Unit - 2

NC and CNC Machines

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Numerical Control (NC)
Numerical Control  control by numbers of
• the machine tool / table movement
• and other auxiliary actions in a machining system.

According to Electronic Industries Association (EIA) definition,

NC system is “A system in which actions are controlled by the
direct insertion of numerical data at some point.”

The system interprets these data in the required format later.

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Basic Components of NC System

1. Program of instructions

2. Controller unit called

machine control unit
(MCU)

3. Machine tool or other

controlled process

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1. Programmed instructions
• A program is a sequence of step by step instructions which tells the machine tool
what to do.
• Written using numeric data and alphabets, i.e. alpha-numeric codes.
• These codes provides instructions for controlling machine movements.
• The program contains blocks of information, wherein each block contains the
numerical data required to produce one segment of the workpiece.
• Each block contains information related to dimensional information + Machining
Information (feed, speed, type of interpolation and other miscellaneous function).
• Dimensional information  from the part drawing,
• Cutting parameters (speed, feed, etc.)  based on Tool, surface finish and
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tolerance requirements.
2. Machine control unit
The controller unit consist of electronics circuits and
hardware that read and interpret program of instructions
 converted into mechanical actions (like movement of
cutting tool and work table)

• These days, all the modern NC machines come with a

microcomputer as the control unit.
• This type of NC machine is called CNC (Computer
Numerical Control Machine).
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2. Typical Elements of Machine control unit
1.Tape reader or other input device - Punched tape
2.Data buffer – Store information for next processing operation
3.Signal output channels to the machine tool – Controller to
machine units
4.Feedback channels from the machine tools – Machine unit to
controller
5.Sequence control to coordinate the overall operations of all
the elements – Coordinating and sequencing operations
6.Control panel – Physical unit (switches, display, overrides,
loading/unloading)
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3. Machine tool and other controlled process
It is the part of the NC system which performs actual
machining work.
For performing the machining work, the machine tool
may consists of work table, spindles and tools, motors
and other controls to drive the motors.
It includes cutting tool, work fixtures and other
auxiliary equipment (like coolant unit).

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3. Applications of NC Machines

Two categories of application of NC

Machines

1. Machining operations

2. Non machining operations

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Machining operations

1. Milling
2. Drilling and related processes
3. Boring
4. Turning
5. Grinding
6. Sawing, etc. 9
NC Machines are ideal when
1. Parts are processed frequently in small lot sizes
2. Part geometry is complex
3. Many operations are to be performed on the same part
4. Engineering design changes are likely
5. Close tolerances are to be maintained
6. Expensive part where errors will be costly
7. The parts required 100% inspection
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Non-Machining operations
1. Press working machine tools
2. Welding machines
3. Inspection machines
4. Automatic drafting
5. Assembly machines
6. Tube bending Flame cutting
7. Plasma arc welding
8. Laser beam processes
9. Automated knitting machines 11
Advantages of NC Machines
1. Reduced Lead time
2. Elimination of operator errors and increased quality
3. Increased operator performance
4. Reduction in setup time and downtime
5. Longer tool life
6. Flexibility
7. Reduced Inventory, Inspection and lesser scrap.
8. Easy Production management:
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Disadvantages of NC Machines
1. Higher investment: Higher capital cost

2. Higher maintenance cost: Higher maintenance cost since

ideal environmental conditions are to be maintained. Also
require closer monitoring and diagnostics.

3. Scarcity of trained personnel: Training operators in the filed

of NC programming is a difficult task, with more and more
programming features

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NC Motion Control System
• Motion control system in NC refers to control of the movement
of the table with respect to the cutting tool.
• The input for motion control is in the form of numerical data
through programs.
Types of NC motion control
1. Point to Point system
2. Straight cut system
3. Contouring system.

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Point to Point NC System (PTP system)

• Tool moves from Point to Point

• Path is immaterial
• No machining while tool moves
from one point to another
• E.g.: Drilling, spot welding

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Straight cut NC System (PTP system)
• Moved parallel to the axes
• Cutting takes place along
movement
• Controlled feed rate
• Simultaneous movement
along two axes not possible
• E.g.: Milling

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Contouring NC System (PTP system)
• Simultaneous move along
different axes
• Cutting takes place while
moving
• Path is continuously controlled
• Any mathematically defined
profile can be machined
• E.g: Complicated profiles like
turbine blade
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CNC System
• Computer Numerical Control is an NC system that utilizes a dedicated,
stored program computer to perform some or all the basic numerical
control function.

• NC systems use conventional hard wired controllers for interpreting

the codes in the program and converting into to necessary machine
instructions to manufacture a part.

• In CNC system, this hard wired controller is replaced by a computer.

• This computer performs all the functions of the NC system. In a
typical CNC system, one computer is used as the central control unit
for one machine.
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 Factor NC CNC
1 Controller Hard wired controller is used Microprocessor (computer) is used
which is not flexible control flexible.
2 Part programming Errors are common as Errors and easily corrected without
errors programs are stored in tapes. repeating the entire work
3 Optimization of Difficult to achieve optimum It is possible to change speed and
speed and feed. speed and feed. Speed change feed during machining process.
during process is not possible

4 Storing of Stored in Punch card  Stored in magnetic disks. So storing

programs Difficult store, error prone and modifying is easily done

5 Input device Usually tape reader which is Floppy disk and hard disk drives are
unreliable used which are very reliable
6 Management NC machines does not store CNC do Management functions
information management information (process plans, schedules etc.)

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CNC Control System

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Functions of CNC System
Functions of CNC system which are difficult to achieve in
NC system
• Machine tool control
• In process compensation
• Improved programming and operating features
• Diagnostics

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1. Machine Control
• The primary purpose of CNC is to control the machine tool. This
involves conversion of part program instructions into machine tool
motions through the computer interface and servo system.
• Some of the control functions such as circular interpolation can be
accomplished more efficiently with hard wired system. This has led to
two approaches in the design of CNC systems
1. Hybrid CNC: Here the controller contains both soft wired computer and hard wired
logic circuits. The hard wired unit does some functions which it can do best such as
circular interpolation. Computer software does the remaining functions

2. Straight CNC: Here the hard wired circuit is eliminated and the computer does all the
NC functions. Interpolation, tool position feedback and other functions are performed
by the computer.
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2. In process compensation
In process compensation refers to the dynamic correction to the
machine tool motions for changes or errors which occur during
processing.

Options included in the compensation are

1. Adjustments for errors sensed by process inspection probes
2. Precomputation of axis positions through inspection probe
3. Offset adjustment for tool radius and cutter length compensation
4. Adaptive control adjustments to speed and feed
5. Computation of predicted tool life and alternative tooling
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3. Improved programming and operation features
The flexibility of software control permits introduction of many convenient
programming and operating features. Some of these features are
1. Editing of part program on the machine (correction and optimization)
2. Graphic display of tool path for verifying the program (simulation)
3. Various types of interpolation (circular, parabolic etc.)
4. Support for both British and metric systems.
5. Availability of specially written sub routines (canned cycles)
6. Manual data input (e.g.: spindle speed, feed overrides )
7. Local storage of more than one program
8. Computation of predicted tool life and alternative tooling when required.
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4. Diagnostics
• CNC systems are complex units.
• The increase in complexity increases the chances of failure
of components leading to system break down.
• In addition, as CNC systems are costly, the down time must
be eliminated as far as possible.
• CNC systems are usually equipped with a diagnostic
capability which continuously monitors the system and
guides in maintenance and repair of the system.

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4. Diagnostics functions
1. If failure occurs, it should be able to identify the actual fault
so that repair personnel can quickly repair the fault
2. It should alert the operator about the possibility of
imminent failures. This will allow the maintenance
personnel to replace the component during regular shut
down.
3. The system should have certain amount of planned
redundancy. It involves having more additional
components for certain components which are usually
considered unreliable.
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Configuration of CNC Control Unit
1.Central Processing Unit (CPU)
2.Memory
3.I/O interface
4.Controls for Tool Movement and Spindle Speed
5.Sequence control and other machine functions

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1. Central Processing Unit
It is the brain of Machine Control Unit. It manages all other
components of the machine control unit based on the software
fed into the memory. CPU consists of three parts

1. Control section: To control the operations of the other units

2. Arithmetic Logic Unit (ALU): To perform arithmetic and logic
functions
3. Immediate Access Memory: To store small part of
instruction for immediate execution
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2. Memory
The programs to be executed by the CNC machines are stored in the
memory. Various program are stored in the memory.
Only required program is loaded into the computer based on the part
to be produced.

Memory consists of

1. Main memory or program memory which is volatile. It is of small

capacity
2. Secondary memory: It is the permanent memory like magnetic
drives or flash drive. They can store very large amount of data
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3. Input Output Interface
•Various devices are connected to the CPU through I/O
interface.
These devices include
• Monitor for viewing the programs and seeing simulations of cutting
operations,
• keyboards or other input devices for deeding data
• Interface for connecting the machining unit to the computer
• Printer to print programs etc.

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4. Control for machines tool axes and spindle speed
• These are the hardware elements which control the
movement of the tool/table along the three axes.

• It also controls the rotational speed of the spindles

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5. Sequence control of other machines tool functions

In addition to table movements and spindle speed control,

many other functions are to be done in the CNC machines like

• making actuators ON/OFF,

• making coolant ON/OFF etc.

These are included in Sequence Control functions

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CNC Software
The software used in CNC fall under three categories

1. Operating system software

2. Machine Interface Software
3. Application Software

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CNC Software
1. Operating System Software: It is installed by the manufacturer of
the CNC and stored in ROM. It is used to interpret the CNC part
program and generate corresponding signals to operate the machine

2. Machine Control Interface: It is used to operate the

communication link between the CPU and the machine tool to
accomplish auxiliary functions like Tool change, Coolant ON/OFF,
clamping devices, load and unload counters etc.

3. Application software: This consists of CNC part programs written by

user depending on the type of component to be prepared by the
machine.
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Direct Numerical Control (DNC)
• DNC  A number of machines are
controlled by a computer through
direct connection and in real time.
• DNC refers to the control of a
number of machine tools by a
central computer.
• The part programs are stored in the
central  sent to machine tool on
demand.
• Transfer of data through the
telecommunication lines in real time
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 Distributed DNC

• When the number of machines to be handled is very large, the

central computer is connected to satellite computers.
• Each of these satellite computers serves a group of machines. Data
to the machines also are routed through these satellite computers.
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Functions of DNC
1. NC without punched tape
2. NC part program storage
3. Data collection, processing and reporting
4. Communication

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1. NC without punched tape
• The use of punched tape presents a number of practical
difficulties both in terms of preparation and storage.
• DNC avoids the use of punched tapes altogether as the
programs are stored in the memory of a central computer.

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2. NC Part Program storage
In DNC, all the part programs are stored in a central computer. This
storage sub system must satisfy the following requirements.
•

 Program must be made available to individual machines whenever

required
 There should be provision to add new programs, delete old programs
and edit the existing programs
 DNC software must accomplish the processing function.
 The data storage sub system must be structured to perform certain
processing and management functions such as file security, file back
up, display of programs
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3. Data collection, processing and reporting
• Previous two functions are concerned with transfer of data from
computer to machine tool.
• This is the reverse function where data is transferred from
machine tool to the computer.
• The basic purpose to getting the feedback data from the
machine tool is to monitor the production process.
• Data are collected on production piece counts, tool usage,
machine utilisation and other parameters related to production.
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4. Communication
• This communication link is vital in making a DNC system. There should
be direct communication link between the following elements
•

 Central computer ↔ machine tools

 Central computer ↔ NC part programming stations
 Central computer ↔ bulk memory which stores the NC programs
 The communication system can be extended to include CAD system,
Remote diagnostics, shop floor control etc.
 Other computer automated systems in the plant
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Advantages of DNC
1. Elimination of punch card and tape readers: Punched cards are problematic
component
2. Greater computational capacity and flexibility: DNC system have powerful
processing ability and perform computations faster
3. Convenient storage of NC programs in central computer: Storage is more
efficient, avoids duplication, backup and recovery are more systematic.
4. Programs are stored in CFILE (Cutter path file): Can be sent to any required
machine.
5. Reporting shop performance: Data is received back from machine tool which
gives information regarding the performance on shop floor
6. Establishment of frame work for further automation: More advanced
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computer systems are built on the basis of extending DNC.