Unit 2: CNC Hardware Basics: Prepared By: MR.B.K Patil, DTC

Unit 2 : CNC Hardware Basics
Prepared by : Mr.B.K Patil,DTC

Diploma in Mechatronics Semester 5 CNC Technology
Syllabus:
2.0 CNC Hardware Basics
2.1 Structure of CNC Machine Tool, Spindle Design & Drives
2.2 Actuation Systems,
2.3 Feedback Devices, Axes—Standards

2.1 Computer Numerical Control (CNC)
CNC machine is designed to meet the requirements of,
High productivity, Flexibility, and High reliability to produce components of

consistently High quality and Accuracy levels combined with reduction in
manufacturing cost.

CNC milling machine (VMC)

CAD/CAM
Design Analyzing
Planning and
Scheduling
Stress/strain
Product Design
Vibration analysis CAPP
M/c Tool
Flow/Thermal MRP
Tool Design
Tool Design ERP
Jigs and Fixture
ANSYS
Auto CADD NASTRAN,NISA
Manufacturing
Pro - E C- Mould
Ideas Mould Flow
UG Master Cam
UG
Inspection
Cematron
Catia
CMM
Difference between NC and CNC
machines
“The major difference between NC and CNC machine lies in the
improved flexibility and reliability of the NC systems.”
In case of NC machine the entire data input and data handling sequence
including control functions are determined only by the fixed circuitry
interconnections of different elements and storage devices.
Hence it requires change in circuitry for any additional features. Also the
machine control data are read in time to time from tape.

Difference between NC and CNC
machines
In case CNC machine, a dedicated computer is used to perform

all the basic NC functions as per the part program by interacting with a
dedicated program called executive program, which is stored in computer
memory.
A CNC machine incorporates a microprocessor based control

system that accepts a set of program instructions and sends out put
control information to the machine tool based on the feed back information
received from machine interface elements.

WHY CNC ?
High Accuracy Achieved Due to Rigid Construction.

Program Can be reused any number of times without further study.
In built safety while programming for machining operations.
Change in program parameters, units etc are easy for required
dimensional control.
Display of errors and trouble shooting on the system console.
Flexibility.
Accuracy and Robust.
Less operator dependency.
Easy in development of new products.

WHY CNC ?
Error Compensation.
Absence of Complex Jigs and Fixtures.
Ease of complex profile machining.
High productivity and Interchangeability.
Less Rejection.
Lead time reduction for supply = 30 to 50%

WHY CNC ?
Cycle time reduction = 30 to 60%
Lesser inspection due to consistency in machining
With automatic tool change the idle time is reduced.
Floor space requirement for carrying out the job

compared to conventional machines is less. Two to three
m/c job can be done by one NC Machine.

Advantages of NC m/c
Reduced Nonproductive Time

 Less time in setting up, reducing the work piece handling time,
automatic tool changes on some machines and etc.
Reduced fixturing
 Requires fixtures which are very simpler and less cost to fabricate
because the positioning is done by the Numerical tape rather than the
jigs or fixtures.

Reduced Manufacturing Lead Time
• Here work piece can be set more quickly with

numerical controlled machines and few setups are
generally required with NC, the lead time to deliver a
job to the customer is reduced.
Greater Manufacturing Flexibility
 It is less difficult to adapt to engineering design changes, alteration
of the production schedule and changes over in jobs for rush order
and etc.

Improved Quality Control

 Ideal for complicated work parts where the changes of human
mistakes are high. NC parts with greater accuracy, reduced scrap
and inspection requirements.
Reduced Inventory
 Owing to some setups and shorter lead times with numerical
controlled machines, the amount of inventory carried out by the
company is minimized.

Reduced Floor Space Requirements

 One numerical controlled machine centre can often accomplish the
production of several conventional machines, the amount of floor
space required in an NC shop is usually less than in a conventional
shop.
Disadvantages of NC m/c
a) Higher investment cost.
b) Higher maintenance cost.
c) Requires trained personnel.

Higher Investment Cost
 NC machine tools represent a more sophisticated and complex

technology. This technology costs more to buy than its non NC
counter part. The higher costs requires manufacturing
managements to use these machines more aggressively than
ordinary equipment.
 High machine utilization is essential in order to get reasonable

returns on investments. Machine shops must operate their NC
machines two or three shifts per day to achieve this high
machine utilization.

Higher Maintenance Cost

 NC machine is a more complex technology and because NC
machines are used harder, the maintenance problem become more
acute even though the reliability of NC systems has been improved
over the years, the maintenance costs for NC machines will generally
be higher than for conventional machine tools.
Requires Trained Personnel
 NC/CNC shop operations requires a higher skill level than
conventional operations. Part programmers and NC/CNC
maintenance personnel are two skill areas where available personnel
are in short supply. The problems of finding, hiring and training these
people must be considered as a disadvantage to the NC shop.

Problems With NC Machines
Part programming mistakes

 In preparing the punched tape, part programming mistakes are
common. The mistakes may be either syntax or numerical errors and
it is not uncommon for three or more passes to be required before
the NC machine tape is correct, another related problem in part
programming is to achieve the best sequence of processing steps.
This is mainly a problem in manual part programming.
Non-optional speeds and feeds

 In conventional NC machines the control system does not provide the
opportunity to make changes in speeds and feeds during the cutting
process. As a consequence the programmer must set the speeds and
feeds for worst case conditions. The result is lower than optimum
productivity.

Punched tape
 The paper tape is especially fragile and its susceptibility to wear and
tear causes it to be an unreliable NC machine component for
repeated use in the shop.
Tape reader
 The tape reader that interprets the punched tape is generally
acknowledged among NC machine user to be least reliable hardware
component of the machine, when breakdown is encountered on an
NC machine , the maintenance personnel is usually begin their
search for the problems with the tape reader.

Controller
 The conventional NC controller unit is hardwired. This means that its

control features can not be easily altered to incorporate
improvements into the unit.
Management information
 The conventional NC system is not equipped to provide timely

information on operational performance to management. Such
information might include piece counts, machine breakdowns and
tool changes.

What is CNC system?
A system in which actions are controlled by direct instruction of data at

some point, the system must automatically interrupt the portion of data.
Trends in development of CNC m/c

Productivity
Flexibility
Efficiency
Quality
Minimum cost of component

Where Applicable?
 Number of operations per component are many.
 Complex of the operations carried out is high.
 Size of batches are medium.
 Repetition of batches is large.
 Layout cost of component is high.
 Ratio of cutting time to non cutting time is low.

Where Applicable?
 Setup time and inspection time are high.
 Number of dimensions to be maintained is large.
 Precision involved in component is high.
 Variety of components to be produced more.
 Cost of special tooling involved is high.
 Design changes are frequent.
 Non uniform cutting condition are required.

Areas Of Application
 Metal cutting machines.

 Metal forming machines.
 Tool handling system.
 Work handling system.
 Inspection and quality control system.
 Welding machines.
 Heat treatment equipment.
 Assembly, testing and dispatch equipment.
 Machines employing nontraditional machining such as EDM,
plasma arc, Laser beam , Ion beam, Ultrasonic, high speed water
jet machining etc.

Types Of CNC Machines
 Vertical machining centres.

 Horizontal machining centres.
 Machining centres with indexing heads.
 Multi axis machining centres.
 Unmanned machining centres.
 Head changer machines.
 Piano millers.
 Milling machines.
 Drilling machines.
 Horizontal axis turning machines.
 Vertical axis turning machines

 Surface grinding machines.

 Cylindrical grinders.
 Internal grinders.
 Tool and cutter grinders.
 Thread grinders.
 Special type of grinders.
 Fixed RAM type EDM.
 Wire EDM.
 Punching and nibbing machines with plasma arc or laser beam
machining.

 Forming machines.
 Pipe Bending machines.
 Sheet bending machines.
 Gear Cutting machines.
 Gear Hobbing machines.
 Gear Grinders.
 Coordinate measuring machine.
 Heat treatment equipment & welding machines.
 Inspection Systems.

Benefits Of CNC Machine
 High accuracy and repeatability.
 Reduced inspection.
 Easy to assembly and interchange ability.
 Less scrap and rework.
 Space saving.
 Less material handling.
 High flexibility for design changes.
 Reducing tooling.
 Better machine utilization.

Benefits Of CNC Machine
 Less inventory cost.
 Less paper work.
 Design freedom for complex shapes and contours.
 Ability for Higher levels of integration such as,
 Flexible manufacturing systems (FMS)
 Computer Aided Design (CAD)
 Computer Aided Manufacturing (CAM)
 Computer Integrated Manufacturing (CIM)

Salient Features
• Thermal stabilization of head stock, feed drive elements and

machine structural elements by re-circulating oil or coolant.
• Axial calibration for all fixed mechanical elements.
• Usages of touch trigger probes for post process metrology

purpose. Tool condition monitoring and thermal error compensation.
• Centralized lubrication to slides, turret, spindle and to all moving

parts controlled by timer or software.

Salient Features
• Coolant system of either flood type or mist type and servo

controlled for better positioning of coolant.
• Chip conveyors for collection and disposal of chips.
• Parts catchers for collecting the finished components.
• Bar feeding attachments.
• Safety interlocks.
• Auto diagnostic facilities to aid for maintenance and service

personnel.

Direct Numerical Control (DNC)
In production situation, when several CNC machines are used,

it has become a common practice to use a central computer to connect
all the machine CNC systems for preparing part programs at a central
place and to transfer the same to the CNC system when required.
This feature is called DNC linking. The RS 232, 2 way

communication interface option on the system enables the user to
immediately access any program from the library of program in the
host computer.

Direct Numerical Control (DNC)
This link permits transmission of messages and other critical data.

the transmission may be effected in the foreground, i.e. operating the
system in a specific mode (like input mode or output mode), or it may
be done in the background, i.e. without interrupting the machining
process (like auto mode).
That by off loading the preparation of part program and other

preparatory work to the central computer, the machine availability
for cutting can be enhanced considerably.

The sequence of activities in CNC
machine
 Data (work piece geometry and cutting conditions) is supplied to the

CNC system via a suitable medium.
 Machine control does the calculations and generates the commands

and feeds to the axis controllers.
 Axis controllers amplifies the signals and activate corresponding

axis drive motors.

machine (Cont..)
 Axis motors rotate the exact amount, which in turn moves the slides
to the prescribed position in a predetermined path and at a
predetermined feed rate.
 Position of the slides are monitored continuously by the measuring

systems and feed back is sent to the control which compares the
commanded value and the resultant and issues further commands
to the drives. By doing so the positional accuracy within permissible
limits is guaranteed in a CNC machine.

machine (Cont..)
 Axis motors rotate the exact amount, which in turn moves the slides
to the prescribed position in a predetermined path and at a
predetermined feed rate.
 Position of the slides are monitored continuously by the measuring

systems and feed back is sent to the control which compares the
commanded value and the resultant and issues further commands
to the drives. By doing so the positional accuracy within permissible
limits is guaranteed in a CNC machine.

2.2 Actuation systems
NC actuation system are commonly in three types
1.Electromechanical
2.Hydraulic
3. Pneumatic
Group of mechanical, electrical, hydraulic or pneumatic

components to control the position of machine slide is known as
servo.
There are 2 basic servo control systems as follows

Actuation systems
Classification of NC system
1. Based on feed back control system
Open loop control system

Closed loop control system
2. Based on motion control system
Position or Point to Point Control System.

Straight cut or Straight Line Control System.
Continuous path or Contouring System.

2.2 Block diagram of an Open loop
control system
TAPE INPUT
DRIVE
TAPE READER AMPLIFIER MOTOR
MACHINE TOOL SLIDE

GEAR BOX
DISPLACEMENT

 Machine tool controls in which there is no provision to compare the

actual position of the cutting tool or work piece with the input
command value, are called open-loop systems.
 The electric motor continues to run until the absence of power, from
input command signal, indicates that the programmed location has
been attained.
 There is no monitoring of the actual displacement of the machine

slide.
 The control may indicate a movement of 50mm. Whereas actually

the slide may have moved only 49.8mm.

 The actual displacement of the slide may vary with change in external
conditions and due to the wear of components of the drive mechanism
i.e. backlash errors in lead screw, etc.
 Since there is no provision of feedback in the control system periodical

adjustments are required to compensate for the changes due to various
factors.
 Less accurate compared to a closed loop system.
 Less expensive than closed-loop systems due to the absence of

monitoring devices and their maintenance is not complicated.

Block diagram of a Closed loop
control system
AMPLIFIER&
COMPARATOR SIGNAL
TAPE READER
UNIT PROCESSING
UNIT
MEASURING
COMMAND DEVICE
SIGNAL
CONTROLLING
MACHINE TOOL SLIDE UNIT
DISPLACEMENT e.g.: Hydraulic ram
That is why CNC is called “Error driven system”.

Diploma in Mechatronics Semester 5
CNC Technology
 The actual output from the system i.e. actual displacement of the
machine slide, is compared with the input signal.
 Characterized by the presence of feed-back devices in the system.
 The displacement can be achieved to a very high degree of accuracy

because a measuring or monitoring device is used to determine the
displacement of the slide.

 The feedback from the monitoring device is then compared with the
input signal and the slide position is regulated by the servo system until
it agrees with the desired position.
 In order to measure the speed of the motor and compare the actual
speed with the programmed speed, a velocity feedback system is
added to the system.

Position or Point to Point Control
System
8 7
5 2 1
6
4 3
Drilling, Boring, tapping, Jig boring

Rapid traverse
Individual Axis Control

Position or Point to Point
Control System
 Point-to-point control is one where accurate positional control is
required only to place the machine slides in fixed position and the
machine tool slide is required to reach a particular fixed coordinate
point in shortest possible time.
 The machining operations are performed at specific points and there

is no machining while the machine table/slides move from one point
to the next.
 No machining takes place until the machine slides have reached the
programmed coordinate point and slide movement ceases.

Position or Point to Point
Control System
 Since there is no machining when the machine slides move from

one point to other point, all the slide movements are made in rapid
traverse to save time.
 Also the path of movement is not important but care must be taken
to ensure that the cutting tool should not hit the work piece while
moving from one position to the next.
 The movement along different axis may be sequential or

simultaneous and each axis is controlled independently. The
simultaneous movement along the axis results in reduced cycle
time.
 Point-to-point system is suitable for drilling, boring, tapping, punch

presses and jig boring machines.
Straight Line Control System
Turning, Milling
Feed Rate

Straight Line Control System
 Straight line or straight cut system is an extension of point-to-point

control system with the provision of machining along a straight line as
in case of milling and turning operations.
 This is obtained by providing movement at controlled feed rate along

the axis in the line of motion. It is possible to machine along diagonal
lines with movement in two axis at a controlled feed rate.
 In such cases the control system must be capable of calculating and

displacing the slides simultaneously at suitable feed rates to reach
the desired points because in this case the feed rates along different
axis will have to be different.

Continuous path or contouring
System
Turning, Milling, All type of machining

Feed Rate, Interpolation
Linear & Circular
High Technology & Economical
Control system
System
 The contouring system is a high technology and most versatile control
systems. The contouring system generates a continuously controlled
motion of the tool and work piece along different coordinate axis.
 This control system enables the machining of profiles, contours and

curved surface.
 A system designed for continuous path machining can, of course, be

used for point-to-point and straight line machining but that will result in
under utilization of the system.
 In contouring system, the movement of several machine slides has to

be controlled simultaneously so that their relative positions and
velocities are established at every point and continuously throughout
the operation.

System
 The method by which continuous path system moves from one point to
another point is called “interpolation” .
 There are three types of interpolation i.e. linear, circular and parabolic.
Most of the NC/CNC system are capable of providing linear and circular
interpolation only. But few control system use parabolic interpolation
also.
 Linear interpolation means moving from one programmed point to

another programmed point in straight line. Linear interpolation enables
machining along a straight line including taper cuts.
 While programming with linear interpolation, the coordinates of the end

point of line act as the beginning of next line.

System
 The control system calculates the intermediate points and decides the
speeds of the axis motors if simultaneous movement in two axes is
required as in case of taper cuts.
 Circular interpolation is used to machine circles and arcs. In circular

interpolation also the current point acts as the starting point for the
circular interpolation and the programmer has to specify end point of
the arc and the radius of the arc.

SLIDEWAYS
• In the conventional machine tools, there is a direct metal to metal

contact between the slide way and the moving slides. Since the slide
movements are very slow and machine utilization is also low, this
arrangement is adequate for conventional machine tools.
• However, the demand on slide ways is much more in CNC machines

because of rapid movements and higher machine utilization.
• The conventional type of arrangement with metal to metal contact does

not meet the requirements of numerically controlled machine tools.

SLIDEWAYS
The design of slide way in a CNC machine tools should,

1. Reduce friction.
2. Reduce Wear.
3. Satisfy the requirements of movement of the slides.
4. Improve smoothness of the drive.
To meet these requirements in CNC machine tool slide ways, the

techniques used include hydrostatic slide ways, linear bearings
with balls, rollers or needles and surface coatings.

Hydrostatic Slide ways

Hydrostatic Slide ways
• In the hydrostatic slide ways, air or oil is pumped into small pockets or
cavities machined into the carriage or slides which are in contact with the
slide way.
• The pressure of the fluid gradually reduces to atmospheric pressure as it

seeps out from the pockets, through the gap between the slide and the
slide ways.
• The hydrostatic slide way provides almost a frictionless condition for the
movement of the slide. For efficient operation, it is very important that the
fluid and slide ways are kept clean.
• Also, the hydrostatic slide ways need a very large surface area to provide
adequate support.
57
Linear Bearing with Balls, and Rollers
• The sliding friction, due to direct metal to metal contact, between the
slide and slide ways is replaced with rolling friction by the use of
antifriction ball or roller bearings.
Linear ball bushing
• A linear ball bush shown in Fig. uses
re-circulating balls within a bush type
of bearing.
• These are designed to run along

precision ground shafts and offer
frictionless movement over varying
strokes of length with high linear
precision.

Linear Bearing with Balls, and
Rollers
• For movement along a flat plane, re-circulating linear roller bearings are
used.
• The main characteristic of the linear roller bearings is that there is a

continuous roller circulation which allows unlimited linear movement.

• A linear roller bearing, also called a Tychoway, consists of hardened

and precision ground supporting elements and a number of cylindrical
rollers.
• As in case of roller bearings, the rollers are guided between shoulders

of the supporting elements with very close tolerances.
• The guiding element prevents the rollers from falling out and sliding
against each other. Also the guiding element assists in smooth return of
the rollers to the loading zone.
• The rollers are in contact with guide ways machined on the bed of the
machine. This arrangement provides smooth and easy movement but
the machine bed has to be machined to an accurate form.

• Also the machine bed surfaces coming in contact with rollers have to be
hardened.
• To reduce the problem of accurate machining of machine bed, hardened

steel guides with special guide forms may be attached to the bed of
machine and the rollers can move on the rails.
• The linear roller bearings can be mounted horizontally for load carrying
applications such as machine tool table or they can be mounted vertically to
provide support, guidance and motion for the vertical elements of the
machine tool.

Vee and flat roller
• Vee and flat roller arrangement shown in Fig. can also be used to
provide frictionless linear movement.

Surface Coatings
• The guiding surfaces of the machines are sometimes coated with low
friction material such as Poly Tetra Fluoro Ethylene (PTFE) or
replaceable strips of low friction material are used.
• When the strips wear to such an extent that the alignment is in error
these can be replaced.

Elements of Motion Transmission
• The conventional machines use lead screw for motion transmission
purposes.
• The lead screw with acme-threads is not suitable for CNC machines
due to high friction between the lead screw and the nut and poor power
transmission efficiency and inaccuracy due to backlash.
• These problems have been overcome with the use of re-circulating ball
screw and nut arrangement. Here again, the approach is to replace
sliding friction by rolling friction.
64
Recirculating ball screw and nut

• The connection between the screw and the nut is through an endless
stream of re-circulating steel balls. The screw thread is, actually, a
hardened and ground ball race in which the steel balls, in the nut,
circulate.
• The balls rotate between the screw and the nut and at some point the
balls are returned to start of the thread in the nut. The rigidity of the drive
system and positioning accuracy can be further improved by pre-loading
the nut assembly.

(i) High Efficiency
As compared to conventional lead screw the efficiency of ball screw and
nut assembly is very high (over 90%). The power requirement for the ball
screw arrangement is also less due to reduced friction.
(ii) Reversibility
The ball screw and nut assembly is reversible which makes it possible to
back drive the unit i.e., by applying axial force to either nut or screw, the
unconstrained member can be made to rotate.

2.3 Feedback Devices
Closed - Loop Control System
Types of feedback devices
1. Velocity feedback
To measure and monitor the speed of the drive motor.
2. Positional feedback
To measure and monitor the position or displacement
of the machine slides.

1. Velocity Feedback
 Velocity feedback is normally provided by a device called

“Tachogenerator”.
 A tachogenerator is simply a voltage generator that gives voltage

output which is proportional to its speed.
 The tachogenerator is normally built in the servomotor case and is

directly fitted on the servomotor shaft.
 The output voltage from the tachogenerator is used as feedback to

monitor the motor speed.

Encoders
● A device used to convert linear or rotational position information into

an electrical output signal.
● Rotary encoders are also used to provide feedback for velocity

control.

2. Positional Feedback
 The ideal methods of measuring the displacement or position of the

cutting tool will be continuously measure the position of the cutting tool
edge relative to the datum point.
 This will result in accurate displacements and it will take into account
the tool wear, etc.
 But measurements from cutting edge are not possible due to the
presence of chips, coolants, holding devices and in some cases, due to
the component geometry itself.
 The positional feedback is provided by measuring the slide movements

with measuring device.

2. Types of Positional Feedback
1. Rotary position measuring transducers.
2. Linear position measuring transducers.
1. Rotary Position Measuring Transducers

 Angular position measuring transducers operate by measuring the
angular speed of a rotating element, normally of a lead screw.
 From the known value of lead of the lead screw, movement of worktable
or machine slide is calculated by the control system.
 Most commonly used angular position measuring transducers operate on

the “Photo Electric Principle”.

1. Rotary Position Measuring
Transducers
 The transducer consists of a disc fitted on the axial of lead screw .
 The disc is made of uniform alternate transparent and opaque areas . A

light source is fitted on one side of the disc and photocell on the other
side.
 When the disc rotates with the rotation of the lead screw the photocell
will sense light and dark areas alternately .
 As the dark area of disc is gradually uncovered, the light intensity falling
on the photocell goes on increasing until it reaches a maximum when
the transparent part of the disc comes in front of the light source.

Transducers
 As the disc continues to rotate the dark area starts to reduce the light
intensity falling on the photocell which will gradually reduces to zero when
the dark area comes between the photocell and the light source.
 The photocell gives output voltage based on the intensity of light

falling on it and the output from the photocell resembles a sine-wave,
which is converted into square shaped pulses to make it useful for control
purposes.
The number of output are then counted. As the output from the photocell
is related to the rate at which the transparent areas of the disc come in
front of the light source, the rotary speed of the lead screw is calculated
from the known number of lines engraved on the rotating disc.

Transducers
 The displacement of the slide is then calculated from the lead of the
lead screw .The direction of rotation of the lead screw is sensed by a
second photocell in the circuit.
 The second photocell is positioned in such a way that the output

from this photocell is identical to that of first photocell but the output
from the two photocells will be out of phase.
 This phase difference is used to determine the direction of the

rotation of lead screw.
 Position measurement by angular position measuring transducer is

indirect as the output of the transducer has to be converted into
table displacement.

Grating
The heart of a encoder is its measuring standard, usually in

the form of a grating with typical line widths of 0.25 µm to 10 µm.

Grating
• These precision graduations are manufactured in a process and are

a decisive factor in the function and accuracy of encoders.
• The graduations consist of lines and gaps at defined intervals with

very little deviation, forming structures with very high edge definition.
• These graduations are resistant to mechanical and chemical

influences as well as to vibration and shock. They have a defined
thermal behavior.

Linear Position Measuring
Transducers
 Linear position measuring transducer also operates on the “photo
electric principle”.
 The Linear measuring system measures the displacement of the

machine slide from a fixed datum.
 A linear measuring system consists of a precision linear scale engraved

with closed spaced alternate transparent and opaque parallel lines as
one unit and a photocell and light source as the second unit.
 One of the units is fixed on the stationary element of the machine tool
and the other unit is fixed to the moving worktable.

Transducers
 A pulse is generated by the photocell as it is exposed to the light source
through the transparent areas of the linear scale.
 From the known number of engraved lines per unit length on the linear
scale and by counting the number of pulses, the displacement of the
worktable can be established.
 The linear system may have either a glass scale in which case light
passes through the transparent area or a stainless steel scale in which
case the light is reflected from the transparent areas.

Transducers

Spindle design

CNC Technology
• A high speed spindle that will be used in a metal
cutting machine tool must be designed to provide
the required performance features. The major
performance features include:
• Desired Spindle Power, Peak and Continuous
• Maximum Spindle Load, Axial and Radial
• Maximum Spindle Speed Allowed
• Tooling Style, Size and Capacity for ATC
• Belt Driven or Integral Motor-Spindle Design

CNC Technology
High Speed Spindle Design: Major
Component List
• The major components required for a high speed milling
spindle design include:
• Spindle Style; Belt Driven or Integral Motor-
Spindle
• Spindle Bearings; Type, Quantity, Mounting, and
Lubrication Method
• Spindle Motor, Belt-Type, Motor-Spindle,
Capacity, Size
• Spindle Shaft; Including Tool Retention Drawbar
and Tooling System Used
• Spindle Housing;Diploma
Size, Mounting
in Mechatronics
CNC Technology
Semester Style,
5 Capacity
• Each of these components will be discussed, with
emphasis on selection criteria and effectiveness for
a given machine tool specification. The machine
tool we will assume is a modern CNC machining
center with automatic tool changing ability (ATC).

CNC Technology
• A typical spindle arrangement used in CNC turning
centre is shown schematically in Fig. 24. Typical
feature to be noted in the design is that the spindle
is well supported with very little overhang beyond
the end bearings. The spindle is supported with
sufficiently large ball and roller bearings to take
care of the large axial and radial cutting forces.

CNC Technology
Radial Roller Bearing
Work Holding End Power from spindle motor
Ball Thrust Bearing

CNC Technology
• The heat generated in the spindle will be
substantial because of the large power used and
high spindle speeds used.
• It therefore becomes necessary to provide proper
cooling of the spindle so as to maintain thermal
equilibrium so that the spindle growth is
maintained in reasonable limits.
• For this purpose, many methods are employed.
The oil circulated through the spindle is provided
with a heat exchanger so that the heat is removed
continuously from the spindle.
CNC Technology
• Optionally, it may also be provided with a chilling
arrangement for more efficient heat removal from
the spindle.
• The spindle motor and the gearbox are isolated
from the main structure so that part of the heat
generated in them is not transmitted to the
machine tool structure.
• Bridgeport has introduced a temperature
compensation system in which four temperature
sensors (three on the machine spindle and one for
measuring the ambient temperature) are used to
continuously measure and then get compensated
by the MCU. Diploma in CNC
Mechatronics Semester 5
Technology
• Another system being pioneered for high speed
machining is the building in of the spindle motor
directly in the spindle housing as shown in Fig. 25.
This reduces the overall inertia and allows faster
cutting speeds.
• However, the motor is thermally separated from
the spindle with a gap and is also provided with a
spindle cooling arrangement as shown in Fig. 25.
The spindle is supported in hybrid bearings
(ceramic balls).

CNC Technology

Unit 2: CNC Hardware Basics: Prepared By: MR.B.K Patil, DTC

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Unit 2: CNC Hardware Basics: Prepared By: MR.B.K Patil, DTC

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Unit 2 : CNC Hardware Basics

Prepared by : Mr.B.K Patil,DTC

2.0 CNC Hardware Basics

2.1 Structure of CNC Machine Tool, Spindle Design & Drives

2.2 Actuation Systems,

2.3 Feedback Devices, Axes—Standards

Diploma in Mechatronics Semester 5 CNC Technology

High productivity, Flexibility, and High reliability to produce components of

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

In case CNC machine, a dedicated computer is used to perform

A CNC machine incorporates a microprocessor based control

Diploma in Mechatronics Semester 5 CNC Technology

High Accuracy Achieved Due to Rigid Construction.

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Cycle time reduction = 30 to 60%

Lesser inspection due to consistency in machining

With automatic tool change the idle time is reduced.

Floor space requirement for carrying out the job

Diploma in Mechatronics Semester 5 CNC Technology

Reduced Nonproductive Time

Diploma in Mechatronics Semester 5 CNC Technology

Reduced Manufacturing Lead Time

• Here work piece can be set more quickly with

Diploma in Mechatronics Semester 5 CNC Technology

Improved Quality Control

Diploma in Mechatronics Semester 5 CNC Technology

Reduced Floor Space Requirements

b) Higher maintenance cost.

c) Requires trained personnel.

Diploma in Mechatronics Semester 5 CNC Technology

Higher Investment Cost

 NC machine tools represent a more sophisticated and complex

 High machine utilization is essential in order to get reasonable

Diploma in Mechatronics Semester 5 CNC Technology

Higher Maintenance Cost

Diploma in Mechatronics Semester 5 CNC Technology

Part programming mistakes

Non-optional speeds and feeds

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

 The conventional NC controller unit is hardwired. This means that its

 The conventional NC system is not equipped to provide timely

Diploma in Mechatronics Semester 5 CNC Technology

A system in which actions are controlled by direct instruction of data at

Trends in development of CNC m/c

Diploma in Mechatronics Semester 5 CNC Technology

 Number of operations per component are many.

 Complex of the operations carried out is high.

 Size of batches are medium.

 Repetition of batches is large.

 Layout cost of component is high.

 Ratio of cutting time to non cutting time is low.

Diploma in Mechatronics Semester 5 CNC Technology

 Setup time and inspection time are high.

 Number of dimensions to be maintained is large.

 Precision involved in component is high.

 Variety of components to be produced more.

 Cost of special tooling involved is high.

 Design changes are frequent.

 Non uniform cutting condition are required.