CNC LATHE MACHINE

INTRODUCTION TO CNC MACHINE: CNC stands for computer numeric controlled. It refers
to any machine tool (i.e. mill, lathe, drill press, etc.) which uses a computer to electronically
control the motion of one or more axis on the machine.
The development of NC machine tools started from a task supported by the US Air Force in the
early 1950s, involving MIT and several machine-tool manufacturing companies. The need was
recognized for machines to be able to manufacture complex jet aircraft parts.
As computer technology evolved, computers replaced the more inflexible controllers found on
the NC machines; hence the dawn of the CNC era.
CNC machine tools use software programs to provide the instructions
necessary to control the axis motions, spindle speeds, tool changes and so on.
CNC machine tools allow multiple axes of motion simultaneously,
resulting in 2D and 3D contouring ability.
CNC technology also increases productivity and quality control by
allowing multiple parts to be produced using the same program and tooling.

TYPES OF CNC MACHINES: There are many types of CNC machines used in the industries,
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

ELEMENTS OF A
CNC MACHINE
ELEMENTS OF A CNC MACHINE: The various units are as follows:
INPUT UINIT: It receives all the commands from the operator interface (operation station
containing all switches, push buttons, displays required to operate and monitor machine
activities) and feedback or status of machine in the form of a.c, d.c, analog signals, or by
digitally.
Different ways of data input are:
MDI: Manual Data Input
PROGRAM PREPARATION WITH CAD CAM
PROGRAM DATA TRANSFER FROM PC TO CNC M/C
PROGRAM DATA TRANSFER FROM PC TO DNC OPERATIONS

CONTROL UNIT: It takes instructions from the memory unit and interprets them one at a time.
It processes information received from the operator and machine interface. These informations
are then interpreted and manipulated with hardware logic and computer programmes. It sends
appropriate instructions to other units to cause instruction execution. It turns on and off
machine outputs and controls motion via machine interface.
TYPES OF CNC MACHINE CONTROL UNITS:
FANUC CONTROLL
SIEMENS
GSK
MECH3

MEMORY UNIT: It stores instructions and data received from the input. It also stores the results
of arithmetic operations and supply information to output unit. Part programs are usually
stored in a Random Access Memory, which provide immediate access to any storage location
point in memory.

ARITHMATIC UNIT: It performs calculations and makes decisions. Its results are stored in memory
unit.

OUTPUT UNIT: it receives data from the memory at the command of control unit. The signals
are made compatible with output devices so that commands issued by output unit can be
obeyed by them.

OPERATOR AND MACHINE INTERFACE: operator stations forms a major operator interface. It is
used to initiate automatic operation, to input data, and to monitor activities using display
devices. A host computer also serves as operator interface, when a part is made on this
machine the host computer modifies the part programme, while it is running by making
corrections based on the error table, to obtain improved accuracy on the part.
OPERATIONAL FEATURES of CNC MACHINES:


CNC OPEN LOOP AND CLOSE LOOP SYSTEM: The open and closed loop system describes the two
primary types of CNC control systems. Open and closed loop describes the control process of a
system. Open loop refers to a system where the communication between the controller system
and the motor is one way.
OPEN LOOP SYSTEM: Refers to a system using a stepper motor, where the communication
between the controller system and motor is one way. The process is fairly simple. The machinist
will decide what he/she wants to accomplish and will generate the G-code and the software will
create the necessary steps and direction signals to perform the desired task. The computer will
relay this information to the controller which then energizes the motor. What distinguishes open
looped from a close looped system is after the motor moves to the desired position; there is no
feedback to the controller system to verify the action.

CLOSE LOOP SYSTEM:
The closed-loop system has a feedback subsystem to monitor the actual output and correct
any discrepancy from the programmed input. The feedback system could be either analog or
digital. The analog systems measure the variation of physical variables such as position and
velocity in terms of voltage levels. Digital systems monitor output variations by means of
electrical pulses.
Closed-loop systems are very powerful and accurate because they are capable of monitoring
operating conditions through feedback subsystems and automatically compensating for any
variations in real-time.
Most modern closed-loop CNC systems are able to provide very close resolution of 0.0001 of
an inch. Closed-looped systems would, naturally, require more control devices and circuitry in
order for them to implement both position and velocity control. This, obviously, makes them
more complex and more expensive than the open-loop system.



CNC COORDINATE SYSTEM: In order to shape metal by machine tools, the cutting tool
should move in contact with the work piece at certain specific points, while the work piece or
cutting tool is rotating.
Coordinate system is required to define the movement on the machine.
Basically there are two common Coordinate systems:
CARTESIAN COORDINATE SYSTEM
POLAR COORDINATE SYSTEM
If the motor does not operate as instructed
there is no way for the system to know that
this is occurring. The controller system will
continue performing the next task or step as
if there is no problem until a limit switch is
tripped or the operator resets the machine.
Open loop systems run the risk overloading
the machine and losing steps which can ruin
the work piece or cause harm to the
machine. These are the drawbacks of open
loop system.

2D Cartesian coordinate system: When dealing with 2 dimensions (2D), the two-
dimensional coordinate system is used.

3D CARTESIAN COORDINATE SYSTEM: When dealing with three dimensions (3D), the
three dimensional coordinates system is used;
Three Axis Milling machine: In a Three Axis Vertical Milling Machine:
X is the direction of the Table travel
Y is the direction of the Cross travel
Z the Spindle travel up down


6 AXIS MILLING MACHINE
Polar Coordinate System: The point is located by its distance (radius r) to the point of
origin and its angle (alpha ) to a specified axis.

The angle is positive if it is measured in counterclockwise direction starting from positive X-axis

CNC Lathe (turning) Machines coordinate system:
Machine Zero Point (M): The origin of the coordinate system. It is defined by the manufacturer
and cannot be changed. In general, the machine zero point M is located in the center of the work
spindle nose for cnc lathe.

The work pieces zero point (W) it is the origin of the work part-based coordinate system.
Its location is specified by the programmer.
CNC PROGRAMMING:
Offline programming linked to CAD programs.
Conversational programming by the operator.
MDI ~ Manual Data Input.
Manual Control using jog buttons or `electronic hand wheel'.
Word-Address Coding using standard G-codes and M-codes.
Basics of NC Part Programming: During secondary motion, either the tool moves relative
to the work piece or the work piece moves relative to the tool. In NC programming, it is always
assumed that the tool moves relative to the work piece no matter what the real situation is.

The position of the tool is described by using a Cartesian coordinate system. If (0, 0, 0) position can
be described by the operator, then it is called floating zero.
In defining the motion of the tool from one point to another, either absolute positioning mode or
incremental positioning mode can be used.

Absolute positioning: In this mode, the desired target position of the tool for a particular
move is given relative to the origin point of the program.
Incremental positioning: In this mode, the next target position for the tool is given
relative to the current tool position.
Structure of an NC Part Program: Commands are input into the controller in units called
blocks or statements.
Fixed sequential format
Tab sequential format
Word address format-----sample block N135 G01 X1.0 Y1.0 Z0.125 F5
Programming Key Letters:
O- Program number (Used for program identification)
N - Sequence number (Used for line identification)
G - Preparatory function
X - X axis designation
Y - Y axis designation
Z - Z axis designation
R - Radius designation
F - Feed rate designation
S - Spindle speed designation
H - Tool length offset designation
D - Tool radius offset designation
T - Tool Designation
M - Miscellaneous function
Table of Important G codes:










G44 Tool length compensation
(minus)
G49 Tool length compensation
cancel
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning

G00 Rapid Transverse
G01 Linear Interpolation
G02 Circular Interpolation, CW
G03 Circular Interpolation, CCW
G17 XY Plane
G18 XZ Plane
G19 YZ Plane
G20/G70 Inch units
G21/G71 Metric Units
G42 Cutter compensation right
G43 Tool length compensation(plus)

LIST OF IMPORTANT M CODES:
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps on
M11 Clamps off
M30 Program stop, reset to start


PROGRAMMING EXAMPLE:


M00 Program stop.
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stops.

M06 TOOL CHANGE
M08 COOLANT ON
M09 COOLANT OFF
M10 CLAMPS ON
M11 CLAMPS OFF
M30 PROGRAM STOP.