productivity
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Multiple-Axis Turning Centres
• Two spindles are maintained in line for machining a
component that requires two set-ups
• Machining of first set-up is completed in left spindle
and workpiece is transferred right spindle
CNC Turning Centers
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Multiple-Axis Turning Centres
• Y-axis machining in addition to X, Z and C axes
• Combination of a turning and machining centres
CNC Turning Centers
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CNC Turning Centers Multiple-Axis Turning Centres
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CNC Turning Centers Vertical Turning Centres
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CNC Turning Centers Vertical Turning Centres
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Vertical Turning Centres
• Pick-up turning centres
CNC Turning Centers
1 - DV-Transfer, 2 - Movable spindle, 3-Turret head on cross slide, 4-unloading
gripper on cross slide, 5-Workpiece supply, 6-Stationary turret head, 7 -
Stationary spindle, 8-Workpiece removal.
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Multi-functional Production centre EMAG VSC 400, (Courtesy
EMAG Maschinenfabrik, Germany)
Multi-functional Production centre
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Some options for the multi-functional Production centre EMAG
VSC 400, (Courtesy EMAG Maschinenfabrik, Germany)
Multi-functional Production centre
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Some options for the multi-functional production centre EMAG
VSC 400, (Courtesy EMAG Maschinenfabrik, Germany)
Multi-functional Production centre
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High-speed machine tools High speed machining
Chip load = feed rate/(no. of teeth X rpm) = f/NZ
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Chatter Recognition and Control (CRAC) system used for
optimising the metal cutting process parameters in HSM
High-speed machine tools
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Tool database of stable cutting parameters for
MAKINO A55
• Kennametal Short Series Holder with HSS end mill (b -
Ball end, f - Flat end) with allowable speed = 20000
rpm.
High-speed machine tools
• Material : Al 7075
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High-speed machine tools Specifications of High Speed Machines Vertical Axis
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Machine Control Unit
• Larger part program storage running to MB rather than
kB or single blocks in the previous controllers.
• Part program graphical proving and editing.
• Part program generation using conversational part
Machine control unit
programming methods such as FAPT TURN.
• Tool life management function, which includes larger
number of tool offset registers as well as monitoring
the life of the individual tools used.
• Background part programming methods.
• Drip feeding of part programs when they are very large
in cases such as finish machining of 3D contours of
dies and moulds.
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Machine Control Unit (Contd.)
• Enhanced part programming facilities such as
• Complex interpolations such as parabolic and helical
• Additional canned cycles (other than the drilling series G 80
to 89)
• Repetitive part programming using functions such as DO
Machine control unit
loops,
• Use of subroutines and macros
• Probes for inspection programs
• Use of parameters in part programming
• Help for operator instructions
• Special geometric calculation facilities
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Machine Control Unit (Contd.)
• Better interfaces to outside world (serial as well as parallel
communications)
• Diagnostic facilities with the possibility of direct linking
with the service centres using modems.
• Enhanced DNC functions with links to factory networks
Machine control unit
• Use of standard operating systems such as Windows 95/98
with the associated use of the controller for other
functions.
• Better shop floor control by the use of two-way linking
through the PLC with the outside world.
• Enhanced machine control such as adaptive control, lead
screw pitch error compensation, thermal compensation,
etc.
• Enhanced machine control for high speed machining by
having a look-ahead facility.
• Multiple axis machining with more axes simultaneously.
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Organisation of the modern Machine Control Unit
functions
Machine control unit
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Present generation Machine Control Unit showing the various options present
on the front panel Yamazaki Mazak Mazatrol PC Fusion CNC
Machine control unit
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Organisation of the keypad of a Machine Control Unit in
traditional lines (Yamazaki Mazatrol)
Machine control unit
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Organisation of the keypad of a Machine Control Unit with
QWERTY format as used in personal computer (Heidenhain)
Machine control unit
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Adaptive Control
• In CNC Machine Tools, Adaptive control implies that
the CNC system is responsive to adapt itself to operate
at those machining parameters that result in higher
productivity
Adaptive Control
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Adaptive Control
• In indirect adaptive control, the system performance
parameters are estimated on-line and used to
calculate the controller parameters.
• It is also called as adaptive control optimization or ACO.
• In direct adaptive control, the system performance
Adaptive Control
model is parameterized in terms of the controller
parameters that are estimated directly without
intermediate calculations involving system
performance parameter estimates.
• It is also called as adaptive control with constraints or ACC.
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Adaptive Control Optimization (ACO)
• In adaptive control optimization, the system
performance model P(PI) is parameterized with
respect to some known or unknown parameter vector
PI.
• For example, in the case of CNC machine tools, the
Adaptive Control
system performance model, PI may represent some
parameter that identifies a performance index (PI) as
follows:
MRR
PI
TWR
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Adaptive Control Adaptive Control Optimization (ACO)
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Advantages of AC systems
• to increase productivity
• to maintain high levels of workpiece precision
• to raise the level of automation by reducing operator
intervention
Adaptive Control
• to increase cutter life by reducing tool loads
• to increase workpiece accuracy and CNC machine life
by maintaining low levels of vibration
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Adaptive Control with Constraints (ACC)
• In this system the control is simplified by incorporating
certain safe limits for any of the relevant process
parameters in the form of constraints. A few examples
are:
• use the available spindle power to maximum
Adaptive Control
• limit the deflection of the cutter
• limit the cutting tool temperature
• limit the cutting force
• limit the vibration amplitude of the cutter
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Adaptive Control Adaptive Control with Constraints (ACC)
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Chip Removal
• High amount of chip generation
Support Systems
Chip removal facilities in turning and machining centres
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Work Support in Turning Centres
• To support long workpieces
• Tailstock may be fully programmable in CNC lathe
• Steady rest
Support Systems
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Chuck Jaw Changer
• For unattended operation of
a CNC turning centre
• Consists of a jaw magazine
required for a variety of jobs
arranged in a cylindrical
Support Systems
drum above the chuck
• Jaws needs to be pushed into
the slots in the drum for
replacement purpose
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Touch Trigger Probes
• A tool used for measurement
• Consists of a spherical sapphire unit connected
elastically to a rigid measuring unit
• When the probe moves along a direction and touches a
surface, the elastic connection deflects and triggers the
measuring system. The moment probe touches a
workpiece surface it is sensed and a signal is sent to the
Touch-Trigger Probes
control to stop the movement of the axes. From that the
physical position of the surface where the probe
contacts gets recorded.
• Probe shaft actually deflects since the axes over travels
due to inertia.
• Possible to use these probes in CNC machine tools for
the purpose of measurement as well as tool setting
• The CNC controller has a tool probing instruction or cycle
through which the measured position can be stored into
parametric variables.
• These parameters may be computed to evaluate the
necessary inspection function. This system not only
enhances the utility of the CNC machine tool, but also
improves the productivity by reducing the setting time
for complex jobs. by measuring the tool offsets on the
machine. etc.
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Touch-Trigger Probes Inductive Transmission
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Touch-Trigger Probes Optical Transmission
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Applications of touch trigger probes
• Datuming of the workpiece
• Workpiece dimension measurement
• Tool offset measurement
• Tool breakage monitoring
Touch-Trigger Probes
• Digitizing
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Touch-Trigger Probes Datuming of the Workpiece
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Touch-Trigger Probes Workpiece Dimension Measurement
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Workpiece Dimension Measurement
Touch-Trigger Probes
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Touch-Trigger Probes Tool Probing
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Touch-Trigger Probes Digitising
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Direct Numerical Control
• Communications
• Part program storage
• Ancillary functions
DNC
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Communications
• Functions wherein the communication takes place
between the CNC machine tool and the DNC computer
• Sending part programs to the CNC machine tool (part-
program downloading)
• Receiving the part-programs from the CNC machme tool after
it has been edited or prepared on the machine control unit
(part-program uploading)
DNC
• Provide a remote program buffer. Program will be fed in parts
into the controller, termed as drip feed
• Tool offsets to be used in the current program can be down
loaded into the MCU
• CNC machine tool can be operated directly from the DNC
computer
• To bring the CNC machine tool to its datum position remotely
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Part-Program Storage
• Large number of functions that can he carried out by the DNC
computer in terms of the part program manipulation that can not be
done inside the MCU
• Possible to store a large number of part programs (low cost)
• To input, edit. copy and delete programs at the DNC computer.
• Familiar look and feel of Windows operating system
• One of the more common editing function done on the part programs is the
removal and renumbering of block numbers, which can be easily done in the
DNC computers.
• Same job is to be made on different machine tools
• Calculation facility for estimating the machining times of the various part
DNC
programs.
• It can be used as a part program preparation system as well
• Geometric help
• Calculator help
• Controller (G-codes and M-codes) and machine tool function help
• It can manage the tool offsets
• Database for calculating the feeds and speeds for the various tools
• Complete tool management functions can also be embedded into the DNC
program
• Carry out the tool life management function as described earlier in a DNC
program
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DNC Ancillary Functions
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Ancillary Functions
• Integrating with the CAD/CAM system or the part programming
system for the purpose of direct transfer of the part programs
into the disk storage of the DNC computer.
• Possibility of integrating with the shop floor control system for
proper integration purpose, which is discussed in greater detail
later in the form of enhanced DNC.
• Getting the data from the machine control unit, the information
about the health of the machine in the form of sensor signals or
diagnostic messages, which can be used for
predictive/preventive maintenance purpose (Fig 20 6).
DNC
• Getting the data from the machine control unit, information
about the parts that are completed in term; of part numbers,
quantity, etc.
• If probes are used in a given program, then the metrological
data in terms of the dimensional acceptance can also be
uploaded from the MCU.
• Also getting the data from the machine control unit, the
information about the tools and the lives that were used up for
proper tool management system.
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DNC Typical Installations
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Requirements
• It is a general practice to use the part program number to classify the program. For this purpose a
standard procedure needs to be followed to classify the program in terms of the machine tool on
which it is to be used, the tools required, etc.
• Each of the part programs should be provided with a header which can provide all the my information
in terms of the part number, drawings, cutting tools, fixtures. machine tools, revision data, etc.
• The operator instructions should be provided in the pan program where necessary. The use of
comments (using parentheses) can be made use for this purpose.
• The basic instructions for communication between the MCU through the operator and the DNC
computer should be simple enough so that they can be handled easily by the shop personnel who may
not be very well versed with computers.
• At the time of planning the DNC installation care has to be taken to see that the requirements of the
individual machine tools for better utilisation of the resources are met.
• Similarly the cabling when planned should be such that in case of future expansion it should be
DNC
possible to add more machine tools or change the DNC requirements.
• The use of DNC involves additional cost in terms of the network, computer, terminals and the
software. Therefore, it is necessary to see when DNC will be useful. The use of DNC can be justified
under the following conditions.
• When the interconnected CNC machines are large in number. With smaller number of machine tools it
is easier to handle the machines directly unless the drip fading becomes necessary such a in tool
moms.
• When the part program sizes are very large and can not be held in the part program memory of the
MCU.
• Part program variety is large and batch sizes are small. In such cases the machine tools need to be fed
by a large number of part programs in a day which can easily justify the use of DNC.
• Very frequent changes in program designs require that programmers spend more time at the part
programming terminal which is easier than the MCU.
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DNC Enhanced DNC
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Enhanced DNC
• The area manager will send the following information
to the work preparation area.
• Work orders, the part numbers of the planned jobs with
quantity.
• Fixturing information that gives the details of fixtures used as
well as instructions for fixturing.
• Palletization data in terms of the pallet numbers to be used
DNC
for the individual parts along with the pallet offsets if any.
• Similarly the area manager will send the following
information to the tool crib.
• Tool requirements in terms of the actual tools that are
required for the jobs that are scheduled for the day.
• The tool setting up instructions in terms of the type of
adopter, tool holding method to be used, etc.
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DNC Advantages of DNC
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Advantages of DNC
• Helps in the elimination of the local input device such as
the tape reader. This helps in the entry of error free part
programs.
• The large storage capacity of the DNC computer makes it
possible to store several part programs.
• If the same job is to be made on different machine tools
then separate part program entry into the individual
controllers is eliminated
• DNC software helps in managing the part programs in a
DNC
better and easier way.
• Because of management function software, the shop floor
running of machines, inventories of tooling, etc. can be
handled much better.
• DNC provides the starting point for factory integration.
With the experience gained, it is possible to extend the
integration into the various aspects of manufacturing
ultimately leading to CIM
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Bibliography
• P.N. Rao, "CAD/CAM Principles and Applications”, 3rd
Edition, Tata McGraw Hill, New Delhi, 2010
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