INDUSTRIAL VISIT AND TECHNICAL SEMINAR

REPORT II
DIVISION

KARTHIKEYAN P - 16MD08
JEGAVEERAPANDIAN S - 16MD06

INTRODUCTION
Starting from an enterprise geared to meet the rural economy, PSG has diversified its activities to
meet the requirements of industrial sector as well. Its customers range from small/medium scale
to giant aero space industries supported by a large number of academic and industrial personnel
and modern state-of-the art R & D laboratories, Rapid Prototyping, CAD/CAM facilities and
sophisticated testing and measuring equipments along with hi-tech CNC machineries.
PSG Machine Tools like CNC Lathes and Centre Lathes which are indigenously developed enjoy
high reputation in the country and are exported all over the world.
Now, PSG have specially designed and developed CNC Trainer Lathe machine and Vertical
Machining Centre with six tools, automatic tool changer to cater to the needs of educational
institutions like engineering colleges, polytechnics and industrial training institutes to train the
students to meet the challenges of high-tech requirements for the engineering industries. Our
machine tool products are of high quality for its functional reliability.
COMPUTER NUMERICAL CONTROL (CNC)
Computer Numeric Control (CNC) is the automation of machine tools that are operated
by precisely programmed commands encoded on a storage medium (computer command
module, usually located on the device) as opposed to controlled manually by hand wheels or
levers, or mechanically automated by cams alone. Most NC today is computer (or computerized)
numerical control (CNC), in which computers play an integral part of the control.
In modern CNC systems, end-to-end component design is highly automated using
computer-aided design (CAD) and computer-aided manufacturing (CAM) programs. The
programs produce a computer file that is interpreted to extract the commands needed to operate a
particular machine by use of a post processor, and then loaded into the CNC machines for
production. Since any particular component might require the use of a number of different tools
drills, saws, etc. modern machines often combine multiple tools into a single "cell". In other
installations, a number of different machines are used with an external controller and human or
robotic operators that move the component from machine to machine. In either case, the series of
steps needed to produce any part is highly automated and produces a part that closely matches
the original CAD design.

Elements of CNC machine tools:

1. Drives
Basic function of a CNC machine is to provide automatic and precise motion
control to its elements such work table, tool spindle etc. Drives are used to provide such
kinds of controlled motion to the elements of a CNC machine tool. A drive system
consists of drive motors and ball lead-screws. The control unit sends the amplified
control signals to actuate drive motors which in turn rotate the ball lead-screws to
position the machine table or cause rotation of the spindle.
2. Power drives
Drives used in an automated system or in CNC system are of different types such
as electrical, hydraulic or pneumatic.
Electrical drives these are direct current (DC) or alternating current (AC) servo
motors. They are small in size and are easy to control.
Hydraulic drives these drives have large power to size ratio and provide step less
motion with great accuracy. But these are difficult to maintain and are bulky. Generally
they employ petroleum based hydraulic oil which may have fire hazards at upper level of

working temperatures. Also hydraulic elements need special treatment to protect them
against corrosion.
Pneumatic drives this drives use air as working medium which is available in
abundant and is fire proof. They are simple in construction and are cheaper. However
these drives generate low power, have less positioning accuracy and are noisy.
In CNC, usually AC, DC, servo and stepper electrical drives are used. The various
drives used in CNC machines can be classified as: a. Spindle drives to provide the main
spindle power for cutting action b. Feed drives to drive the axis
2.1 Spindle drives
The spindle drives are used to provide angular motion to the work piece or a
cutting tool. These drives are essentially required to maintain the speed accurately
within a power band which will enable machining of a variety of materials with
variations in material hardness. The speed ranges can be from 10 to 20,000 rpm. The
machine tools mostly employ DC spindle drives. But as of late, the AC drives are
preferred to DC drives due to the advent of microprocessor based AC frequency
inverter. High overload capacity is also needed for unintended overloads on the
spindle due to an inappropriate feed. It is desirous to have a compact drive with
highly smooth operation.

2.2 Feed Drives

These are used to drive the slide or a table. The requirements of an ideal feed
drive are as follows.
The feed motor needs to operate with constant torque characteristics to
overcome friction and working forces.
The drive speed should be extremely variable with a speed range of about 1:
20000, which means it should have a maximum speed of around 2000 rpm and at a
minimum speed of 0.1 rpm.
The feed motor must run smoothly.
The drive should have extremely small positioning resolution
Other requirements include high torque to weight ratio, low rotor inertia and
quick response in case of contouring operation where several feed drives have to
work simultaneously. Variable speed DC drives are used as feed drives in CNC
machine tools. However now-days AC feed drives are being used.
Types of CNC machine
There are many different types of CNC Machines used in industry, Such as:
Mills and Machining Centers
Lathes and Turning Centers

Drilling Machines
EDM Sinker and wire cut Machines
Flame and Laser-Cutting Machines
Water Jet Profilers
Vertical Milling Center (VMC)

Vertical milling machine.

1: milling cutter 2: spindle 3: top slide or over arm 4: column 5: table 6: Y-axis slide 7:
knee 8: base
In the vertical mill the spindle axis is vertically oriented. Milling cutters are held in the
spindle and rotate on its axis. The spindle can generally be extended (or the table can be
raised/lowered, giving the same effect), allowing plunge cuts and drilling. There are two
subcategories of vertical mills: the bed mill and the turret mill.

A turret mill has a stationary spindle and the table is moved both perpendicular and
parallel to the spindle axis to accomplish cutting. The most common example of this type
is the Bridgeport, described below. Turret mills often have a quill which allows the
milling cutter to be raised and lowered in a manner similar to a drill press. This type of
machine provides two methods of cutting in the vertical (Z) direction: by raising or
lowering the quill, and by moving the knee.

In the bed mill, however, the table moves only perpendicular to the spindle's axis, while
the spindle itself moves parallel to its own axis.

Turret mills are generally considered by some to be more versatile of the two designs.
However, turret mills are only practical as long as the machine remains relatively small. As
machine size increases, moving the knee up and down require considerable effort and it also
becomes difficult to reach the quill feed handle (if equipped). Therefore, larger milling machines
are usually of the bed type.

A third type also exists, a lighter machine, called a mill-drill, which is a close relative of
the vertical mill and quite popular with hobbyists. A mill-drill is similar in basic configuration to
a small drill press, but equipped with an X-Y table. They also typically use more powerful
motors than a comparably sized drill press, with potentiometer-controlled speed and generally
have more heavy-duty spindle bearings than a drill press to deal with the lateral loading on the
spindle that is created by a milling operation. A mill drill also typically raises and lowers the
entire head, including motor, often on a dovetailed vertical, where a drill press motor remains
stationary, while the arbor raises and lowers within a driving collar. Other differences that
separate a mill-drill from a drill press may be a fine tuning adjustment for the Z-axis, a more
precise depth stop, the capability to lock the X, Y or Z axis, and often a system of tilting the head
or the entire vertical column and power head assembly to allow angled cutting. Aside from size
and precision, the principal difference between these hobby-type machines and larger true
vertical mills is that the X-Y table is at a fixed elevation; the Z-axis is controlled in basically the
same fashion as drill press, where a larger vertical or knee mill has a vertically fixed milling
head, and changes the X-Y table elevation. As well, a mill-drill often uses a standard drill presstype Jacob's chuck, rather than an internally tapered arbor that accepts collets. These are
frequently of lower quality than other types of machines, but still fill the hobby role well because
they tend to be bench top machines with small footprints and modest price tags.

PSG VMC T 01 LATHE

FEATURES

Compact and aesthetically designed

3 Axis CNC System

Spindle runs on Precision

Suitable for the bearings

Slide motion on hardened and ground guide ways with Precision ball screws

AC servo spindle

AC Servo axis drive

Programmable spindle speeds

Reliable 6 tools ATC, Production of variety

BT 35 Spindle taper

Built in coolant tank and chip tray, Centralized lab system of Light milling

Suitable to Train Students of Engineering / Polytechnic / Industrial Training

Institute

To Train Industry Workmen and also for small components production work

Drilling and Boring parts

CAPACITIES
X - axis travel (Longitudinal)

250 mm

Y - axis travel (Cross)

165 mm

Z - axis travel (Vertical)

235 mm

Axis drive

AC servo

Max. boring length

90 mm

SPINDLE
Spindle taper

BT 35

Tool holder clamping

Draw bar

Tool holder

BT 35

Speed range (Infinitely variable)

50 - 2500 rpm

Speed control

Direct

TABLE
Working surface

435 x 165 mm

T - slot size

10 mm

No. of T - slots

Height above from floor

1010 mm

Horizontal Milling Center (HMC)

Horizontal milling machine.

1: base 2: column 3: knee 4 & 5: table (x-axis slide is integral) 6: over arm 7: arbor
(attached to spindle)
A horizontal mill has the same sort but the cutters are mounted on a horizontal arbor
across the table. Many horizontal mills also feature a built-in rotary table that allows milling at
various angles; this feature is called a universal table. While end mills and the other types of
tools available to a vertical mill may be used in a horizontal mill, their real advantage lies in
arbor-mounted cutters, called side and face mills, which have a cross section rather like a circular
saw, but are generally wider and smaller in diameter. Because the cutters have good support from
the arbor and have a larger cross-sectional area than an end mill, quite heavy cuts can be taken
enabling rapid material removal rates. These are used to mill grooves and slots. Plain mills are
used to shape flat surfaces. Several cutters may be ganged together on the arbor to mill a
complex shape of slots and planes. Special cutters can also cut grooves, bevels, radii, or indeed
any section desired. These specialty cutters tend to be expensive. Simplex mills have one spindle,
and duplex mills have two. It is also easier to cut gears on a horizontal mill. Some horizontal
milling machines are equipped with a power-take-off provision on the table. This allows the table
feed to be synchronized to a rotary fixture, enabling the milling of spiral features such
as hypoid gears.

PSG CNC T 110 LATHE

FEATURES

Compact and aesthetically designed

2 Axis CNC System

Anti-friction, Pre-loaded, Suitable for the High precision spindle bearings

Slide motion on hardened and ground guide ways with Precision ball screws

Programmable spindle speeds

8 Station turret

Built in coolant Production of variety and lab systems

AC Servo axis drive

Suitable to Train Students of Engineering / Polytechnic / Industrial Training Institute

To Train Industry Workmen and also for small of Turned Parts components production
work.

CAPACITIES

Type of bed

inclined 45 to vertical

Swing over bed covers

300 mm

Swing between centres

180 mm

Max. turning dia. of chucking job

110 mm

Max. boring length

90 mm

Max. turning length

210 mm

Chuck size

125 mm

AXES TRAVEL
Feed range X & Z axis

1-3750 mm/min

Rapid traverse rate X & Z axis

5000 mm / min

Threading pitch

0.25 - 16 mm

Cross slide stroke

80 mm

CONCLUSION
Thus we have visited the CNC division, we have gathered information about various operations
done by CNC machine & milling centers.