Advanced Machine Tool Revision

INTRODUCTION
1-Raw Material Processing Part.

2- Processing (Forming- Machining- Additive).

3- Forming (Change in material, dm=0).

4- Machining (dm<0).

5- Additive (dm>0).

6- Forming like (Rolling – Forging).

7- Machining/ Metal cutting Classification (Cutting processes- Abrasive processes-

Advanced processes).

8- Cutting processes (Single and multi-point cutting tools). like Shaping & Turning &
Milling & Drilling.

9- Abrasive processes (Cutting tool has many abrasive particles).

10- Advanced processes (non-contact and non-mechanical action). Like EDM & Laser
cutting.

Machine Tool Development

1-From Conventional Machine Tools to Factory of the Future

a- Conventional Machine Tool b- Semi Automatic Machine Tool

c- Automatic Machine Tool d- Numerical Control Machine

e- Computer Numerical Control Machine f- Direct NC Machine

g- Modular Machine Tools h- Machining Centre

i- Flexible Manufacturing Systems

j- Computer Integrated Manufacturing Systems

2- Operations in metal cutting (Cutting – Handling).

3- Processing or main operations in which actual cutting that is, chip removal takes
place.

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4- Handling or auxiliary operations, which include:

a) loading and clamping of the work b) releasing and unloading of the work

c) changing or indexing the tool d) checking the size of the work

e) changing speeds and feeds f) and switching on and off the machine tool.

5- Semi-Automatic Machine Tools (like capstan lathe)

-some major auxiliary motions and handling operations like bar feeding, speed change,
tool change etc. are done quickly and consistently with less human involvement.

-The operators need lesser skill and putting less effort and attention.

-Suitable for batch or small lot production.

5- Automatic Machines

- used for large lot or mass production of small rod type of jobs.

- Automatic lathes are also classified based on constructional features, operational

characteristics, number of spindles and applications as follows:

*Single spindle (screw cutting) like lathe Swiss type.

* Multi-spindle automatic lathe.

6- Numerical Control

- Machine tools and lathes that are automated by other than mechanical means (NC
and CNC, using numerical data to control its operating cycle).

- can be set up for new jobs much more rapidly, and are therefore efficiently employed
in lot, batch, and even single-piece production.

- Numerical control is a programmable automation in which process is controlled by

Numbers, Letters, and symbols.

- CNC Machining is a process used in the manufacturing sector that involves the use of
computers to control machine tools like lathes, mills, and grinders.

- DNC involves controlling more than one machine using the same computer and data
transmission lines.

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-why NC?

*The setup time is large in conventional machining.

*Frequent changes in tooling and machine setting are required.

*Parts are produced intermittently.

*Complex-shaped components are needed.

*Expensive parts where human errors are costly.

*Design changes are frequent.

*100% inspection is required.

- NC costs compared to other:

-Advantages of NC include the following:

a. Greater flexibility. b. Elimination of templates, models, jigs, and fixtures.

c. Easier setups. d. Reduced machining time.

e. Greater accuracy and uniformity. f. Greater safety.

g. Conversion to the metric system.

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-Disadvantages of NC include the following:

a- NC follows programmed instructions that can lead to machine destruction if not

properly prepared.

b- NC cannot add any extra machining capability to the machine tool.

c- NC machines cost five to ten times more than conventional machines of the same
working capacity.

d- The skills required to operate an NC are usually high.

e- Special training for personnel in software and hardware is very important for
successful adoption and growth of the NC technology.

f- NC requires high investments in terms of wages of highly skilled personnel and

expensive spare parts.

7- Computer Integrated Manufacturing Systems

-Components of CIM:

*Information storage, retrieval, control, and introduction system.

* Real-time sensors for detecting the present status and for adjusting measures.

* Data processing algorithms.

- Advantages of CIM:

a. It improves the quality of the product. b. It is cost-effective.

c. It saves time. d. CIM reduces errors in the manufacturing process.

e. It is more flexible compared to the traditional manufacturing.

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8-Machining Center

-The CNC machine tool center is an advanced manufacturing machine tool that can
perform a variety of machining operations with high precision, high quality, and high
surface finish.

-A CNC machine tool center can perform

* drilling * milling * lathe operations.

-The advanced mechanisms used is as follows:

• ATC (automatic tool changer). • APC (automatic pallet changer).

• CNC servo system. • Feedback system.

• Re-circulating ball screw and nut.

-CNC machine center is classified according to configuration as:

a. Horizontal Machine Center. b. Vertical Machine Centers.

c. Universal Machining Centers.

9-Flexible Manufacturing Systems.

-highly automated machine cell.

-Consisting of a group of processing workstations (usually CNC machine tools),

interconnected by an automated material handling and storage system, and controlled
by a distributed computer system.

-The reason the FMS is called flexible is that it is capable of processing a variety of
different part styles.

-The FMS is most suited for the mid-variety, mid-volume production range.

-What Makes It Flexible?

*The ability to identify and distinguish among the different part or product styles
processed by the system.

*Quick changeover of operation instructions.

*Quick changeover of physical setup.

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10-Modular Machine Tools.

-A Modular tooling system enables you to assemble tools from a set of common
building blocks.

-This reduces the cost of tooling, and the lead time to make special-purpose tool
holders. It’s like a Lego set.

-Module Types (Function-Motion-Accessory)

-Function modules are interchangeable provide a machining process.

-Motion modules are modules that contribute to the Degrees of Freedom (DOF)
possessed by a machine tool.

-Accessory Modules are not directly involved in the cutting process; however, they are
essential to the successful completion of a task. Such modules include work clamps
and work piece stabilizers.

-Modular Design Principles:

a. Modules must be interchangeable without the use of measuring equipment.

b. Module must either be self-contained with its own power drive, feedback, and
lubrication systems or form accessories for simply expanding such systems.

c. Each unit must have its own servo pack with electronic interfacing to digital input.

d. Modules must be usable in any orientation.

e. Modules must be interchangeable within about a half-hour.

f. Machining operations to be allowed in the first instance are turning,

drilling, boring, and milling.

-Modular Design Benefits:

a. Notwithstanding the order volume, the standardized module was produced with

economically reasonable cost.

b. Ease of production planning and control together with cost-effective production.

c. Reconfiguration was simplified with less additional cost.

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Capstan and Turret Lathe
-Lathes are generally considered to be the oldest machine tools still used in industry.

- One-third of machine tools operating in engineering plants are lathe machines.

- In operations performed on lathes (turning operations), the primary cutting motion v

(rotary) is given to the WP, and the feed motion f (in most cases straight along the axis
of the WP) is given to a single-point tool.

- The tool feed rate f is usually very much smaller than the surface speed v of the WP.
𝜋𝜋D.N 𝐷𝐷.−𝐷𝐷𝐷𝐷
-cutting speed 𝑣𝑣 = -Depth of cut 𝑑𝑑 =
1000 2

1-Center Lathe Main Components.

- Single-point tools are clamped in a square turret (tool post) mounted on the carriage.

- Tools such as drills, core drills, and reamers are inserted in the tailstock after
removing the center.

- The carriage, to which the apron is secured, may traverse along the guideways either
manually or powered.

- Surfaces of revolution are turned by longitudinal motion of the carriage.

- The cross slide feeds the tool in the cross direction to perform facing, recessing,
forming, and knurling operations.

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2- Work Piece fixation.

- WP fixation on an engine lathe depends mainly upon the geometrical features of the
WP and the precision required.

- The WP can be held:

a) between centers. b) on a mandrel. c) in a chuck/collet. d) faceplate.

- Holding the WP between centers. It is an accurate method for clamping a long WP

which is rotating at high speed.

- Mandrels are used to hold WPs with previously machined holes.

-In chuck clamping method If the work length is considerably large relative to its
diameter, supporting the free end with the tailstock center is also used.

- Chucks may be universal (self-centering) of three jaws, which are expanded and
drawn simultaneously, or they may be independent of four jaws.

- The three-jaw chucks are used to clamp circular and hexagonal rods, whereas the
independent four-jaw chucks are especially useful in clamping irregular workpieces.

-A collet is a holding that forms a collar around the object to be held and exerts a
strong clamping force on the object when it is tightened.

-Large WPs cannot be clamped in a chuck and are there for mounted either directly on
a faceplate.

3- Tool Holding Method.

a) Clamping plate. b) tool post. c) Four-way tool post.

4-Capstan and Turret Lathes.

-Advantage:

a) Less-skilled operators are needed, as compared with center lathes.

b) No need to change tooling or move the work to another machine.

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-Essential components and operating principles of capstan and turret lathes.

* Capstan or ram-type lathe:

- In a capstan or ram-type lathe, the hexagon turret is mounted on a slide that moves
longitudinally in a stationary saddle.

- During setup of the machine, the saddle is positioned along the bed to give the
shortest possible stroke for the job.

- The disadvantage is that the hexagonal turret slide is fed forward such that the
overhang is increased, resulting in the deflection of the ram slide, especially at the
extreme of its position, which produces taper and reduces accuracy.

* Turret (saddle-type):

- This machine is designed for machining chuck work, in addition to bar work.

- The bed must be designed to allow free and rapid escape of swarf and coolant.

- It is more rigid and hence most suitable for heavier chucking work.

- Jobs up to 300 mm diameter can be machined on it.

- Its design eliminates the turret slide overhang problem inherent in the ram-type
lathes.

- The power rapid traverse reduces the operator’s handling effort.

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5- Bar Feeding Mechanism.

- Bar feeding is accomplished by four elementary operations:

a) Parting off. b) Unclamping of the job by opening the collet.

c) Feeding of bar by pushing it forward. d) Touches the bar stop.

e) Clamping the bar by closing the collet. f) Free return of the bar pushing element.

6- Turret Indexing Mechanism (Geneva Mechanism).

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7- Machine Selection Criteria.

- Select a machine with sufficient power and rigidity to remove the metal at the most
economical rate.

- Choose the smallest machine that has ample swing and bed length for the job to be
performed.

- Long, accurate turning and boring operations dictate a saddle-type machine, while the
ram-type is preferred for ease of handling.

- Determine whether a power feed or a manual feed machine is required.

8- Capstan VS Turret.

- Turret lathes are relatively more robust and heavy-duty machines.

- Capstan lathes generally deal with short or long rod type blanks held in collet,
whereas turret lathes mostly work on chucking type jobs held in the quick acting
chucks.

- In capstan lathe, the turret travels with limited stroke length within a saddle type
guide block, called auxiliary bed, which is clamped on the main bed.

- Whereas in turret lathe, the heavy turret being mounted on the saddle which directly
slides with larger stroke length on the main bed.

- External screw threads are cut in capstan lathe, using a self-opening die being
mounted in one face of the turret.

- whereas in turret lathes external threads are generally cut, by a single point or
multipoint chasing tool being mounted on the front slide and moved by a short lead
screw and a swing type half nut.

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9- Center Lathe Vs Capstan & Turret Lathes.

10- Cutting tools.

- Performance Characteristics (Geometry- Material).

- Geometry (Single point- Multipoint- Abrasive).

- Single Point tool used in turning operation.

- Multipoint used in milling and drilling operation.

- Single point cutting tool has an effective cutting edge and removes excess material
from the work piece along the cutting edge. These tools may be left-handed or right-
handed.

- Single point cutting tools classified as (solid type- tipped tool- Indexable insert type)

11- Cutting Tool Materials.

- A cutting tool is subjected to severe conditions.

a)High temperatures (can exceed 1000C). b)Severe friction. C) High local stresses.

- Properties of Cutting Tool Materials:

1. Harder than work piece. 2. High hot hardness 3. High strength and toughness.

4. High wear resistance. 5. High thermal shock resistance. 6. Chemical Stability.

7. Low coefficient of friction. 8. Low Cost.

- Cutting Tool Materials (ferrous-nonferrous).

- ferrous (Carbon tool steel- Alloy tool steel- High Speed Steel (HSS)).

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* Carbon tool steel (CTS):

-Contains 0.6-1.4 % C – Hardenable up to 0.6 % C – Tempered at 100-280 deg Celsius

– Machinable – Has soft core (resist shocks and vibrations). – Used for tool holders.

* Alloy tool steel:

– Carbon tool steel + Cr+V+W+Mn. – Cutting speed= 140 % CTS.

– Quenched in oil + tempered at 300 deg C. – Works at 250 deg C.

– Milling cutters+ Twist drills + Knurling tools.

* High Speed Steel (HSS):

- Contains 0.8-1.5 % C + 19 % W + 4 % Cr.

- Works at maximum temperature of 600 deg C.

*Typical composition and applications:

1-M-series: Higher, abrasion resistance, most HSS tools.

2-T-series: Undergoes less distortion during heat treating, Used in Drills, Reamers, Taps
& Gear Cutters, for high-speed machining HSS tools are replaced by carbides, coated
carbides and coated HSS inserts.

- nonferrous (cast alloy-cemented carbide-ceramics-diamond-CBN).

*Cast cobalt alloys:

-Used as tool tips. - Cut at temperature of 925 deg C.

-Cutting speeds reach twice that of HSS. - Do not respond to heat treatment.

-Resist corrosion and crater wear formation.

-More brittle and sensitive to vibrations than cemented carbides.

*Cemented carbides:

-Also called tungsten carbide or Widia, is a hard material used in machining tough
materials.

-Most of the time, carbide will leave a better finish on the part, and allow faster
machining.

-Carbide tools can also withstand higher temperatures than standard HSS tools.

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*P-Type (blue):

-machining ferrous material with long chip.

*M-Type (yellow):

-machining hard steel, high temperature, and cast iron.

*K-Type (red):

-suitable for machining ferrous and non-ferrous material with short chip.

*Ceramics (Cemented oxides):

-Tips are made by pressing the powder of Al2O3 which is followed by sintering at 1700
deg C.

-Types of ceramics:

-Hot pressed: Black/grey in color where Al2O3 is pressed under high pressure and
at a very high temperature.

-Cold pressed: White color, Al2O3 is pressed under high pressure but at a lower
temperature.

-Characteristics of ceramics:

1. Poor thermal conductivity as a result of the high refractoriness.

2. High corrosion resistance. 3. High compressive strength.

4. Higher cutting speeds of 200-600 m/min. 7. Reduced built up edge (BUE).

8. Longer tool life. 9. Superior surface finish. 10.Coolant is not needed.

11.Lower coefficient of friction. 12.Greater machining flexibility.

*Diamond:

-Manufactured by sintering carbon under high pressure and temperature.

-Artificial diamond: More superior to natural diamond when machining nonferrous

alloys and abrasive materials such as pre-sintered carbides and ceramics, graphite, and
high silicon aluminum alloys.

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- Characteristics of Diamond:

1. Expensive. 2. Work at 1600 deg C. 3. Work at 1600 deg C.

4. Tool life is 50 to 100 times of WC. 5. High brittleness.

6. High heat conductivity (2 times of steel). 6. Low coefficient of friction.

* Cubic boron nitride (CBN):

- Tremendous high pressure and high temperature conditions is used to produce of

CBN crystals.

- Used for finishing very hard materials except titanium and its alloys.

- The machine tool rigidity is necessary.

- Cutting Tool Materials:

12- Job Analysis

- Type of tooling:

1. standard tools and holders should be used as much as possible.

2. Simple tool layout should be employed for small batches.

- The use of maximum speeds and feeds depends on the machine power available as
well as the rigidity of tooling, the holding mechanism, and the WP itself.

- The cutters for the larger diameters will be carbide, while HSS will give the best results
on smaller diameters with correspondingly lower machining speeds.

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Automatic Lathe
1-Classification of automated lathes:

*Spindle location

-Horizontal or vertical, Vertical machines are heavier, more rigid, more powerful.

*Degree of automation

-Fully or semiautomatic.

*Number of spindles

-Single or Multi-spindle automated lathes.

-These machines have 2–8 horizontal or vertical spindles.

-Their production capacity is higher than that of single-spindle machines, but their
machining accuracy is somewhat lower.

*Nature of workpiece stock

-Bar or magazine (needs chucking).

-Automated lathes use either coiled wire stock (up to 6 mm in diameter), bar, pipe, or
separate blanks.

-The blanks should approach the shape and size of the finished product; otherwise, the
cycle time increases, thus increasing the production cost.

*WP size and geometry

-The size and geometry of the WP determine the suitable machine to be used.

-In this regard, long accurate parts of small diameters are produced on the Swiss type
automatics.

-Whereas parts of complex external and internal surfaces are machined using turret-
type automatic screw machines.

*Machining accuracy

-The machining accuracy of multi-spindle automatics is generally lower than single

spindle automatics due to the errors in indexing of spindles and large number of
spindle head fittings.

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2-Automation in Manufacturing Systems:

Fully automatic lathes: 1. single spindle 2. multi spindle

-These are mainly based on mechanical control systems and are characterized by a
rigid linkage between the working and auxiliary operations.

-The two following mechanical systems are frequently employed:

1. single camshaft. 2. main and an auxiliary camshaft.

-Cam Types: 1. plate cam 2. cylindrical cam 3. liner cam

-Follower Types: 1. knife 2. Roller 3. flat 4. spherical

-single camshaft:

- This is the simplest arrangement and is further classified into two types:

1– Constant speed 2– Variable speed

- The mass of the camshaft with the cam drums and disks is comparatively large
and has large inertia torques.

- This system is most extensively used for multi-spindle automatics and semi-
automatics.

- main and an auxiliary camshaft:

- The machining cycle is completed in one revolution of the main camshaft.

- Trip dogs on the main camshaft perform the auxiliary operations through
signals that link the operative devices for auxiliary movements to the auxiliary
camshaft.

- It is used in automatic screw machines and vertical multi-spindle

semiautomatic chucking machines.

1.single spindle

* Automatic cutting off lathe

- These machines produce short parts of simple form by means of cross sliding tools.

- Machines are simple in design. - Typical simple parts 3 to 20 mm diameters.

- 2 cross slides are located on bed at front end of spindle.

- Stock is held in collet/chuck of rotating spindle.

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-Machining is done by tools that are held in slides operating only in cross wise direction

*Automatic Screw Machine

-Used for producing small screws (12.5 to 60 mm diameter).

-These are completely automatic bar type turret lathes, designed for machining
complex internal & external surfaces.

-2 cross slides (front & rear) are employed for cross feeding tools.

-Bar stock is held in collet chuck & advanced after each piece is finished & cut off.

-By stock feeding mechanism bar is fed out for next part.

-Machining of central hole is done by tools that are mounted on turret slide.

*Swiss-Type Automatic

-Swiss-type automatic is also called a long part, sliding headstock, or bush automatic.

-This type of automatics was originally developed by the watch-making industry of

Switzerland to produce small parts of watches.

-It is now extensively used for the manufacture of long and slender precise and
complex parts.

-To machine parts with small diameter (2-10 mm).

-Used for mass production.

-Automatic Vs Swiss Type -Swiss Type Vs Capstan & Turret Lathes

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2.multi spindle

*Parallel action type

-Machine consists of frame with head stock at right end.

-Horizontal work spindles that are arranged one above the another is housed in this
head stock.

-Cross slides are located at right- & left-hand sides of spindles & carry cross feeding
tools.

-In this type of machine same operation is performed on each spindle, w/p is finished
in each spindle in one working cycle.

-means that No. of components being machined = No. of spindles in machine.

-Rate of production is high & machine can be used to machine simple parts only since
all the machining processes are done at one position.

-These are fastest type of production machines and are made in a variety of models
with 2,4,5,6,8 spindles.

-Production capacity is higher; machining accuracy is lower compared to single spindle.

*Progressive action type

- the part is machined in states & progressively in station after station.

-Head stock is mounted on left end of base of machine.

-It carries spindle carrier which rotates about a horizontal axis through center of
machine.

-Bar stock is fed through each spindle from rear side.

-No. of slides === No. of spindles.

-Stock moves round the circle in counterclockwise direction & returns to station no. 6
for cutting off.

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Computer Numerical Control Machines
1-Components of CNC Machines

*Input Devices:

-These are the devices which are used to input the part program in the CNC machine.

-There are three commonly used input devices, and these are punch:

1-tape reader 2-magnetic tape reader 3-and computer

*Display Unit:

-A monitor is used to display the programs, commands, and other useful data of CNC
machine.

*Machine Control Unit (MCU):

-It is the heart of the CNC machine.

-It reads the coded instructions fed into it.

-It decodes the coded instruction.

-It implements interpolation (linear, circular, and helical) to generate axis motion
commands.

-It feeds the axis motion commands to the amplifier circuits for driving the axis
mechanisms.

-It receives the feedback signals of position and speed for each drive axis.

-It implements the auxiliary control functions such as coolant or spindle on/off and tool
change.

-Open-loop system:

-Programmed instructions are fed into the controller through an input device.

-These instructions are then converted to

electrical pulses (signals) by the controller
and sent to the servo amplifier to energize
the servo motors.

-The cumulative number of electrical pulses

determines the distance each servo drive
will move, and the pulse frequency determines the velocity.

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-The primary drawback of the open-loop system is that there is no feedback system to
check whether the program position and velocity has been achieved.

-If the system performance is affected by load, temperature, humidity, or lubrication

then the actual output could deviate from the desired output.

-For these reasons, the open-loop system is generally used in point-to-point systems
where the accuracy requirements are not critical.

-Closed 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.

-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.

*Machine Tool:

-A CNC machine tool always has a slide table and a spindle to control of the position
and speed.

-The machine table is controlled in X and Y axis direction and the spindle is controlled
in the Z axis direction.

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*Driving System:

-The driving system of a CNC machine consists of amplifier circuits, drive motors and
ball lead screw.

-The MCU feeds the signals (i.e., of position and speed) of each axis to the amplifier
circuits.

-The control signals are than augmented(increased) to actuate the drive motors.

-And the actuated drive motors rotate the ball lead screw to position the machine
table.

-Stepper Motors:

-Stepper motors are motors that move in slow, precise, and discrete steps.

-Valued for their precise position control, they find a myriad of applications such as
desktop printers, security cameras, and CNC milling machines.

-Servo Motors:

-Servo motors are motors capable of providing very precise motion control.

-The feedback in a servo motor system senses the difference between the actual and
desired speed or position.

-So that the controller can adjust the output to correct any drift from the target
position.

*Feedback System:

-This system consists of transducers that act as sensors. It is also called a measuring
system.

-It contains position and speed transducers that continuously monitor the position and
speed of the cutting tool located at any instant.

-The MCU receives the signals from these transducers, and it uses the difference
between the reference signals and feedback signals to generate the control signals for
correcting the position and speed errors.

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2-Tool Magazine

-tools in magazine is specified with a unique number (T01, T02, T03....), call tool
number.

-A motor and gearbox followed by a chain rotates the magazine.

- Types of Magazines:

• Turret. • Drum type magazine.

• Chain type magazine. • Matrix/Rack magazine.

1-Turret:

-CNC lathe machine tool turret is part of the CNC machine where all tooling is
mounted.

-Has an integral Disk like part (Tool turret disk) on which all the tools are mounted.

-CNC lathe tool turret is mounted on the x-axis carriage.

-Can hold an average of 10 tools.

2-Drum type magazine:

-The Drum or disc type tool magazine rotates to get the desired tool in position with
the tool change arm.

-The Larger the diameter of the disc/drum more the number of tools it can hold.

-It has pockets where tool can be inserted.

-It carries about 12 to 50 tools.

-A motor and gearbox are provided to rotate the tool and bring it to the desired
position.

3-Chain type magazine:

-When the number of tools is more than 50, chain type of magazines is used.

-The magazine is mounted overhead or as a separate column.

-In chain magazines the tools are identified either by their location in the tool holder or
by means of some coding on the tool holder.

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4-Matrix/Rack magazine:

-Rack magazines are cost-efficient alternative to usual tool magazine systems.

-The high storage capacity of up to 400 tools permits a large production capacity of
varying work pieces without tool changes.

-A AS/RS Automatic storage and retrieval system or robot has been provided for picking
and placing the tool.

3-Automatic tool changer (ATC):

-An Automatic tool changer or ATC is used in CNC machine to improve the productivity
and tool carrying capacity of the machine.

-ATC changes the tool very quickly, reducing the non-productive time.

-Generally, it is used to improve the capacity of the machine to work with a number of
tools.

-The call tool arrives to waiting position.

-All axis goes back to its reference point/position.

-ATC arm get rotated by motorized cam follower mechanism and spindle tool switched
by pot tool and vice versa.

-Tool clamp command generates, and ATC arm returns to home position.

-Advantages of ATC:

1. It can reduce the tool changing time.

2. High tool repeating positioning accuracy.

3. Enough tool storing capacity.

4. Compact structure, easy to manufacture, maintenance, and setup.

5. Reasonable layout.

6. Better rigidity, to avoid impact, vibration, and noise.

7. To run with safety and reliability.

8. Chip-proof, dust-proof.

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4-Automatic pallet changer (APC):

-In order to working with CNC machine to reduce the job setting and clamping cycle
time on fixture one or more additional pallet is being provided.

-Machining can be carried out on one pallet, while the others can be used for
preparation.

-The palletizing system consists of two, or more pallets (per customer requirements).

5-Coordinate axis and position control:

*Coordinate system:

-The axis definitions themselves are straightforward:

• X is the left–right axis, with values increasing from left to right.

• Y is the front–back axis, with values increasing from front to back.

• Z is what you would expect, vertical axis pointing up, so the "altitude" if you will.

*Motion Control:

1-Point to point Systems:

• Also called position systems.

• System moves to a location and performs an operation at that location (e.g., drilling)
Also applicable in robotics.

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2-Continuous path systems:

• Also called contouring systems in machining.

• System performs an operation during movement (e.g., milling and turning).

6-CNC machines classification according to Axis:

*3-axis CNC:

-3 axis machining implies that the workpiece remains in the same position while the
cutting tool operates along the XYZ plane to trim away material.

-This is suitable for parts that don’t require a lot of depth and detailing.

-3 axis machining is most commonly used to produce mechanical components and is

best suited for:

• Automatic/interactive operation.
• Milling slots.
• Drilling holes.
• Cutting sharp edges.

*4 Axis CNC:

-4 axis machining implies that a workpiece is processed in the same way it would be
with a 3- axis machine but has an additional rotary movement around the X axis, which
is named the A axis.

-This rotation allows the workpiece to be cut around the B axis. This method is
beneficial when holes or cuts need to be made on the sides of a workpiece.

-The addition of a fourth axis (A axis) allows a workpiece to be automatically flipped

over, so the machine can remove material from both sides.

-4 axis machining is multifunctional and can be used for:

• Intermittent cutting.
• Continuous cutting.
• Engraving curved surfaces.

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*5 Axis CNC:

-5 Axis machining implies that a workpiece can be automatically manipulated from five
sides at one time.

-In addition to automatic movements along the X, Y, and Z axes, 5 axis CNC machines
can select two of the three rotational axes (A, B, C) to use.

-The A, B, and C axes perform a 180° rotation around the X, Y, and Z axes,
correspondingly.

-5 axis machining requires greater CNC programming preparation time to

accommodate complex rotatory movement but allows one workpiece to be worked on
all five sides during one operation.

-This type of machining is used in the automobile, aerospace, and boating industries.

-Application is commonly favored for extremely complex components that are solid
and would otherwise have to be cast.

-5 axis machining is beneficial when components require a great deal of intricacy and
quick precision. This includes:

• Feature accuracy.
• Increased productivity.
• Higher quality finishes.
• Cutting intricate details.
• Machining complex shapes.

*6-axis CNC:

-The primary benefit 6-axis CNC milling offers over the closely related 5-axis
configuration is faster cutting times.

-With an additional axis of freedom, certain tool movements and transitions can be
executed with greater speed and efficiency.

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