Ch 7 Numerical Control

Sections: 1. Fundamentals of NC Technology 2. Computer Numerical Control 3. DNC 4. Applications of NC 5. Engineering Analysis of NC Positioning Systems 6. NC Part Programming

Numerical Control (NC) Defined

Form of programmable automation in which the mechanical actions of a machine tool or other equipment are controlled by a program containing coded alphanumeric data The alphanumeric data represent relative positions between a workhead (e.g., cutting tool) and a workpart When the current job is completed, a new program can be entered for the next job

Basic Components of an NC System

1. Program of instructions Part program in machining 2. Machine control unit Controls the process 3. Processing equipment Performs the process

Program of Instructions
Step-by-step commands Part programmer The program is coded on a suitable medium for submission to the machine control unit Three class of language to be coded: - Machine language - Assembly language - High level language C++, Pascal, Fortran - Object Oriented Language

Machine Control Unit

Microcomputer and related control hardware Stores and executes the program Hardware includes interface component and reading devices Software system software, calculation algorithms, and translation software Computer numerical control (CNC)

Processing Equipment
Performs the actual productive work Driven by instructions Common examples the worktable and spindle, motors and controls

Basic Components of an NC System

NC Coordinate Systems
Two axis systems Flat and prismatic workparts Rotational parts

NC Coordinate Systems
For flat and prismatic (block-like) parts Milling and drilling operations Conventional Cartesian coordinate system Rotational axes about each linear axis Right hand rule

Coordinate Axis System for Flat and Prismatic Parts

Coordinate Axis System for Flat and Prismatic Parts

The x- and y-axes are used to move and position the worktable to which part is attached The z-axis is used to control the vertical position of the cutting tool

NC Coordinate Systems
For rotational parts: Turning operations Conventional Cartesian coordinate system, but only x- and z-axes y-axis not needed in turning

Coordinate Axis System for Rotational Parts

Motion Control Systems

Point-to-Point systems Continuous path systems

Point-to-Point Systems
Also called position systems System moves to a location and performs an operation at that location (e.g., drilling) The programs consists of a series of points locations at which operations are performed Also applicable in robotics

Point-To-Point Control in NC Drilling of Three Holes in Flat Plate

Continuous Path Systems

Capable of continuous simultaneous control of two or more axes Also called contouring systems in machining System performs an operation during movement (e.g., milling and turning)

Continuous Path Control in NC Profile Milling of Part Outline

Interpolation Methods
Important aspect of contouring Why it is needed? Continuous (Equipment) vs Digital (NC)

Interpolation Methods
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 higher order equations

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Circular Interpolation

Approximation of a curved path in NC by a series of straight line segments, where tolerance is defined on only the inside of the nominal curve

Circular Interpolation

Approximation of a curved path in NC by a series of straight line segments, where tolerance is defined on only the outside of the nominal curve

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Circular Interpolation

Approximation of a curved path in NC by a series of straight line segments, where tolerance is defined on both the inside and outside of the nominal curve

Absolute and Incremental Positioning

Absolute positioning Locations defined relative to origin of axis system Incremental positioning Locations defined relative to previous position Example: drilling

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Absolute vs. Incremental Positioning

The workhead is presently at point (20, 20) and is to be moved to point (40, 50) In absolute positioning, the move is specified by x = 40, y = 50 In incremental positioning, the move is specified by x = 20, y = 30.

Computer Numerical Control (CNC) Definition

An NC system whose MCU is based on a dedicated microcomputer rather than on a hard-wired controller.

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Computer Numerical Control (CNC) Additional Features

Please discuss!!! Storage of more than one part program - More memory expansions Various forms of program input - multiple data entry capabilities - RS-232 (Serial), Parallel, USB Program editing at the machine tool - can be tested and corrected at the machine site - can also be optimized

Computer Numerical Control (CNC) Additional Features

Fixed cycles and programming subroutines - full instructions vs call statement Interpolation Positioning features for setup - By software options Cutter length and size compensation - Manual entering may differ from program, thus computed tool path will do the compensation - Use of tool length sensor

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Computer Numerical Control (CNC) Additional Features

Acceleration and deceleration computations Communications interface - Downloading part programs - Collecting operational data - Interfacing with peripheral equipment Diagnostics - Detect malfunctions - Diagnose system breakdowns

Configuration of CNC Machine Control Unit

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CPU
Brain of the MCU Three section: control section - retrieves command and generate signals ALU unit - perform calculations Immediate access memory - temporary storage

Memory
Main memory - ROM, RAM - Operating system software and machine interface programs Secondary memory - Store large programs and data files

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Input/Output Interface
Provides communication between components Transmit and receives data and signals to and from external devices Eg., Operator control panel, display

Machine Tool Controls

Hardware component control position and velocity, and rotational speed of the machine tool spindle Consist of a drive control circuit and a feedback sensor interface

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Sequence Controls
Additional functions Eg., on/off actuations, interlocks, and discrete numerical data

CNC Software
Operating system software - editor - control program - executive program Machine interface software - communication link Application software - for machining applications

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DNC
Direct numerical control (DNC) control of multiple machine tools by a single (mainframe) computer through direct connection and in real time 1960s technology Two way communication Distributed numerical control (DNC) network consisting of central computer connected to machine tool MCUs, which are CNC Present technology Two way communication

Components of Direct NC
Central Computer Bulk memory at the central computer site Set of controlled machines Telecommunications line to connect the machines to the central computer

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General Configuration of a Direct Numerical Control System

Connection to MCU is behind the tape reader (BTR). In distributed NC, entire programs are downloaded to each MCU, which is CNC rather than conventional NC

Distributed NC (DNC)
The central computer is connected to MCUs, which are themselves computers. Advantages - easier and less cost - possible of expansion - flexibility and reliability

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Distributed Numerical Control Configurations

Switching network

Distributed Numerical Control Configurations

Local area network (LAN)

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Applications of NC
Machine tool applications: Milling, drilling, turning, boring, grinding Machining centers, turning centers, mill-turn centers Punch presses, thermal cutting machines, etc. Other NC applications: Component insertion machines in electronics Drafting machines (x-y plotters) Coordinate measuring machines Tape laying machines for polymer composites Filament winding machines for polymer composites

Common NC Machining Operations

Turning

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Common NC Machining Operations

Milling Drilling

CNC Horizontal Milling Machine

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NC Application Characteristics (Machining)

Where NC is most appropriate: 1. Batch production 2. Repeat orders 3. Complex part geometries 4. Much metal needs to be removed from the starting workpart 5. Many separate machining operations on the part 6. The part is expensive

Advantages of NC
Nonproductive time is reduced Greater accuracy and repeatability Lower scrap rates Inspection requirements are reduced More complex part geometries are possible Engineering changes are easier to make Simpler fixtures Shorter lead times Reduce parts inventory and less floor space Operator skill-level requirements are reduced

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Disadvantages of NC
Higher investment cost CNC machines are more expensive Higher maintenance effort CNC machines are more technologically sophisticated Part programming issues Need for skilled programmers Time investment for each new part Repeat orders are easy because part program is already available Higher utilization is required

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

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Analysis of Positioning NC Systems

Two types of 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 Precision in NC positioning - three measures: 1. Control resolution 2. Accuracy 3. Repeatability

Open-Loop Motion Control System

Operates without verifying that the actual position achieved in the move is the desired position

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Closed-Loop Motion Control System

Uses feedback measurements to confirm that the final position of the worktable is the location specified in the program

Optical Encoder

Device for measuring rotational position and speed Common feedback sensor for closed-loop NC control

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Precision in NC Positioning
Three measures of precision: 1. Control resolution - distance separating two adjacent addressable points in the axis movement 2. Accuracy - maximum possible error that can occur between the desired target point and the actual position taken by the system 3. Repeatability - defined as 3 of the mechanical error distribution associated with the axis

Definitions of Control Resolution, Accuracy, and Repeatability

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NC Part Programming
1. 2. 3. 4. Manual part programming Computer-assisted part programming Part programming using CAD/CAM Manual data input

Binary Coded Decimal System

Each of the ten digits in decimal system is coded with four-digit binary number The binary numbers are added to give the value BCD is compatible with 8 bits across tape format, the original storage medium for NC part programs Eight bits can also be used for letters and symbols

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Creating Instructions for NC

Bit - 0 or 1 = absence or presence of hole in the tape Character - row of bits across the tape Word - sequence of characters (e.g., y-axis position) Block - collection of words to form one complete instruction Part program - sequence of instructions (blocks)

Block Format
Organization of words within a block in NC part program Also known as tape format because the original formats were designed for punched tape Word address format - used on all modern CNC controllers Uses a letter prefix to identify each type of word Spaces to separate words within the block Allows any order of words in a block Words can be omitted if their values do not change from the previous block

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Types of Words
N - sequence number prefix G - preparatory words Example: G00 = PTP rapid traverse move X, Y, Z - prefixes for x, y, and z-axes F - feed rate prefix S - spindle speed T - tool selection M - miscellaneous command Example: M07 = turn cutting fluid on

Example: Word Address Format

N001 G00 X07000 Y03000 M03 N002 Y06000

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Issues in Manual Part Programming

Adequate for simple jobs, e.g., PTP drilling Linear interpolation G01 G94 X050.0 Y086.5 Z100.0 F40 S800 Circular interpolation G02 G17 X088.0 Y040.0 R028.0 F30 Cutter offset G42 G01 X100.0 Y040.0 D05

Computer-Assisted Part Programming

Manual part programming is time-consuming, tedious, and subject to human errors for complex jobs Machining instructions are written in English-like statements that are translated by the computer into the low-level machine code of the MCU APT (Automatically Programmed Tool) The various tasks in computer-assisted part programming are divided between The human part programmer The computer

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Computer-Assisted Part Programming

Sequence of activities in computer-assisted part programming

Part Programmer's Job

Two main tasks of the programmer: 1. Define the part geometry 2. Specify the tool path

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Defining Part Geometry

Underlying assumption: no matter how complex the part geometry, it is composed of basic geometric elements and mathematically defined surfaces Geometry elements are sometimes defined only for use in specifying tool path Examples of part geometry definitions: P4 = POINT/35,90,0 L1 = LINE/P1,P2 C1 = CIRCLE/CENTER,P8,RADIUS,30

Specifying Tool Path and Operation Sequence

Tool path consists of a sequence of points or connected line and arc segments, using previously defined geometry elements Point-to-Point command: GOTO/P0 Continuous path command GOLFT/L2,TANTO,C1

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Other Functions in Computer-Assisted Part Programming

Specifying cutting speeds and feed rates Designating cutter size (for tool offset calculations) Specifying tolerances in circular interpolation Naming the program Identifying the machine tool

2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist. No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

Cutter Offset
Cutter path must be offset from actual part outline by a distance equal to the cutter radius

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Computer Tasks in Computer-Assisted Part Programming

1. Input translation converts the coded instructions in the part program into computer-usable form 2. Arithmetic and cutter offset computations performs the mathematical computations to define the part surface and generate the tool path, including cutter offset compensation (CLFILE) 3. Editing provides readable data on cutter locations and machine tool operating commands (CLDATA) 4. Postprocessing converts CLDATA into low-level code that can be interpreted by the MCU

NC Part Programming Using CAD/CAM

Geometry definition If the CAD/CAM system was used to define the original part geometry, no need to recreate that geometry as in APT Automatic labeling of geometry elements If the CAD part data are not available, geometry must be created, as in APT, but user gets immediate visual feedback about the created geometry

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Tool Path Generation Using CAD/CAM

Basic approach: enter the commands one by one (similar to APT) CAD/CAM system provides immediate graphical verification of the command Automatic software modules for common machining cycles Profile milling Pocket milling Drilling bolt circles

Examples of Machining Cycles in Automated NC Programming Modules

Pocket milling

Contour turning

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Examples of Machining Cycles in Automated NC Programming Modules

Facing and shoulder facing

Threading (external)

Manual Data Input

Machine operator does part programming at machine Operator enters program by responding to prompts and questions by system Monitor with graphics verifies tool path Usually for relatively simple parts Ideal for small shop that cannot afford a part programming staff To minimize changeover time, system should allow programming of next job while current job is running

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