Unit 5 Numerical Control

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

Process Planning
A manufacturing plan is needed to convert the product
design into a physical entity. The activity of developing
such a plan is called process planning.
Process planning involves determining the sequence of
processing and assembly steps that must be
accomplished to make the product.

Process Parameters

Selecting quality assurance

methods

Routing Sheet
It is the sheet which describes all the processes used to
manufacture the part.
Routing sheet is the step of process panning.
It is the physical representation of process planning step.

Routing Sheet

Numerical Control (NC) Defined

Programmable automation in which the mechanical actions of a machine
tool are controlled by a program containing coded alphanumeric data
that represents relative positions between a work head (e.g., cutting
tool) and a work part
Program
Program
Instructions
Instructions

Machine
Machine
Control
Control Unit
Unit

Transformation
Process
Power
Power

NC Coordinate Systems
For flat and prismatic (block-like) parts:
Milling and drilling operations
Conventional Cartesian coordinate system
Rotational axes about each linear axis
For rotational parts:
Turning operations
Only x- and z-axes

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)

Interpolation Methods
1.

2.

3.
4.

Linear interpolation

Straight line between two points in

space
Circular interpolation

Circular arc defined by starting point,

end point, center or radius, and
direction
Helical interpolation

Circular plus linear motion

Parabolic and cubic interpolation

Free form curves using higher order

equations

Absolute vs. Incremental Positioning

Absolute positioning
Move is: x = 40, y = 50
Incremental positioning
Move is: x = 20, y = 30.

Computer Numerical Control (CNC)

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
Communications interface
Diagnostics

Machine Control Unit

DNC
Direct numerical control (DNC) control of multiple
machine tools by a single (mainframe) computer
through direct connection and in real time
1960s technology
Two way communication
Distributed numerical control (DNC) network
consisting of central computer connected to machine
tool MCUs, which are CNC
Present technology
Two way communication

Applications of NC

NC Application Characteristics
(Machining)

Batch and High Volume production

Repeat and/or Repetitive orders
Complex part geometries
Mundane operations
Many separate operations on one part

Cost-Benefits of NC
Costs
High investment cost
High maintenance effort
Need for skilled programmers
High utilization required
Benefits
Cycle time reduction
Nonproductive time reduction
Greater accuracy and repeatability
Lower scrap rates
Reduced parts inventory and floor space
Operator skill-level reduced

NC Part Programming
1.
2.
3.
4.

Manual part programming

Manual data input
Computer-assisted part programming
Part programming using CAD/CAM

Manual Part Programming

Binary Coded Decimal System
Each of the ten digits in decimal system (0-9) 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

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

Example: Word Address Format

N001 G00 X07000 Y03000 M03
N002 Y06000

Cutter Offset
Cutter path must be
offset from actual
part outline by a
distance equal to
the cutter radius

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

Computer-Assisted Part Programming

Write machine instructions using natural language

type statements
Statements translated into machine code of the MCU
APT (Automatically Programmed Tool) Language

6.1.1 Coordinate System/

Cartesian coordinate
system:
the xyz system is a righthand system
Positive motion: moving the
cutting tool away from the
workpiece.

6.1.1 Coordinate System/

Z // rotating spindle
Z AXIS
workpiece-rotating machine:
Z is parallel to the spindle
tool-rotating machine:
Z is parallel to the tool axis

6.1.1 Coordinate System/

XX//AXIS
table
workpiece-rotating machine:

X is the direction of tool movement

horizontal milling machine :
X axis is parallel to the table
vertical machine :
+X axis points to the right
when the programmer
is facing the machine.

Z
X

6.1.5 NC Words/
N, G, X, Y Z, A, B, C, I, J, K, F, S, T, R, M

N: specify the sequence number

G: preparatory word
to prepare for control functions (the motion of each axis, coordinate
system, coordinate plane, cutter radius compensation, tool length
offset)

M: miscellaneous word
to control miscellaneous functions (spindle on/off, start/stop the
machine, turn on/off the coolant, change the tool, and rewind the
program tape)

6.1.5 NC Words/

6.1.5 NC Words/
M CODES
M00

Program stop

M06

Tool change

M01

Optional stop

M07

Flood coolant on

M02

End of program

M08

Mist coolant on

M03

Spindle CW

M09

Coolant off

M04

Spindle CCW

M30

End of tape

6.1.5 NC Words/
N, G, X, Y , Z, A, B, C, I, J, K, F, S, T, R, M

F: feed rate of the tool motion

S: cutting-speed

T: tool number

G codes
Unit selection:
G70 (inch), G71(metric)

Coordinates selection:
G90(absolute), G91(incremental)

Working plane selection:

G17(X-Y), G18(Z-X), G19(Y-Z)

Set up working coordinate

Machine zero
is unchangeable and usually is set up with the machine

Working coordinate

Z
23

(is decided by the offset from the machine zero)

X
25.2

G92 X25.2 Z23.0

Rapid traverse: G00

G00:
to make the machine move at maximum speed.
It is used for positioning motion.
G90 G00 X20.0 Y10.0
End

G90: absolute
coordinates

(10,10
)
Start

(0,0
)

(20,10
)

Linear interpolation: G01

G01:
linear interpolation at feed speed.
G91 G0l X200.0 Y100.0 F200.0
G91:
incremental
coordinates

Y
End

100.0

Start

200.0

Circular interpolation: G02, G03

G02, G03:
For circular interpolation, the tool destination and the circle center
are programmed in one block
G02 is clockwise interpolation, G03 is counterclockwise
interpolation
G 02
R

G17
X
__
Y
__

F __;
G 03
I __ J __
G 02
R
X
__
Z
__

G
03

I __

G18

G 02
R
G19
Y __ Z __
G 03
J __

End
point

F __;

K __

F __;

K __

Circle center,
radius

Circular interpolation: G02, G03

Y
X

R=-50mm

End

Specify R with sign

before it:
180 +R

Start

R=50mm

G91 G02 X60.0 Y20.0 R50.0 F300.0

G91 G02 X60.0 Y20.0 R-50.0 F300.0

>180 -R

Return to Machine Zero: G28

G28
The machine passes by the specified point, and then
move to the machine zero.
G91:
incremental
G91 G28 X_, Y_, Z_
coordinates
X,Y,Z are the coordinate of specified point that is saved
in
memory of machine.
Usually this instruction is used in the beginning and end of
program.
Machine
Zero
A

Specified
point

Return to the Specified point : G29

G29
The machine passes from the machine zero by
the point that is specified in G28, and then move
to the new specified point.
G29 X_, Y_, Z_
X, Y, Z are the coordinate of new specified point
G28,G29 are usually used to change tool
Specified point
in G28

Machine
Zero

A
New specified point in
G29

Tool Compensation
Tool-Radius Compensation /
Left hand G41
Right hand G42
Cancel tool-radius compensation G40

Tool-Height Compensation/
Positive G43
Negative G44
Cancel tool-height compensation G49

Tool-Radius Compensation
Tool-radius compensations make it possible to
program directly from the drawing, and thus
eliminate the tool-offset calculation
G41 (G42) H
H: the radius of tool to compensate is saved in a memory unit
that is named H
G41/G42 is directly related with direction of tool movement and
which side of part is cut.

Tool-Height Compensation
G43 (G44) H
H: specified memory unit used to save height
compensation of tool.
Positive compensation (G43):
real position = specified position + value saved in H

Negative compensation (G44):

real position = specified position - value saved in H

Tool-Height Compensation
Example:
N0010 G91 G00 X12.0 Y80.0
N0020 G44 Z-32.0 H02
If we put 0.5mm into H02,
real position = -32.0 - 0.5 = -32.5

G91:
incremental
coordinates

Cancel tool-height compensation: G49

M code
miscellaneous word/
miscellaneous functions:

turn the spindle on/off

start/stop the machine
turn on/off the coolant
change the tool
rewind the program (tape)

M code
M00

Program stop

M06

Tool change

M01

Optional stop

M07

Flood coolant on

M02

End of program

M08

Mist coolant on

M03

Spindle CW

M09

Coolant off

M04

Spindle CCW

M30

End of tape

modal groups/

M code: M00, M01

M00 and M01 both stop the machine in the
middle of a program.
M01 is effective only when the optional stop
button on the control panel
is depressed. The program can be
resumed through the control panel.

M code: M03, M04, M05

M03 turns on the spindle clockwise.
M04 turns the spindle on counterclockwise.
(The spindle rpm must be specified in the same
line or in a previous line. )
M05 turns off the spindle.

M code: M07, M08, M09

M07 and M08 turn on different modes of coolant.
M07: flood coolant on
M08: mist coolant on

M09 turns off the coolant.

M code: M06
M06 signals the tool-change operation.
On a machine equipped with an automatic tool
changer, it stops the spindle, retracts
the spindle to the tool-change position, and
then changes the tool to the one specified in the
T-code.

M code: M02, M30

M02 marks the end of the program.
M30 marks the end of the tape. It stops the
spindle and rewinds the program (tape)

6.2 MANUAL PART PROGRAMMING/

Summary
Adequate for many simply point-to-point processes
Time-consuming
Error correction can be cumbersome Errors made
by the programmer are often not discovered until the
program is tested graphically or on the machine tool

6.4 CAD PART PROGRAMMING/

CAD
The modern way ---Creation of NC programs from CAD
allow geometry to be described in the form of points, lines,
arcs, and so on, just as it is on an engineering drawing,
rather than requiring a translation to a text-oriented notation
(compared with APT).
Use of a graphics display terminal allows the system to
display the resulting cutter-path geometry
allow earlier verification of a program, which can avoid
costly machine setups for program testing.

Several CAD/CAM systems

Computervision System
CADAM System
CATIA System
MasterCAM
UG

6.4 CAD PART PROGRAMMING/

CAD
Procedures
Modeling
CAD drawing
Part-programming
Tool path
Verification
NC program

6.4 CAD PART PROGRAMMING/

CAD
Part-programming
Modeling

Tool
path

Cutting mode selection

- Contour line rough cutting
- Contour line finishing
- Remainder cutting

Execute
calculation

Set target
shape model

Specify tool
- Tool diameter
- RPM
- Feed rate

Enter cutting conditions

- Tool origin
- Cutting pitch
- Approach
- Precision, etc.

6.4 CAD PART PROGRAMMING/

CAD
rough cutting semi-finishing finishing
with end mill to remove cavity
Straight
end mill

Work

Ball end mill

Straight end mill

Axial
cutting
depth

Axial
cutting
depth

Work

Layer by layer/

Axial
cutting
depth

Work

6.4 CAD PART PROGRAMMING/

CAD
Tool path patterns (most popular)

direction-parallel milling

contour-parallel milling

6.4 CAD PART PROGRAMMING/

CAD
Applications

Contour Line

(Zig-Zag)

6.4 CAD PART PROGRAMMING/

CAD
Tool path patterns (advanced)

(extra spiral at corners)

Plunge into part)

6.4 CAD PART PROGRAMMING/

CAD
Tool path patterns (advanced)

Same roughness

6.4 CAD PART PROGRAMMING/

CAD
Part-programming
Modeling

Tool
path

Cutting mode selection

- Contour line rough cutting
- Contour line finishing
- Remainder cutting

Execute
calculation

Set target
shape model

Specify tool
- Tool diameter
- RPM
- Feed rate

Enter cutting conditions

- Tool origin
- Cutting pitch
- Approach
- Precision, etc.

6.4 CAD PART PROGRAMMING/

CAD
Part-programming
Modeling

Tool
path

Cutting mode selection

- Contour line rough cutting
- Contour line finishing
- Remainder cutting

Execute
calculation

Set target
shape model

Specify tool
- Tool diameter
- RPM
- Feed rate

Enter cutting conditions

- Tool origin
- Cutting pitch
- Approach
- Precision, etc.

6.4 CAD PART PROGRAMMING/

CAD
Part-programming
Modeling

Tool
path

Cutting mode selection

- Contour line rough cutting
- Contour line finishing
- Remainder cutting

Execute
calculation

Set target
shape model

Specify tool
- Tool diameter
- RPM
- Feed rate

Enter cutting conditions

- Tool origin
- Cutting pitch
- Approach
- Precision, etc.

6.4 CAD PART PROGRAMMING/

CAD

Approach/Engage/Entry

Departure/Retract/Exit

6.4 CAD PART PROGRAMMING/

CAD
Part-programming
Modeling

Tool
path

Cutting mode selection

- Contour line rough cutting
- Contour line finishing
- Remainder cutting

Execute
calculation

Set target
shape model

Specify tool
- Tool diameter
- RPM
- Feed rate

Enter cutting conditions

- Tool origin
- Cutting pitch
- Approach
- Precision, etc.

6.5 TOOL-PATH VERIFICATION/

Purposes/
to detect geometric error of the cutter path
to detect potential tool interference
to detect incorrect cutting conditions

6.5 TOOL-PATH VERIFICATION/

/Overcut and undercut

potential problems in sculptured surface machining

6.5 TOOL-PATH VERIFICATION/

Ways to verify a part program/

To make a dry cut on the machine without the workpiece
to actually machine a prototype in wax, plastic, wood, foam,
or some other soft material.
In a CAD-based system, cutter-path abnormalities can be
detected by visual inspection i.e. the display of an
animation sequence that shows the tool moving along its
generated path which is superimposed on the part
geometry.

6.5 TOOL-PATH VERIFICATION/