Computer and Numerically Controlled Machines

Numerically Controlled (NC)

NC is the operation of M/c tool by a series of coded instructions consisting of numbers, letters of the
alphabets and symbols, which the MCU (Machine Control Unit) can understand.
Computer numerically controlled (CNC)
When numerical control is performed under computer supervision, it is called computer numerical
control (CNC). Computers are the control units of CNC machines. A programmer enters some
information in the program, but the computer calculates all necessary data to get the job done.
For both NC and CNC systems, working principles are the same. Only the way in which the execution is
controlled is different. Normally, new systems are faster, more powerful, and more versatile.
Various popular CNC control systems
1. ECS
2. LECS
3. NUM
4. SELCA
5. MARPOSS
6. Z-16
7. FANUC
8.

FAGOR

9.

FIDIA

10. DECKEL
11. SINUMERIC
12. HINUMERIC
13. HEIDENHAIN
14. GILDEMEISTER
Important terms related to CNC machining

Machine Zero - Machine zero is a point at the origin of the machines coordinate measuring
system. All the Axis movements and other dimensions are measured from this point. It is similar
to the origin of coordinate measuring system.

Machine reference point - It refers to the initial point of return for the purpose of measuring/
feedback systems. Whenever a CNC machine is switched on the feedback system has to be
initialized by referring this point on every axis.

Work Zero - This is the origin for the measuring of dimensions of workpiece. The programmer is
free to select it anywhere on the drawing.

Absolute measuring system - In this measuring system all the dimensions are made from the
work zero, which defined. The machine control uses work zero as the reference point to position
the tool during program execution. The main advantage of programming in absolute system is
that any point can be readily changed without affecting subsequent dimensions.

Incremental measuring system - The movements are based on the change in position between
two successive points. It expresses the relative distance between the current location and the
next position. This type of measuring system is called Incremental Measuring system. The main
advantage of this system is that sum of the dimensions must always be zero if start point and
finishing point is same at the end of programming which makes it easy to check a program.

Axis designation (conventions) - Axis designation for each type of machine tool is suggested
in the EIA (Electronic Industries Association) RS 274-B standard. This conforms to ISO
Recommendations R831. The nomenclature of the three main axes (X, Y AND Z) is based on the
Left hand rule. The thumb indicates the orientation of the X-axis; the index finger indicates the
Y-Axis, and the middle finger points in the direction of the Z-axis.

Tool and tool offset - The T function is used to call the particular tool and tool offset in the
program. The tool offset is used to correct the values entered in the coordinate system preset
block. Using the tool offsets, it is easy to set up the tools and to make adjustments in part size.

Spindle speed - The spindle speed is the rotational frequency of the spindle of the machine,
measured in revolutions per minute (RPM). The preferred speed is determined based on the
material being cut. Using the correct spindle speed for the material and tools will greatly affect
tool life and the quality of the surface finish.

Feed rate - Feed rate is the velocity at which the cutter is fed, that is, advanced against the
workpiece. It is expressed in units of distance per revolution for turning and boring (millimeters
per revolution). For milling it is expressed in units of distance per time for milling (millimeters
per minute).

Cutting Speed - Cutting speed may be defined as the rate (or speed) that the material moves
past the cutting edge of the tool , irrespective of the machining operation used the surface
speed.

Process Chart S.no.

Process no.

process

M/C

time

tool

remark

Tool Chart S.no.

Process
no.

Tool
description

Tool length

Tool radius

Tool
material

Tool insert
specification

The construction of CNC machines

1. Elements of motion transmission

Ball-screws and nut assembly

In a CNC machine, the connection between the screw and the nut is through an endless stream of
re-circulating steel balls, replacing sliding friction threads with rolling friction. Advantages are higher
efficiency, reversibility and reduction in wear and tear.

Hydrostatic slideways

In the hydrostatic slideways air or oil is pumped into small pockets machined into slides which are in
contact with the slideway.
2. Computers
CNC machines use an on-board computer that allows the operator to read, analyze, and edit
programmed information. In CNC machine, computer works on a binary principle, 0 for information and
1 for processing. Special built-in software compiles the user entered program (in code language) into

machine language and the machine moves the tool by its servomotors.
3. Control systems
There are two types of control systems on CNC machines:

Open loop (less accurate)

Closed loop (more accurate)

The open loop control system does not provide positioning feedback to the control unit. Since this
control system only counts tool movement pulses and cannot identify discrepancies in positioning, it is
slightly inaccurate.
In closed loop control system, the electronic movement pulses are sent from the control to the
servomotor, enabling the motor movement. Movements are detected by a feedback device
(transducer), which can send a signal to the control for checking after each step.
4. Drive motors
The drive motors control machine slide movement on CNC equipment. Types used :
1. Stepper motors (convert a digital pulse into a small rotation, mostly used in applications where
low torque is required )
2. DC servo motors (rotate in response to the applied voltage, used to drive lead screw and gear
mechanisms, provide higher-torque output)
3. 3. AC servo motors (controlled by varying the voltage frequency to control speed, more power
than a DC servo, used to drive a lead screw and gear mechanism )
4. 4. Fluid servo motors (variable speed motors, produce more power, in the case of pneumatic
motors, than electric servomotors)
5. Tool changers
Several different cutting tools are used to produce a part. The tools must be replaced quickly for the
next machining operation. For this reason, the majority of NC/CNC machine tools are equipped with
automatic tool changers. They allow tool changing without the intervention of the operator.
An automatic tool changer grips the tool in the spindle, pulls it out, and replaces it with another tool.
Tool changers are equipped for either random or sequential selection.
In random tool selection there is no specific pattern of tool selection.
In sequential tool selection, the tools must be loaded in the exact order in which they are called for in
the program.

1. Modes of Operation
Automatic operation
1. Memory operation The required program is already registered in the CNC memory. We can just
select the program and start the operations
2. MDI Operation - In the MDI mode, program can be inputted in same format as normal programs
and executed from the MDI panel. Mostly used for simple test operation.
3. Program restart - Restarting of a program for automatic operation from an intermediate point, a
Sequence No. is assigned to a block. MDI also usable as High Speed Program Check Function.
4. Manual handle interruption - Movement by manual handle operation can be done by overlapping it
with the movement by automatic operation
5. Sequence number search - Function is used to search for a sequence number within a program and
to start or rescue the program from the block having that sequence number.

Manual operation
1. Jog feed
In the jog mode, a feed axis and direction selection switch on the machine operators panel moves the
tool along the selected direction. The jog feed rate can be adjusted with the jog feed-dial rate.
2. Incremental feed
In the incremental (STEP) mode, pressing a feed axis and direction selection switch on the machine
operators panel moves the tool one step along the selected axis in the selected direction. Each step
can be 10, 100, 1000 times he least input increment ( minimum distance moved by tool).
3. Manual handle feed
In the handle mode, rotating the manual pulse generator on the machine operators panel can move
the tool. The minimum distance the tool is moved when the manual pulse generator is rotated by one
graduation.
4. Manual absolute on and off
When the switch is turned on, the distance the tool is moved by manual operation is added to the
current coordinates.

2. Processing of CNC programs

1. Determination of the sequence of operations required in machining process ( involves
examining the shape features of the components to be produced) .

2. Selection of cutting tools, order of use corresponding to the sequence of operations and
determination of feeds and cutting speeds for each operation.
3. Settings of program auxiliary functions, including tool changes, spindle starts and stops, coolant
on and off and so on.

3. Analyses of drawing for CNC programming

3.1 STUDY OF DRAWING

Verification of drawing quadrant/angle~ 1st and 3rd

Unit of measurement: mm and inch

Raw material size

Drawing zero/work piece zero

Marking of all the turning points (where profile is changing) & working points (for drilling, boring
etc.)

Section of measuring system-Absolute, Incremental

Making of co-ordinates for all turning points and working points.

Study of tolerances and important dimensions.

3.2 PART PROGRAM STRUCTURE

1. Name of the program
2.

Selection of Working plane, Measuring system ( Absolute or incremental ), unit of measurement

(mm or inch)

3. Defining and calling work origin

4. Tool changing position (Remote area away from work piece), Tool call & Tool change
5. First position (Movement in working Plane) and Second positioning (Movement in spindle axis)
for working, Spindle start & coolant on
6. Third positioning for working (for mechanizing, tool movement with tool radius compensation)
7. Depth of cut (in feed only)
8. Definition of geometry/preparation of profile (feeding of CNC drawing data)
9. Return to second position, spindle stop & coolant off

10. Cancellation of fixed cycles, Macro instructions, Special commands, Tool Radius compensation
11. Return to tool change position
12. Movement in spindle axis and in working plane
13. If required, repeat step Nos. to 16 as required.
14. End of part program

Points of difference b/w CNC and Conventional Machines

CNC Machine

Conventional Machine

CNC machines can be used continuously for long

intervals and only need to be switched off for
occasional maintenance.

Conventional machines are difficult operate for

several hours at a stretch. The operator has to
continuously focus on the job at hand.

CNC machines can produce several products, all

similar and dead accurate

Resemblance of the products formed depends

on the skill of the operator. Visible differences
may occur

Less skilled/trained persons can operate the

CNC machines.

Highly skilled operators are required to work on

conventional machines

CNC machines can be updated by using

improved software to drive the machines.

Chances for major improvement in the same

conventional machines are very less.

One person can supervise several CNC

machines, and they can be left to work
themselves.

One person cannot operate more than one

conventional machine at a time