CNC Machines
CNC Machines
CNC Machines
1955 - John Parsons and US Air Force define a need to develop a machine tool capable of machining complex and close tolerance aircraft parts with the same quality time after time (repeatability). MIT is the subcontractor and builds the machine for the project. 1959 - MIT announces Automatic Programmed Tools (APT) programming language 1960 - Direct Numerical Control (DNC). This eliminates paper tape punch programs and allows programmers to send files directly to machine tools 1968 - Kearney & Trecker machine tool builders market first machining center 1970s - CNC machine tools & Distributed Numerical Control 1980s - Graphics based CAM systems introduced. Unix and PC based systems available 1990s - Price drop in CNC technology 1997 - PC- Windows/NT based Open Modular Architecture Control (OMAC) systems introduced to replace firmware controllers.
1. Program of instructions. It is the detailed step by step set of instructions which tell the machine what to do. And its types are:a- 1-inch wide punched tape b- punched cards c- magnetic tape d- 35 mm motion picture film 2. Controller unit, also called machine tool unit. It consists of electronics and hardware that read and interpret the program of instructions convert it to mechanical actions of the machine tool. (closed loop or open loop) - Controller components : 1. Data Processing Unit (DPU) Input device [Tape Reader/ Punched Tape Reader] Data Reading Circuits and Parity Checking Circuits Decoders to distribute data to the axes controllers. 2. Control-Loops Unit (CLU) Interpolator to supply machine-motion commands between data points Position control loop hardware for each axis of motion 3. Machine tool or other controlled process. The part that performs useful work.
Extension on NC
CNC : computer numerical control DNC : direct numerical control Adaptive numerical control Industrial robots
Control Systems
- Open-Loop Control Stepper motor system Current pulses sent from control unit to motor Each pulse results in a finite amount of revolution of the motor 001 is possible - Limitations Control unit assumes desired position is achieved No positioning compensation Typically, a lower torque motor - Advantages Less complex, Less costly, and lower maintenance costs - Closed-Loop Control Variable DC motors - Servos Positioning sensors - Resolvers o Feedback to control unit o Position information compared to target location o Location errors corrected Advantages DC motors have the ability to reverse instantly to adjust for position error Error compensation allows for greater positional accuracy (.0001) DC motors have higher torque ranges vs.. stepper motors Limitations Cost
BLU = p (pitch) / number of pulses per rev (encoder output). Table speed = p * RPM = BLU * pulse rate (frequency)
Flexibility in job change, automatic tool settings, less scrap More safe, higher productivity, better quality Less paper work, faster prototype production, reducing lead times Easier to program; Easy storage of existing programs; Easy to change a program Avoids human errors Usually generates closer tolerances than manual machines Disadvantages: Costly setup, skilled operators Computers, programming knowledge required Maintenance is difficult
Types of Machine
Lathes for metal and plastics - Used to produce 3D product shapes & moulds for plastic products Milling machine for mould making and surface milling. - Used to produce dies for die cutting printed products.
CNC Lathe
Automated version of a manual lathe. Programmed to change tools automatically. Used for turning and boring wood, metal and plastic.
Tools
Most made from high speed steel, tungsten carbide or ceramics. Tools are designed to direct waste away from the material. Some tools need coolant such as oil to protect the tool and work.