NC Machining Technique01

NC Machining Technique
Hong-tao Wang
Email: meehtwang@nuaa.edu.cn
College of Mechanical and Electrical Engineering
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Welcome
Welcome you to study the important

technology about NC machining
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Introduce myself
My name is Hong-tao Wang
Nowadays, I had been in College of Mechanical and Electrical
Engineering for about 25 years.
My research field are as follows:
• Computerized numerical control (CNC) processing technology

• Design and control of robot
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Text Book for NC Machining Technique
Mike Mattson, CNC Programming

Principles and Application,2004
This book is different from other programming
books in that it follows a systematic path from
planning to programming an NC machining job.
Our course content is

mainly from this text book.
Our course mainly introduces

the basic concept and principle
of CNC technology.
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Score & Exam
 Student’s score is made up of two parts:

1,Hand in assignments in class. (This score is 30% of total
score)
Sometimes teacher will lay out some assignments about the current
lecture in class. Every student needs to finish assignments and hands in
assignments before you leave the classroom.
2,Final exam (This score is 70% of total score)
Every student will take part in the final exam.
Your score is the sum of two parts.
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NC Programming Technique is presented in
three sections:
1,Provide the groundwork for modern manufacturing and

take the fundamentals of CNC machine tools,
manufacturing processes and technical mathematics.
2,introduce the concept of NC part programming and
present the fundamental aspects of the NC language.
3,provide advanced programming concepts and
techniques for milling center and lathe.
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Lathe bed is tilted
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The bed is horizontal
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vertical spindle lathe
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Machine Center
 chapter1\Machine Center.avi
 chapter1\Hermle德国C400 basic Five-axis
Machining Center -轮毂wheel hub.mp4
 chapter1\Hermle德国C30U Five-axis
Machining Center -Titanium alloy
impeller.mp4
 chapter1\G550 Flange machining pump
housing - Pumpengehäuse-
Flanschbearbeitung.mp4
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Machine Center
 chapter1\CAM- Using Mastercam 2017

Dynamic Tool Paths_高清.mp4
 chapter1\1.DMG(Additive Manufacturing
of 3D-parts in Milling quality -
LASERTEC 65 3D).mp4
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You are from the different country and have different knowledge
background, so I have some questions about NC machining
technology:
(1) How many students have learned CAM software?
(2) How many students have seen the machine tool?
(3) How many students had used the machine tool?
I hope that you will get basic knowledge of NC machining technology

after you had finished this course.
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Syllabus
 Chapter 1 CNC of Machine Tools and CAD/CAM
 Chapter 2 The NC Programming Process
 Chapter 3 NC Tooling and Machining Processes
 Chapter 4 Tool and Workpiece Setup
 Chapter 5 Programming Concepts and Job Planning
 Chapter 6 Codes for Positioning and Milling
 Chapter 7 Basic Codes to Control Machine Functions
I will teach the content of Chapter 1-7.
The other teacher, Dr.Zhang will teach the content of Chapter 8-13.
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Chapter 1 CNC of Machine Tools and CAD/CAM
Learning Objectives:
 Identify the components of a CNC control system
 Understand some of the additional features of a CNC machine tool
 Have familiarity with the common hardware used in motion control

systems, including motors and encoders
 State the function of a feedback loop and determine the system input
and output
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1.CAD/CAM technique
In today’s age of rapidly evolving computer technology, there seems to

be an abundance of industrial processes and techniques that want to
attach computer-aided to their name.
CAD(Computer Aided Design）

CAM(Computer Aided Manufacturing）
CAE(Computer Aided Engineering）
CAPP（Computer Aided Process Planning）
…….
THE OBJECTIVE:
TO be competitive through increasing productivity and total

quality assurance
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Computer-Aided Design (CAD)

 Use of computer systems to assist in the
creation, modification, analysis, and
optimization of a design
 Typical tools:
 Tolerance analysis
 Mass property calculations
 Geometry modeling and visualization
 Defines the geometry of the design
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Computer-Aided Manufacturing (CAM)
 Use of computer systems to plan,

manage, and control manufacturing
operations
 Direct or indirect computer interface
with the plant’s production
resources
 Numerical control of machine tools
Parameter: Feed speed and depth of cut
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Computer-Aided Engineering (CAE)
 Use of computer systems to

analyze CAD geometry
 Allow designer to simulate and
study how the product will behave,
allowing for optimization
 Finite-element method (FEM)
 Divide model into
interconnected elements
Intensity analysis of  Solve continuous field
a crank connecting rod problems
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Why Need for CAD/CAM
• To increase productivity of the designer

•To improve quality of the design
•To improve communications
•To create a manufacturing database
•To create and test toolpaths and optimize them
•To help in production scheduling and MRP(material
requirements planning) models
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What is machine tool?
Machine tool is to control the workpiece-cutting tool

positional relationship in such a way as to achieve a
desired geometric shape of the workpiece with
sufficient dimensional accuracy.
What is machining?
MACHINING is the removal of materials in forms of
chips from the workpiece by shearing with a sharp tool.
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Part machining
CNC programming
Define Tool
CNC data
Make 3D model
Simulate
cutting
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2. CNC technique
2.1 What is CNC?

CNC means Computer Numerical Control.
Computer Numerical Control is the automated control of

machine tools by a computer and computer program. In other
words, a computer rather than a person will directly control the
machine tool. Before CNC, the motion of the machine tool had
to be controlled manually or mechanically.
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History of CNC
1947 – J.Parsons (Parsons Corporation) began

experimenting for using 3-axis curvature data to control
machine tool motion for the production of aircraft components
1949 – Parsons awarded a US Air Force contract to build

the first NC machine
1951 – MIT was involved in the project
1952 – NC achieved when MIT demonstrated that simultaneous

3-axis movements were possible using a laboratory-build controller
and a Cincinnati HYDROTEL vertical spindle
1955 – after refinements NC become available to industry
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The first successful N/C machine, funded
by the Air Force, was demonstrated by the
Massachusetts Institute of Technology in
1952. It was a "retrofitted" Cincinnati
milling machine (Figure 1.15). It had the
ability to coordinate the axis motions to
machine a complex surface. The first
"commercial" N/C machines were shown at
the 1955 National Machine Tool Show.
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History of CNC
 Early NC machines run off punched cards and tape
 Due to the time and effort for editing and changing tapes,
computers where introduced for programming
Computer’s involvement
Computer Aided
Direct Numerical Control
Programming Languages
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History of CNC
Computer Aided Programming Languages:
 Allow the development of an NC program using a set of Universal

“pidgin English” commands
 Computer translate commands into machine codes
 Machine codes are punched into the tapes (earlier use to store the data)
Direct Numerical Control:
 A computer is used as a partial or complete controller of one or more

NC machines
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2.2 conventional tool VS. CNC machine tool
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From the figure we could conclude:

CNC machines could produce complicated parts
Conventional machines only produce simple parts
CNC machines save more cost than conventional machines
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CNC APPLICATIONS
 Machining
-2.5D / 3D
-Turning ~ Lathes, Turning Centre
-Milling ~ Machining Centre
 Forming
- 2D / 3D
- Laser Cutting
- Blanking and punching
 Rapid Prototyping(3D printer)
Powder and liquid resin was sintered to form part
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Why use CNC machining?
Engine Block Different parts

This part can not been produced by manual machining.
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AEROSPACE
INDUSTRY
Aircraft Turbine
Machined by
5-Axis CNC Milling
Machine
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CNC MOLD MAKING ELECTRONIC INDUSTRY
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CNC machine can do:
Improve automation
Improve the quality and accuracy of manufactured parts
Flexibility to manufacture complex or otherwise impossible
jobs
2D and 3D contours
Stabilize manufacturing costs
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CNC Machines- Advantages
High Repeatability and Precision e.g. Aircraft parts
Volume of production is very high
Complex contours/surfaces need to be machined. E.g. Turbines
Flexibility in job change, automatic tool settings, less scrap
More safe, higher productivity, better quality
Less paper work, faster prototype production, reduction in lead times
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CNC Machines- Disadvantages
Costly setup
CNC machine tool is more expensive than the conventional machine tool
Skilled operators, programming knowledge required

the CNC machine tool’s control is complex. Operators need to be trained
and get much programming knowledge before beginning to operate the
CNC machine tool
Maintenance is difficult
CNC machine tool needs special maintenance that usually is provided
by the manufactured corporation.
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NC of Machine Tools Overview(1):
•A numerical control, “NC”, system controls many machine functions and

movements which were traditionally performed by skilled machinists.
•Numerical control developed out of the need to meet the requirements of high
production rates, uniformity and consistent part quality.
•Programmed instructions are converted into output signals which in turn control
machine operations such as spindle speeds, tool selection, tool movement, and
cutting fluid flow.
simplechip
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CNC of Machine Tools Overview(2):
• By integrating a computer processor, computer numerical control, or “CNC”

as it is now known, allows part machining programs to be edited and stored in
the computer memory as well as permitting diagnostics and quality control
functions during the actual machining.
• All CNC machining begins with a part program, which is a sequential
instructions or coded commands that direct the specific machine functions.
• The part program may be manually generated or, more commonly, generated
by computer aided part programming systems.
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3 Common Types of CNC Machining Tools

 Any machine tool that can be controlled manually can also be
manufactured with CNC controls.
 CNC and conventional machine tools share many of the
foundation components that make a machine tool.
 Therefore, it is not a great leap in thinking to see that hand
wheels can be replaced with motors, micrometer dials can be
replaced with electronics. This is true for milling machines, lathes,
and many other machine tools and fabrication equipment found in
industry.
In the next section the machine tools (such as milling machines, lathes)
will be introduced in detail.
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3.1 Milling Machines
Type of milling machine:
 vertical CNC milling machine/vertical machine center (VMC)
 Horizontal machine center (HMC)
The vertical CNC milling machine and the vertical machining center are
probably the most common CNC machine tools found in shops today.
They are very agile machines and can be easily adapted to a great
variety of workpieces.
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Vertical CNC milling machines are easy to load and operators have
good visibility.
 Parts could be fixed on the machining table easily
 Operator could observe the
machining process from many
angles of view
But
 Vertical CNC milling are not as

heavy-duty as their horizontal cousin
 Chips can also be difficult to remove,
as they tend to fall back into the
cutting zone
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Vertical CNC milling & Vertical Machining Center (VMC)

There are few difference between a standard vertical CNC milling
machine and a VMC. If you call a VMC a vertical mill, nobody is going
to give you a funny look.
We can observe some common

differences between the two:
VMC are typically made in a bed-
type construction, whereas a
vertical CNC milling machine uses
the knee and column construction.
So VMC is heavier and harder to
move than the vertical CNC milling.
VMC
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Vertical machining centers are

often manufactured with three
linear axes of motion much like
a standard milling machine.
However, a fourth or fifth
rotational axis is sometimes
added.
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5-axis milling machine tool
Horizontal Machining Center (HMC)
A HMC is basically a VMC that has been tipped over 90 degrees.
There are some advantages to the HMC construction and configuration:
 the spindle is mounted to a stationary and extremely rigid base. This

rigid construction is ideal for heavy cutting and high material-removal rates.
 the tool and the workpiece are mounted horizontally. If we are going to
remove a lot of material, then we are going to produce many, many chips.
The reason is that the horizontal configuration allows gravity to help
remove the chips.
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Horizontal Milling machine architecture
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Milling machines movie 1
An american football was

Machined using 5-axis
milling machines
Milling machines movie 2
An automobile engine was

Machined using 5-axis
milling machines
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3.2 Lathe
The CNC Lathe is another common sight in job shops and production
facilities.
Lathe work has historically been
a high-volume affair. Because
cylindrical parts such as
bearings, small fittings, and
fasteners are needed in great
quantities.
In contrast, milling machines,

which tend to produce smaller
quantities, prove much more
difficult to automate.
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CNC lathes have some unique advantages:

 They can cut circular arcs that
were all but impossible to cut on
a conventional lathe without
special tooling.
 CNC lathes also excel at
threading. There are no gears to
change or dials to watch while
threading. It can even cut
variable pitch threads without
selecting or changing the gears.
 the CNC Lathe makes it easy
to maintain a constant surface
speed at the cutting edge as the
diameter changes.
V＝πDn
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Automatic Tool Changer on the CNC turning:

The cutting tools on a CNC turning center are
usually mounted in a device called a turret. The
turret can be indexed very rapidly to automatically
change to the next tool.
Another design for automatic tool changing is

the tool magazine. A tool magazine carries the turret
tools on a belt and loads each tool onto the tool
post when needed. This is slower than a turret,
and each tool must be mounted in a special
holder, which adds to the cost.
The main advantage of a magazine is that it can

hold several dozen or more tools. A typical turret
can only hold 16 tools.
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Automatic Tool Changer movie1 Automatic Tool Changer movie2
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Many CNC turning centers are also equipped with some enhanced features
to make them more productive:
 One example is
multiple turrets.
CNC turning centers

with multiple turrets can
perform two operations
at the same time. For
example, the top turret
can cut a groove on the
outside diameter while
the bottom turret
performs a drilling
operation on the face of
the workpiece.
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Another productivity enhancement is live tooling. This so-called live

tooling is in fact a small, light-duty milling spindle mounted in the tool holder.
Live tooling can be used to drill cross holes or hole patterns on the face of
the part, or in milling operations such as cutting a keyway or milling a
wrench flat into the workpiece. Live tooling can dramatically reduce the
number of secondary operations that are required. Rather than going from
the lathe to the milling machine, the part might be able to go directly to the
customer.
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Live tooling
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3.3 Grinder
Surface grinders and
cylindrical grinders were
probably the last frontier for
CNC systems. The tight
tolerances required in
grinding meant they had to
wait for the motion control
technology to catch up.
Today, the positioning
systems are capable of the
50 millionths of an inch
tolerances that are common workpiece Grinder
in precision grinding. Grinding wheel
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It is now common to see CNC

surface grinders and CNC
cylindrical grinders with some
impressive features.
For example, most CNC

precision grinders will
compensate for wheel wear
and automatically redress the
wheel when it becomes too
worn. CNC precision grinders
that automatically dress special
shapes into the wheel and
create profile on the workpiece
are also available. Grinding wheel
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4 System View of CNC

4.1 Motion and coordinate system for NC machine
 Cartesian coordinate system:
the xyz system is a right-hand
system
 Positive motion:
moving the cutting tool away
from the workpiece.
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Z-axis:
Always aligned with the
spindle that imparts
cutting power.
 z axis is perpendicular to
work-holding surface if there
is no such spindle.
 Positive motion in z axis
tends to increase the
separation between the work-
piece and the tool
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X axis: Positioning the moving element,

parallel to the work-holding surface,
horizontal (if possible).
 On machines with rotating work-
pieces, it is radial and parallel to the
cross-slide
 On machines with rotating tools,

If the Z-axis is horizontal, the positive x
motion is to the right when looking
from the spindle to the work-piece.
If the z axis in vertical, the positive x axis
is to the right when looking from the
spindle to the column
 On machines with non-rotating work-
pieces and non-rotating tools, the x-
axis is parallel to and directed toward
the principal cutting direction
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Y-axis: be in such a direction as

to complete a right-handed
Cartesian coordinate system
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Using a vertical milling

machining center as an
example, there are typically
three linear axes of motion.
Each is given an alphabetic
designation or address.
The head movement up and

down the column is the “Z” axis.
The machine table motion side
to side is called the “X” axis.
Table movement in and out is
the “Y” axis.
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4.2 CLASSIFICATION OF NUMERICAL CONTROL

 Motion control: point to point (PTP),
continuous (contouring) path
 Control loops: open loop, closed loop
 Power drives: hydraulic, electric, pneumatic
 Positioning systems: incremental positioning,
absolute positioning
 Hardware and software: Hardware NC,
software computer numerical control (CNC)
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4.2.1 Motion Control (1)
 PTP motion-control
 To move the machine table or spindle to a specified position so
that machining operations may be performed at that point.
 Path taken to reach the specific point is not defined.
 Movement from one point to the next is non-machining, it is
made as rapidly as possible.
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4.2.1 Motion Control (2)
 continuous (contouring) control

 To control two or more axes simultaneously to get desired shape.
 To control not only the destinations, but also the paths through
which the tool reaches these destinations.
 In the process of machining, the tool contacts the workpiece.
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4.2.2 Control Loop
Whether there is position feedback?
 Open-loop control
 Closed-loop control
 Half closed-loop control
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4.2.3 Power drives

 Electric motor
 widely used
 small size, ease of control, low cost
 Hydraulic drive
 much larger power/size ratio
 Pneumatic drive
 rarely used in NC positioning system
 can be used to drive the auxiliary devices
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4.2.3 Power drives

 Electric motor
 Stepping motor
 Servo motor (DC or AC)
(Direct current/Alternating current)
 Most closed-loop systems control use servo
motors (either DC or AC), while, open- loop NC
machines normally use stepping-motor drives
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4.2.4 Positioning system
 Incremental positioning system

 absolute positioning system
depends on the position transducer used
 When the transducer reports the absolute position

of the machine table, the machine is an absolute
positioning machine.
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4.3 A Typical CNC machine tool structure
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A typical CNC system consists of the following six elements

(1) Part program (2) Program input device (3) Machine control unit
(4) Drive system(5) Machine tool (6) Feedback system
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Control system in NC machine:
(1) Part program
A computer program within the control ( called the control program)

handles the job of interpreting the part program and turning it into a
series of electrical signals. The control program will read an
instruction within the part program, generate a minute electrical signal
to turn on a motor.
 NC part programmer should be a skilled operator and good

part programmer for maximum utilization of machine
capabilities and available resources like jigs and fixtures,
cutting tools, without violating the machine constraints.
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 A part program is a series of coded instructions required to produce a

part. It controls the movement of the machine tool and the on/off
control of auxiliary functions such as spindle rotation and coolant.
 The coded instructions are composed of letters, numbers and
symbols and are arranged in a format of functional blocks as in the
following example
 N10 G01 X5.0 Y2.5 F15.0

| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number
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(2) Program input device

 The program input device
is the mechanism for part
programs to be entered
into the CNC control.
 The most commonly used
program input devices
are keyboards, punched
tape reader, diskette
drivers, throgh RS 232
serial ports and networks.
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(3) Machine control unit

The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:
 Read coded instructions
 Decode coded instructions
 Implement interpolations (linear, circular, and helical) to
generate axis motion commands
 Feed axis motion commands to the amplifier circuits for
driving the axis mechanisms
 Receive the feedback signals of position and speed for
each drive axis
 Implement auxiliary control functions such as coolant or
spindle on/off, and tool change
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Technically the control is called the Machine Control Unit(MCU), but

the most common names used in recent years are controller, control
unit, or just plain control. Controls come in two basic flavors:
 Proprietary
Proprietary controls have a closed architecture. The systems are
custom built by the manufacturer and often contain closely guards
circuits, algorithms, and control programs. You cannot run down to
the local megastore or load the latest Microsoft operating system
onto its hard drive. This type of control is expensive but offers rock-
solid reliability.
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 PC-based
In recent years, there has been a push toward so-called open
architecture controls- that is, controls made from commonly available
components and software. To some control builders this has meant PC-
based controls. In fact, there are dozens of models of CNC controls
that run on the same components that drive your desktop PC. You can
go to the local computer vendor and buy parts for these controls.
However, the reliability of these systems is somewhat suspect at the
moment. In the future, expect great improvements and widespread
adoption of the open architecture concept based on common PC
hardware.
Control signs
Data
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(4) Drive system

A drive system consists of drive motors and ball lead-screws. The
MCU feeds control signals (position and speed) of each axis to the
amplifier circuits. The control signals are augmented to actuate
stepping motors which in turn rotate the ball lead-screws to
position the machine table.
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(4.1) Ball screw

The Ball screw is a high-precision lead
screw.
On a conventional machine tool,
turning a hand wheel attached to a
lead screw moves the table. A nut is
mounted on the underside of the table
so that the table moves when the
screw is turned.
CNC machine tools use a similar setup,
but the lead screw has been improved
by added ball bearings that ride
between the nut and the screw. The
bearings recirculate through a tube on
the nut. The resulting performance is
outstanding with very low friction and
zero backlash.
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Why ball-bearing screw is better?
Sliding friction, conventional screw
Rolling friction, ball-bearing screw
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Backlash:
Backlash in a ball screw is eliminated because a slight interference fit
is created when the screw, ball bearing, and nut are assembled. In
other words, the space between the nut and the screw is a little
smaller than the balls that must fit in between them.
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Eliminating backlash is very important for two reasons:

 high-precision positioning can not be
achieved if the table is free to move slightly
when it is supposed to be stationary. The
control will constantly try to adjust for any
positioning errors, so a loose table will drive
the feedback system crazy as it moves around.
 material can be climb-cut safely if the
backlash has been eliminated. Climb cutting is
usually the most desirable method for
machining on a CNC machine tool. However,
climb cutting pulls the workpiece into the cutter. •Climb cutting(down
If there is backlash in the screw, the materical milling):Chip thickness
will jump into the tool and may cause the tool to is large when cutting in
shatter or possibly damage the workpiece. and zero when exiting
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•Climb cutting(down milling):Chip •Up milling:Chip thickness is zero
thickness is large when cutting in when cutting in and increases when
and zero when exiting exiting
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(4.2) drive motor

Drive motors are the second specialized component in the drive system.
The turning of the motor will turn the ball screw to directly cause the
machining table to move. Several types of electric motors are used on
CNC control systems, and hydraulic motors are also occasionally used.
There are many different types of electric

motors, but they all work on the same
basic principle of magnetic attraction and
repulsion.
Electric motors work by creating a
moving magnetic field with an
electromagnet within the motor to attract
or repel another set of magnets. This
attraction and repulsion causes the shaft
of the motor to rotate.
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chapter1\DC.mp4 82
(4.2.1) Stepper motor

The simplest type of electric motor used in CNC positioning system is the
stepper motor (sometimes called a stepping motor). A stepper motor
rotates a fixed number of degrees when it receives an electrical pulse and
then stops until another pulse is received.
Stator 30° 30°

定子
Rotor
转子
Phase U Phase V Phase W

electrified electrified electrified
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 Stepping motor/步进电机
 When the pattern of the Three-phase motor
signals shifts, the motor clockwise
Step U V W
rotates one step angle. stepping
 The direction of rotation 1 1 0 0
depends on the pattern- 2 0 1 0
shifting direction. 3 0 0 1
 NC sends one stepping
4 1 0 0
signal and a direction signal.
5 0 1 0
 Stepping motor：pulse control
6 0 0 1
 The number of steps
(displacement) is determined Counter
by the number of stepping clockwise
signals (pulses) received. stepping

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UVW
30°
step angle/步距角
UUVVVWW
15°
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 Stepping motor：pulse control

 The number of steps (displacement) is determined by
the number of signals (pulses) received.
angle of rotor = number of pulses  step angle
 The speed of a stepping motor is determined by the rate

at which the signals (pulse rate) are received.
angular speed of rotor = pulse rate  step angle

pulse rate=Pulses per second
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Example：
 If we would like to turn a 1.8°step angle motor 2000 steps at 360

rpm, what is the number of pulses and pulse rate to be sent to the
motor?
 The number of pulses should be the same as the steps. Therefore,

number of pulses = 2000.
 360 rpm＝(360rev/min)/(60s/min)＝6 rev/s

 Number of steps a revolution: N＝360°/1.8°=200 steps/rev
 Pulse rate＝6 rev/s200 steps/rev＝1200 pulses/s
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Stepper motor analysis:

Stepper motor is relatively easy and inexpensive to design CNC systems
with stepper motors. Stepper motor systems can operate without expensive
and complicated positioning feedback. In other words, the control can
simply tell motor “A” to turn 100 pulses and motor “B” to turn 75 pulses, but
there is no guarantee that the table is actually where you expected it to be.
If an inexpensive, low-precision system is needed, then stepper motors may
be the proper choice.
Drawbacks:
 Stepper motors tend to jerk as they are pulsed. This can lead to poor
surface finishes and excess wear resulting from the constant acceleration
and deceleration.
 Stepper motor tend to produce a stair-step effect when attempting to
produce angled lines and circular arcs.
Modern industrial CNC machines seldom use stepper motors.
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(4.2.2) Servo motor

Servomotors operate in a smooth, continuous motion-not like the discrete
movements of the stepper motors. This smooth motion leads to highly desirable
machining characteristics, but they are also difficult to control. Specialized
hardware controls and feedback system more expensive and complex, but it
also provides stop-on-a-dime control and smooth acceleration curves.
差动放大器
转速计
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Servomotors differ greatly from stepper motors in the way they are
constructed and controlled. When an electrical signal is sent to a
servomotor, it will turn continuously until the current stop. The speed of a
servo motor can be controlled by the strength of the signal or by varying
the frequency of the signal, depending on the particular construction.
 DC servomotor: voltage control

When a higher voltage is applied to the motor, a large current flows through
the motor coil, which in turn produces more torque and makes the motor
run faster.
Some of the earlier servo-based CNC machine tools used DC (Direct
Current) servomotors. Direct current is the type of electrical current that
flows from a battery. DC servomotors were powerful, but DC current
has some inherent inefficiencies and limitations.
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 AC servomotor: frequency control

The higher the power-source frequency, the faster the motor rotation.
As control technologies evolved, machine tool builders started to

use Alternating Current (AC) servomotors. AC servomotors are
currently the standard choice for industrial CNC machine tools.
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 chapter1\DC and AC直流电机和交流电
机的比较.mp4
 chapter1\Liner motor直线电机.mp4
 chapter1\Motorized spindle电主轴.avi
2020/9/28
(5) Feedback System

The function of a feedback system is to provide the control with
information about the status of the motion control system.
The feedback system is also referred to as the measuring system.
It uses position and speed transducers to continuously monitor the
position at which the cutting tool is located at any particular time.
The MCU uses the difference between reference signals and
feedback signals to generate the control signals for correcting
position and speed errors.
For example, You use a feedback system every time you drive a car
or ride a bike. Your brain tells your hands to move the steering wheel
in one direction or another, and then your eyes give feedback to your
brain about your trajectory. If you happen to steer off the road, your
brain will take corrective action.
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There are two main types of feedback systems:

 Open-loop control
An open-loop feedback system is really a no-feed-back system. It does

not have any device to determine if the instructions were carried out.
For example, in an open-loop feedback system, the control could give
instructions to turn the motor 10 revolutions. However, no information
can come back to the control to tell it if it actually turned.
Open-loop feedback is not used for critical systems, but it is a good
choice for inexpensive motion control systems in which accuracy and
reliability are not critical.
2020/9/28 95
 Close-loop control
Close-loop feedback uses external sensors to verify that certain

conditions have been met. Of course, positioning and velocity
feedback is of primary importance to an accurate CNC system.
Feedback is the only way to ensure that the machine is behaving
the way the control intended it to behave.
2020/9/28 96
Components of Servo-motor controlled CNC

Motor lead screw rotation table moves
Motor speed control feedback position sensed by encoder
Two types of encoder configurations
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(5.1) Feedback Devices
A variety of sensors are used with close-loop feedback systems

to report information about the position of the machine and the
velocity of the motors or spindle. A sensor called an encoder is
used to measure linear displacements of the machining table.
Sometimes a less expensive tachometer will be used in conjunction

with encoders to measure the angular velocity of the motors. We
might also find a variety of less sophisticated sensors, such as limit
switches, that determine certain conditions are safely met before
operation.
2020/9/28 98
Currently there are two main categories of encoders in use with

CNC system: rotary encoders and linear encoders.
A rotary encoder is a
type of sensor that when
mounted to the shaft of
the motor can detect its
angular position. You will
usually find these
conveniently mounted to
the backside of the
motor. Furthermore,
many motors come
equipped with a rotary
encoder as an integrated
part of the design.
2020/9/28 99
A rotary encoder is made from a light source, an optical sensor, and a

disk with small slits cut into it like spoke. The slotted disk is mounted
to the shaft of the motor, and the light source and the light sensor are
mounted on opposite sides of the disk.
As the disk turns,
the light shines
through the slits onto
an optical sensor.
The optical sensor
acts like a switch
that turns on and off
as the light strikes it.
In this way, the
optical sensor sends
an electrical signal
back to the control.
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Direction of Rotation
A rotary encoder with only one set of slots has a fatal defect?
It cannot tell which direction it is turning. It only knows that the switch
keeps turning on and off.
Another set of slots on the same disc and another optical sensor is
needed to determine the direction of rotation.
This is accomplished by setting
the second set of slots out of
phase by 90 degree. The graph
shows that while the disk is
turning clockwise, sensor A
leads sensor B. In other words,
if we reverse direction, sensor
A will trail sensor B.
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Drawbacks of rotary encoder :

Rotary encoders are subject to a small degree of uncertainty. Because
they are mounted on the motor, they do not directly measure the table
position-they give a calculated position based on the pitch of the ball
screw. The position will be incorrect if there are any errors in the screw.
rotary encoder
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Linear encoders are constructed by etching fine graduations into a

glass beam at specific intervals. The glass beam is mounted directly
to the machining table and essentially becomes a very accurate ruler.
A stationary encoder head Light Source window Glass Beam

that contains a light source
and an optical sensor reads
the ruler. A beam of light is
show onto the scale, and
optical sensor catches the
reflection.
Glass Scale Reference Point Receiver
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CNC systems also need to obtain information about the angular

velocity of the motors and the linear velocity of the table. This
can be accomplished in two ways.
 the control can calculate the velocity of the table or motor by

simply dividing the number of encoder ticks by the elapsed time.
For example, if each tick

translates to 0.001, and
the control is counting
200 every second, then
the linear velocity is 0.2
per second.
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 Tachometers are used to

measure angular velocity
(RPM). A tachometer is a
simple sensor that can,
directly or indirectly,
measure the number of
revolutions the shaft will
make every minute.
The spindle RPM is a
critical quantity that every
machinist and NC
programmer is acutely
aware of the spindle RPM. Tachometer
it will greatly affect the
surface finish and tool life.
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(1) We plan the NC

part program and feed
it to the control (MCU)
1
2020/9/28 106
(2) The controller sends a

signal into the motor and
the motor begins to turn.
2 2
107
2020/9/28
(3) The encoder provides

feedback to the control. The
feedback is compared to the
input at the summing junction.
The input is then adjusted,
1 which in turn changes the output.
2 2
3
a velocity loop
3
a position loop
108
2020/9/28
For example, the input is to turn the motor 1000 clicks. The motor
turns for a while and the encoder sends feedback indicating that it
only turned 990 clicks. The two values are compared and the error
is determined to be 10 click. So a new input is sent to turn the motor
10 click. The motor turns for a while, and this time the encoder
indicated that it has turned 12 click. The cycle then repeats itself
over and over again at a very rapid rate until it is close enough.
Attention:
It is important to note that each subsystem must be properly matched
to work within the CNC system. For example, if the control system is
programmed and designed for servomotors, then you cannot use
stepper motor.
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5. A standardized Programming Language

The most popular language for NC programming is G & M code
programming, based on the Electronics Industries Alliance and
International Standards Organization standard (EIA/ISO). This is a
language standardized by American and European industry / standards
organizations in an attempt to make NC programming uniform.
One of the early adopters/creators of the EIA/ISO standard was Fanuc.
Their controls became quite popular, and now the terms G& M codes
and Fanuc-style are virtually synonymous.
Today the standardization of G & M codes makes the transition from one
machine to another a relatively easy process. The machinist does not
need to learn a whole new language- just a slightly different vocabulary.
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Chapter Summary(1)
 Computer numerical control replaces manual controls with
electronic systems to perform machine movements. Virtually any
machine tool can be controlled with a CNC system.
 The movement of the CNC machine tool are accomplished with s

set of instructions called a NC part program that is written by an NC
programmer. This program is commonly written with G & M codes,
but other languages and methods are available.
 The CNC system consists of three subsystems: control, drive,

and feedback.
2020/9/28 111
Chapter Summary(2)
 The control system is a computer that interprets the part program
and generates an electronic signal to the drive system.
 The drive system uses motors and actuators to turn the electronic
signals into tool movements and other machine functions.
 The feedback system uses sensors such as rotary and linear

encoders to send positioning and velocity information back to the
control to maintain the proper positioning.
2020/9/28 112

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NC Machining Technique

Welcome you to study the important

My research field are as follows:

• Computerized numerical control (CNC) processing technology

Mike Mattson, CNC Programming

Our course content is

Our course mainly introduces

 Student’s score is made up of two parts:

Your score is the sum of two parts.

1,Provide the groundwork for modern manufacturing and

 chapter1\CAM- Using Mastercam 2017

(1) How many students have learned CAM software?

(2) How many students have seen the machine tool?

(3) How many students had used the machine tool?

I hope that you will get basic knowledge of NC machining technology

 Identify the components of a CNC control system

 Understand some of the additional features of a CNC machine tool

 Have familiarity with the common hardware used in motion control

In today’s age of rapidly evolving computer technology, there seems to

CAD(Computer Aided Design）

TO be competitive through increasing productivity and total

Computer-Aided Design (CAD)

 Mass property calculations

 Geometry modeling and visualization

 Defines the geometry of the design

Computer-Aided Manufacturing (CAM)

 Use of computer systems to plan,

Computer-Aided Engineering (CAE)

 Use of computer systems to

• To increase productivity of the designer

What is machine tool?

Machine tool is to control the workpiece-cutting tool

2.1 What is CNC?

Computer Numerical Control is the automated control of

1947 – J.Parsons (Parsons Corporation) began

1949 – Parsons awarded a US Air Force contract to build

1951 – MIT was involved in the project

1952 – NC achieved when MIT demonstrated that simultaneous

1955 – after refinements NC become available to industry

 Early NC machines run off punched cards and tape

Computer Aided Programming Languages:

 Allow the development of an NC program using a set of Universal

Direct Numerical Control:

 A computer is used as a partial or complete controller of one or more

2.2 conventional tool VS. CNC machine tool

From the figure we could conclude:

Why use CNC machining?

Engine Block Different parts

CNC MOLD MAKING ELECTRONIC INDUSTRY

CNC machine can do:

CNC Machines- Advantages

High Repeatability and Precision e.g. Aircraft parts

Volume of production is very high

Complex contours/surfaces need to be machined. E.g. Turbines

Flexibility in job change, automatic tool settings, less scrap

More safe, higher productivity, better quality

Less paper work, faster prototype production, reduction in lead times

CNC Machines- Disadvantages

Skilled operators, programming knowledge required

NC of Machine Tools Overview(1):

•A numerical control, “NC”, system controls many machine functions and

CNC of Machine Tools Overview(2):

• By integrating a computer processor, computer numerical control, or “CNC”