NUMERICAL CONTROL OF MACHINE TOOL (DE)

ME453
UNIT 2

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 Unit 2
•NC machine tools
Structure:
Drives:
Actuation systems: open loop servo systems
closed loop servo systems
reciprocating ball screws
linear motion systems
rotary and linear transducers
Tool holding devices : Automatic tool changers (ATCs)
Work holding devices : Automatic pallet changers
Controller unit (MCU): Type of controller units

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 STRUCTURE
Structure of an NC machine tool links all it’s components
and is the basic platform on which all these components
are laid upon.

Considerations
• Sustain loads over long periods of time.
• Vibration problem in machining process.
• Large quantity of swarf should be handled which
requires handling of hot chips along with thermal
distortions.
• Higher magnitudes of multidirectional forces.
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 STRUCTURE
Consequences

• NC machines tend to be heavier structures as they

have to provide adequate strength and rigidity.
• To avoid vibration problems the structure is properly
damped by means of spring, mass and dampers.
• Overhangs of cutting forces, motor forces and frictional
forces are to be reduced.
• Implementation of proper heat management arising
within the machine tool due to drives and pumps.
• Designs involving better swarf removal, like Slant bed
are employed.
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 STRUCTURE
Consequences
• Air conditioning is often maintained to eliminate the
distortion of the structure due to variations of
environmental temperatures.
• Alloyed Iron and fabricated steel structures are used
the structure.
• They are made of cast iron.

Slant Bed for a turning center for easy chip flow and operation 5
 DRIVES
• The drive components are the mechanical
components that “drive” the NC/CNC machines
along its axis.
• The most common components associated with the
drive system are the motors, lead or ball screw or
rack and pinion.
• The whole idea of a drive system is to convert
controlled rotary motion to controlled linear
motion with the help of a NC/CNC controller.
• The driving system is an important component of a
NC/CNC machine as the accuracy and repeatability
depends very much on the characteristics and
performance of the driving systems.
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• Basic function of a NC/CNC machine is to provide
automatic and precise motion control to its
elements such work table, tool spindle etc.
• The driving system is classified as spindle drives and
feed drives.
• The spindle drives are used to provide angular
motion to the work piece or a cutting tool.
• The feed drives are used to drive the slide or a table.
• The feed drives consists of an electric motor and
mechanical transmission elements.

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 SPINDLE DRIVES
Spindle drives
Provide angular motion to the workpiece or a cutting tool.

Requirements
• To maintain the speed accurately which will enable machining of a variety of
materials with variations in material hardness.
• The speed ranges from 10 to 20,000 rpm.
• Compact drive with highly smooth operation.
• Mostly machine tools employ DC spindle drives.

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Schematic of a spindle drive
 FEED DRIVES
Spindle drives
These are used to drive the slide or a table.

Requirements
• The driving system has to response accurately according to the programmed
instructions.
• Extremely variable drive speed.
• The feed motor must run smoothly.
• Extremely small positioning resolution.
• High torque to weight ratio.

Schematic of a Feed drive 9

 TYPES OF DRIVES
• Electrical drives
Small in size and easy to control. They have the following types
• Direct current (DC)
• Alternating current (AC)

• Hydraulic drives
Have large power to size ratio and provide step-less motion
with great accuracy.
• Difficult to maintain and are bulky.

• Pneumatic drives
This drives use air as working medium.
Although simple in construction and quite cheap, these drives
generate low power having less positioning accuracy and are
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 Classification of NC systems

Based on Motion Type:

Point-to-Point or Straight line or Continuous path

Based on Positioning System

Incremental or Absolute

Based on Control Loops:

Open loop or Closed loop

Based on Power Supply:

Electric or Hydraulic or Pneumatic

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 OPEN LOOP SYSTEM
No feedback to verify that the actual position achieved is the desired position

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13
 OPEN LOOP SYSTEM
• Stepper motor is generally employed as the driving component to provide the
machine slide motion.
• Digital input of 10-20V is supplied in such a way giving rotor a precise movement
of one step.
• Step angle of 1.8 Degrees is common with 200 steps per revolution.
• One Step of Stepper Motor rotates the screw by
1/200 revolution ≡ 0.02mm (if the screw having a lead of 4mm is directly
coupled with the O/P Shaft.)
• Restricted to small machines because of limited power O/P of Stepper Motors.
(Max. 5 kW and a torque of 200 Nm)
• No. of pulses per second restrict the speed of the drive.
Max. 8000 pulses per second.
This when applied to a system requiring 0.001mm accuracy a maximum speed of 0.48m/min
is achieved which is not sufficient for higher accuracy.
Conclusion
Open loop servo control is limited to light duty machine and not suitable for higher
precision applications.

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 CLOSED LOOP SYSTEM
Uses feedback measurements to confirm that the final position is the specified
position

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16
 CLOSED LOOP SYSTEM
• DC/AC Servo motors are generally employed as the driving component to
provide the machine slide motion.

• Requires external encoders/sensors for observing the position of the

work table and sending the feedback signal to the feedback controller.

• This kind of control have capabilities up to 0.0001 mm resolution and

speeds up to 20m/min.

Conclusion
Closed loop servo control is best suited to high precision heavy duty machine
application.

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 Electric Motor
• The electric motor is an electric machine that converts
electrical energy into mechanical energy.

• Most electric motors operates through the interaction between

an electric motor’s magnetic field and winding current to
generate force within the motor.

• Two types of electrical motors are commonly used in NC/CNC

machines :

1. Servomotors
a) DC Servomotors
b) AC Servomotors

2. Stepper motors

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 SERVOMOTOR
Electric Motor + Servomechanism

Servomotor
DC Motor + Servomechanism

DC Servomotor

AC Motor + Servomechanism

AC Servomotor
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• The main reason for using servomotor is to obtain
angular precision.

• Normal electric motor starts rotating as when power

is supplied and rotation continues unless power is
switched off.

• With servomotor the desired angular position is

obtained. Suppose one wants to rotate the shaft from
0 to 35 degree. The shaft will stop at 35 degree and
there will be no further movement.

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 Servomechanism
• Servomechanism is an automatic closed loop feedback
control system.
Motor
Output sensor
Control Device
1 Output signal of
the system
The signal 1st and
2nd are compared 3 feedback
and the 3rd signal Reference
from the error Input Signal
detecting amplifier 2
is fed to the
Error
control device
detector
which is the
amplifier
motor.
Servo-system consists of the following components:
1. Control device
2. Output sensor 21
3. Feedback system
• Suppose we want to rotate the shaft from 0 to 5 degree and
then from 5 to 45 degree.
• Once it reaches 45 degree the output signal from the output
sensor will be automatically equal to the Reference electrical
Input .
• When they become equal the difference between signal 1st and
2nd is zero and there will be no signal to be amplified hence
there will be no signal to power the control device. Therefore
motor stops rotating.
• And to produce a further action by the control dvice it requires
a 3rd signal.
• As long as there is a logical difference between 1st and 2nd the
3rd signal will be generated and once the motor achieves its
desired output the difference will get zero.
• This is SERVOMECHANISM.
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• Servo control consists of all the activities, which
allow several axes to effectively maintain the
trajectory calculated by the interpolator.
• In CNC systems the position and velocity of the
machine tool axes must be controlled closely and in a
coordinated manner.
• Each axis is separately driven and follows the
command signal produced by the interpolator.
• The control system can be either open-loop (as in
PTP systems) or closed-loop (as in contouring
systems).

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 DRIVES IN NC MACHINE TOOLS
CLASSIFICATION OF SERVOMOTOR MOTORS

POSITIONAL
DC SERVOMOTORS AC SERVOMOTORS
ROTATION MOTOR
BRUSHLESS DC CONTINUOUS
SERVOMOTORMOTORS ROTATION MOTOR

LINEAR
SERVOMOTORS

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 DC SERVOMOTORS
Working Principle of DC Servo Motor
A servo motor is basically a DC motor (in some special cases it is AC motor)
along with some other special purpose components that make a DC motor a
servo.
Potentiometer acts as transducer or SPECIAL PURPOSE
output sensor which takes position of COMPONENTS
the input of shaft of the motor and
generates voltage signal as output.

GEAR INTELLIGENT
POTENTIOMETER
ARRANGEMENT CIRCUITRY

As we know, a small DC motor will rotate with MAKES THE SERVO

high speed but the torque generated by its ROTATE ACCORDING
rotation will not be enough to move even a light
TO OUR WISHES
load.
The gear mechanism will take high input speed
of the motor (fast) and at the output, we will
get an output speed which is slower than
original input speed but more practical and 25
widely applicable.
Working Principle of DC Servo Motor

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• Say at initial position of servo motor shaft, the position of
the potentiometer knob is such that there is no electrical
signal generated at the output port of the potentiometer.
• This output port of the potentiometer is connected with
one of the input terminals of the error detector amplifier.
• Now an electrical signal is given to another input terminal
of the error detector amplifier.
• Now difference between these two signals, one comes
from potentiometer and another comes from external
source, will be amplified in the error detector amplifier and
feeds the DC motor.
• This amplified error signal acts as the input power of the DC
motor and the motor starts rotating in desired direction.
• As the motor shaft progresses the potentiometer knob also
rotates as it is coupled with motor shaft with help of gear
arrangement.

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• As the position of the potentiometer knob changes there will
be an electrical signal produced at the potentiometer port.
• As the angular position of the potentiometer knob
progresses the output or feedback signal increases.
• After desired angular position of motor shaft the
potentiometer knob is reached at such position the electrical
signal generated in the potentiometer becomes same as of
external electrical signal given to amplifier.
• At this condition, there will be no output signal from the
amplifier to the motor input as there is no difference
between external applied signal and the signal generated at
potentiometer.
• As the input signal to the motor is nil at that position, the
motor stops rotating. This is how a simple conceptual servo
motor works.

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 Servo Motor Control
• For understanding servo motor control let us consider an
example of servomotor that we have given a signal to rotate by
an angle of 45o and then stop and wait for further instruction.
• This signal i.e. electrical potential is increased with angular
movement of potentiometer knob along with the system shaft
from 0o to 45o.
• This electrical potential or voltage is taken to the error detector
feedback amplifier along with the input reference commends i.e.
input signal voltage.
• As the angle of rotation of the shaft increases from 0o to 45o the
voltage from potentiometer increases. At 45o this voltage
reaches to a value which is equal to the given input command
voltage to the system.
• As at this position of the shaft, there is no difference between
the signal voltage coming from the potentiometer and reference
input voltage (command signal) to the system, the output
voltage of the amplifier becomes zero.
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• As shown in the figure above the output electrical voltage signal
of the amplifier, acts as input voltage of the DC motor.
• Hence, the motor will stop rotating after the shaft rotates by
45o.
• The motor will be at this rest position until another command is
given to the system for further movement of the shaft in the
desired direction.
•
NB: Although in practical servo motor control system, instead
of using simple potentiometer we use digital or analog position
sensor encoder.

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 DC Servo Motor
• The motor which is used as a DC servo motor generally have a
separate DC source in the field of winding & armature winding.
• The control can be archived either by controlling the armature
current or field current. Based on the applications the control
should be applied to the DC servo motor.
• DC servo motor provides very accurate and also fast respond to
start or stop command signals due to the low armature inductive
reactance.
• DC servo motors are used in similar equipments and
computerized numerically controlled machines.

DC Servo Motor
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 AC Servo Motor

• AC servo motor is an AC motor that includes encoder is used

with controllers for giving closed loop control and feedback.
• This motor can be placed to high accuracy and also
controlled precisely as compulsory for the applications.
• Frequently these motors have higher designs of tolerance or
better bearings and some simple designs also use higher
voltages in order to accomplish greater torque.
• Applications of an AC motor mainly involve in automation,
robotics, CNC machinery, and other applications a high level
of precision and needful versatility.

AC Servo Moto 33
 Servo Motor

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Electric motor rotor (left) and stator (right)
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Cutaway view through stator of induction motor. 36
 DRIVES IN NC MACHINE TOOLS
STEPPER MOTORS
• A stepper motor is a pulse-driven motor
that changes the angular position of the
rotor in steps.
• Due to this nature of a stepper motor, it is
widely used in low cost, open loop
position control systems.
• A stepper motor is a device that converts
the electrical pulses into discrete
mechanical rotational motions of the
motor shaft.
• Typical step resolution is 1.8 degrees.
However, micro-step motors are capable
of 0.0144 degree steps.
• Stepper motors are usually used in open
loop control systems, though an encoder
may be used to confirm positional
accuracy.
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 ACTUATION SYSTEMS IN NC MACHINE TOOLS

Hardware devices that convert a controller command signal into a change

in a physical parameter usually mechanical (e.g., position or velocity)

• A transducer because it changes one type of physical quantity into some

alternative form.
• Is usually activated by a low-level command signal, so an amplifier is
often required to provide sufficient power to drive the actuator.
• Actuation Systems are provided corresponding to each of the automatic
control functions.
• Receive commands from the MCU.
• Desirables
⁻ Efficient
⁻ Stiff
⁻ Quick response
⁻ Virtually free from backlash influences

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 ACTUATION SYSTEMS IN NC MACHINE TOOLS

• An actuator is a component of a machine that is responsible for

moving or controlling a mechanism or system.

• An actuator requires a control signal and a source of energy.

• The control signal is relatively low energy and may be electric

voltage or current, pneumatic or hydraulic pressure, or even
human power.

• The supplied main energy source may be electric

current, hydraulic fluid pressure, or pneumatic pressure.

• When the control signal is received, the actuator responds by

converting the energy into mechanical motion.

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 BALL SCREW MECHANISM: LINEAR MOTION
• A ball screw is a mechanical linear actuator that
translates rotational motion to linear motion with little
friction.
• Sliding friction is reduced to rolling friction.
• A threaded shaft provides a helical raceway for ball
bearings which act as a precision screw.
• As well as being able to apply or withstand high thrust
loads, they can do so with minimum internal friction.
• They are made to close tolerances and are therefore
suitable for use in situations in which high precision is
necessary.

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• The ball assembly acts as the nut while the
threaded shaft is the screw.
• In contrast to conventional lead screws, ball
screws tend to be rather bulky, due to the need
to have a mechanism to re-circulate the balls.
• Efficiency is generally > 90% whereas sliding
friction type lead screws is rarely above 25%.

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BALL SCREW MECHANISM

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Ball Screw Mechanism

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 PRECISION IN NC POSITIONING
Precision:
• Precision is a measure of the spread of different
readings.
• Precision and accuracy are unrelated to each other,
meaning that you can be very PRECISE but not
ACCURATE.
• Precision is also as a synonym for the RESOLUTION of
the measurement.
• Measurement that can distinguish the difference
between, 0.01 and 0.02 is more precise (has a greater
resolution) than one that can only tell the difference
between 0.1 and 0.2 even though they may be equally
accurate.
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The Green is more precise than the Red.

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Three measures of precision:

• Accuracy

• Resolution

• Repeatability

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• Accuracy:
The “accuracy” of a measurement refers to how close a
measurement is to a “true” (actual) value.
Maximum possible error that can occur between the desired
target point and the actual position taken by the system.
Example:
This is the Actual In Drilling: If a tool
value. Accuracy is is instructed to go
the distance of
to a point in the
the measurement
from the Actual work envelope,
value. The Red is will it go where it
more accurate was told to?
than the Green.

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Resolution:

The smallest change in the quantity that can be detected.

Example:

In Drilling: How close the center of the tool can be position

to a point in the work envelope?

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Repeatability:
The ability of an operator to consistently repeat the same
measurement of the same part, using the same gauge,
under the same conditions.
Operator 1 measures a single part with
Gauge A 20 times, and then measures the
same part with Gauge B.
The solid line is the measurements from
Gauge A.
The dashed line is the measurements from
Gauge B.
Gauge A has less variation, so it is more
repeatable than Gauge B.
Example:
In Drilling: Can the tool consistently return to
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a previously visited point?
 FEEDBACK DEVICES IN NC MACHINE TOOLS
• Feedback system is actually a measuring device.
• The feedback allows the control system to compare
the machine’s actual position with the
programmed command.
• The result of this comparison provides the ability
of velocity and position control.
• The standard feedback devices are either digital
transducers or analogue transducers whose
output is converted to digital form.
• Transducers may be linear or rotary devices, where
the rotary type is more commonly used in the NC
machine tools.
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 FEEDBACK DEVICES IN NC MACHINE TOOLS
Positioning Feedback Devices
These are basically feedback devices for the positioning of the table,
and are classified as:
• Rotary Transducers
Generally connected directly to the screw or by means of
precision gearing.

• Linear Transducers
One part of the device is fixed to the machine tool structure,
whereas the other part is attached to a slide which moves over
the stationary part.

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 ROTARY TRANSDUCERS
Positioning Feedback Devices which are rotary in nature
There are following two basic types of rotary transducers .

• Encoders
‒ Numerical device.
‒ Outputs digital data directly

• Resolvers
‒ Analog device.
‒ Require conversion of analog to digital form.
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•Resolvers and Encoders are vastly different though
they serve the same purpose in many applications.
•In rotary applications, both of them are used to sense
the speed, direction and position of a rotating shaft.
•They function as transducers by transforming
mechanical motion into electronic information.
•This electronic information is feedback to electronic
devices controlling the mechanical motion.
•Feedback is the vital link that closes the control
system loop to improve the system performance.

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 ENCODER
• An encoder is a sensor of mechanical motion that
generates digital signals in response to motion.
• As an electro-mechanical device, an encoder is able to
provide motion control system users with information
concerning position, velocity and direction.
• There are two different types of encoders:
– linear and rotary
• A linear encoder responds to motion along a path,
while a rotary encoder responds to rotational motion.
• An encoder is generally categorized by the means of its
output.
• An incremental encoder generates a train of pulses
which can be used to determine position and speed.
• An absolute encoder generates unique bit
configurations to track positions directly.
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55
Encoders
Advantages
• low cost
• high accuracy
(e. g. by gear ratio)

Disadvantages
• elastic effects
and back lash
 Metal scale
LINEAR ENCODER
Magnitude of movement • The encoder is
composed of Reed
Head and the Scale.
Light
Reed • The Reed Head
Source
Head travels with the
Sensor axis, while the scale
is stationary.
Solar Cell
• The scale can be
produces
made of either glass
voltage
Moved up and or metal.
down • In the encoder the
metal scale has
Voltage Oscilloscope reflective markings
• The light from the
source in the Reed
Head , reflects off
the marking and are
in turn picked by
Time (sec) the sensor. 57
• Each time the light touches the tick mark voltage
is produced
• If the tick mark is 1mm apart and if one gets
voltage spikes, it is known that it has travelled
one tick mark i.e., 1 mm.
• So suppose one gets 5 voltage spikes then the
movement is 5 mm.
• If oscilloscope is connected at the Reed Head
voltage peaks are generated on the oscilloscope.
• By counting these peaks the movement is
known.

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Direction of movement

Metal scale
Light
Reed Source
Head
Sensor
Solar Cell
produces
voltage
Moved
Oscilloscope downward
Voltage

Signal 1 Signal 2
Signal 1
Signal 2

Time (sec)
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• For this second light source and sensor are
added to determine direction.
• So we will have two bits of light emitted and
after striking the reflective tick will be received
by the sensor.
• If moving downward first signal will on the top of
the tick mark first and its square/sine wave peak
will be first as compared to second signal.
• Signal 1 is in front of signal 2 hence we are
travelling downward.

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 Home
Reference Point

Metal scale
Light
Reed Source
Head
Sensor
Solar Cell
produces
voltage

Oscilloscope
Voltage

Signal 1 Signal 2
Signal 1
Signal 2

Time (sec)
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• This is accomplished by proximity sensors.

• When the axis is moved in the specific direction, they

recognize the home switch and call it (0,0) point.

• Hence it will be determine where the things are kept on

table.

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 ROTARY ENCODERS : OPTICAL ENCODER

• Device for measuring rotational position and speed

• Common feedback sensor for closed-loop NC control

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 OPTICAL ENCODER
Rotary Encoders
Working
• Optical encoders rely on opto electronic components to detect rotary motion.
• A light source emits a beam across a gap onto a photodetector.
• A code-wheel with graduated patterns of opaque and clear spaces rotates
between the source and detector.
• The clear areas allow light to pass through the code-wheel to the
photodetector.
• The photodetector produces an electrical current proportional to the intensity
of the illumination reaching it.
• Opaque areas in the code-wheel interrupt the light beam allowing little or no
light to reach the photodetector.

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The optical encoder's disc is made of glass or plastic with
transparent and opaque areas.

A light source and photo detector array reads the optical pattern
that results from the disc's position at any one time.

This code can be read by a controlling device, such as

a microprocessor or microcontroller to determine the angle of the
shaft.

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 ROTARY TRANSDUCERS
Resolver

It is a rotary electrical transformer used for measuring

degree of rotation.
It is considered an analogue device, and has a digital
counterpart, the rotary (or pulse) encoder.

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 RESOLVERS

• A resolver is a rotary
transformer that
produces an output
signal that is a function
of the rotor position.

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SERVOMOTOR with RESOLVER

68
 ROTARY TRANSDUCERS
Resolver
Construction
• Typically small AC motors in construction.
• Consists basically of a stator and a rotor.
• Resolvers are made of tough materials
that withstand harsh environments over
extended periods of time like copper wire,
iron laminations, steel housings, and high
temperature coatings.
• With few exceptions, resolvers can
operate at higher temperatures.
• Electronic circuitry known as converter is
used to transform cyclic output signals into
digital representation of shaft angle.

Construction of a Resolver
69
 ROTARY TRANSDUCERS
Resolver
Working
• Resolvers use magnetic flux between windings on iron cores much like
transformers.
• The typical resolver has two stator output coils at 90 degrees mechanical from
each other.
• An AC voltage (6 V to 60 V, 400 Hz to 10,000 Hz) applied to the rotating coil
(rotor) induces a voltage across the gap in the stationary coil (stator).
• As a result, transformer stator coil induces the input voltage across the gap to
the transformer rotor on the rotating member of the resolver.
• The current in the transformer rotor flows through the resolver rotor creating
the magnetic field of the rotor coil.
• Again the voltage is induced back across the gap to the resolver stator coils.
• The amplitude of the induced stator voltage is proportional to the relative
angular positions of the rotor and stator coils.

70
 ROTARY TRANSDUCERS
Resolver
Working
• Since there are two stator windings at 900, the output voltages are at 900
electrical phase. These voltages are called sine and cosine as given by the
equations:
Vs = K E * sin θ
Vc = K E * cos θ
Where
K, transform ratio (max output voltage / input voltage)
E, excitation voltage (E = Vo sin wt)
θ, rotor angle with respect to the stator

• The output of a resolver is therefore an analog AC voltage equivalent to the

absolute angle between the rotor and the stator. The absolute position is
calculated by:
θ = ARCTAN (sin θ / cos θ) = ARCTAN (Vs / Vc)

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 TOOL & WORK HOLDING DEVICES FOR NC MACHINES
Considerations
Tools & work holding devices should have the following
uniqueness:

• Must have required accuracy.

• The devices are allowed to perform a number of

operations on different faces in a single setting.

• Must enable quick loading and unloading.

• Must be fool-proofing to avoid incorrect loading of the

job. 72
TOOL & WORK HOLDING DEVICES FOR NC MACHINES

Considerations
• Must be of sufficient rigidity to fully withstand the
cutting forces.

• Must be safe in use for loading and unloading.

• Must have a sufficient clamping force for use of full

roughing cuts.

• Must be simple in construction as far as possible.

73
 TOOL HOLDING DEVICES FOR NC MACHINES
AUTOMATIC TOOL CHANGERS (ATC)

• Machining centers are equipped with tool storage known as

tool magazine.

• CNC tool changers allow a machine to perform more than one

function without requiring an operator to change the tooling.

• CNC machine tool raises the productivity by automatically

translating designs into instructions for a computer controller
on a machine tool.

• A CNC tool storage system is an organized, efficient, and

secure method of storing tools at all stages and time.
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• The concept of the ATC is that the range of tools for a specific job
shall be made available for automatic selection and positioning.

• Tool Magazines are available in two basic varieties: chain type

and wheel type.

• Chain type magazines are available with capacities of up to 60

tools although higher capacities of 120 tools can be developed.

• Wheel type magazines are generally limited to a strong capacity

of 20 to 30 tools.

• Magazine drives are electrically operated through indexing

mechanisms.

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 TOOL HOLDING DEVICES FOR NC MACHINES

Automatic Tool Changer

76
 TOOL HOLDING DEVICES FOR NC MACHINES
Automatic Tool Changer Types

• Wheel Type
• Chain Type

Wheel Type Automatic Tool Changer (ATC)

• It is a kind of automatic tool changer, in which the storage of
the tools are usually in the form of a circular rotating drum
type of magazine.
• Drums are indexed in the form or a circular array
• Equally spaced radial slots form the magazine in the drum
• For holding small number of tools usually not more than 30.
• Stored on periphery of drum and tool search speed is faster. Wheel Type

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Wheel type magazine

78
78
Wheel Type Magazine

79
79
 TOOL HOLDING DEVICES FOR NC MACHINES
Automatic Tool Changer Types

Chain Type Automatic Tool Changer (ATC)

• It is a kind of automatic tool changer, in which the storage of

the tools are usually in the form of a linearly moving chain
type of magazine.
• Chains are linearly indexed in the form or a linear array.
• Equally spaced linear slots form the magazine in the chain.

80
 TOOL HOLDING DEVICES FOR NC MACHINES
Automatic Tool Changer

Chain Type Automatic Tool Changer (ATC)

81
Chain Type Magazine

82
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 TOOL HOLDING DEVICES FOR NC MACHINES
Automatic Tool Changer Advantages

a) Lines changed in seconds instead of hours.

b) Increase operator safety by changing tools
automatically.
c) Change tools in seconds for maintenance and repair.
d) Increase flexibility.
e) Heavy and large multi-tools that are automatically
exchanged.

83
 WORK HOLDING DEVICES FOR NC MACHINES
Characteristics
• Machining operations on turning centers or NC machine tools are
carried out mostly for axi-symmetrical components.
• Surfaces are generated by the simultaneous motions of X and Z
axes. Identification or fixation of datum surfaces.
• Mounting of jobs is quick, accurate locating , supporting and
clamping.
• Quick and easy loading and unloading of the unfinished and
finished job to and from the machine tool.
• Avoidance of jigs and fixtures.
• Ability to cover wide range of size and shape of the blanks. 84
 WORK HOLDING DEVICES FOR NC MACHINES
• Work holding includes any device used to present and hold a
work piece to a cutting tool.

• The work holding devices are used to hold and rotate the
workpieces along with the spindle.

• Different work holding devices are used according to the shape,

length, diameter and weight of the workpiece and the location of
turning on the work.

85
 WORK HOLDING DEVICES FOR NC MACHINES
These devices include:
• Chucks
• Face plate
• Driving plate
• Carriers
• Mandrels
• Centres
• Rest

86
 WORK HOLDING DEVICES FOR NC MACHINES
Chucks

• Workpieces of short length, large diameter and irregular shapes,

which can not be mounted between centres, are held quickly
and rigidly in chuck.

• There are different types of chucks namely, Three jaw universal

chuck, Four jaw independent chuck, Magnetic chuck, Collet
chuck and Combination chuck.

87
 WORK HOLDING DEVICES FOR NC MACHINES
Three Jaw self-centering chuck

• The three jaws fitted in the three

slots may be made to slide at the
same time by an equal amount by
rotating any one of the three
pinions by a chuck key.

• This type of chuck is suitable for

holding and rotating regular
shaped workpieces like round or
hexagonal rods about the axis of
the lathe.

• Workpieces of irregular shapes

cannot be held by this chuck.

88
 WORK HOLDING DEVICES FOR NC MACHINES
Four Jaw Independent Chuck
• There are four jaws in this chuck.
• Each jaw is moved independently
by rotating a screw with the help
of a chuck key.
• A particular jaw may be moved
according to the shape of the
work. Hence this type of chuck
can hold woks of irregular shapes.
• But it requires more time to set
the work aligned with the lathe
axis.
• Concentric circles are inscribed on
the face of the chuck to enable
quick centering of the workpiece.
89
 WORK HOLDING DEVICES FOR NC MACHINES
Magnetic Chuck
• The holding power of this chuck is
obtained by the magnetic flux
radiating from the Electromagnet
placed inside the chuck.
• Magnets are adjusted inside the
chuck to hold or release the work.
• Workpieces made of magnetic
material only are held in this
chuck.
• Very small, thin and light works
which can not be held in a or-
dinary chuck are held in this
chuck.
90
 WORK HOLDING DEVICES FOR NC MACHINES

Collet Chuck
• Collet chuck has a cylindrical
bushing known as collet.
• It is made of spring steel and
has slots cut lengthwise on
its circumference.
• So, it holds the work with
more grip.
• Collet chucks are used in
capstan lathes and automatic
lathes for holding bar stock in
production work.
91
 WORK HOLDING DEVICES FOR NC MACHINES
Face plate
• Faceplate is used to hold large, heavy and irregular shaped
workpieces which can not be conveniently held between
centres.
• It is a circular disc bored out and threaded to fit to the nose of
the lathe spindle.
• It is provided with radial plain and ‘T’ – slots for holding the
work by bolts and clamps.

92
 WORK HOLDING DEVICES FOR NC MACHINES
Mandrel
• A previously drilled or bored workpiece is held on a
mandrel to be driven in a lathe and machined.
• There are centre holes provided on both faces of the
mandrel.
• The live centre and the dead centre fit into the centre
holes.
• A carrier is attached at the left side of the mandrel.
• The mandrel gets the drive either through a catch plate
or a driving plate.

93
 Carrier

When a workpiece is held and machined between centres, carriers are useful in
transmitting the driving force of the spindle to the work by means of driving plates
and catch plates.

The work is held inside the eye of the carrier and tightened by a screw.

er fits into the slot of the catch plate to drive the work. 94
Carriers are of two types and they are :

Straight tail carrier

Bent tail carrier

Straight tail carrier is used to drive the work by means of the pin provided in
the driving plate.

The tail of the bent tail carrier fits into the slot of the catch plate to drive the
work.

95
 WORK HOLDING DEVICES FOR NC MACHINES
Rests
• A rest is a mechanical device to support a long
slender workpiece when it is turned between centres
or by a chuck.
• It is placed at some intermediate point to prevent
the workpiece from bending due to its own weight
and vibrations setup due to the cutting force.

96
 Centres

• Centres are useful in holding the work in a lathe between centres.

The shank of a centre has Morse taper on it and the face is conical in
shape.

There are two types of centres namely

• Live centre
• Dead centre

• The live centre is fitted on the headstock spindle and rotates with the
work.
• The centre fitted on the tailstock spindle is called dead centre. It is
useful in supporting the other end of the work.

97
98
 WORK HOLDING DEVICES FOR NC MACHINES
Automatic pallet change over systems
The APC is an automated system for changing the pallet on the table of the
machine, picking/depositing from and to individual pallet stations or from and to a
magazine via a shuttle.

• Automatic pallet change over systems are used

in NC as modern CNC machines.
• These pallets simply move for interchanging
their positions on the machine table.
• While machining is being done on a job kept
on one pallet, the other pallets are accessible
to the operator for clamping and unclamping
raw material or finished product.
Automatic Pallet Changer99
 WORK HOLDING DEVICES FOR NC MACHINES

Milling vices
 WORK HOLDING DEVICES FOR NC MACHINES

Multiple vises
 MACHINE CONTROLLER UNIT MCU
The machine control unit (MCU) is the backbone of CNC systems. Consists of
some electronic hardware that reads the NC program, interprets it and
conversely translates it for mechanical actions of the machine tool.

Following six functions are being done by MCU:

• Read coded instructions

• Decode coded instructions

• Implement interpolations to generate axis motion commands

• Feed axis motion commands to amplifier circuits to drive axis mechanisms

• Receive the feed back signals of position and speed for each drive axis

• Implement auxiliary control functions such as coolant ON/OFF, spindle

ON/OFF, and tool change
102
 MACHINE CONTROLLER UNIT MCU

Dell 2135CN & 2155CN Machine Control Unit Board (MCU)

103
INTRODUCTION OF CNC SIEMENS CONTROLLER
105
106
 MACHINE CONTROLLER UNIT MCU

The MCU may be of three types :

• Housed MCU Machine Control Unit

May be mounted on the machine tool or may be built in the casing of the
machine.

• Swing Around MCU Machine Control Unit

It is directly mounted on the machine, which can swing around it and can
be adjusted as per requirement of the operator’s position.

• Machine Control Unit

It is enclosed in a separate cabinet which is installed at some remote or

same place near to the machine.
107
 (G&M Code Program)

MCU
Computer Numerical Control
Master Control Unit

The Axis amplifier

increases the
electrical current
from the CNC
control unit

•The CNC program contains all the G&M code of that is interpreted
by the motion control unit.
•When the machine is instructed to move to a position in X, Y
(lathe), or X,Y and Z (for a 3 axis machine) then a designated number
of pulses are sent to the axis drive amplifier.
 MACHINE CONTROLLER UNIT MCU
• This in turn pulses the drive motor which moves the
machine table or axis.
• There is axis feedback from the drive motor which is fed
back into the axis drive amplifier to ensure that the
motor has moved the correct amount of divisions.
• As the machine table or tool moves there is a linear
encoder which reads the actual position of the
table/tool and feeds this back to the motion control
unit.
• This will be compared to the original value and the
control unit will adjust the amount of pulses needed to
move the tool/table to the correct position
109
 A TYPICAL CNC LATHE/MILLING MACHINE PROGRAM BEING
INTERPRETED BY THE MACHINE CONTROL UNIT
CNC Program
G and M codes

Send signals to Encoder sends Are axis

G00 Servo interface Servo motors
servo interface for Positional data at position?
X20 z30 to amplify signals move axis
X and Z axis To control unit
yes

Request machine Electrical pulse to

Is T01 Fitted? Is T01 Fitted?
T01 to have T01 fitted Tool change
yes
yes
no

Send signals to Encoder sends Is spindle

M04 Servo interface Servo motors to
Spindle servo Positional data at speed?
S200 to amplify signals rotate spindle
interface To control unit yes
no

Send signals to Encoder sends Are axis

G01 Servo interface Servo motors
servo interface for Positional data at position?
X20 Z0 to amplify signals move axis
X and Z axis To control unit
yes

Program Continues
 TYPES OF CNC MACHINE CONTROL UNITS

FANUC CONTROLL
SIEMENS
GSK
MECH 3 etc
A 5-axis CNC travelling column machining centre for aerospace 112
machining applications (Courtesy Jobs S.p.A., Italy)
A gantry type CNC machining centre DMC 65V for high speed machining (Courtesy
113
Deckel Maho Gildemeister, Germany)
Twin spindle CNC Turning centre (Courtesy Georg Fischer, Switzerland
114
115
116
117
END OF 2nd UNIT

118