ORGANISATION PROFILE

Bharat Heavy Electricals Limited is the largest engineering and

manufacturing enterprise in India in the energy related / infrastructure
sector today and ranks among the top twelve manufacturers of power
equipment in the world.
Today BHEL has 14 Manufacturing Divisions, 4 Power Sector
regional Centers, 8 Service Centers 18 regional offices and large number
of Project Sites spread all over India and abroad enables the Company to
promptly serve its customers and provide them with suitable products ,
systems and services efficiently and at competitive prices.
BHEL caters to core sectors of the Indian Economy viz, power
Generation and Transmission, Industry, transportation, Renewable
energy, Defence etc.
BHEL has already attained ISO 9000 and all the major units/divisions
of BHEL have been upgraded to the latest ISO-9001: 2000 version
quality standard certification for quality management. All the major
units/divisions of BHEL have been awarded ISO-14001 certification for
environmental management systems and OHSAS-18001 certification for
occupational health and safety management systems.

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 DEVELOPMENT OF MACHINE TOOLS

To stay in business, the main motive is profit. Better services offered

on schedule, reliable, improved and consistent quality of product also
mean profit.
Productivity in manufacturing is a parallel term to profit in business.
Productivity is a positive difference between output and input. To
increase the productivity therefore one has to maximize the output and
while keeping the input as low as possible.
To meet the objective of consistency of quality particularly required in
accurate and complex components calls for use of special purpose or
automatic equipment. The cost of such equipment could only be met if
the quantity of production and the productivity is very high.
Thus if quantity and quality and delivery schedule are prime importance,
the answer is mass production.
However on the entire spectrum of production activities around 15-
20% of demand desires the use of mass production. The remaining
requirements can be met only by batch production.
Automation has been associated with advancement in technology. In
the process of automation for small batch production, hydraulic tracer
controlled machine tools and programmed special purpose machine tools
have been evolved.
However these require cams, templates, stops, electrical trip dogs etc,
calling for a longer set up time while changing over to new jobs.
These problems of automation of small lot (batch) production have
been overcome by Numerical control machine tools to a great extent.
NC has long been considered a technology to produce engineering
goods of good quality and accuracy.
NC is not a particular machining and forming method but only a better
and effective way of controlling machine tool functions and performance
independent of operator skill.It does not substitute good tools or
production engineering practicesbut supplements them both.

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Comparison of GPM / SPM / CNC :
GPM - Completely manual
SPM - Built in automatic cycles / For mass production / Changes are
difficult
CNC - Highly flexible / Suitable for batch production / Job production as
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per requirement

COMPUTER NUMERICAL CONTROL OF MACHINE TOOLS

By controlling the relative movements between the tool and the work
piece geometrical shapes are machined. Control of these relative
movements through coded letters numbers is known as Numerical
Control of machine tools.
NC is simply a way of electronically controlling the operations of a
machine. In conventional machine operator directly controlling the
machine functions. Where as in NC machine a separate media which is in
between machine and operator is controlling the machine functions.
These NC machines do not have any memory of their own and hence
capable of only executing a simple block of information fed to it at a
time.
Hardware automation gave way to computer controlled automation in
manufacturing process. Computer numerical control is the term used
when the control system of an NC includes a computer. The availability
of a dedicated computer permits new control features to be made
available on CNC machines.

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Program of instructions:
The program instructions is the detailed step by step of directions
which tell the machine tool, what to do.

Machine control unit:

This consists of the electronics and hardware that read and interpret
the program and convert it into mechanical actions of the machine tool.

Machine tool:
It is the part of the NC system which performs the useful work.

OPERATING PRINCIPLE :
Conventional machine tool NC machine tool
Operators brain = NC controller
Hands = DC servo drives
Eyes = Feed back system

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ADVANTAGES OF CNC MACHINES :
CNC machines offer the following advantages in manufactur

• Higher flexibility.
• Increased machine utilization
• Increased productivity.
• Consistent quality.
• Reduced scrap rate.
• Reliable operation.
• Reduced non-productive time.
• Reduced man power.
• Shorter cycle time.
• Higher accuracy.
• Reduced lead time.
• Automatic material handling.
• Lesser floor space.
• Increased operational safety.
• Machining of advanced material.
• Savings in jigs and fixtures.
• Changes in the design can be easily incorporated.
• Ability to combine operations.
• Stored programs
• Editing facility near the machine
• Graphic simulation
• User written programs
• First step in CIM

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CRITERIA FOR SELECTION OF COMPONENTS FOR NC
MACHINING:

• Number of operations per component - MANY

• Complexity of the operations carried out - HIGH
• Size of batches – MEDIUM
• Repetition of batches – OFTEN
• Labor cost of the component – HIGH
• Skill required by the operator – HIGH
• Ratio of cutting time to non cutting time – HIGH
• Variety of components to be produced - MORE
• Cost of special tooling involved – HIGH
• Design changes – FREQUENT
• Number of dimensions to be maintained – MANY
• Setup time and inspection time – HIGH
• Precision involved in the component – HIGH
• Time lag between the operations – HIGH
• Non- uniform cutting conditions - REQUIRED

EMERGING TRENDS AND NEW DEVELOPMENTS IN CNC

TECHNOLOGY

• Special purpose machine tools

• Coordinate measuring machine and Inspection probes
• Adaptive control
• Tool condition / collision monitoring
• DNC / Windows based CNC systems
• Work oriented program (WOP) / Conversational automatic
programming (CAP )
• CAD / CAM
• Flexible manufacturing systems ( FMS )
• Robotics
• Computer integrated manufacturing ( CIM )
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Special purpose machine tools :

Because of the CNC technology new types of machines are being

made like machining centers which are predominantly made for
prismatic components. Turning centers are being made for machining
components which have more of turning operations but also having
operations which call for milling, drilling and tapping. These machines
are also called CNC lathes with driven tools or live tools. These
machines have turret which has independent drive, programmable
through CNC system and some of the tool positions can have tools which
will rotate. Using these machines, the operations like slotting, key way
milling, drilling and tapping can be completed after completing the
turning operations. Similarly, the machining centers are equipped with
CNC controlled facing and turning attachments to complete the turning
operations in the prismatic components.

Coordinate measuring machine and inspection probes :

One of the types of CNC machine is coordinate measuring machine and

it is used mainly to inspect components which come out of CNC
machines. The machine has a touch probe which will measure the
dimensions as per program and can give out the deviations in the form of
a chart or plot the actuals against the acceptance band. These machines
can also be linked to the CNC machines to give suitable offsets to correct
for the dimensional variations.
The use of in-process inspection probes is becoming more common in
modern NC machine tool systems. These inspection probes are
sophisticated dial indicators which can be mounted in the machine tool
spindle or holder. In machines with automatic tool changers, the probe
would be placed in the tool storage drum and loaded in to the spindle or
holder when needed, just like any of the regular cutting tools. Sensors in
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the probe detect when contact has been made with a surface of the work
part being checked.

The software in the controller performs the necessary computations to

interpret the signals from the probe.
The principal benefits that drive from the use of inspection probes are
time savings and improved accuracy. Measurements taken with the probe
are generally more accurate than traditional techniques used to measure
part dimensions.

Adaptive controls

For machining operations, the term adaptive control denotes a control

system that measures certain output process variables and uses them to
control the process. Some of the process variables that have been used in
adoptive control are spindle deflection ,torque, cutting temperature,
Vibration, amplitude and horse power. The motivation for developing an
adaptive machining system lies in trying to operate the process more
efficiently. The typical measure of performance in machining have been
Removal rate cost per volume of metal removed.

Benefits of adaptive control machining:

1. Increased production rates
2. Increased tool life
3. Greater part protection
4. Less operator intervention
5. Easier part programming

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CNC PROGRAMMING:

A program of instructions for a NC machine tool is termed as a part

program. A NC part program is a series of coded instructions that direct
the operations of a numerically controlled machine.
These instructions contains all the machine and control functions
necessary to make the machine perform a specific task.
The NC machine recovers the directions for operations from program.
The program is prepared by listing coordinates values.
The coordinate values are prefixed with preparatory with preparatory
codes to indicate the type of movement required from one coordinate to
the next and supplemented with feed rate figures.
The coordinates are suffixed with miscellaneous codes for initiating
the machine tool function like start, stop etc.
All these elements in a time of information form one meaningful
command for the system / machine to execute and is called a block of
information.
The preparation of a set of instructions to carry out the machining of a
work piece is called part programming. This work is carried out by a part
programmer. He prepares the planning sheet and write the instructions in
a coded form which is acceptable to the controller of the machine tool.

Part programming is of three types

1. Manual part programming
2. Computer assisted part programming using NC programming
languages
3. Generation of program using CAD / CAM package

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RESPONSIBILITIES OF THE CNC PROGRAMMER WHILE
PREPARING THE MANUAL PART PROGRAM :

The programmer studies the engineering drawing and translates the

operations to be performed into a manuscript in a prescribed format. The
individual who programs the job for NC machine generally
• Study the relevant component drawing thoroughly
• Chooses the NC machine tool to be used
• Identify the type of material to be machined
• Knows the specifications and functions of machine tool and features
of the CNC system
• Check the tooling required
• Establish the sequence of machining operations
• Determine the cutting parameters for the job/tool combination
• Prepares the program
• Decide the mode of storing the part program once it is completed

While preparing the part program, depends upon the availability of the
features in the system, the below shown system features or the
combination of different features can be used advantageously depending
upon the amount of material to be removed, machining sequence,
machine and the programmers convenience. Some of the CNC system
features are listed below.

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VARIOUS OPERATOR AND PROGRAM CONTROLS ON
CONTROL PANNEL OF A CNC MACHINE

• Manual program editing

• Back ground editing
• Single mode / Auto mode
• Cycle start
• Dry run
• Feed control ( 0 – 120 % )
• Feed hold
• RPM control ( 50 – 120 % )
• Reset
• Block search
• Optional stop
• Block skip
• MDI (Manual data input)
• Mirror image in selected Axis
• Reference
• Preset position
• Reposition
• incremental
• Jog continuous
• Chuck ON / OFF
• Direction of rotation
• Gear change
• Coolant ON / OFF
• Emergency
• Indicators for machine / system alarms
• Program verification by graphic simulation

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VARIOUS CNC SYSTEMS :
Various types are CNC systems are available in the market. These
systems are having their own advantages and disadvantages.
• SINUMERIK / HINUMERIK
• FANUC
• GE
• MARK ++
• FAGOR
• GE-FANUC
• ANILAM
• KONGSBERG
• CRUSADOR
• LAXMI etc
The popular systems are Sinumerik from Siemens, Germany and
Fanuc from Fanuc corporation , Japan.

Alphabetical characters
A - Angle 0-3590
B - Radius / Chamfer
D - Tool offset
F - Feed rate
G - Preparatory function
H - Auxiliary function
I - Arc center offset in X- axis
K - Arc center offset in Z- axis
L - Sub program / Machining cycle
M - Miscellaneous function
N - Block Number
P - Number of passes
R - Assignable Parameters / Variables
S - Spindle speed in RPM or CCS in mts / min
T - Tool number
X - Transversal axis
Z - Longitudinal axis
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Numerical characters
0–9

Special characters
+ Addition
- Subtraction
* Multiplication
/ Division
= Equal to
% Main Program file
LF End of Block
@ At the rate function
/ Slash

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ACTIVITY FLOW CHART FOR CNC MACHINES

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 FRONT TURNING LATHE
( MACHINING BEFORE TURNING CENTER )

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REAR TURNING LATHE
( MACHINING AFTER TURNING CENER )

CNC MACHINE REF CONCEPT ( REAR TURNING LATHE )

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