Numerical Control

Sections:
1. Fundamentals of NC Technology
2. Computer Numerical Control
3. Distributed Numerical Control
4. Applications of NC
5. NC Part Programming
 Numerical Control (NC) Defined

Programmable automation in which the mechanical actions of a machine

tool are controlled by a program containing coded alphanumeric data
that represents relative positions between a work head (e.g., cutting
tool) and a work part

Program Machine
Instructions Control Unit

Transformation
Process
Power
 NC Coordinate Systems
For flat and prismatic (block-like) parts:
Milling and drilling operations

Conventional Cartesian coordinate system

Rotational axes about each linear axis

For rotational parts:

Turning operations
Only x- and z-axes
 Motion Control Systems

Point-to-Point systems
Also called position systems
System moves to a location and performs an
operation at that location (e.g., drilling)
Also applicable in robotics

- - Straight Cut motion

Continuous path systems

Also called contouring systems in machining
System performs an operation during movement
(e.g., milling and turning)
 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
 Absolute vs. Incremental Positioning

Absolute positioning
Move is: x = 40, y = 50

Incremental positioning
Move is: x = 20, y = 30.
 Computer Numerical Control (CNC)

Storage of more than one part program

Various forms of program input
Program editing at the machine tool
Fixed cycles and programming subroutines
Interpolation
Acceleration and deceleration computations
Communications interface
Diagnostics
Machine Control Unit
 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
 Distributed Numerical Control

Central
Computer NC Pgms

Computer Network

BTR BTR BTR

Machine Machine Machine
Control Unit Control Unit Control Unit

Transformation
Process
Applications of NC
 NC Application Characteristics
(Machining)

Batch and High Volume production

Repeat and/or Repetitive orders
Complex part geometries
Different operations
Many separate operations on one part
 Cost-Benefits of NC
Costs
High investment cost
High maintenance effort
Need for skilled programmers
High utilization required

Benefits
Cycle time reduction
Nonproductive time reduction
Greater accuracy and repeatability
Lower scrap rates
Reduced parts inventory and floor space
Operator skill-level reduced
Precision
 NC Part Programming
1. Manual part programming
2. Manual data input
3. Computer-assisted part programming
4. Part programming using CAD/CAM
 Manual Part Programming
Binary Coded Decimal System
Each of the ten digits in decimal system (0-9) 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
 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
 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

Codes
 Example: Word Address Format
N001 G00 X07000 Y03000 M03
N002 Y06000
 Cutter Offset

Cutter path must be

offset from actual
part outline by a
distance equal to
the cutter radius
 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
 Example
NC part program code Comments
N001 G21 G90 G92 X-050.0 Y-050.0 Z010.0; Define origin of axes.
N002 G00 Z-020.0 S1989 M03; Rapid to cutter depth, turn spindle on.
N003 G01 G94 G42 Y0 D05 F398; Bring tool to starting y-value, start cutter offset.
N004 G01 X075.0; Mill lower horizontal edge of part.
N005 G01 X150.0 Y043.02; Mill angled edge at 35 degrees.
N006 G01 Y070.0; Mill vertical edge at right of part.
N007 G01 X080.0; Mill horizontal edge leading to arc.
N008 G17 G02 X050.0 Y100.0 R030.0; Circular interpolation around arc.
N009 G01 Y125.0; Mill vertical step above arc.
N010 G01 X0; Mill top part edge.
N011 G01 Y0 Mill vertical edge at left of part.
N012 G40 G00 X-050.0 Y-050.0 Z010.0 M05; Rapid move to target point, cancel offset, spindle stop.
N013 M30; End of program, stop machine.
 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
 Computer-Assisted Part Programming
Write machine instructions using natural language
type statements
Statements translated into machine code of the MCU
APT (Automatically Programmed Tool) Language
 Sample Statements

Part is composed of basic geometric elements and

mathematically defined surfaces
Examples of statements:
P4 = POINT/35,90,0
L1 = LINE/P1,P2
C1 = CIRCLE/CENTER,P8,RADIUS,30

Tool path is sequence of points or connected line and arc

segments
Point-to-Point command: GOTO/P4
Continuous path command: GOLFT/L1,TANTO,C1
NC Part Programming Using
CAD/CAM
YouTube

CNC Milling
CNC Punching
CNC Adhesive Bonding
CNC Drug Insertion
CNC Bioprocessing
CAD/CAM
Etc.