Computer Numerical Control

Sections:
1. Computer Numerical Control
2. Fundamentals of NC Technology
3. Applications of CNC
4. CNC Part Programming

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 Numerical Control (NC) Defined

Form of programmable automation in which the

mechanical actions of a machine tool or other equipment
are controlled by a program containing coded
alphanumeric data.

 The alphanumeric data represent relative positions

between a work head (e.g., cutting tool) and a work part.
 When the current job is completed, a new program can be
entered for the next job.

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 Basic Components of an NC System

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 Basic Components of an NC System

1. Program of instructions
 Part program in machining
2. Machine control unit
 Controls the process
3. Processing equipment
 Performs the process

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 Computer Numerical Control (CNC)
Computer Numerical Control (CNC) is a microprocessor
based system to store and process the data for the control
of slide motions and auxiliary functions of the machine
tools.
 Storage of more than one part program
 Various forms of program input
 Program editing at the machine tool
 Fixed cycles and programming subroutines
 Interpolation
 Acceleration and deceleration computations

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 Computer Numerical Control (CNC)

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 Computer Numerical Control (CNC)

Basic Elements of CNC Systems:

 Central Processing Unit (CPU)
 Servo Control unit
 Operator control panel
 Machine control panel
 Other Peripheral device
 Programmable logic controller (PLC)

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 Configuration of
CNC Machine Control Unit

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 F1) NC Coordinate Systems
For flat and prismatic (block-like) parts
 Milling and drilling operations
 Conventional Cartesian coordinate system
 Rotational axes about each linear axis
 Right hand rule

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 Coordinate Axis System for
Flat and Prismatic Parts

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 CNC Milling and Drilling Operations

Milling
Drilling

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CNC Milling Machine
CNC Machining Centre
 NC Coordinate Systems
For rotational parts:
 Turning operations
 Conventional Cartesian coordinate system, but only x- and
z-axes
 y-axis not needed in turning

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 Coordinate Axis System for
Rotational Parts

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 CNC Turning Operations

Turning
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CNC Lathe
CNC Lathe – Turning Centre
 F2) Motion Control Systems
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
Continuous path systems
 Also called contouring systems in machining
 System performs an operation during movement (e.g.,
milling and turning)

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 Point-To-Point Control in NC
Drilling of Three Holes in Flat Plate

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 Continuous Path Control in NC
Profile Milling of Part Outline

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 F3) Interpolation Methods
1. Linear interpolation
 Straight line between two points in space
2. Circular interpolation
 Circular arc defined by starting point, end point, center
or radius, and direction
3. Helical interpolation
 Circular plus linear motion
4. Parabolic and cubic interpolation
 Free form curves using higher order equations

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 F3) Interpolation Methods

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 F4) Absolute and Incremental
Positioning

Absolute positioning
 Locations defined relative to origin of axis system
Incremental positioning
 Locations defined relative to previous position
 Example: drilling

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 Absolute vs. Incremental Positioning

The work head is presently

at point (20, 20) and is to be
moved to point (40, 50)
 In absolute positioning,
the move is specified by x =
40, y = 50
 In incremental positioning,
the move is specified by x =
20, y = 30.

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Absolute vs. Incremental Positioning
 Advantages of CNC
 Nonproductive time is reduced
 Greater accuracy and repeatability
 Lower scrap rates
 Inspection requirements are reduced
 More complex part geometries are possible
 Engineering changes are easier to make
 Simpler fixtures
 Shorter lead times
 Reduce parts inventory and less floor space
 Operator skill-level requirements are reduced
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 Disadvantages of CNC

 Higher investment cost

 CNC machines are more expensive
 Higher maintenance effort
 CNC machines are more technologically sophisticated
 Part programming issues
 Need for skilled programmers
 Time investment for each new part
 Repeat orders are easy because part program is
already available
 Higher utilization is required
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 Applications of CNC

 Machine tool applications:

 Milling, drilling, turning, boring, grinding
 Machining centers, turning centers, mill-turn centers
 Punch presses, thermal cutting machines, etc.
 Other CNC applications:
 Component insertion machines in electronics
 Drafting machines (x-y plotters)
 Coordinate measuring machines
 Tape laying machines for polymer composites
 Filament winding machines for polymer composites
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 NC Part Programming
1. Manual part programming
2. Computer-assisted part programming
3. Part programming using CAD/CAM
4. Manual data input

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 1) Manual part programming

Binary Coded Decimal System

 Each of the ten digits in decimal system is coded with
four-digit binary number
 The binary numbers are added to give the value
 BCD is compatible with 8 bits across tape format, the
original storage medium for NC part programs
 Eight bits can also be used for letters and symbols

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 1) Manual part programming

Creating Instructions for NC

 Bit - 0 or 1 = absence or presence of hole in the tape
 Character - row of bits across the tape
 Word - sequence of characters (e.g., y-axis position)
 Block - collection of words to form one complete
instruction
 Part program - sequence of instructions (blocks)

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 1) Manual part programming
Block Format
Organization of words within a block in NC part program
 Also known as tape format because the original formats were
designed for punched tape
 Word address format - used on all modern CNC controllers
 Uses a letter prefix to identify each type of word
 Spaces to separate words within the block
 Allows any order of words in a block
 Words can be omitted if their values do not change from
the previous block
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 1) Manual part programming
Types of Words
N - sequence number prefix
G - preparatory words
 Example: G00 = PTP rapid traverse move
X, Y, Z - prefixes for x, y, and z-axes
F - feed rate prefix
S - spindle speed
T - tool selection
M - miscellaneous command
 Example: M07 = turn cutting fluid on
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 1) Manual part programming

Example: Word Address Format

N001 G00 X07000 Y03000 M03
N002 Y06000

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 1) Manual part programming
Examples of Manual Part Programming
 Adequate for simple jobs, e.g., PTP drilling, milling and
turning.
 Linear interpolation
G01 G94 X050.0 Y086.5 Z100.0 F40 S800
 Circular interpolation
G02 G17 X088.0 Y040.0 R028.0 F30
 Cutter offset
G42 G01 X100.0 Y040.0 D05

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Gate Questions

Ans : (C)
Gate Questions

Ans : (C)
 2) Computer-Assisted Part
Programming
 Manual part programming is time-consuming, tedious,
and subject to human errors for complex jobs
 Machining instructions are written in English-like
statements that are translated by the computer into
the low-level machine code of the MCU
 APT (Automatically Programmed Tool)
 The various tasks in computer-assisted part
programming are divided between
 The human part programmer
 The computer

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 2) Computer-Assisted Part
Programming

 Sequence of activities in computer-assisted part

programming

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 2.1 ) Part Programmer's Job

 Two main tasks of the programmer:

1. Define the part geometry
2. Specify the tool path
3. Specific other functions: Speed, Feed, etc.,

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 2.1.1)Defining Part Geometry

 Underlying assumption: no matter how complex the part

geometry, it is composed of basic geometric elements and
mathematically defined surfaces
 Geometry elements are sometimes defined only for use in
specifying tool path
 Examples of part geometry definitions:
P4 = POINT/35,90,0
L1 = LINE/P1,P2
C1 = CIRCLE/CENTER,P8,RADIUS,30

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 2.1.2) Specifying Tool Path and
Operation Sequence

 Tool path consists of a sequence of points or connected

line and arc segments, using previously defined geometry
elements
 Point-to-Point command:
GOTO/P0
 Continuous path command
GOLFT/L2,TANTO,C1

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 2.1.3) Specific Other Functions in
Computer-Assisted Part Programming

 Specifying cutting speeds and feed rates

 Designating cutter size (for tool offset calculations)
 Specifying tolerances in circular interpolation
 Naming the program
 Identifying the machine tool

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 2.1.4) Computer Tasks in Computer-
Assisted Part Programming
1. Input translation – converts the coded instructions in the
part program into computer-usable form
2. Arithmetic and cutter offset computations – performs the
mathematical computations to define the part surface and
generate the tool path, including cutter offset
compensation (CLFILE)
3. Editing – provides readable data on cutter locations and
machine tool operating commands (CLDATA)
4. Postprocessing – converts CLDATA into low-level code
that can be interpreted by the MCU

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 3) NC Part Programming Using
CAD/CAM
 Geometry definition
 If the CAD/CAM system was used to define the original
part geometry, no need to recreate that geometry as in
APT
 Automatic labeling of geometry elements
 If the CAD part data are not available, geometry must
be created, as in APT, but user gets immediate visual
feedback about the created geometry

 Master cam is the leading commercial CAD/CAM

software package.
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 3) Tool Path Generation Using
CAD/CAM

 Basic approach: enter the commands one by one (similar

to APT)
 CAD/CAM system provides immediate graphical
verification of the command
 Automatic software modules for common machining
cycles
 Profile milling
 Pocket milling
 Drilling bolt circles

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 3) Examples of Machining Cycles in
Automated NC Programming Modules

Pocket milling

Contour turning

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 3) Examples of Machining Cycles in
Automated NC Programming Modules

Facing and shoulder facing

Threading (external)

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 4) Manual Data Input

 Machine operator does part programming at machine

 Operator enters program by responding to prompts and
questions by system
 Monitor with graphics verifies tool path
 Usually for relatively simple parts
 Ideal for small shop that cannot afford a part programming
staff
 To minimize changeover time, system should allow
programming of next job while current job is running

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14ME530 – Manufacturing systems and
Automation