Module 4 – Part 1

N. C. MACHINE TOOLS
Introduction
 Numerical control is a form of programmable automation in which the processing equipment (machine
tool) is controlled by a set of instructions called as program (which contains numbers, letters, and
symbols).
 The numbers, letters, and symbols are coded in an suitable format which form a program of instructions
for a particular work part or job.
 When the job changes, the program of instructions also changed.
 The capability of changing programs makes NC suitable for low and medium volume production.

I. Basic components of NC
1. Program of Instructions
2. Machine Control Unit
3.
4. Processing Equipment

Basic components of NC
Program of Instructions
 The program of instructions is the detailed step by step commands that direct the machine tool.
 Commands refer to position of spindle w. r. t. worktable on which the part is fixtured
 More advanced instructions include selection of spindle speeds, cutting tools etc.
 The common medium used for coding of program is 1- inche wide punched tape. Punched cards,
magnetic tape cassettes and floppy diskettes are also used also.
Machine Control Unit (MOU)
 MCU consists of the electronics control and hardware that read and interpret program of instruction and
convert it into mechanical actions of the machine tool or other processing equipment.
 The elements of MCU consists of a tape reader, data buffer, signal input/output channels, feedback
channels and sequence control,

 The tape reader has an electromechanical device used to read and wind the tape.
 The data buffer then interprets the program of instructions and also stores the instructions in logical blocks
of information.
 From here signals are sent to through the signal output channels which are connected to the
 servomotor and other controls in the machine tools.
 Feedback signals are provided for ensuring proper execution of the given instructions
 The sequence control coordinates the activities of the other elements of the control unit Processing
Equipment.
Machine Tool
 The machine tool consists of worktable and spindle to hold tools, motors and controls necessary to
drive them.

NC Procedure
 Process planning
 Part programming
 Tape preparation
 Tape verification
 Production
Process Planning
 The engineering drawing of the work part must be interpreted in terms of the manufacturing processes to
be used. It consists of preparation of route sheet.
Part Programming
 A part programmer plans for the portions of the job to be accomplished byNC
 The part programmers are responsible for planning the sequence of operations to be performed by NC
 There are two ways to program for NC
1. Manual part programming
2. Computer-assisted part programming
Manual part programming
In this, the machining instructions are prepared on a form called a part program manuscript. The
manuscript is a listing of the relative cutter/ work piece positions which must be followed to
machine the part.
Computer assisted part programming
In this computational work required in manual part programming is transferred to the computer. This is
used for complex work piece geometries and jobs with many machining steps . It also saves part
programming time.

Tape Preparation
 A punched tape is prepared from the part programmer’s NC process plan.
 In manual part programming, the punched tape is prepared from the part program manuscript or a
typewriter like device equipped with tape punching capability
 In Computer assisted part programming, the computer interprets the list of part programming instructions,
performs the necessary calculations to covert this into detailed set of machine tool commands, and then
controls a tape punched device to prepare tape for specific NC machine.
Production
 This involves ordering the raw workparts, specifying and preparing the tooling and any special fixturing
that may be required.
 The Operator’s function is to load the workpart in the machine and establish the starting position of
the cutting tool relative to the workpiece.
 The NC system then takes over and machines the part according to the instructions on tape.

Classification of NC Systems
1. Classification NC systems based on Motion Control
 There are three types of motion control used in Numerical control
1. Point to point
2. Straight cut
 3. Contouring
Point to point NC
 Point to point (PTP) is also called positioning system.
 In PTP, the objective of the machine control unit is to move the cutting tool to a predefined
location
 The speed or path by which this movements is accomplished is not important in point to point
NC
 Once the tool reaches the desired location , the machining operation is performed at that position
 Example of this system is NC drill press.
 Positioning system are the simplest machine tool control systems.
 This system is least expensive of the three types.

Straight-cut NC
 Straight cut control systems are capable of moving the cutting tool parallel to one of the major axis at a
controlled rate suitable for machining.
 It is appropriate for performing milling operations on work pieces of rectangular
shape.
 Angular cut would not be possible.
 An NC tool capable of straight cur movements is also capable of point to point movements

Contouring NC (Continuous path NC )

 Contouring is most complex, the most flexible and most expensive type of machine tool control.
 It is capable of performing both PTP and straight cut operations
 In addition, it can control more than one axis movement of the machine tool.
 The path of the cutter is continuously controlled to generate desired geometry of the machine tool.
 Turing and milling are commonexamples
 In order to machine a curved path in a NC system the direction of feed rate is to be changed
continuously to follow desired path.

Applications of NC Machines
 Milling
 Drilling and related processes
 Boring
 Turning
 Grinding
 Sawing
 Other applications
 Press working machine tools
 Welding machines
 Inspection machines
 Automatic drafting
 Assembly machines
 Tube bending
 Flame cutting
 Plasma arc cutting
 Laser beam processes
 Cloth cutting
 Automatic riveting

NC machines are suitable for

1. Parts are processed frequently and in small lot sizes
2. The part geometry is complex
3. Many operations must be performed on the part in its processing
4. Much metal needs to be removed
5. Engineering design changes are likely
6. Close tolerance must be held on the part
7. It is an expensive part where mistakes in processing would be costly
8. The parts require 100 % inspection.

Advantages of NC over conventional systems:

 Flexibility with accuracy, repeatability, reduced scrap, high production rates, good quality
 Reduced tooling costs
 Easy machine adjustments
 More operations per setup, reduced leadtime, accommodate design change, reduced
inventory
  Rapid programming and program recall, less paperwork
 Faster prototype production
 Less-skilled operator , multi-work possible
 Reduced fixturing

Limitations of NC Machines
 Relatively high initial cost of equipment
 Need for part programming
 Special maintenance requirements
 More costly breakdowns
 Finding and/or training NC personnel

Numerical control programming:

Steps in NC/CNC programming procedure:
 Interpret part drawing
 Define zero point
 Define x-, y-, z-axes
 Determine machining requirements Determine required operations & sequence
 Determine tooling requirements Determine feeds, speeds, depth(s) of cut
 Complete part program
 Complete post processor
 Store part program (e.g., punch tape, disk file)
 Verify completed program: "check it out;" is it accurate?

Classification of NC Machines based on Feed Back System

1. Open-loop NC System
An open-loop NC system is one that does not use feedback signals to indicate the table position to the
controller unit. Open-loop NC systems typically make use of stepping motors. The stepping motor is
a motor that is driven and controlled by an electrical pulse train generated by the MCU (or other
digital device). Each pulse drives the stepping motor by a fraction of one revolution, called the step
angle.
By controlling the number and rate of pulses to the motor, the position of the table is controlled
without the need for feedback sensors. One of the disadvantages of the stepping motor as the drive
unit for an NC system is the possible loss of one or more pulses when the motor is operating under
load. This results in a loss in accuracy of the table position. Accordingly, stepping motors are used on
NC systems in which the load is relatively small. Point-to-point drilling and most of the non
machining applications of NC are cases where stepping motors can be used to good advantage.
Closed Loop System
A closed loop system uses position sensors attached to the machine tool table to measure its position
relative to the input value for the axis. Any difference between the input value and the measured value
is used to drive the system toward a zero difference.The function of the feedback loop in a numerical
control system is to assure that the table and work part have been properly located with respect to the
tool. Closed-loop NC systems generally use dc servomotors or hydraulic actuators.
Various feedback sensor devices are used in NC.

COMPUTER NUMERICAL CONTROL

Today, NC means computer numerical control. Computer numerical control CNC is defined as an NC
system whose MCU is based on a dedicated microcomputer rather than on a hard-wired controller.
Features of CNC
1. Storage of more than one part program
2. Various forms of program input
3. Program editing at the machine tool
4. Using programming subroutines and macros.
5. Interpolation.
6. Positioning features for setup
7. Cutter length and size compensation
8. Acceleration and deceleration calculations
9. Communication interface
10. Diagnostics

Block Diagram of CNC Machine

Main Parts of CNC Machine
The main parts of the CNC machine are
Input Devices: These are the devices which are used to input the part program in the CNC machine.
There are three commonly used input devices and these are punch tape reader, magnetic tape reader
and computer via serial data communication.
Machine Control Unit (MCU): It is the heart of the CNC machine. It performs all the controlling
action of the CNC machine.

MCU consists of the following components and subsystems:

 Central processing unit
 Memory
 I/O interface
 Controls for machine tool axes and spindle speed
 Sequence controls for other machine tool functions
These subsystems are interconnected by means of a system bus.

Central Processing Unit

Manages the other components in the MCU based on software contained in memory. The CPU can be
divided into three sections:
 Control section
 Arithmetic-logic unit
 Immediate access memory

Memory
 Consists of main memory and secondary memory. Main memory (Primary storage) consists of
ROM (read-only memory) and RAM (Random access memory) devices.
 Operating system software and machine interface programs are generally stored in ROM.
 Numerical control part programs are stored in RAM devices. Current programs in RAM can be
erased and replaced by new programs as jobs are changed..
 High-capacity secondary memory (also called auxiliary storage or secondary storage) devices are
 used to store large programs and data files, which are transferred to main memory as needed.

Input/Output Interface
Provides communication between the various components of the CNC system, other computer
systems, and the machine operator.

Controls for Machine Tool Axes and Spindle Speed

These are hardware components that control the position and velocity (feed rate) of each machine axis
as well as the rotational speed of the machine tool spindle.

Sequence Controls for other Machine Tool Functions

In addition to control of table position, feed rate, and spindle speed, several additional functions are
accomplished under part program control. These auxiliary functions are generally ON/OFF (binary)
actuations and interlocks.

The various functions performed by the MCU are

 It reads the coded instructions fed into it.
 It decodes the coded instruction.
 It implements interpolation ( linear, circular and helical ) to generate axis motion commands.
 It feeds the axis motion commands to the amplifier circuits for driving the axis mechanisms.
 It receives the feedback signals of position and speed for each drive axis.
 It implements the auxiliary control functions such as coolant or spindle on/off and tool change.
Machine Tool: A CNC machine tool always has a slide table and a spindle to control of the position
and speed. The machine table is controlled in X and Y axis direction and the spindle is controlled in
the Z axis direction.
Driving System: The driving system of a CNC machine consists of amplifier circuits, drive motors
and ball lead screw. The MCU feeds the signals (i.e. of position and speed) of each axis to the
amplifier circuits. The control signals are than augmented (increased) to actuate the drive motors.
And the actuated drive motors rotate the ball lead screw to position the machine table.
Feedback System: This system consists of transducers that acts like sensors. It is also called as
measuring system. It contains position and speed transducers that continuously monitor the position
and speed of the cutting tool located at any instant. The MCU receives the signals from these
transducers and it uses the difference between the reference signals and feedback signals to generate
the control signals for correcting the position and speed errors.
Display Unit: A monitor is used to display the programs, commands and other useful data of CNC
machine.

How CNC Machine Works

 First the part program is inserted into the MCU of the CNC.
 In MCU all the data process takes place and according to the program prepared, it prepares all the
motion commands and sends it to the driving system.
 The drive system works as the motion commands are send by MCU. Drive system controls the
motion and velocity of the machine tool.
 Feedback system, records the position and velocity measurement of the machine tool and sends a
feedback signal to the MCU.
 In MCU, the feedback signals are compared with the reference signals and if there are errors, it
corrects it and sends new signals to the machine tool for the right operation to happen.
 A display unit is used to see all the commands, programs and other important data. It acts as the
eye of the machine.
Advantages of CNC machines
It can produce jobs with highest accuracy and precision than any other manual machine.
It can be run for 24 hours of a day.
The parts produced by it have same accuracy. There is no variation in the parts manufactured by a
CNC machine.
Highly skilled operator is not required to operate a CNC machine. A semi-skilled operator can
also operate accurately and more precisely.
Operators can easily make changes and improvements and reduces the delay time.
It has the capability to produce complex design with high accuracy in minimum possible time.
The modern design software, allows the designer to simulate the manufacturer of his/her idea.
And this removes the need of making a prototype or model and saves time and money.
Fewer workers are required to operate a CNC machine and saves labour cost.
Disadvantages of CNC machines
Despite of having so many advantages, a CNC machine has some disadvantages too. And these
are:
The cost of the CNC machine is very high as compared with manually operated machine.
The parts of CNC machines are expensive.
The maintenance cost in the case of CNC is quite high.
It does not eliminate the need of costly tools.

Applications of CNC
Almost every manufacturing industry uses CNC machines. With increase in the competitive
environment and demands, the demand of CNC usage has increased to a greater extent. The
machine tools that comes with the CNC are lathe, mills, shaper, welding etc. The industries that
are using CNC machines are automotive industry, metal removing industries, industries of
fabricating metals, electrical discharge machining industries, wood industries etc.
 Differentiate between NC and CNC machines
SL.
NC Machine CNC Machine
No.

1 Here NC stands for Numerical Control CNC stands for Computer Numerical Control.

It is defined as the machine which is It is defined as the machine which is used to

controlled by the set of instructions in the control the motions of the workpiece and tool
2
form of numbers, letters and symbols. The with the help of prepared program in computer.
set of instructions is called as program. The program is written in alphanumeric data.

In CNC machine the programs are fed directly

In NC machine the programs are fed into
3 into the computer by a small key board similar
the punch cards.
to our traditional keyboard.

4 Modification in the program is difficult. Modification in the program is very easy.

5 High skilled operator is required. Less skilled operator is required.

6 Cost of the machine is less. Cost of the CNC machine is high.

7 Maintenance cost is less Maintenance cost is high.

8 The programs in the NC machine cannot be In CNC machines, the programs can be stored in
stored. the computer and can be used again and again.
9 It offers less flexibility and computational It offers additional flexibility and computational
capability. capability.
10. The accuracy is less as compared with the It has high accuracy.
CNC.
11 It requires more time for the execution of It takes very less time in the execution of the
the job. job.
12. It is not possible to run it continuously. It can be run continuously for 24 hours of a day.

Economic of NC
There are a number of reasons why NC systems are being adopted so widely by the metalworking
industry. It has been estimated that 75% of manufacturing is carried out in lost sizes of 50 or less. As
indicated above, these small lot sizes are the typical applications for NC. Following are the
advantages of numerical control when it is utilized in these small production quantities:
Reduced nonproduction time: - It accomplishes this decrease in nonproductive time by means of
fewer setups, less setup time, reduced workpiece handling time, automatic tool changes on some
machines, and so on.
Reduced fixturing: - NC requires simpler fixtures because the positioning is done by the NC
program rather than the fixture or jig.
Reduced lead time: - Jobs can be set up more quickly with NC.
Greater manufacturing flexibility: - NC adapts better to changes in jobs, production schedules, and
so on.
Easier to accommodate engineering design changes on the workpiece: -
Improved accuracy and reduced human error; - NC is ideal for complicated parts where the
chances of human mistakes are high.

G-Code Commands
Miscellaneous Commands