Unit 4: CNC Machine Tools & Control Systems: Prepared By: MR.B.K Patil, DTC

Unit 4 : CNC Machine Tools
& Control Systems
Prepared by : Mr.B.K Patil,DTC

Diploma in Mechatronics Semester 5 CNC Technology
Syllabus:
4.0 CNC Machine Tools and Control Systems
CNC Machining Centers, CNC Turning Centers & High

4.1
Speed Machine Tools
Machine Control Unit, Support Systems & Touch

4.2
Trigger Probes

.
4.1 Machining Center Programming & Operation
Lesson One:
Machine Configurations

You must understand the
machine you’ll be working with!

Key Concept
Number One
FANUC 10M
POWER O NG P A 789
X00.0000
RESET
ON XUYV ZWQ B 456 START
I J KRC Sp 123
FE D?H@EOB
L@ #, -0
OFF Y00.0000 MS[ ] T( ) /*
PAGE CURSOR
+ = CAN
CALC
INPUT
NC/PC
Z00.0000
SHIFT
AUX
CYCLEFEED MDI JOG

STARTHOLDAUTO ON
HANDLE OFFDRY SINGLE
MACHINE
OPTIONAL
BLOCK
EDIT ZERO
MODE RETURN RUNBLOCK
100%
LOCK STOPDELETE
OFF ON ORIGIN
25%50% X Z
X+ 10% 100% MEMORY X1X10X100
Z- Z+ PROTECT X Z
X- 0% 200% 8 9101112
RAPID 67
JOYSTICK FEEDRATE
OVERRIDE OVERRIDE 45 0
EMERGENCY 3
STOP ON OFF 2
SPINDLESLOW FAST TURRET
1 INDEX
100% 100%
0% 130% 0% 130%
OD ID
SPINDLE LOAD AXIS LOAD
X Z CLAMP
DIRECTION
MV 4VA
You must understand machining

centers from two perspectives

1 Basic machining practice
1 Vertical machining centers
1 Horizontal machining centers

1 Horizontal machining center



Basic machining practice Programmable functions
Machine components Spindle
C frame style vertical Feedrate
Gantry style vertical Coolant
Horizontal Tool changing
Directions of motion Double arm
C frame style vertical Single arm
Gantry style vertical Others
Horizontal

Hole Machining Tools:
Center Drill
Spot Drill
Twist Drill
Countersink
Tap
Counter Bore
Reamer
Boring Bar

End Mills
CNC Technology
Shell Mills
Face Mills
Dovetail Mills
Chamfer Mills
Milling Cutters:
Semester 5
Radius Mills
Diploma in Mechatronics
Slotting Mills
HIGH SPEED MACHINING (HSM)

CONTENTS
Introduction
Definition of HSM
Advantages
Application areas
Machining system
Some recommended parameters
Comparison
Disadvantages
Conclusion
DEFINITIONS
• High cutting speed machining
• High rotational speed machining
• High feed machining
• High speed and feed machining
• High productive machining
Finally,
“HSM is a powerful machining method that combines high feed rates
with high spindle speeds, specific tools and specific tool motion.”

ADVANTAGES
• High material removal rate
• High surface finish
• Increased productivity
• Possibility of machining of very thin walls
• Reduction in lead times
• Low cutting force
• Cutting tool and work piece temperature are kept low
• Connection time between the cutting edge and work piece is short
• It eliminates the need of coolant
• Reduction of production process

FEATURES EFFECTS
Reduced heat transfer in Part accuracy

to the work piece
Reduction of cutting Part accuracy

forces Surface quality
Increased cutting speed Stability of rotating

cutting tool feed rate
Increased material removal

APPLICATION AREAS
• Industry which deals with the machining of Al to produce

automotive components, small computer parts or medical
devices
• Aircraft industry involves machining of Al often with thin walls
• Die mould industry which requires dealing with finishing of hard
materials .
• Used to machine such parts as die casting dies, forging dies,
injection moulds and blow moulds, milling of electrodes in
graphite and copper, modeling and prototyping of dies and
moulds.

MACHINING SYSTEM
MACHINE TOOLS
• 3-axis horizontal and vertical milling machines

• CNC 4-axis milling machine offers the option of tilting the milling
cutters to improve the cutting conditions
• 5-axis machine with inter changeable spindle units allow to rough,
semi finish and finish with a single set up.

DEMANDS ON THE MACHINE
• Spindle speed range <=40000 rpm

• Spindle power >22 KW
• Programmable feed rate 40-60 m/min
• Rapid travels <90 m/min
• Block processing speed 1-20 ms
• High thermal stability and rigidity in spindle
• Air blast/coolant through spindle
• Advanced look ahead function in the CNC

CUTTING TOOLS
1. TiN and TiCN coated Carbide for materials with hardness less
than 42 HRC
2. TiALN coated Carbide for materials with hardness 42 HRC and
above
3. For special applications like hard turning (HRC 60-65)
PCBN is used
4. Cubic boron nitrite (CBN) and ceramic for cast iron
5. Poly crystalline diamonds (PCD) and Cermets are used for
aluminum

RECOMMENDED PARAMETERS
1.True cutting speed
As the speed is dependent on both spindle speed and diameter of

tools HSM should be defined as “true cutting speed” above a
certain level

2.Material removal rate
Material removal rate,

Q = (ap* ae * vf)/1000 cm3/min
where ap = vertical dist from tool tip to the reference point mm
ae = step over distance mm
vf = feed speed mm/min

3. Surface finish
Surface finish is depends upon cutting tool geometry, coating of the

cutting tool, wear status of the cutting tool etc.

COMPARISONS
Conventional machine High speed machine
Max speed 600 m/min Speed starts at 600 m/min
Max feed ~40 ipm Feed starts at 100 ipm
Require high levels coolant With coolant ,feed rate can go

more than 2000 ipm
No need for coolant for low
feed rate

Comparison between speeds used in conventional and high speed machining

Comparison between convl and HSM process
Conventional HSM
The contact time between tool and Contact time is short
work is large
Less accurate work piece More accurate work piece
Cutting force is large Cutting force is low
Low surface finish High surface finish
Material removal rate is low Material removal rate is high
Cutting fluid is required Cutting fluid is not required

Comparison between HSM and EDM
HSM EDM
Material removal rate high Material removal rate is low
Dimensional tolerance 0.02 mm Dim tolerance

0.1- 0.2 mm
There is no need of making Cutting tool has to be made

cutting tool according to the according to the contour to be
contour to be machined machined

DISADVANTAGES
• Need for expensive and special machine tools with advanced

spindle and controllers
• Excessive tool wear
• Good work and process planning necessary
• It can be difficult to find and recruit advanced staff

CONCLUSIONS
 HSM is not simply high cutting speed .It should be regarded as a

process where the operations are performed with very specific
methods and precision equipment
 HSM is not necessarily high spindle speed machining. Many HSM

applications are performed with moderate spindle speeds and
large sized cutters
 HSM is performed in finishing in hardened steel with high speeds

and high feeds often with 4-6 times conventional cutting speeds

 HSM is high productive machining in small sized components in
roughing to finishing and in finishing to super finishing in components
of all sizes.
 Even though HSM is known for a long time, the research are still
being developed for further improvement of quality and optimization
of cost.

4.2 Machine Control Unit, Support
Systems & Touch Trigger Probes
A small, powerful
computer that controls
machine control unit
and operates a CNC
machine.

CONTROL UNIT FLOW CHART

CONTROL INTERFACING
MODE SELECTION
This switch selects the machine operation mode. They are
classified into three groups
Program Edit
Automatic Operation
Edit mode (EDT)
Memory Operation mode (MEM)
MDI Operation mode (MDI) Manual Operation
Single block (SBK) Handle mode (MPG)
Direct Numerical Control (DNC) Jog mode (JOG)
Zero Return mode (ZRN)

MODE
In EDIT mode following operations are possible:

Inputting and storing the programs to the NC memory
Changing and deleting the program to the NC memory
Outputting a program stored in the NC memory using the
search functions ( Program number and search, sequence
number search)
MDI
A program created in the MDI mode will be cleared after it has
been executed, when the RESET key is pressed or when the power
is turned off.
For this reason MDI mode is often used to rotate the spindle or to
carry out tool change operation.
Setting parameter and other data.
CAD/CAM
Two computer-based systems which impact the use of CNC technology

are computer aided design and computer aided manufacturing.
A computer aided design, or CAD, system uses computers to
graphically create product designs and models. These designs can be
reviewed, revised, and refined for optimum end use and application.
Once finalized, the CAD design is then exported to a computer aided
manufacturing, or CAM, system.
CAM systems assist in all phases of manufacturing a product, including
process planning, production planning, machining, scheduling,
management and quality control.

Touch Trigger Probes :- This types of probes are
used to measure /sense the jobs in high accuracy
Benefits
highest accuracy, even when used with
long styli - up to 180mm long ("GF" range)
compatible with full range of multi-wired
probe heads and extension bars for
flexible part access
plus general strain-gauge benefits:
non-lobing
no reseat failures
extended operating life
6-way measuring capability

Piezo probes
• A piezo probe uses one or more piezo ceramic elements as the

sensor. The advantage of piezos is that they are able to detect the
mechanical shock signal generated when the stylus ball impacts the
workpiece. This is due to their ability to respond to frequencies
higher than those detected by many other sensors. The result is that
piezo probes "hear" the stylus ball touch the surface.
• When the stylus meets the surface, it ‘rings as the shock waves
passes up the stylus and into the probe body.

Piezo probes
• These signals are at very high frequencies and travel very

quickly, meaning that a shock sensor can respond to a surface
contact more quickly than other types of probe.’
• Similarly to strain-gauge probes, at the frequencies and forces

concerned, the kinematic elements act as a solid, transmitting the
shock waves from the stylus further into the probe structure

Shock sensing
Piezo ceramic
• piezo sensors generate a voltage sensor detects
when subjected to pressure shock of
impact
• piezos can detect the mechanical
shock signal generated when the
stylus ball impacts the workpiece Stylus
changing
– they can respond to frequencies kinematics
higher than those detected by
many other sensors Shock wave
travels up stylus
– the result is that piezo probes and is
"hear" the stylus ball touch the transmitted
surface through
kinematics

Working principle

Unit 4: CNC Machine Tools & Control Systems: Prepared By: MR.B.K Patil, DTC

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Unit 4: CNC Machine Tools & Control Systems: Prepared By: MR.B.K Patil, DTC

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Unit 4 : CNC Machine Tools

& Control Systems

Prepared by : Mr.B.K Patil,DTC

4.0 CNC Machine Tools and Control Systems

CNC Machining Centers, CNC Turning Centers & High

Machine Control Unit, Support Systems & Touch

Diploma in Mechatronics Semester 5 CNC Technology

4.1 Machining Center Programming & Operation

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

ON XUYV ZWQ B 456 START

CYCLEFEED MDI JOG

You must understand machining

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Reduced heat transfer in Part accuracy

Reduction of cutting Part accuracy

Increased cutting speed Stability of rotating

Diploma in Mechatronics Semester 5 CNC Technology

• Industry which deals with the machining of Al to produce

Diploma in Mechatronics Semester 5 CNC Technology

• 3-axis horizontal and vertical milling machines

Diploma in Mechatronics Semester 5 CNC Technology

• Spindle speed range <=40000 rpm

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

1.True cutting speed

As the speed is dependent on both spindle speed and diameter of

Diploma in Mechatronics Semester 5 CNC Technology

Material removal rate,

Diploma in Mechatronics Semester 5 CNC Technology

Surface finish is depends upon cutting tool geometry, coating of the

Diploma in Mechatronics Semester 5 CNC Technology

Conventional machine High speed machine

Max speed 600 m/min Speed starts at 600 m/min

Max feed ~40 ipm Feed starts at 100 ipm

Require high levels coolant With coolant ,feed rate can go

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Cutting fluid is required Cutting fluid is not required

Diploma in Mechatronics Semester 5 CNC Technology

Material removal rate high Material removal rate is low

Dimensional tolerance 0.02 mm Dim tolerance

There is no need of making Cutting tool has to be made

Diploma in Mechatronics Semester 5 CNC Technology

• Need for expensive and special machine tools with advanced

Diploma in Mechatronics Semester 5 CNC Technology

 HSM is not simply high cutting speed .It should be regarded as a

 HSM is not necessarily high spindle speed machining. Many HSM

 HSM is performed in finishing in hardened steel with high speeds

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology

Diploma in Mechatronics Semester 5 CNC Technology