Unit 5

Topics
1. NC
2. NC Modes
3. NC Elements
4. NC Machine Tools
5. Structure of CNC Machine Tools
6. Features of Machining Center
7. Features of Turning Center
8. CNC Part Programming
1. Fundamentals
2. Manual Part Programming Methods
3. Computer Aided Part Programming
Numerical Control
Numerical Control can be defined as a form of
programmable automation in which the process is
controlled by numbers, letters, and symbols.
In NC, the numbers form a program of instructions
designed for a particular work part or job. When the
job changes, the program of instructions changed.
This capability to change the program for each new
job is what gives NC its flexibility.
NC Modes
Point to Point
Drilling & Boring
Point to Point Straight Line
Frame Milling
2 Axis contouring with switchable plane
2 Axix contour milling
3 Axis contouring continuous path
3 Axix contour milling
NC Elements/ Basic Components of an NC system
1. Program of Instructions
2. Controller Unit/Machine Control Unit (MCU)
Data Processing Unit (DPU), Control Loop Unit (CLU), Data Buffer
3. Machine Tool/Other Controlled process
NC Procedure
1. Process Planning
Preparation of route sheet
2. Part Programming
Manual, Computer Assisted
3. Tape preparation
4. Tape verification
5. Production
NC Advantages/Disadvantages
Advantages
1. Less time & less cost per piece
2. Better accuracy
3. Less manual intervention
4. Less scrap
5. Independent of operator skills
6. Reduced number of jigs & fixtures
7. Less inspection time
8. Reduced lead times/setup time depending upon the complexity involved in the geometry
9. Reduced number of machine tools on shop floor
10. Machining times & costs are predictable to a great accuracy
11. No operator fatigue
12. Modifications are easy
13. Metal removal rate is high
14. Reduced inventory, Reduced floor space
15. Greated manufacturing flexibility
Limitations
1. High initial cost
2. Required skilled people(well trained & experienced part programmers) to operate NC machine
3. Need special training for the people to work
4. Higher maintenance costs
CNC
Advantages of CNC
1. Part program and tape reader are used only once
2. Tape editing at the machine site
3. Unit conversion
4. Greater flexibility
5. User written programs
6. Total manufacturing system
DNC
Central Computer/Server
With bulk memory
Telecommunication
Lines
CNC Turning Centers, CMM etc. DNC machining Centers

Advantages of DNC
1. Elimination of punched tapes and tape readers
2. Greater computational capability & flexibility
3. Convenient storage of NC part programs
4. Programs stored in general format (CLFILE)
5. Reporting of shop performance
6. Establishes the framework for the evolution of the
future computer automated factory
Classification of NC Machine Systems
1. Based on Work & Tool relationship
Rotating tool, Rotating work piece, Non-rotating work piece & non
rotating tools, Unconventional NC Machines, Others like CMM etc..
2. Based on Motion type
Point to Point, Straight cut, Contouring
3. Based on Type of Control system
Open Loop, Closed Loop
4. Based on Positioning System

Incremental, Absolute
5. Based on Power Supply

Electric, Hydraulic, Pneumatic
NC Coordinate System
Coordinate system for milling & drilling operations

NC Part Programming
Manual Part Programming
Computer Assisted Part
Programming
Manual Part Programming
Standard ‘G’-Codes
Standard ‘G’-Codes - Contd…
Some Common ‘G’-Codes
Some Common ‘M’-Codes
Sample Problem
Computer-Assisted Part Programming
Part Programmer’s Job
1. Defining the work part geometry
2. Specifying the operation sequence and tool path
Computer’s Job
1. Input Translation
2. Arithmetic Calculations
3. Cutter offset Computations
4. Post Processor
Some of the important NC Part
Programming Languages in current use
1. APT (Automatically Programmed Tools)
2. ADAPT (Adaptation of APT)
3. EXAPT (Extended Subset of APT)
4. UNIAPT
5. SPLIT (Sundstrand Processing Language Internally
Translated)
6. COMPACT II
7. PROMPT
8. CINTURN II
* Refer Zimmers & Groover text book for more info…
APT Language
Types of Statements :
1. Geometry Statements
2.Motion Statements
3.Postprocessor Statements
4.Auxiliary Statements
Geometry Statements
Symbol = geometry type/descriptive data
Ex:
 P1 = POINT/5.0,4.0,0.0
 L3 = LINE/P3,P4
 L4 = LINE/P5,PARLEL,L3
 PL1 = PLANE/P1,P4,P5
 PL2 = PLANE/P2,PARLEL,PL1
 C1 = CIRCLE/CENTER,P1,RADIUS,5.0
 P1 = POINT/INTOF,L1,L2
P1 = POINT/5.0,4.0,0.0
P2 = POINT/5.0,4.0,0.0
P1 = POINT/2.0,4.0,0.0
Motion Statements
Motion command/descriptive data
Ex:
 GOTO/5.0,4.0,0.0
 GOTO/P1
 FROM/TARG
 GODLTA/2.0,1.0,0.0
CONTOURING MOTIONS
DRIVE SURFACE, PART SURFACE, CHECK SURFACE
 FROM/TARG
GO/TO, PL1,TO,PL2,TO,PL3
 GORGT/PL3,PAST,PL4 is same as GORGT/L3,PAST,L4
TO ---- ON ---- PAST
POST PROCESSOR STATEMENTS
 COOLNT/
 END
 FEDRAT/
 MACHIN/
 RAPID
 SPINDL/
 TURRET/
AUXILIARY STATEMENTS
 CLPRNT
 CUTTER
 FINI
 INTOL/
 OUTTOL/
 PARTNO

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Topics

CNC Turning Centers, CMM etc. DNC machining Centers

4. Based on Positioning System

5. Based on Power Supply

Coordinate system for milling & drilling operations

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