Introduction to

Machine Tool Automation

What is common in Manufacture of Automobiles?
 What is common in
Manufacture of Plastic products?

5th JAGRUTI-IMTMA YOUTH

PROGRAM
 What is common in
Manufacture of Computers?
 What is common in
Manufacture of Aircrafts?
 What is common in
Manufacture of Rockets and satellites?
 What is common in
Manufacture of windmills?
 What is common in
Manufacture of white goods?
 What is common in
Manufacture of Health care products?

5th JAGRUTI-IMTMA YOUTH

PROGRAM
It is Machine tools and Machining
that is common in
Manufacturing of any product
• Lathe Machine
• Lathe Machine
• Vertical Milling Machine
• Horizontal Milling Machine
History of CNC

1949
US Air Force asks MIT to develop a "numerically controlled"
machine.

1952
Prototype NC machine demonstrated (punched tape input)

1980-
CNC machines (computer used to link directly to controller)

1990-
DNC: external computer “drip feeds” control programmer
to machine tool controller
Today, computer numerical control (CNC) machines
are found almost everywhere, from small job shops
to large companies.
NUMERICALLY CONTROLLED M/C TOOLS

An NC machine tool is functionally the same as a

conventional machine tool. The technological
capabilities NC machine tools in terms of machining
are no different from those of conventional ones. The
difference is in the way in which the various machine
functions and slide movements are controlled.
What is Numerical Control (NC) Machine ?

• The electronic industries association (EIA) defined

NC as
• “A system in which actions are controlled by the direct
insertion of numerical data at some point. The system
must automatically interpret at least some portion of
this data.”

Why It Is Called As NC ?
•Numerical control (NC) is a form of flexible (program
mable) automation in which the process is controlled
by numbers, letters, and symbols.
Basic Components

• An NC system consists of the machine tools, the part-

program, and the machine control unit (MCU).
Definition of CNC

• In CNC (Computer Numerical Control), the instructions are stored as

a program in a dedicated micro-computer attached to the machine.

• The computer will also handle much of the control logic of the
machine, making it more adaptable than earlier hard-wired
controllers.

• The complete part programme to produce a component is input and

stored in the computer memory and the information for each
operation is fed to the machine tools.

• The program can be stored and used in future

Functions of a CNC machine

The basic function of any CNC system is to provide

automatic positioning of one or more machine slides
independently or simultaneously from one point to
another point either through the shortest path or pre-
determined path.

Also it has to control certain machine functions like

spindle on / off, coolant on / off, tool change, pallet
change, etc., and the machining parameters like cutting
speed, feed, rpm, etc.,
Advantages of CNC machines

Reduced non productive time

 Reduced need for inspection because of greater repeatability,

 Less time spent on set up changes because a single machine is capable of
performing a variety of operations
 Reduced part loading / unloading time because of simple fixturing
 Less movement time between machines because of fewer setup changes
 Less tool changing time because of auto tool changing

Reduced tooling .
 Use of form tools is minimal on CNC machines.
Advantages of CNC machines

Reduced manufacturing lead time.

 Because average setting time per part is lower and there are fewer setups,
the lead time to start manufacturing a new part is reduced by 25% to 40%
Greater manufacturing flexibility.
 It is less difficult to adapt to design changes , alterations of production
schedule, change over in jobs due to rush orders etc .
Reduced Inventory.
 The amount of inprocess inventory carried is reduced owing to fewer
setups and shorter lead times .
Advantages of CNC machines

Reduced floor space requirements.

 Since one CNC machine does the job of several conventional machines, the
amount of floor space required is reduced.
Reduced operator skill level.
Disadvantages of CNC machines

Higher initial investments.

 CNC machines cost more than their conventional counter parts ( 3 to 5 times
more). High machine utilisation is essential in order to get reasonable returns
on the investment. Hence CNC machines must work 2 to 3 shifts per day to
achieve the utilisation.
Higher maintenance costs.
 The maintenance cost of CNC machines is on an average 150% of that for
conventional machines. The level of skill required in the maintenance
personnel is also very high.
 CNC Applications and Machines

Based upon the industrial usage, the machines controlled by

CNC can be classified into the following eight categories:
1. CNC machining centers
2. CNC turning centers
3. CNC EDM
4. CNC grinding machines
5. CNC cutting machines (laser, plasma, electron, or flame)
6. CNC fabrication machines (sheet metal punch press, bending
machine, or press brake)
7. CNC welding machines
8. CNC coordinate measuring machines
CNC TURNING

2 axes CNC Lathe / CNC Turning centre

CNC MILLING
CNC LASER CUTTING
CNC PLASMA CUTTING
CNC PRESS
CNC RAPID PROTOTYPING
 SAMPLE PRODUCTS
OF
CNC MANUFACTURING

34
AUTOMOTIVE INDUSTRY

Engine Block

35
AUTOMOTIVE INDUSTRY(Cont’d)

Different Products

36
AEROSPACE INDUSTRY
Aircraft Turbine Machined by
5-Axis CNC Milling Machine

37
CNC MOLD MAKING

38
ELECTRONIC INDUSTRY

39
RAPID PROTOTYPING PRODUCTS

40
CNC TURNING

 2 axes CNC Lathe / CNC Turning centre

 3 axes CNC Turn Mill centre
 4 axes CNC Mill turn centre
 6 axes CNC Mill turn centre
 9 axes CNC Mill turn centre
CNC TURNING

2 axes CNC Lathe / CNC Turning centre

3 axes CNC Turn Mill centre
CNC Mill Turn Centres
CNC Mill Turn centres
Typical parts in Mill turn centres
CNC Machining Centres
CNC Machining Centres

• 3 axes VMC / HMC

• New folder\XSM400 - aluminium pet bottle mold_1.mpg
• New folder\XSM400 - aluminium pet bottle mold_2.mpg
• New folder\XSM400 - aluminium pet bottle mold_3.mpg

• 4 axes VMC / HMC

• 5 axes VMC
CNC Multi tasking machines
• Integration of Turning and Milling technologies
Mechanical elements of CNC m/cs

• Machine structure • Tool turret

• Slideways • Hydraulic system
• Spindle • Lubrication system
• Feed system • Coolant system
 SERVO FEED MOTOR TURRET BALL SCREW
BALL SCREW
CROSS SLIDE

TAILSTOCK

SLIDEWAY

SERVO FEED CROSS SLIDE CARRIER

MOTOR
Machine
Structure
SLIDE WAY BED
SPINDLE DRIVE MOTOR BASE
Machine spindle

 Spindle is the heart of the machine

 Depending on the application & type of the machine it
may hold the tool or the component and provides the
necessary rotation
Machine spindle

𝑁∗ 𝑇
Spindle Power P =
9750
Where, Power P = KW
Torque T = Nm
Speed N = RPM

 The input device to the spindle is provided by a spindle

motor through a gear, or pulley or coupling.

 In high speed spindles the built in motor with the spindle

as the rotor shaft is used
Machine spindle
Feed Drive
Ball screw/ ball bearing screw/ recirculating
ballscrew Mechanism

 The flanged nut is attached to the

moving part of CNC machine tool.
As the screw rotates, the nut
translates the moving part along
the guide ways.
Ball screw/ ball bearing screw/ recirculating
ballscrew Mechanism
Ball screw/ ball bearing screw/ recirculating
ballscrew Mechanism
Linear Motion Guideways
Linear Motion Guideways
Ball screw/ ball bearing screw/ recirculating ballscrew Mechanism
Use of Stepping Motors in Slide Movement

 The slides and spindle of the CNC machine are driven by

stepper motors.

 STEPPERMOTOR–A digital signal is sent from the controller to

the motor in the form of pulses, which will cause the motor to
rotate through a specified angle, which causes the slide to move
by the required distance.
Stepper Motor
Permanent Magnet Stepper Motor
Variable Reluctance Stepper Motor
Hybrid Stepper Motor
Hybrid Stepper Motor
Hybrid Stepper Motor
Servo Motor
Servo Motor
Servo Motor
Servo Motor
Encoders

• Rotary encoders.
• convert a mechanical input into
electrical signals
• which can be processed by
counters, tachometers,
programmable logic controllers
and industrial PCs..
• are used as sensors for angle,
position, speed and
acceleration.
• Most of the Proximity sensors
are active in design.
Basic Construction
Basic types

• Rotary encoders are manufactured in two basic

forms:

• the absolute encoder where a unique digital word

corresponds to each rotational position of the shaft,

• the incremental encoder, which produces digital pulses

as the shaft rotates, allowing measurement of relative
position of shaft. Most rotary encoders are composed of
a glass or plastic slotted disk.
Absolute Encoder

• Digital absolute encoders produce a unique digital

code for each distinct angle of the shaft

• Singleturn
• Multiturn
Working Principle - Absolute
Incremental Encoder

• The incremental encoder, sometimes called a relative

encoder, is simpler in design than the absolute
encoder.
• It consists of two tracks and two sensors whose
outputs are called channels A and B.
• The signals from the two channels are a 1/4 cycle out
of phase with each other and are known as
quadrature signals.
• Often a third output channel, called INDEX, yields one
pulse per revolution, which is useful in counting full
revolutions.
Incremental Encoder
Working Principle
Automation in CNC Machining

• Machine Tending by Robots

• Unattended machining
• Reduced cycle time

Haas SL-20 With Staubli Tx60L.mp4 Robotic Machine Tending_(360p).flv

Automation using Robots
Automation using Robots

 Robot is a machine, Which can replace human beings

as regards to physical work.

 A manipulator (or an industrial robot) is composed of a

series of links connected to each other via joints. Each
joint usually has an actuator (a motor for eg.)
connected to it.

 These actuators are used to cause relative motion

between successive links. One end of the manipulator
is usually connected to a stable base and the other end
is used to deploy a tool.
Automation using Robots
How 6 axis Robot works
Thank You