TECHNOLOGY STUDY FILE 5

COMPUTER NUMERICALLY CONTROLLED (CNC) MACHINING

INTRODUCTION

TO

CNC

Numerical control means quite simply, control by numbers. Numerically controlled machine tools, are those lathes, milling machines, drilling machines and punch presses that have their movements and other functions controlled by instructions or data received as a series of numbers. The numbers are interpreted electronically by the machine tool and are then acted upon. Machine tools that include a computer, able to make calculations and decisions based upon data received are called computer numerically controlled (CNC). Data or information, flows from the computer, and the CNC milling machine sends feedback data back to the computer. A CNC machine runs under the control of a computer, and the moving parts are driven by special electric motors called stepper motors. The computer switches these on and off, and controls their direction and speed. After the computer has been programmed to make the machine tool perform a sequence of operations, the program can be run over and over again to produce many identical components. There are software packages that enable the programmer simply to draw an outline of the required component on the screen, and the software then converts this image automatically into a set of codes in the form of a program.

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HISTORY

OF

CNC

First NC machines: 1801 Jacquard loom

First NC/CNC cutting machines: Large curved surfaces in aerospace components

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Flexible manufacturing systems

Machining centre

Anthropometric robot

Control unit

Vision based inspection

TYPICAL CNC PRODUCTS

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An example of component production for a motor cycle in the form of a disc pad is given.

COMPARISON

OF

CNC

WITH

CONVENTIONAL MACHINING

MANUFACTURING COSTS Cost of preparing for production Planning Programming Costs Tape production Jigs fixtures Design manufacture Proving costs

Production costs Costs of machines

Related costs Machine set up Tooling cost Pre-setting Re-sharpening

ADVANTAGES OF CNC 1 Consistent accuracy - repeatability 2 Increased productivity 3 Less operator involvement 4 Complex shapes easily machined 5 Reduced tooling costs 6 Reduced component rejection 7 Uniformity of product 8 Can work unattended - unsocial times 9 Improved Management control

DISADVANTAGES OF CNC 1 Cost of machines (initial) 2 Cost of maintenance and servicing 3 Installation costs 4 Training of operators

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Operators 80 60 40 20 0 Conventional CNC

Machine Tools 50 40 30 20 10 0 Conventional CNC

Floor Space (sqr metres)

Conventional CNC

Through-put Time (days) 20 15 10 5 0 Conventional CNC 98 97 96 95 94 93

Production Output (%) 15 10 5 0 Conventional CNC

Operations per Part

Conventional CNC

Machine Usage (%) 80 60 40 20 0 Conventional CNC

Comparisons between conventional and CNC machining

A typical CNC lathe

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Head Chuck Z axis Cutter

Table

X axis

Y axis

Vertical milling machine

PROGRAM WRITING
Before CNC machining can take place, we have to write a program to tell the machine tool what you want it to do. What do we need to know? 1. Where the tool starts from - DATUM 2. Where the tool moves to - X, Y, Z (axis) 3. What path will the tool trace? 4. How is it getting there? - G CODES 5. How does it know it has got there? - FEEDBACK 6. How does the machine know how to start and stop? - M CODES 7. How do we turn on the coolant? - M CODES

PROGRAMMING LANGUAGE
FEEDBACK - This tells the machine where to go and how to get there. Feedback tells the composer where the tool is and when to move to the next line in the program.

Machine tool

Composer

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G CODES - These tell the control the facilities required for machining to be carried out and how to move to the target point. Here are a selection of G CODES: G00 G01 G02/G03 Rapid positioning - moves the tool quickly to its required position without removing material A linear move - moves the tool in a straight line whilst removing material Circular move - to a position around a radius while removing material

M CODES - These tell the control when to start or stop coolant or when to switch the machine on or off. Here are a selection of M CODES: M00 M01 M03 M08 Program Stop Program Optional Stop Start Spindle Start Coolant

A typical line of program would be: N01 G00 X50 Z60 F120 M03 This is called 'Word Address'. The word is, for example, G00 X50

The line of program is called a block. Note that in the block above the 'F' refers to the feed rate of the machine.

N01
Line number

G00
G CODE tells the machine how to move the slideways

X50

Z60

F120 M03
Feed Rate m/min M CODE tells the machine when to start/ stop, switch coolant, etc.

Co-ordinates in the X and Z axes with reference to the component Datum

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SAFETY PROCEDURES
1. Always ensure guards are in use 2. Always ware safety glasses when using the machinery 3. Do not wear loose or baggy clothing when operating the machines 4. All long hair must be tied back or covered with a hat 5. All tools must be treated with respect 6. The machine must be cleaned and tidied before leaving the workshop 7. Oil and coolant can be dangerous if spilt on the floor. Always ensure any spillage is cleaned up

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