ME8691 Notes 006 4 Edubuzz360

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UNIT 4
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NUMERICAL CONTROL SYSTEM
– Numerical control refers to the automation of machine tools

operated by programmed commands encoded on a storage
medium against to manual control through hand wheels or
mechanically automated through cams alone.
– Controlling a machine tool by means of a prepared programme is
known as Numerical Control or NC
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Definition of NC System
– A system in which actions are controlled by the direct insertion of

numerical data at some point is known as NC system.
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TYPES OF NC SYSTEM
– Traditional numerical control (NC)

– Computer numerical control (CNC)
– Distributed numerical control (DNC)
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Controlled axes in NC systems
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NC axis conventions
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Basic components of NC
– Software
– Machine Control Unit (MCU)
– Machine tool
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Machine Control Unit
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– Input or reader unit

– Memory
– Processor
– Output channel
– Control panel
– Feed back channel
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CLASSIFICATION NC MACHINES
BASED ON CONTROL SYSTEM
– Open- loop system in NC machines

– Closed loop system in NC machines
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Open- loop system in NC machines
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Closed loop system in NC

machines
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Classification NC machines based

on numerical control system
– Point to point NC system

– Straight cut NC system
– Contouring NC system
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Point to point NC system
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Straight cut NC system
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Contouring NC system
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Driving system of NC Machines
– Electromechanical devices
– Digital circuits
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AC Drives
Principle of operation
The velocity of AC synchro motor is controlled by
manipulating the voltage frequency supplied by the motor. The
frequency manipulation requires the use of an electrical inverter, the
inverter contains DC power supply and the circuit inverts DC voltage
into AC voltage with a continuously controllable frequency.
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DC MOTORS
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STEPPING MOTOR
– Principle of operation
The drive unit contains a steering circuit and a power
amplifier. It translates the input pulses into the correct switching
sequence required to step the motor.
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HYDRAULIC SYSTEMS
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PNEUMATIC DRIVES
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TOOLING SYSTEMS IN NC
MACHINES
– Using quick change tool holders
– Automatic tool selection
– Changing tools automatically for sequence of operations
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APPLICATIONS OF NC
MACHINES
– Metal cutting machine tools
– Press working machine tools
– Welding machines
– Inspection machines
– Assembly machines
– Industrial robots
– Cloth cutting
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ADVANTAGES OF NC
MACHINES
– It provides greater accuracy
– Less production cost
– Less operator skill is required
– Machine utilization is better
– Tooling cost is less
– Cycle time is reduced thereby increasing the tool life.
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DISADVANTAGES OF NC
MACHINES
– Machine cost is high
– Highly knowledgeable person in this field
– Flexible is not there
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CNC SYSTEM
– Computer numerical control is a NC system that utilizes a stored

programme to perform the basic numerical control functions. A
mini or micro computer based controller unit is used.
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The type of CNC used in these

above- said fields are given below
– CNC lathes
– CNC turning centres
– Gear hobbing machines
– Gear shaping machines
– Tube bending
– Electron beam welding
– Press brakes
– Abrasive water jet machines
– Coordinate measuring machines
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Types of CNC
– Hybrid CNC
– Straight CNC
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Major Elements of CNC systems
– Hardware
– Software
– Information
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CNC Machine Constructional

details
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Special features of CNC

machines
– CNC drive systems
– Feed drive
– Slide movement element
– Swarf and coolant control
– Working of automatic tool changer
– Work holding system
– CNC controller
– Type of CNC machines
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Special features of CNC

machines
CNC drive systems
1.Cutting spindle
A spindle drive is a primitive type of transmission. A rod, referred to
as a spindle, is attached to the output of an engine. This rod then
comes in direct contact with a tired. A spindle tooling provides an
objective connection between cutting tool and spindle of the
machine tool.
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Special features of CNC machines
CNC drive systems

1.Spindle heads
Types
i) Inclinable head
ii) Robot-head
iii) Horizontal spindle head
iv) Vertical spindle head
v) Universal head.
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CNC drive systems
Feed drive
Feed drive consists of a feed servomotor and electronic controller. Unlike a spindle drive, the feed
drive motors has some special characteristics such as constant torque and positioning. Also, in
contouring operations, several feed drives have to work simultaneously because of the requirement
to follow a prescribed path continuously.
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Slide movement Element
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Working of automatic tool changer
– Drum type
– Chain type
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Swarf and coolant control
In CNC grinding process metal chips are formed in the form

of micro particles. This particles is known as swarf.
During of CNC machining process, the coolant will be mixed
with the swarf and the mixture will be deposited on the
tray.
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Work holding system
– Collet chuck
– Jaw chuck
– Arbors
– Fixtures
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MACHINING CENTRES
The following operations are carried out

– Milling
– Drilling
– Reaming
– Boring
– Tapping
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Classification of machining centres
– Horizontal spindle machining centres

– Vertical spindle machining centre
– Universal machining centre
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Horizontal spindle machining

centres
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Vertical spindle machining centre
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TURNING CENTRES
– Horizontal machines
– Vertical machines
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CLASSIFICATION OF
HORIZONTAL MACHINES
– Chucking machines
– Shaft machines
– Universal machines
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Chucking machines
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CNC ELECTRICAL DISCHARGE

MACHINING
– RAM type EDM CNC machine
– Orbital type EDM CNC machine
– Wire cut EDM CNC machine
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DESIGN CONSIDERATIONS OF
CNC MACHINES
– Static load
– Dynamic load
– Thermal load
– Guideways
– Measuring system
– Tool monitoring system
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APPLICATION OF CNC MACHINES
– Metal cutting industry for processes

– In addition to metal cutting machines, CNC has also been applied
to the following
– Press working machine tools
– Welding machines
– Inspection machines
– Assembly machines
– Industrial robots
– Cloth cutting
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ADVANTAGES OF CNC
MACHINES
– It increases in capacity for storing large part programs
– It increases the memory for part programme processing
– It is easy to edit the part programs on the control console
– CNC is more compatible
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DISADVANTAGES OF CNC
MACHINES
– Costly setup and skilled operators are required
– Computer programming knowledge is essential
– Maintenance is difficult
– Machines have to be installed in air conditioned places
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DNC
– DNC can be defined as a manufacturing system in which a number

of CNC machines are controlled by a single computer through
direct connection and in real time.
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Configuration of a DNC System
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ADVANTAGES OF DNC
– The computer can be remotely located even a thousand miles

away
– The computer can simultaneously programme for many NC
machines
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PART PROGRAMMING
FUNDAMENTALS
– The conversion of engineering blueprint to a part
programme can manually be performed or with the
assistance of a high level computer language.
– Part program
– Methods of creating part programming
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Part program
– The part programme is a set of instructions proposed to get the
machined part starting with the desired blank and NC machine
tool.
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Methods of creating part

programming
– Manual part programming
– Computer assisted part programming (CAD/CAM)
– Manual data input
– Computer automated part programming
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CNC MANUAL PART

PROGRAMMING
– To prepare a part programme using a manual method, the
programmer writes the machining instructions on a special format
called part programming manuscript.
– The manual programming jobs can be divided into two categories
– Point to point jobs
– Contouring jobs
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DATA REQUIRED FOR PART

PROGRAMMING
– Job dimensions/workpiece
– Work holding
– Feed/cutting speed
– Finished dimension with tolerance
– Sequence of operation
– Types of tools
– Mounting of tools
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COORDINATE SYSTEMS IN
PART PROGRAMMING
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ZERO POINTS
– Origin is considered as zero point of the coordinate
system. NC machines have either of two methods for
specifying the zero point.
– Fixed zero
– The origin is always located at the southwest corner (lower left
hand corner).
– Floating zero
– The machine operator sets zero point at any positions on the
machine table.
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REFERENCE POINT
– The part programmer decides the zero point to be located. It is

known as reference point.
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NC related dimensioning in part

programming
– There are two type of positioning
– Absolute positioning
– The tool locations are always defined in relation to zero point. G90
code is used in a part programme to represent absolute mode
– Incremental positioning
– The next tool location must be defined with reference to the
previous tool location. G91 code is used in a part programme to
represent incremental mode
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There are two types of unit system

follows
– Inch system
– G70 command is used
– Metric system
– G71 command is used
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The following steps should be kept in

mind while writing the programme
– Fixation of coordinate system

– Reference of G and M codes
– Dimensions of work and tools
– Locating the fixture and machine table
– Speed and feed according to the work and tool material.
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PREPARATORY FUNCTIONS (G) IN

PART PROGRAMMING
– Preparatory commands which prepare the machine or

tool for different modes of movement positioning.
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MISCELLANEOUS FUNCTION IN
PART PROGRAMMING
– The function not relating the dimensional movement of the

machine but it denotes the auxiliary or switching information is
called miscellaneous functions.
– For example coolant on/off, spindle speed
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Address characters and their

meaning
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INTERPOLATION IN PART
PROGRAMMING
– It is the process of developing coordinate points in between start
and finish coordinates.
– Interpolation in NC machining is required to calculate the
intermediate points of a curve or straight line when its start and
end coordinates are given. Interpolation may be linear, circular or
cubic/parabolic.
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INTERPOLATOR
– External interpolator
– Internal interpolator
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CLASSIFICATION OF
INTERPOLATION
– Linear interpolation
– Circular interpolation
– Parabolic interpolation
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SUBROUTINES
– The same machining operation which was carried out already is to

be performed at many different operations on the work piece. It
can be executed by means of a means of programme called as
subrouties.
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CANNED CYCLE
– A canned cycle is a combination of machine moves that performs

anyone particular machining function drilling, turning, milling,
boring, tapping etc.
– G81 to G89 are used for canned cycles
– G80 is used for cancelling the canned cycle
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MICROMACHINING
– Micromachining refers of the technique for the fabrication of 3D

structure on the micrometer scale. Micromachining refers the
super finishing, a metalworking process for producing very fine
surface finishes.
– The various types of micromachining process are given below
– Bulk micromachining
– Surface micromachining
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SURFACE MICROMACHINING
– In surface machining process, the structures are created on top of

a substrate. In this case, a silicon substrate (wafer) is selectively
etched to produce structures.
– In this machining the microstructures are built by deposition and
etching of different structural layers on top of the substrate.
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WAFER MACHINING
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www.edubuzz360.

NUMERICAL CONTROL SYSTEM

– Numerical control refers to the automation of machine tools

– A system in which actions are controlled by the direct insertion of

– Traditional numerical control (NC)

Controlled axes in NC systems

Machine Control Unit

– Input or reader unit

– Open- loop system in NC machines

Open- loop system in NC machines

Closed loop system in NC

Classification NC machines based

– Point to point NC system

Point to point NC system

Straight cut NC system

Driving system of NC Machines

– Computer numerical control is a NC system that utilizes a stored

The type of CNC used in these

Major Elements of CNC systems

CNC Machine Constructional

Special features of CNC

Special features of CNC

Special features of CNC machines

CNC drive systems

CNC drive systems

Slide movement Element

Working of automatic tool changer

Swarf and coolant control

In CNC grinding process metal chips are formed in the form

Work holding system

The following operations are carried out

Classification of machining centres

– Horizontal spindle machining centres

Horizontal spindle machining

Vertical spindle machining centre

CNC ELECTRICAL DISCHARGE

APPLICATION OF CNC MACHINES

– Metal cutting industry for processes

– DNC can be defined as a manufacturing system in which a number

Configuration of a DNC System

– The computer can be remotely located even a thousand miles

Methods of creating part

CNC MANUAL PART

DATA REQUIRED FOR PART

– The part programmer decides the zero point to be located. It is

NC related dimensioning in part

There are two types of unit system

The following steps should be kept in

– Fixation of coordinate system

PREPARATORY FUNCTIONS (G) IN

– Preparatory commands which prepare the machine or

– The function not relating the dimensional movement of the

Address characters and their

– The same machining operation which was carried out already is to

– A canned cycle is a combination of machine moves that performs

– Micromachining refers of the technique for the fabrication of 3D

– In surface machining process, the structures are created on top of