History of CNC

1955 - John Parsons and US Air Force define a need to develop a machine tool capable of machining complex and close tolerance aircraft parts with the same quality time after time (repeatability). MIT is the subcontractor and builds the machine for the project. 1959 - MIT announces Automatic Programmed Tools (APT) programming language 1960 - Direct Numerical Control (DNC). This eliminates paper tape punch programs and allows programmers to send files directly to machine tools 1968 - Kearney & Trecker machine tool builders market first machining center 1970s - CNC machine tools & Distributed Numerical Control 1980s - Graphics based CAM systems introduced. Unix and PC based systems available 1990s - Price drop in CNC technology 1997 - PC- Windows/NT based Open Modular Architecture Control (OMAC) systems introduced to replace firmware controllers.

What is Numerical Control?

Numerical control can be defined as a form of programmable automation in which process is controlled by numbers, letters and symbols In NC machine tools one or more of the following functions may be automatic: a) Starting and stopping of machine tool spindle b) Controlling the spindle speed c) Positioning the tool tip at desired locations and guiding it along desired paths by automatic control of the motion of slides d) Controlling the rate of movement of the tool tip (i.e. feed rate) e) Changing of tools in the spindle.

Basic components of NC system

1. Program of instructions. It is the detailed step by step set of instructions which tell the machine what to do. And its types are:a- 1-inch wide punched tape b- punched cards c- magnetic tape d- 35 mm motion picture film 2. Controller unit, also called machine tool unit. It consists of electronics and hardware that read and interpret the program of instructions convert it to mechanical actions of the machine tool. (closed loop or open loop) - Controller components : 1. Data Processing Unit (DPU) Input device [Tape Reader/ Punched Tape Reader] Data Reading Circuits and Parity Checking Circuits Decoders to distribute data to the axes controllers. 2. Control-Loops Unit (CLU) Interpolator to supply machine-motion commands between data points Position control loop hardware for each axis of motion 3. Machine tool or other controlled process. The part that performs useful work.

The N.C Method (Procedure)

To utilize NC in manufacturing the following steps must be accomplished :- The engineering drawing - The part programmer plans the process - A punched tape is prepared from part programmer's process plan - The tape is checked or verified - The job is produced on an N.C machine under tape control

Two ways to program of N.C

1- Manual part programming : the machining instructions are prepared on a document called a part program manuscript. 2- Computer assistant part programming : the part programmers work consists of typically two tasks : - First : he must define the configuration of the workpart in terms of basic geometric elements (lines, points, planes, circles, ..) - Second : he must direct the cutting to perform the machining steps along these geometric elements.

Extension on NC
CNC : computer numerical control DNC : direct numerical control Adaptive numerical control Industrial robots

Direct Numerical Control (DNC)

It can be defined as a manufacturing system in which a number of machines are controlled by a computer through direct connection and in real time. Instead of using tape reader the part program is transmitted to the machine tool directly from the computer memory. In principle, one computer can be used to control more than 100 separate machines.

What is a CNC Machine?

CNC : Computer and Numeric Control Conventionally, an operator decides and adjusts various machines parameters like feed , depth of cut etc depending on type of job , and controls the slide movements by hand. In a CNC Machine functions and slide movements are controlled by motors using computer programs.

General configuration of CNC

Motivation and uses

To manufacture complex curved geometries in 2D or 3D was extremely expensive by mechanical means (which usually would require complex jigs to control the cutter motions) Machining components with repeatable accuracy Unmanned machining operations

Features of CNC Machinery

The tool or material moves. Tools can operate in 1-5 axes. Have a machine control unit (MCU) which manages operations. Movement is controlled by a motors (actuators). Feedback is provided by sensors (transducers) Tool magazines are used to change tools automatically.

Types of CNC machines

- Based on Motion Type: - Based on Control Loops: - Based on Power Supply: - Based on Positioning System : Point-to-Point or Continuous path Open loop or Closed loop Electric or Hydraulic or Pneumatic Incremental or Absolute

Control Systems
- Open-Loop Control Stepper motor system Current pulses sent from control unit to motor Each pulse results in a finite amount of revolution of the motor 001 is possible - Limitations Control unit assumes desired position is achieved No positioning compensation Typically, a lower torque motor - Advantages Less complex, Less costly, and lower maintenance costs - Closed-Loop Control Variable DC motors - Servos Positioning sensors - Resolvers o Feedback to control unit o Position information compared to target location o Location errors corrected Advantages DC motors have the ability to reverse instantly to adjust for position error Error compensation allows for greater positional accuracy (.0001) DC motors have higher torque ranges vs.. stepper motors Limitations Cost

Components of Servo-motor controlled CNC (closed loop)

Motor Motor speed control

lead screw rotation feedback

table moves position sensed by encoder

CNC terminology (Motion Control and feedback)

Encoder outputs : electrical pulses (e.g. 500 pulses per revolution) Rotation of the motor linear motion of the table : by the lead screw The pitch of the lead screw horizontal distance between successive threads One thread in a screw (single start screw) Dist moved in 1 rev = pitch Two threads in screw (double start screw) Dist moved in 1 rev = 2* pitch BLU: basic length unit smallest programmable move of each axis.

BLU = p (pitch) / number of pulses per rev (encoder output). Table speed = p * RPM = BLU * pulse rate (frequency)

Basic CNC principle coordinates system

G 90 absolute programming

G91 incremental coordinate

Three basic categories of motion systems

Point to Point - No contouring capability Straight cut control - one axis motion at a time is controlled for machining Contouring - multiple axiss controlled simultaneously

Comparison between CNC & Conventional Machine

Axis identification of CNC

- Hold the thumb, forefinger and middle finger at 90 to each other - Thumb (X-axis), Forefinger (Y-axis) and Middle finger (Z-axis)

CNC vs. NC Machine Tools

CNC .. Advantages Increased Program storage capability at the machine tool Program editing at the machine tool Control systems upgrades possible Option -resident CAM system at machine tool Tool path verification

Advantages and disadvantage of CNC

Advantages: High Repeatability and Precision e.g. Aircraft parts Volume of production is very high Complex contours/surfaces need to be machined. E.g. Turbines

 Flexibility in job change, automatic tool settings, less scrap More safe, higher productivity, better quality Less paper work, faster prototype production, reducing lead times Easier to program; Easy storage of existing programs; Easy to change a program Avoids human errors Usually generates closer tolerances than manual machines Disadvantages: Costly setup, skilled operators Computers, programming knowledge required Maintenance is difficult

Types of Machine
Lathes for metal and plastics - Used to produce 3D product shapes & moulds for plastic products Milling machine for mould making and surface milling. - Used to produce dies for die cutting printed products.

CNC Lathe
Automated version of a manual lathe. Programmed to change tools automatically. Used for turning and boring wood, metal and plastic.

CNC Milling Machine

Has 3 to 5 axes. Used for wood, metal and plastic. Used to make 3D prototypes, moulds, cutting dies, printing plates.

How CNC Works

Controlled by G and M codes. These are number values and co-ordinates. Each number or code is assigned to a particular operation. Typed in manually to CAD by machine operators. G&M codes are automatically generated by the computer software.

Tools
Most made from high speed steel, tungsten carbide or ceramics. Tools are designed to direct waste away from the material. Some tools need coolant such as oil to protect the tool and work.