Module: Engineering Process ( Milling ) Module code: MT2103FP

Topic 4 : Create CNC Milling Part Programs Precision Engineering

4.3 Features and applications of a CNC milling machine

CNC machining centres

CNC machining centres are quite similar to CNC Milling machines except with the
addition of tool magazines and more features.

There are two categories (types) of CNC machining centres in these days, they are:

 Horizontal Machining Centre (HMC).

• Is normally used to machine medium to large size

jobs, including tall workpieces requiring machining
on a number of their surfaces, with the use of
automatic pallet changer.
• Can be installed in the Flexible Manufacturing
System (FMS).

Horizontal Machining Centre (HMC).

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Topic 4 : Create CNC Milling Part Programs Precision Engineering

Vertical Machining Centre (VMC).

 Used for machining small to medium size jobs.

 Suitable for machining flat surfaces with deep

cavities, such as mould and die making.

 Because the thrust forces are directed

downward, this machine have high stiffness and

produce parts with good dimensional accuracy.

 Less expensive than Horizontal Machining

Center

Vertical Machining Centre (VMC).

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Topic 4 : Create CNC Milling Part Programs Precision Engineering

The Basic Components of a CNC Machine

An operational CNC machine consists of the following basic components:

Program of instructions

These are coded instructions, i.e. G and M codes, are created by the programmer by
using the Machine Control Unit, CAD/CAM or others to form a program. This program
will be stored in the form of storing media such as hard disk, floppy diskette, magnetic
tape, punched tape, etc.

Machine Control Unit or Machine Controller (MCU)

To generate, store, input, edit, test and process CNC programs. It is the main brain of
the CNC machine, and it controls all machine motions and special functions.

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Machine Tool (Structural Configurations) The machine itself, the hardware, e.g. machine
structure, table, slide and slide-way, spindle, AC or servo motor, sensor, transmission linkage,
Tool magazines, power supplies, etc.

i) Machine Spindle

Is one of the main components of the CNC Machining Centre. It is driven by either AC
servomotor, Stepped motor, DC motor. The spindle housing to support the spindle shaft must
has adequate support by bearing, counter-balance and minimum overhang must be provided
to prevent deflection.

MACHINE
SPINDLE

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Types of drives:

Gear drive: this drive is meant to drive the spindle from low to medium speeds. It is more
positive and rigid in providing the accurate desirable speeds. It is nosiest compare to the
others type of drive.

Belt drive: this drive is meant to drive the spindle for higher speeds. It is quieter but less
rigid, and tends to skip, hence do not really providing positive speed.

Belt

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Direct drive: this drive is directly mounted to the spindle shaft which can provides
accurate and rigid drive speeds. It is the quietest drive among the rest of the drives.

ii) Motion Transmission

The Acme forms of lead screws are usually used on conventional machines. But this form of
thread has not proved to be satisfactory on CNC machines; hence CNC machines are normally
fitted with re-circulating ball screws, which replace sliding motion with rolling motion, resulting in
reduced frictional resistance.

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The advantages of re-circulating ball screws over Acme Screws are:-

• Longer life
• Less wear
• Low frictional resistance
• Less drive power required due to reduced friction
• Higher traversing speeds can be used
• Move precise positioning over many years

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iii) Machine Slides

The movement of a machine slide must be smooth and responsive. The frictional
resistance on motion on the slides must be kept to minimum. In addition, wear, with its
resulting dimensional inaccuracies, must be kept to a minimum.

The slides of a large number of CNC machines have flat bearing surfaces. These
surfaces are usually hardened, ground and coated. This surface has a low coefficient of
friction, is slightly porous, and therefore is lubricant retaining. The load-bearing properties
of flat surfaces are superior to those of other types of slides.

Re-circulating Roller Slide

Tool Magazines

A tool magazine is an indexable storage facility used on

machining centers to store tools and also for automatic tool
changing.
When a tool is called into use, the magazine will index, on
most machines by the shortest route, to bring the tool to a
position where it is accessible to a mechanical handling
device to complete the auto-tool change.

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There are four types of tool magazine:

• Carousel (circular) type (either in horizontal rotation or vertical rotation

• Chain type
• Rotary Drum type

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5. Power Supply

The power supply is the key factor must be included in order to run the machine in the
CNC machine design.

The power supply are categories in three major areas, they are:

• Electric power: this is the main source the power supply to supply the electricity to
various parts of the machine which require electricity to function, such as the
Controller, Spindle AC servomotor, Drives for motion transmission, Coolant motor,
lighting and so on'.

• Pneumatic power: this is mainly to provide the power for automatic tool-change and
tool holding mechanism.

• Hydraulic power: this is mainly to provide the power for chucking, clamping of jobs or
tool changing.

6, Swarf (Chip) Control

The handling of chips control is great important during the machining processes. If
the chip is not properly controlled the life span of the machine and the quality of the
product will be greatly affected. Hence, Chip Conveyer is built to remove the
unwanted chip or swarf instantly during the machining process, to avoid ill effects to
the machine and product caused by the chip.

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