What is CNC?

Computer Numerical Control

Introduction to CNC
The process of manufacturing machined parts using a
computerized controller to command motors which drive
each machine axis.
Lecture 22

Engineering 475
Automated Production Processes

History of CNC History of CNC

(Continued)
John Parsons, Parsons Corporation,
1947 Michigan
Developed a control system that directed a 1954 NC was announced to public
spindle to many points in succession
1957 First production NC machines were
Servomechanism Laboratory of delivered and installed
1951 Massachusetts Institute of Technology
(MIT) – Added computer to Parson’s 1960 NC machine tools commonly available
system
Cincinnati Milicron Hydro-Tel Vertical
1952 Spindle Milling Machine
A lot of the initial funding for the development of NC
First three-axis numerically controlled,
machine tools came from the United States Government.
tape-fed machine tool

CNC Workbook CNC Workbook

Why CNC machine tools? Integration with Mathematics

• Increase production throughput

• Improve the quality and accuracy of
manufactured parts y
• Stabilize manufacturing costs
• Manufacture complex or otherwise
impossible jobs – 2D and 3D contours.

x
Complex curves and surfaces can be described mathematically
Kalpakjian, Figure24.1

1
 Integration with Mathematics
(Continued) Advantages of CNC
Vf ≡ feed rate • Flexibility of operation is improved, as is the ability to
along curve Vf produce complex shapes with good dimensional
∆y accuracy, repeatability, reduced scrap loss, and high
Tangent production rates, productivity, and product quality.
Or Slope ∆x • Tooling costs are reduced, since templates and other
fixtures are not required.
• Machine adjustments are easy to make with
∆x microcomputers and digital readouts.
Curve to be followed Vx = Vf • More operations can be performed with each setup, and
Complex curves can be ∆x 2 + ∆y 2 less lead time for setup and machining is required
followed by breaking the compared to conventional methods. Design changes are
curve into a series of small ∆x facilitated, and inventory is reduced.
Vy = Vf
straight lines and using linear ∆x 2 + ∆y 2
interpolation. Kalpakjian, 1135.

Advantages of CNC
(Continued)
• Programs can be prepared rapidly and can be recalled at
any time utilizing microprocessors. Less paperwork is
involved.
• Faster prototype production is possible.
• Required operator skill is less than that for a qualified
machinist, and the operator has more time to attend to
other tasks in the work area.
Limitations of CNC
• Relatively high initial cost of the equipment.
• The need and cost for programming and
computer time.
• Special maintenance with trained personnel.
• High preventative maintenance since
breakdowns are costly.

Kalpakjian, 1135. Kalpakjian, 1136.

Anatomy of a CNC Machine Anatomy of a CNC Machine

(3-
(3-Axis Vertical Mill) (Horzontal Drilling Machine)

Chang, Figure 9.8

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2
 Operational Features of CNC Recirculating Ball Screws
A CNC control system Machine
includes a velocity loop
within an axis drive system
and a position loop external to
the axis drive system.

A - Ball Screw
Microcomputer Controlled X-Y Table
B – Linear Bearings
Degarmo, Figure 29-10. www.thomsonbay.com

Recirculating Ball Screws Recirculating Ball Screws

(Purpose) (Continued)

Transform rotational motion of the motor into translational

motion of the nut attached to the machine table.

Advantages of Recirculating Ball Screws

Ball ACME Fluid Belt, Rack & Cam Pneumatic
Screws Screws Power Chain Pinion Followers Cylinders
Inexpensive
Low Power Use
Low Maintenance
High Accuracy
High Repeatability Recirculating Ball Screws
High Efficiency are generally preloaded to
High Load Capacity give zero backlash.
Compact Size
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Recirculating Ball Screws Recirculating Ball Screws

(Rotational to Linear Velocity Conversion) (Positioning Resolution)

Lead – distance the nut moves æ 1 ö

parallel to the screw axis when l u = l ⋅θ ⋅ç ÷ l
the screw is given one è 360 ø
revolution. u ≡ axial displacement [in]
l ≡ ball screw lead [in/rev]
Vf ≡ Feed Velocity
θ ≡ rotation angle [degrees]
Vf D
n= D æ 1 ö
l ç ÷ ≡ converts revolutions
è 360 ø
[ min ] = [rev ]
in
to degrees érev ù
=>
[in rev] min êë degreesúû

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 Recirculating Ball Screws Recirculating Ball Screws
(Positioning Resolution Example) (Lead Screw Resolution)

l = 0.125 in l = 0.125 in The positioning resolution of a ball

Example screw is directly proportional to the
θ = 15 degrees A ball screw has a lead of 0.125 in/rev. smallest angle that the motor can
What is the distance that the nut will travel u
=l⋅ 1 ( ) turn.
u = l ⋅θ⋅ 1( 360) if the screw is turned 15 degrees? θ 360

u
= (0.125 in/rev ) ⋅ æç rev ö
u = (0.125 in ) ⋅ (15 degrees ) ⋅ æç rev ö θ è 360 degrees ÷ø
è 360 degrees ÷ø
u
= 0.0052 in = 0.00035 in/degree
θ

Stepping Motors Stepping Motors

(Full Step Operation)

Ø Hybrid stepping motors have a

variable-reluctance rotor with a
permanent magnet in its magnetic path,
usually in the rotor.

Ø The term hybrid refers to the use of two

sources of magnetic field, the stator
windings and the permanent magnet.

Ø Hybrid stepping motors are used when

A stepping motor provides open-loop, digital control of the position of a small step angles are required.
workpiece in a numerical control machine. The drive unit receives a direction
input (cw or ccw) and pulse inputs. For each pulse it receives, the drive unit Ø The 1.8 degree stepping motor is the 200 step hybrid motor
manipulates the motor voltage and current, causing the motor shaft to rotate by predominant standard for industrial cross section
a fixed angle (one step). The lead screw converts the rotary motion of the automation.
motor shaft into linear motion of the workpiece. Bateson, Figure 10.15 Bateson, 386. Parker, Figure 1.12

Stepping Motors Stepping Motors

(Angular Positioning) (Lead Screw Positioning Resolution)

360 degrees
u = l ⋅θ⋅ 1 ( 360) ∆θ =
360
N
∆θ =
N steps
Example
N = 200 l l = 0.125 in/rev
∆u =
∆θ =
360 deg
= 1.8 deg/step
N N = 200 steps/rev
200 steps
0.125 in/rev
∆u =
Increased resolution can be 200steps/rev
obtained using a technique
known as microstepping. = 0.000625 in/step

4
 Stepping Motors Stepping Motors
(Microstepping Operation) (Lead Screw Positioning Resolution)

360
The rotor can be positioned in partial steps by
simultaneously controlling the currents supplied
( 360)
u = l ⋅θ⋅ 1
∆θ =
N*m Example
to the stator phase windings. Microstep sizes of
1/10, 1/16, 1/32, and 1/125 of a full step are m = 32 microsteps/steps
most commonly used. l = 0.125 in/rev
l
∆u = N = 200 steps/rev
360 N⋅m
∆θ = m=number of microsteps per full step 0.125
N*m ∆u =
200 ⋅ 32
= 0.0000195 in/microstep

Summary
• The positioning resolution of a ball screw
drive mechanism is directly proportional to
the smallest angle that the motor can turn.
• The smallest angle is controlled by the motor
step size.
• Microsteps can be used to decrease the motor
step size.
• CNC machines typically have resolutions of
0.0001 in or better.
Assignment
A CNC mill has 0.125 inch lead recirculating ball
screws that are driven by a 200 step hybrid step step
motor with 125 microsteps per step. What is the
position resolution of the machine? How many
microsteps will the motor have to undergo in order
to move the mill table attached to the ball screw 1.0
in?
Watch videotape at library on the mill.