Syllabus

• Computer Enabled Subtractive Processes:

• CNC machine: Introduction, principles of operation,
• Types – Vertical machining centres and horizontal machining centres, major elements,
functions, applications, controllers, open loop and closed loop systems
• Types of Automatic Machines, Transfer Lines.
 HISTORY

• The first NC machines were built in the 1940s and 1950s by Prof. John T Parson.

• CNC machine came into existence after evolution of computer around 1980.

• Modern CNC Machine are improving further as the technology is changing with a
variety of functions according to applications.
 Numerical Control Machines

• Numerical Control is a system in which actions are controlled by the direct

insertion of numerical data at some point.

• In other words, Programmable automation in which the mechanical actions of a

‘machine tool’ are controlled by a program

• It is defined as a Method of programmable automation in which various functions

of machine tools are controlled by numbers, letters and symbols.
 NUMERICAL CONTROL ELEMENTS

1.Program of instructions.
2.Machine control unit (MCU).
3.NC machine tool.
1.Program of Instructions:
• The program of instructions is the detailed step - by – step of operations which are
implemented by MCU .
• The program is coded in alphanumerical form on an input medium to the MCU
• The input medium is a punched tape or a magnetic tape .
 Machine Control Unit (MCU)

• NC machine tool has a main unit, which is known as Machine Control Unit.
• It consists of some electronic hardware that reads the NC programme, interprets
it and conversely translates it for mechanical actions of the machine tool.
• MCU consists of two parts : Data processing unit (DPU) and control loops unit
(CLU).
• Function of DPU: read the decode the instructions available on the tape & to
provide the decoded data to the control loops unit (CLU).
• Function of (CLU): To control the drives attached to the axes and receive the
feedback signals from machine tool
 NC Machine Tool

• Machine tool is the main components of a numerical control system, which

executes the operations.
• It may consist of worktable, cutting tools, jigs and fixtures, motors for driving
spindle and coolant and lubricating system.
• The latest development in the numerical control machine tool is the versatile
machining center.
• This is a single machine capable of doing a number of operations such as milling,
boring, drilling, reaming, and tapping by Automatic Tool Changer (ATC) under the
control of tool selection instruction.
• In NC machine numbers form of program of instructions are:
1.TO Start (or) Stop the machine tool spindle .
2. To control the spindle speed.
3.To change the tool.
4.To change the feed rate.
5.To switch the coolant on/off.
6.To position the tool at a desired position
• Principle of operation:
• The program of instructions in terms of part geometry, cutting process parameters and type of
tool serves as the input of machine control unit (MCU) which in turns commands the machine
tool to make the product.
• The machine axes are connected to servomotors , which work under the control of the machine
control unit (MCU)
• The servomotors control the movement of the cutting tool with respect to work piece.
 • BASIC REQUIREMENT OF NC MACHINE CONTROL

a. Preparatory functions: which unit, which interpolator, absolute or incremental programming,

which circular interpolation plane, cutter compensation, etc.
b. Coordinates: three translational, and three rotational axes.
c. Machining parameters: feed, and speed.
d. Tool control: tool diameter, next tool number, tool change.
e. Cycle functions: drill cycle, ream cycle, bore cycle, mill cycle, clearance plane.
f. Coolant control: coolant on/off, flood, mist.
g. Miscellaneous control: spindle on/off, tape rewind, spindle rotation direction, clamps control,
etc.
h. Interpolators: linear, circular interpolation
 Types of Numerical Control

• Conventional Numerical Control (NC)

• Direct Numerical Control (DNC)

• Computer Numerical Control (CNC)

• Conventional Numerical Control (NC)
• Data is sent to the machine tool by means of punch cards or tapes.
• The reader at the machine performs no calculations or interpolations.
• 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
• Cost-Benefits of NC
• Costs
• High investment cost
• High maintenance effort
• Need for skilled programmers
• High utilization required
• Benefits
• Cycle time reduction
• Non-productive time reduction
• Greater accuracy and repeatability
• Lower scrap rates
• Reduced parts inventory and floor space
• Operator skill-level reduced
 CNC (Computer Numeric Control)
• CNC machine can be defined as the machine which is control by computer and the operation is
performed by feeding the program on it.

• Elements of CNC

• Program
• Tape Reader
• Mini-computer
• Servo system
• CNC machine tool
Elements of CNC
 Classification of CNC

a) Based on feedback control

b) Based on control system features

 Open Loop Systems
• Open loop systems have no access to the real time data about the performance of the system and
therefore no immediate corrective action can be taken in case of system disturbance.
 Close Loop Systems
• In a close loop system, feed back devices closely monitor the output and any
disturbance will be corrected in the first instance. Therefore high system accuracy
is achievable.
 Classification Based on control system features

• Point-To-Point Control in CNC: Drilling of Three Holes in Flat Plate

• System moves to a location and performs an operation at that location (e.g.,
drilling)
• Also applicable in robotics
2. Straight line control system
• Straight line or straight cut CNC system is an extension of point-to-point control
system with a provision of machining along a straight line as in case of milling and
turning operations
3. Continuous path control in CNC: Profile Milling of Part Outline
• Also called contouring systems in machining
• System performs an operation during movement (e.g., milling and turning)
 Display Unit

Interface between the machine and the operator.

The Display Unit displays:

• position of the machine slide
• spindle RPM
• feed rate
• part programs
• graphics simulation of the tool path.
 Interpolation Methods

• Linear interpolation:- Straight line between two points in space

• Circular interpolation:- Circular arc defined by starting point, end point, centre or radius, and
direction.

• Helical interpolation:- Circular plus linear motion

• Parabolic and cubic interpolation:- Free form curves using higher order equations
 Machine axes
• Machine axes are established according to the industry standard report
 Axes configuration
• X axes moves from right to left as you face the machine
• Y axes move toward and away from you
• The Z axes is the spindle movement up and down spindle .
• A move toward work is Z(-Z)
• A move away from work is Z(+ Z)
Dimensioning Systems
 CNC Programming

Programming consists of a series of instructions in form of letter codes

Preparatory Codes:

• G codes- Initial machining setup and establishing operating conditions

• N codes- specify program line number to executed by the MCU
• Axis Codes: X,Y,Z - Used to specify motion of the slide along X, Y, Z direction
• Feed and Speed Codes: F and S- Specify feed and spindle speed
• Tool codes: T – specify tool number
• Miscellaneous codes – M codes For coolant control and other activities
 Programming Key Letters
• O - Program number (Used for program identification)
• N - Sequence number (Used for line identification)
• G - Preparatory function
• X - X axis designation
• Y - Y axis designation
• Z - Z axis designation
• R - Radius designation
• F – Feed rate designation
• S - Spindle speed designation
• H - Tool length offset designation
• D - Tool radius offset designation
• T - Tool Designation
• M - Miscellaneous function
 Table of Important G Codes
• G codes are instructions describing machine tool movement
• G00: Rapid Transverse
• G01: Linear Interpolation
• G02: Circular Interpolation, CW
• G03: Circular Interpolation, CCW
• G04 : Dwell
• G17: XY Plane
• G18: XZ Plane
• G19: YZ Plane
• G20/G70: Inch units
• G21/G71: Metric Units
• G40: Cutter compensation cancel
• G41: Cutter compensation left
• G42: Cutter compensation right
• G43: Tool length compensation (plus)
• G44: Tool length compensation (minus)
• G49: Tool length compensation cancel
• G80: Cancel canned cycles
• G81: Drilling cycle (G81-G89: Canned cycles)
• G82: Counter boring cycle
• G83: Deep hole drilling cycle
• G90: Absolute positioning
• G91: Incremental positioning
• G92: Zero preset
• G94: feed rate mm/min
• G95: feed rate mm/rev
• G99: Canned cycle back to R point
Table of Important M codes

• M Codes are instructions

describing miscellaneous
functions like calling the
tool, spindle rotation,
coolant on/off etc.