BTM 3334

CNC MACHINING
TOPIC 2: MACHINE TOOL
CONTROL

LECTURER:
DR. MUSFIRAH ABDUL HADI
Lecture Objectives

• At the end of the lecture, you will be able to:

Describe the two type of major control systems
used to output tool movement.
Explain the two types of loop systems used with
CNC controller.
 Understand CNC machine motion.
 Explain the significant different between
incremental and absolute positioning.
CNC Machine Specification

high speed spindle (> 20,000 rpm)

high feed rate drive ( > 600 ipm)

high precision ( < 0.0001" accuracy)

NC Machine
Motion control is done by: servo-controlled motors

Table
Leadscrew
Encoder A/C Motor
~

Servo Controller

Counter Comparator

Input (converted from analog to digital value)

Components of Servo Motor
Controlled CNC
Components of Servo Motor
Controlled CNC

Servo motor

Servo drive
Servo Motor and Servo Drive

A servo motor is a rotary actuator or linear

actuator that allows for precise control of
angular or linear position, velocity and
acceleration.

A servo drive is an electronic amplifier used to

power electric servomechanisms. A servo drive
monitors the feedback signal from the
servomechanism and continually adjusts for
deviation from expected behavior.
CNC Terminology

BLU: basic length unit 

smallest programmable move of each axis.

Controller: (Machine Control Unit, MCU) 

Electronic and computerized interface between operator and m/c

Controller components:
1. Data Processing Unit (DPU)
2. Control-Loops Unit (CLU)
 Leadscrews
Converting the rotational motion of the motors to a linear motion.
Nut

Leadscrew

Pitch

pitch (p): the distance between adjacent screw threads

the number of teeth per inch (n):
n=1/p
BLU: Basic Length Unit (machine resolution)
BLU = p / N
e.g. an NC machine uses a 0.1" pitch leadscrew and a 100 pulse/rev encoder.

BLU = p / N = 0.1 (in/rev) /100 (pulses/rev) = 0.001"

2 Types of Encoder Configuration
A lead screw is a screw specialized for the purpose of translating
rotational to linear motion. A good example of the use of a lead
screw is the table on your milling machine. The x, y, and z axes all
move along on a lead screw.
Controller components

Data Processing Unit:

Input device [RS-232 port/ Tape Reader/ Punched Tape Reader]
Data Reading Circuits and Parity Checking Circuits
Decoders to distribute data to the axes controllers.

Control Loops Unit:

Interpolator to supply machine-motion commands between data points
Position control loop hardware for each axis of motion
Machine Axes

• Every CNC machine tool has sliding and rotary

controllable axes
• Letters (addresses) used to identify each direction
of table or spindle movement
• Combined with number to form word
establishes distance axis moves
Electronics Industries Association
(EIA) Standard

• Longest horizontal axis movement is X axis, Y axis

assigned to perpendicular to both X and Z axes
• Secondary axes (u,v,w) parallel to X, Y, Z axes
• A, B, and C refer to rotary motion axes around
primary axes
• I, J, and K words used for rotary axes when circular
interpolation used for programming circles or partial
arcs
• R word represents radius of circle
• U and W words for incremental movement parallel to
X and Z primary axes
• Chucking and turning centers
Machines Using CNC

• Used on all types of machine tools, from

simplest to most complex
• Two common: chucking center (lathe) and
machining center (milling machine)
1. Chucking centers
• Developed in mid-1960s
• Operates on two axes
 X axis control cross motion of turret head
 Z axis control lengthwise travel of turret head
Machines Using CNC (CONT…)
2. Engine lathe (two axes)
• X axis controls cross motion of cutting tool
• Z axis controls carriage travel toward/away from
headstock

X axis controls table

movement +X
left or right
Machines Using CNC (CONT…)
3. Machining centers
• Developed in 1960s
• Allow more operations to be done on part in one
setup instead of moving from machine to machine
• Two main types of machining centers
• Horizontal
• Vertical spindle (three axis)
• X axis controls table movement left or right
• Y axis controls table movement toward or sway
from column
• Z axis controls vertical movement of spindle or
knee
 Machines Using CNC (CONT…)
4. Milling machine (three axis)
• Performs operations such as milling, drilling, gear
cutting, contouring
Z axis controls
vertical movement
of knee or spindle

X axis controls table

movement left or right

Y axis control table

movement toward or
away from column
Programming Systems for Positioning

• Two types of programming modes for positioning

system;
• Incremental system
• Absolute system
• Most controls on machine tools capable of handling
both by altering code between G90 (absolute) and
G91 (incremental) commands
Incremental System

• Program dimensions or positions given from

current point
• Disadvantage
• If error made in any location, error automatically
carried over to all following locations
• G91 command tells computer and MCU to be in
incremental mode
 Command codes tell machine to move table,
spindle, and knee on vertical milling machine
Axes

• “plus X” (+X) causes cutting tool to be located to right of the

last point
• “minus X” (-X) causes cutting tool to be located to left of the
last point
• “plus Y” (+Y) causes cutting tool to be located toward
column
• “minus Y” (-Y) causes cutting tool to be located away from
column
• “plus Z” (+Z) causes cutting tool or spindle to move up or
away from workpiece
• “minus Z” (-Z) moves cutting tool down or into workpiece
Absolute System

• All dimensions or positions given from one

reference point on job or machine
• All dimensions given from zero or reference point
• Errors not carried to any other location
• G90 command indicates to computer and MCU that
program is to be in absolute mode
Absolute System Commands
• “plus X” (+X)
• causes cutting tool to be located to right of zero point
• “minus X” (-X)
• causes cutting tool to be located to left of zero point
• “plus Y ” (+Y)
• causes cutting tool to be located toward column (above zero)
• “minus Y” (-Y)
• causes cutting tool to be located away from column (below zero)
• “plus Z ” (+Z)
• causes cutting tool to move above program Z0 (top surface of part)
• “minus Z” (-Z)
• causes cutting tool to move below the program Z0
 Axis and motion nomenclature – CNC mill

On this gantry mill the spindle travels along the X Axis. The travel
direction of the table designates the Y Axis. The Z Axis is
designated by the stationary vertical column.
 Axis and motion nomenclature – CNC lathe

On most CNC lathes the Z Axis is parallel to the spindle and

longer than the X Axis.
 Axis and motion nomenclature – 5-axis CNC contour mill

On this five-axis horizontal contour milling machine, note the

orientation of the X and Y axes in relation to the Z Axis. The rotary
axes for both the X and Y axes are designated by the A and B rotary
tables.
 Axis and motion nomenclature – vertical CNC knee mill

On a common vertical knee CNC mill the spindle is

stationary while the rest of the components move
according to their axis designations (X, Y, and Z).
 Axis and motion nomenclature – CNC punch machine

On a CNC punch press the part is moved in the X

and Y directions while the punch is stationary.
 CNC milling fundamentals – The three Cartesian planes

The three planes in the Cartesian coordinate system are XY, XZ, and YZ.
These are referred to as G17, G18, and G19, respectively, on the mill.
 The Cartesian graph

Cartesian coordinates were

invented by René Descartes, who
is famous for the phrase "I think,
therefore I am." Most Cartesian
graphs for milling and turning
use a three-axis coordinate
system, denoted by the X, Y, and
Z axes. These coordinates are
used to instruct the machine tool
where to move on the workpiece.
Absolute vs. Incremental Positioning

• Absolute positioning
Move is: x = 40, y = 50

• Incremental positioning
Move is: x = 20, y = 30
 CNC milling fundamentals – Absolute coordinates

Absolute coordinates use the

origin as the reference point.
This means that any point on the
Cartesian graph can be plotted
accurately by measuring the
distance from the origin to the
point, first in the X direction,
then in the Y direction, and then,
if applicable, in the Z direction.
EXERCISE 1: Absolute Coordinates
Fill in the X and Y blanks with the appropriate absolute coordinates
for points A through H.
A: X_____, Y_____ B: X_____, Y_____
C: X_____, Y_____ D: X_____, Y_____
E: X_____, Y_____ F: X_____, Y_____

G: X_____, Y_____ H: X_____, Y_____

EXERCISE 2: Incremental Coordinates
Fill in the X and Y blanks with the appropriate incremental
coordinates for points A through H.
A: X_____, Y_____ B: X_____, Y_____
C: X_____, Y_____ D: X_____, Y_____
E: X_____, Y_____ F: X_____, Y_____

G: X_____, Y_____ H: X_____, Y_____

CNC turning fundamentals – Cartesian graph for
turning

When measuring X and Z coordinates, use a central reference point. Start

all measurements at this reference point, the origin point (X0, Z0). For all
our examples the origin is located at the center right-hand endpoint of the
workpiece. Keep in mind that at times the center left-hand endpoint of the
workpiece may be used
 CNC turning fundamentals – Diameter
programming

Diameter (or diametrical)

programming relates the X
axis to the diameter of the
workpiece. For example, if
the workpiece has a 5-in.
outside diameter and you
want to command an
absolute move to the outside,
you would program X5.0.
CNC turning fundamentals – Radial programming

Radius (or radial)

programming relates the X
axis to the radius of the
workpiece. For example, for
the same 5-in. outside
diameter workpiece, you
would program X2.5 to move
the tool to the outside.
 CNC turning fundamentals – Absolute
coordinates
When plotting points using
absolute coordinates, always
start at the origin
(X0, Z0). Then travel along the Z
axis until you reach a point
directly below the point that you
are trying to plot. Write down
the Z value and then go up until
you reach your point. Write
down the X value. You now have
the XZ (or ZX) coordinate for
that point.
 CNC turning fundamentals – Incremental
coordinates
The second method for
finding points in a Cartesian
coordinate system is by
using incremental
coordinates. Incremental, or
relative, coordinates use
each successive point to
measure the next
coordinate. Instead of
constantly referring back to
the origin, the incremental
method refers to the
previous point
 2 Major Control Systems
 Point-to-Point systems
• Also called position systems
• System moves to a location and
performs an operation at that location
(e.g., drilling)
• Also applicable in robotics

 Continuous path systems

• Also called contouring systems in
machining
• System performs an operation
during movement
(e.g., milling and turning)
 Interpolation Methods
• The smaller the line segments the better the accuracy
→ small tolerance .
• It is an important aspect of contouring .

• Tolerance :
Inside , Outside , Inside & Outside .
Inside Tolerance
Outside Tolerance
Inside & Outside Tolerance
 Interpolation Methods for
Continuous Path Control
1. Linear interpolation
– Straight line between two
points in space
2. Circular interpolation
– Circular arc defined by
starting point, end point,
center or radius, and
direction
3. Helical interpolation
– Circular plus linear motion
4. Parabolic and cubic
interpolation
– Free form curves using Helical interpolation
higher order equations
Parabolic and cubic interpolation
 NC Positioning System

• Typical motor and leadscrew arrangement in an NC positioning

system for one linear axis
• For x-y capability, the apparatus would be piggybacked on top of
a second perpendicular axis
 Analysis of Positioning NC Systems

• Two types of analysis for NC positioning systems:

1. Open-loop - no feedback to verify that the
actual position achieved is the desired position
2. Closed-loop - uses feedback measurements to
confirm that the final position is the specified
position
 Loop Systems for Controlling Tool
Movement
Open Loop System
Uses stepping motor to create movement. Motors rotate a
fixed amount for each pulse received from the MCU. The motor
sends a signal back indicating that the movement is completed.
No feedback to check how close the actual machine movement
comes to the exact movement programmed.
 Open-Loop Motion Control System

• Operates without verifying that the actual position achieved in the

move is the desired position
 Loop Systems for Controlling Tool
Movement
Closed Loop System
AC, DC, and hydraulic servo-motors are used. The speed of these
motors are variable and controlled by the amount of current or
fluid. The motors are connect to the spindle and the table. A
position sensor continuously monitors the movement and sends
back a single to Comparator to make adjustments.
Closed-Loop Motion Control System

• They use servomotors and feedback measurements to

confirm that the final position of the worktable is the
location specified in the program
 Closed-Loop Motion Control System

• They use servomotors and feedback measurements to

ensure that the worktable is moved to the desired position.
• A common feedback sensor is the optical encoder :

• Device for measuring rotational position and speed