PowerPoint to accompany
Technology of Machine Tools
6th Edition
Krar Gill Smid
CNC Turning Center
Unit 77
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
77-2
Objectives
State the purpose and functions of chucking, turning, and turning/milling centers
Identify the applications of computer numerical control (CNC) for turning centers Name the machining operations that may be performed simultaneously
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CNC Turning Center
In mid-1960, 40% all metal-cutting operations performed on lathes
Not very efficient
Research led to development of numerically controlled turning centers and chucking lathes
Could produce round work almost any contour automatically and efficiently
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Three Main Types of Turning Centers
1. CNC chucking center
Holds part in some form of jaw chuck Some have dual spindles (work both ends) Can use continuous bar feed system to machine and cut off parts from bar Some have dual tool turrets Uses combination of turning tools
2. CNC universal turning center
3. Combination turning/milling center
77-5
CNC Chucking Center
Designed to machine work held in chuck Variety of sizes from 8 to 36 in. in diameter Four-axis chucking center has two turrets
Type of chucking center machine work at same time Separate sides; each discussed in rest of slides Seven-tool upper turret Seven-tool lower turret
Two-axis model has one or two turrets
Will drive only one turret at a time
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Construction
Main operative parts of all turning centers basically same
Framework components and CNC components
Bed and machine frame must be rugged
Heavy, one-piece cast-iron casting or polymer cast base Slanted 40 from vertical plane
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Turning Center Parts
Framework Components CNC Components
Bed
Headstock
Carriage
Cross slide Turret Housing
MCU
Servos
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Tooling
Toolholders for machining
Outside diameters located in lower turret and are preset Inside diameter mounted in dovetailed block and preset off machine by tool-setting gage
Mounted on upper turret
Automatic tool-setting probe used for presetting tools
Available on some machines
77-9
Computer Numerical Control
Microprocessor
controls logic calculations, mechanism control and input-output control
Video display
Visual output of data, processes, and diagnostics
Input unit
Keyboard and/or diskettes used to communicate with system, enter setup and data
Program storage
77-10
CNC Turning Center
Designed mainly for machining shaft-type workpieces supported by chuck and heavyduty tailstock center On four-axis machines, two opposed turrets, mounted on separate cross-slides
One above and one below center line of work Balance cutting forces so extremely heavy cuts can be taken on workpiece
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Other Operations Can Be Performed by Dual Turrets
Roughing and finishing cuts in one pass Machining different diameters on shaft simultaneously Finish-turning and threading simultaneously Cutting two different sections of shaft at same time
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Other Turning Center Equipment
Steadyrest
Allow facing and threading on end of shafts
Follower rest
Used to support long, thin shafts
Bar-feeding mechanism
Permits machining of shafts and parts from bar stock smaller than spindle through-hole
Production part loader
Can complete part changeover when individual precut shafts machined
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Combination Turning/Milling Center
Allows operations such as drilling, milling, and tapping to be performed on part while still in machine Special tool turret contains pockets that have own drive for live tools Drilling and tapping can be performed if machine has contouring spindle
Can be indexed to exact locations around circumference of workpiece
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Programming Considerations
Programmer must be able to analyze part print and decide on sequence of machining operations Good practice to develop habit of labeling start and end points for both roughing and finishing operations Be certain the programming format suits your equipment before machining parts
77-15
Typical Tooling System
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
77-16
Inserts
Made from many types of material Great variety to suit any workpiece material or machining operation
Include carbide, coated carbide, ceramic, cermet, cubic boron nitride, and diamond coating
Standardized so most inserts fit in same holders
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Tool Nose Radius Compensation
Wide variety of tool nose radii
Starting with sharp point and increase in 1/64 in. increments from 1/64 to 1/8 in.
Theoretical sharp point of tool is programmed
Does not position tool at correct location
G41 or G42 turns on tool nose radius for finish cuts Radius of each insert stored in numbered tool list of control tool management system
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Tool Offsets
Programmer must provide tool setup sheet for setup operator MCU will calculate correct position at which tool should be located to accurately machine part
77-19
Diameter Versus Radius Programming
Method used determined by preset parameters within machine control unit or by correct G-code Diameter (default)
Part print drawn complete with both sides of centerline and full diameter dimensions
Radius
Part print drawn on just one side of centerline
77-20
Establish Part Zero
Programmer's choice to place part zero at most convenient location Location of X axis usually centerline of part Z axis either:
Right-hand (tailstock) end of part
Movements into part will be negative numbers (-Z)
Left-hand (chuck) end of part
Movements into part will be positive numbers (Z)
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Codes
Function of some G-codes and M-codes may differ from function of those on machining center Many of common turning center G-codes and M-codes that conform to EIA standards shown in tables 77.1 and 77.2 in textbook
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Programming Procedures
CNC control units can vary from manufacturer to manufacturer
Important to follow programming manual supplied for each machine
This textbook concentrates on two classes of CNC machines:
Bench-top teaching model Standard turning center
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Bench-Top Teaching Machines
Very easy to program and ideal for teaching Perform turning operations similar to larger machines
Except smaller workpieces and lighter cuts
Relatively inexpensive Most of B- and M- codes apply to both bench-top CNC turning lathes and standard-size turning centers
Few variations
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Simple Programming
Example of notes and code to machine a sample part (radius programming) Program Notes
1. 2. 3. 4. 5. 6. Program in absolute mode (G90) All programming begins a zero point, centerline and right-hand face of part Carbide tool will be used for all operations Use radius programming Position established to right front corner for safety Material aluminum; cutting speed 600 sf/min, feed rate at .010 in.
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Programming Sequence (sample code)
% Rewind stop code/parity check.
. Number of instruction N10 G24 N20 G92 X.690 Z.1
N30 M03
Command to MCU
N40 G00 X.590 Z.050
Information needed N50 G84 X.500 Z-1.250 F.010 H.050 to carry out command N60 G00 X.500 Z.050 N70 G84 X.400 Z-.750 F.010 H.050 N80 G00 X.400 Z.050 : :
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Programming Sequence (sample code)
%
Rewind stop code/parity check. G92 G24 Reference point offset Radius programming N10 G24 N20 G92 X.690 Z.1 X.690 Tool located .100 in. off the outside finish diameter/.690 in N30 M03 M03 Spindle ON clockwise from part centerline (X0) N40 G00 X.590 Z.050 G00 (point a) traverse rate Rapid X.590 Tool Full.100 in. in. Z.1 F.010 H.050 located .590 to Tool located code with N50 G84 X.500 Z-1.250 descriptions from part part face (Z0) right of centerline (point b) N60 G00 X.500 Z.050 Z.050 Tool located.050 in. in text Follow N70 G84 X.400 Z-.750 F.010 H.050 through forface from part better understanding! N80 G00 X.400 Z.050 : :
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Standard-Size Turning Center
To introduce additional machining and use of diameter programming, a full sample program is given in the text Complete with program notes and code with explanations
Similar to previous example
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Turning Center Setup
Before setup, become familiar with control panel and operational procedures Power on to machine:
Turn on servos and zero out/align all axes so control knows location of machine home position Load program if not already in memory Check manuscript, and prepare tools listed by programmer
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Program Test Run
Part never machined without test running program first
Some controls have control screen which allows visual progression through program without cutting part Dry run program without part
Use step/single block mode and feedrate override to slow programmed rate Finger on hold button in case of error in program
Good idea to know where emergency stop button located
