Introduction to CNC Machine

&
Design of CNC Lathe

By:
HV RajaShekara
Sr. Director - Design Institute,
IMTMA
 What is Machine Design?

Creation of new and better machines or

Improving existing ones

So that it is economical in the cost of production and Ease

operation.
 MACHINE

AND

MACHINE TOOL
 MACHINE
Combination of mechanisms and other components that
transforms load or motion for a specific functions with the help
of energy. CONVEYOR

RICE MIXER
MILLING
WATCH

PACKING
M/C EARTH MOVING
CRANE WASHING M/C

SEWING M/C
FORK LIFT

PACKING
M/C
 MACHINE TOOL

It is a power driven machine which has various mechanisms and

components that produce a desired shape by metal working
(cutting or forming) to make another machine OR useful
product.
CNC MACHINING
LATHE CENTER

CNC LATHE

DRILLING M/C
MECHANICAL
PRESS

ROLLING
MACHINE

CNC BENDING
M/C
MACHINE TOOL CLASSIFICATION

GENERAL PURPOSE
MACHINE

AND

SPECIAL PURPOSE
MACHINE
GENERAL PURPOSE MACHINES, GPM’s
It’s a machine tool, designed to carry out various metal
cutting functions which are variable in size, length, speed,
forces for wide range of different nature and size of the parts.
It is widely used for batch production.
Example: Lathe, Milling machine, Drilling machine, Grinding
machine etc.
SPECIAL PURPOSE MACHINES, SPM’s :
It’s also a machine tool, designed to carry out desired metal
cutting function on specific component at pre defined size,
length, speed and cutting forces. It’s a dedicated & tooled up
machine for each part. Generally it is used for mass
production.
VIDEO
 INTRODUCTION TO MACHINE TOOL

Machine tools are power driven metal cutting machines which

enable the removal of excess material from the work piece in
the form of chips.

It is necessary to have relative motion between work piece

and cutting tool for cutting of metal.

It is necessary to have relative hardness between work and

tool material for metal cutting.

It is necessary to have cutting edge to cut the metal

 ADVANTAGES of CNC Machine tool

CONVENTIONAL MACHINE CNC MACHINE

• Greater Flexibility
• Higher accuracy
• Consistency
• Shorter cycle time
• Complex shapes machining
• Short set up time
• No skill requirement
• Higher reliability
 COMPARISON

LATHE
X AXIS

TOOL TURRET

POWER CHUCK
Z AXIS

CONVENTIONAL
LATHE
CLAMPING CYLINDER

HEAD STOCK
POWER TAILSTOCK
CNC LATHE
 COMPARISON
VERTICAL COLUMN
MILLING M/C
HEAD STOCK

Z AXIS

X Y TABLE

Y AXIS

X AXIS

CONVENTIONAL BASE CONVENTIONAL

MILLING M/C MILLING M/C
CNC LATHE - CURRENT TECHNOLOGY
DIFFERENCE BETWEEN MANUAL V.S CNC M/C
Conventional machine CNC machine
 COORDINATE SYSTEM

LINEAR AXES ROTARY AXES

• X AXIS • A AXIS
• Y AXIS • B AXIS
• Z AXIS • C AXIS
Axes on a CNC lathe
Axes on a CNC milling machine
 CNC LATHE
SPINDLE
X AXIS
TURRET

Z AXIS

POWER PACK

BASE
LATHE SPINDLE
 Introduction to spindle

 Spindle is the “Heart” of the machine

 Accuracy and rigidity depend on the design of the spindle,
housing, cartridge, bearings, arrangements and preload
 The major performance features
 Desired power, continuous & intermittent
 Maximum permissible speed
 Maximum spindle load (radial & axial)
 Chucking capacity
 Belt driven or integral Motor
 C N C MACHINES – SPINDLE DRIVE

• C N C Machines commonly have high spindle power and

high speed range
• They have step less variation of spindle speeds
• A C Motors with variable frequency drives are used
• Availability of full power at and above a particular speed
which is as low as possible is desirable
• The spindle speeds are usually obtained by direct drive
or through a two step gear box for range selection
• Some machines have built in integral motor with the
Spindle unit
Spindle Motor characteristics
Ac Servo Spindle Motor with constant
power

Intermittent duty
15mins
Constant torque
Continuous duty

5.5 kW Constant power range

3.7 kW
Power in kw

Speed rpm
1500rpm

5500rpm

9000rpm
 Power Transmission

POWER TRANSMISSION

FLEXIBLE RIGID

BELT CHAIN ROPE GEAR DRIVE

Power Transmission

BELTS AND PULLEYS

TYPE OF BELTS

FLAT V- BELT TOOTHED

 Advantages of Belt Drive
• Belt drive can transmit Power over considerable distance
between axis of Driving & Driven shaft.
• Operation is smooth & Silent.
• Overload protection.
• Absorbs shocks & dampens the vibration.
• Simple in Design. & Low initial cost.

Disadvantages of belt Drives

• Large dimensions & occupies more space.
• Velocity ratio is not constant due to Belt slip.
• Impose heavy loads on shaft & bearings.
 Advantages of Toothed Belts
• Positive drive
• No slip
• No variation output speed
• High pitch line velocity 80m/s
• Small cross section allows smaller pulleys

Disadvantages of Toothed Belts

• High initial cost.
• Pulley manufacturing is costly & accuracies required are
higher.
 Work Holding Devices
• Secured clamping of job or tool against all cutting forces with
min/no distortion and vibrations.
• Requisites of dimensional accuracies through high stiffness
• Ease of loading & unloading.
• Min change job over time.
• Fool proof clamping.
 Rotary Hydraulic cylinder

• Act as the actuators for the work holding devices

• Mounted at rear end of spindle and connected to work
holding by draw bar or draw tube
• Available in different area capacities Incorporates a safety
built in check valve to retain the pull force in case of power
failure
Machine tool slides
 Machine tool slides

• Slides are VERY IMPORTANT parts of machine tools

which provide the necessary constrained movement to
the tool or work piece or tool and the work piece.
• This constrained movement is necessary to produce a
work piece of the required size shape and accuracy.
• Machine tool slides form major structural components
of the machine which are moving such as table, saddle,
column, headstock, carriage, cross slide etc.
• They should be highly rigid, accurately machined,
assembled and aligned.
Slides - Characteristics
• Characteristics CNC Slides
• High rigidity, less weight, high accuracy, smoothness
and ease of operation.
• Low coefficient of friction.
• Velocity
• Thrust force
• The difference in coefficient of friction between static
and dynamic conditions should be as small as possible
to avoid the stick slip phenomenon.
• No jerky movements
• Ease of manufacturing, assembly, alignment and
maintenance.
• Minimum moving mass inertia
Guide ways - Types

• Different types of guide ways are provided in

different types of machines.
• The guide ways types by nature of contact:
• Guide ways with sliding friction
• Guide ways with rolling friction
Sliding friction guide ways
• Guide ways with sliding friction
• Guide ways with metal to metal contact
• Adequate lubrication facilities have to be made.
• Flat type, Prismatic type and Dovetail type guide ways
are commonly used.
L M Guide ways
Linear Motion/Anti Friction Guide ways

• Balls re-circulating in L M Blocks and running on tracks

on the hardened and ground L M rails provide the
necessary guidance.
• The rails and the blocks are available in standard
sizes.
• Sizes of rails and blocks are selected based on load
capacity and traverse lengths.
• This type of guide ways provide smooth movement
and can go up to very high rapid traverse rates.
Ball screws

 The ball screws are used to drive C N C Machine

tool slides have very high efficiency, 90 to 95 %,
because of the very low coefficient of rolling
friction between the screw, nut and the balls.
 The ball screw and nut assemblies are invariably
preloaded to eliminate backlash and associated
errors.
Ball screws Advantages:
• Low frictional resistance
• Low drive power
requirement
• Low temperature rise
• Low wear
• Longer life & efficient
• High traverse speed
Drive mechanisms

• Trapezoidal screw and nut mechanism actuated by an

electric motor through direct drive or a belt or a gear
box.
• Rack and pinion mechanism.
• Hydraulic powered slides.
• Pneumatic powered slide mechanism.
• Cam mechanisms.
 Drive mechanisms

• Cam mechanism actuated by an electric motor through

direct drive or a belt or a gear box.
• One motor may actuate several slides one at a time or
several at a time the selection being made by selection of
gears or clutches.
Hydraulic cylinder drives

• The slide is actuated by a hydraulic cylinder.

• One or several slides may be actuated one at a time or
several at a time or in any required sequence.
• Each slide is operated by a separate cylinder.
• The necessary sequence is usually achieved by a suitable
electrical logic operating the required valves in proper
sequence.
Servo motor drives

• The slide is actuated by a preloaded re-circulating ball

screw and nut mechanism driven by a servo motor.
• High positioning accuracy and step less variation of feed
rates is possible by fine regulation of motor and step less
variation of motor speeds.
• Efficiency of this type of drives is very high- 90 – 95 %.
• Double nuts used are pre loaded to eliminate back lash.
Feed rates
• During metal cutting operation, it is necessary to move
the slides at different velocities to meet the technological
parameters.
• Feed rates should be step less variable and precisely
regulated to get satisfactory machining results.
• They should also have precise position control to get the
desired accuracies.
• These requirements can be easily achieved by using A C
servo drives to drive the slides.
• Machine tool feed rates are normally specified in terms
of:
• Feed in mm / minute
Rapid traverses

• The machine tool slides are moved at rapid traverse rates to

reduce the idle time of the machine and hence reduce the
cycle times.
• Higher the rapid traverse rates the lesser will be the cycle
time.
• However high inertia of the slides, high acceleration and
deceleration rates limit the rapid traverse rates.
Sliding friction guide ways
• Guide ways with sliding friction
• Guide ways with metal to metal contact
• Some times Cast iron to cast iron materials are also
used.
• Adequate lubrication facilities have to be made.
• Flat type, Prismatic type and Dovetail type guide ways
are commonly used.
C N C MACHINES – FEED DRIVES
FEED DRIVES:
• The slides of C N C Machines are commonly actuated by
precision pre-loaded ball screws and nuts driven by A C
Servo Motors with variable frequency drives
• Latest designs use linear Motors
 C N C MACHINES – FEED DRIVES
Motor Mounting:
• Direct coupling of the servo motor to the ball screw through
flexible coupling is desirable.
• Belt drive or gear drive between servo motor and ball screw
is not desirable as it causes lost motion and loss of stiffness
of the drive.

Position Measuring Devices: Facilitate continuous

monitoring of the slides with feed back to the servo
drives
• Direct Measuring devices:
• Linear Scales for linear positioning
• Rotary devices for rotary positioning

• Indirect Measuring Devices:

• Rotary encoders for linear positioning
Flexible couplings
Flexible couplings

•
Home position

• Home Position in a C N C Machine is fixed zero position for

each axis with reference to which all measurements are
made.
• Since it is a fixed reference position its position should not
change by more than the specified value, called drift, over
a period of time.
• This is the ability of a slide to hold its commanded position
over a specified period of time.
• Axis home command brings all axes to back to home
position.
End of traverse
• End of traverse for each axis in either direction is defined
by a limit switch.
• Normally the slide is not expected to travel beyond this
position.
• If for some reason, the slide travels beyond this limit, then
its position is regulated by a soft ware limit switch in
either direction.
• It is a position defined in the software beyond which the
slide will not be allowed to travel.
Dead stops
• If for some reason the slide tries to travel beyond the
soft ware limit switch, then it is stopped by a dead stop
located in either direction for each axis on the machine.
C N C MACHINES
Tool Magazines & Automatic tool changer
• Double Gripper Arm executes a faster tool change. Does not
have to wait for tool search. Required tool will be searched
earlier and kept in ready position for quick interchange
• Some Machines effect the tool change directly from the tool
magazine to the spindle and vice-versa eliminating tool
change arm and associated cost and complicacy. However
the spindle has to wait for tool search
C N C MACHINES-Lubrication
• Centralized automatic lubrication System
• Automatic switching off of the Machine and visual or audible
alarm in the event of lubrication failure
• Timer based systems which periodically lubricate all points
• Software based systems which lubricate only a particular
slide after its completion of specified travel
 Hydraulic power pack MOTOR
PUMP

SOLENOID

VALVE

PRESSURE
GUAGE
 Coolant & chip conveyor System:
Junction box

Coolant motor

Conveyor
motor
Chip Conveyor

Coolant
tank
PROJECT
2 AXES CNC TURNING CENTER
BACK GROUND
• Turning is the basic machining process employed
for metal cutting using a single point cutting tool.

• It is a machining process of generating external

surface of revolution on a rotating work piece
employing a traversing cutting tool.

• In turning generally the work piece will be rotating

and the tool is stationary.
BACK GROUND

• Several other machining operations such as drilling,

reaming, boring, tapping etc. are performed in
conjunction with turning on a turning machine.

• Machining operations such as milling, grinding and

cross hole drilling can also be performed on turning
machines with special attachments.

• When the turning process is applied to internal

surfaces of revolution, it is termed as boring.
INTRODUCTION
TURNING
LATHE OPERATIONS
 LATHE INTRODUCTION
SPINDLE ASSEMBLY TURRET ASSEMBLY
Z AXIS ASSEMBLY X AXIS ASSEMBLY

BASE ASSEMBLY TAIL STOCK

ASSEMBLY

WORK HOLDING
ASSEMBLY
LATHE INTRODUCTION
• CNC lathes normally will have 2 axes, X & Z.

• Axis parallel to spindle is the Z axis, and the axis

perpendicular to the spindle and Z axis on XZ plane is the X
axis.

• In addition to X & Z CNC lathes will have C axis, an

additional axis which is the controlled rotational axis of the
spindle.

• With C axis, operations like milling & offset drilling can be

performed by using live tool turret.

• CNC lathes will have a tool turret where a definite number

of tools can be mounted.
LATHE INTRODUCTION
• The selection of tools on the tool turret can be
programmed and brought in contact with the work
piece.

• CNC lathes with C axis control will have special

turret with provision of live tools called Live tool
turret.

• The spindle speed & traverse (feed), rapid speed,

depth of cut can be programmed.

• Speeds & feeds are required to be changed

depending on the materials & cutting conditions.
 CUTTING FORCES IN TURNING

Px
Pz
Py

Px
Py

Pz
 METAL CUTTING CONDITOINS
• The machining process is dependent on the three
variables:
 Cutting speed(m/min)
 Feed(mm/rev)
 Depth of cut(mm)

• These three variables can be changed depending on

the work piece material, tool material, condition &
power of the machine.

• The three are interdependent and can be optimized to

remove maximum material & extended tool life under
the given conditions.
 2 AXES CNC TURNING CENTER:
MARKET REQUIREMENT
• TURNING DIAMETER MAX : 165mm
• TURNING LENGTH MAX. : 350mm
• SPINDLE SPEED : 4000RPM
• SPINDLE POWER : 5.5 kW /7 Kw
• CHUCKING SYSTEM : POWER OPERATED
• AXES RAPID : 20M/MIN
• TURRET : 8 STATION
• WORK MATERIAL : C45/CAST IRON/AL
• BED CONFIGURATION : SLANT 30⁰
• CNC CONTROLLER : SIEMENS/FANUC
 SPECIFICATION
MACHINE SPECIFICATION
Machine Capacity
Swing over Saddle mm 350
Swing over Cross Slide mm 220
Chuck Size mm 165
Distance b/w Centres mm 380
Turning Diameter max. mm 165
Turning Length max. mm 350
Spindle
Nose A2-5
Bore taper MT-4
Power kW 5.5
Maximum Speed rpm 4000
Speed range at constant power rpm 1000-3500
FANUC
Spindle Bore mm 40
Standard Bar Capacity mm 26
Travels & Feedrates
Stroke X-Axis mm 130
Stroke Z-Axis mm 350
Feed rate mm/min 0-5000
Rapid Traverse Rate m/min 24
Bed slant angle deg 45
STANDARD FEATURES

• 3 JAW POWER CHUCK

• HYDRAULIC POWER CHUCKING
• COOLANT SYSTEM
• CENTALIZED LUBRICATION SYSTEM
• PANEL AC
• TAILSTOCK WITH HYDRAULIC QUILL
• MACHINE LAMP
• 3 TIER LAMP
• SINGLE LIFT
SPECIAL FEATURES

• CHIP CONVEYOR
• FLOOD COOLANT SYSTEM
• 24M/MIN RAPID
• PART CATCHER
• BAR FEEDER
• AUTO DOOR
PRODUCT DEVELOPMENT SCHEDULE
 List of sub assembly
Sub Assembly Assy. Group number
• Base assembly 11-100
• Machine guard and covers assembly 11-110
• Spindle assembly 11-300
• Spindle encoder assembly 11-310
• Z & X axes assembly 11-400
• Work holding assembly 11-600
• Tailstock assembly 11-610
• Hydraulic assembly 11-700
• Coolant assembly 11-720
• Lubrication assembly 11-750
• Mechanical items for electrical assembly 11-800
• Electrical and electronics assembly 11-810
 Design Calculation, Spindle head

Cutting parameter assumptions:

1. Work/Job Material Medium carbon steel.

2. Tool material Carbide coated
3. Cutting speed 150m/min
4. Maximum feed 0.2mm/rev
5. Maximum depth of cut 2.0mm
6. Maximum work diameter 200mm
 Design Calculation

Machining Capacity (Turning)

1. Cutting speed V = *D*N/1000
Speed n (min) = (1000*150) / (3.14*200) = 240rpm
Speed n (max) = (1000*150) / (3.14*25) = 4800rpm

2. Metal removal rate Q max. = s*t*v

Q max. = 0.2*2.0*150 = 60cm^3/min

3. Power at Spindle Ns = U*Kh*Kr*Q max

(U unit Power kW/cm^3/min, Kh & Kr Tool constants, Q, metal removal rate cm^3/min)
= 44*10^-3*1.2*1.02*60 = 3.3kW

4. Power at Motor Nm = Ps/ = 3.3/0.80 = 4.0kW.

5. Selected motor Power, Nm(act) = 5.5kw

Design Calculation

Machining Capacity (Turning)

6. Tangential cutting force, max. Pz = 6120*N/v ( Ns Power at spindle, v cutting
speed)
= 6120*4.4/150 = 179kgf
7. Torque at Spindle, Ts = 975*Ns/n min
= 975*4.4/240 = 17.8kgf m = 178Nm
Machining Capacity
(Drilling)
1. Spindle Power Ns = 1.25*D^2*k*n(0.056+1.5*S)/10^5
(D drill diameter, k material constant, n Spindle speed = 1000v/pi*D, s Feed / min)
Drill diameter D max. = (4.4) / ((1.25*1.12*8*(0.056+1.5*0.2))
D max. = 22mm

2. Drill Thrust force Th max. = 1.16*K*D(100S)^0.85

Th max. = 1.16*1.12*22*(100*0.2)^0.85 = 365kgf
Unit power Table
Axes Motor characteristics

Ac Servo Motor with constant Torque

Constant torque
Torque in Nm

4 Nm

Speed rpm
3000rpm

4000rpm
0
 Design Input for Electrical Design
CNC TURNING CENTER

SPINDLE MOTOR:
Rated power 5.5 kW S1 duty, (7kW S6 duty), Base speed 1500 RPM,
Maximum Speed 9000rpm,
Belt drive with transmission ratio 1:2, External encoder with 1:1 timing belt
drive, Face mounting, IP65 protection,
Make : Siemens

AXES MOTORS:
X Axis motor:
Rated torque: 6 Nm, 3000 RPM, WITH BRAKE, ABSOLUTE ENCODER

Z Axis motor:
Rated Torque: 6 Nm, 3000 RPM, W/O BRAKE, ABSOLUTE ENCODER
 Design Input for Electrical Design
AUXILIARY UNITS AND RELATED ELEMENTS

1. HYDRAULIC POWER PACK OTHER ELEMENTS

• Motor: 1.5 kw • Foot switch for chuck operation
• Chuck clamp solenoid • Control on
• Chuck unclamp solenoid • Cycle start
• Chuck clamp proximity
• Cycle stop
• Chuck unclamp proximity
• Quill forward solenoid • Turret index
• Quill retract solenoid • T/s forward
• Quill forward pressure switch • T/s reverse
• Quill retract pressure switch • Id / od clamp
• Main pressure switch • Emergency
• Oil level switch • Fault indicator
2. LUBRICATION UNIT • Cycle running indicator
• Motor: 120 w • Door close limit switch
• Lubrication pressure switch
• Lubrication oil level switch
3. COOLANT UNIT
• Motor: 0.37 kw START ELECTRICAL SYSTEM
• Coolant level switch DESIGN
4. TURRET UNIT
As per CATALOG
THANK YOU