NC & DNC

• NC developed in 1950’s
• CNC developed in 1970s
• Numerical Control: A system in which actions are
controlled by direct insertion of numerical data. The
system must automatically interpret at least some part
of this data. (EIA)
• Direct Numerical Control is referred to a system
connecting a set of numerically controlled machines to
a common memory for part program or machine
program storage with provision for on-demand
distribution of data to the machines. (ISO 2806:1980)
 CNC Machine Features
• Dedicated computer performs all basic NC
functions
• Part program
– Can be input through keyboard
– Stored in the computer memory for repeated use.
– Can be edited and optimised at the machine tool itself
– May be checked without actually running the machine
– Subprograms may be used for repetitive machining
sequences
– Allow compensation for any change in the dimension
of the cutting tool
Advantages of CNC Machine Tools
• Suitable for small lots size production or
complex part geometry or parts are expensive
• Close tolerances result in reduced scrap, high
accuracy and consistent quality. Therefore
reduced inspection
• Reduced lead time
• Longer tool life
• Elimination of special jigs and fixtures so
reduced lead times and cost
• Increased productivity
• Reduced non productive time
 Disadvantages of CNC Machine Tools
• Higher investment cost
• Higher maintenance cost
• Costlier CNC personnel
 Use of CNC
CNC machines may be used for the following situations:
• Large number of operations are needed per component
• Complex operations
• When batches are repetitive and their size medium
• High labour cost
• Component requires substantial tooling
• Components requires 100% inspection
• Set up and Inspection times are high
• Ratio of cutting time to non cutting time is high
• Large variety of components are to be produces
• Components require highly skilled labour
 Basic Components of NC systems
The components of an NC system are:
• Program of Instructions
• Controller Unit or Machine control Unit
• Machine tool or other controlled equipment
 Control Systems
• Point to point control system
• Straight Line control system
• Continuous Path or Contouring System
 Axes Identification
• Z axis
– Axis of the main spindle
– +z: Direction that increases the distance
between the tool & work-piece
• X axis
– Horizontal & parallel to the work holding
surface
– If Z is vertical: +x is to the right when
looking from the tool to the supporting
column
– If Z is horizontal: +x is to the right when
looking from the spindle towards the
workpiece
• Y axis
– completes the 3D coordinate system
 Coordinate Systems
• Types of coordinate systems
– Absolute Coordinate system
– Incremental coordinate system
• Position commands are given in terms of basic
length unit
If shaft encoder gives 500 pulses / revolution
Ball screw has a pitch of 1mm
Then,
Basic length unit = 1 pulse of shaft encoder
= 1/500 = 0.002 mm
 Machine Control Unit (MCU):
It has two sub-units namely:
• Data Processing Unit
• Interprets & encodes part program into internal machine codes.
• The interpolator calculates the intermediate positions of the
motion in terms of BLU (basic length unit)
• The calculated data are passed to CLU for further action.
• Control Loop Unit
• Data from DPU are converted into electrical signals to control the
driving system to perform the required motions.
• Also controls other functions such as machine spindle ON/OFF,
coolant ON/OFF, tool clamp ON/OFF.
 Control Systems
• Open Loop Control System

• Closed Loop Control System

Feedback Systems
 Construction Of CNC: Slide-ways
• Efficient cooling & lubrication is needed to avoid
thermal distortion
• No direct metal to metal contact
• Hydrostatic Slideways:
– Use air or oil
– Almost frictionless
– Need a large surface area
 Construction Of CNC: Slideways
• Linear bearings with ball and rollers
– Linear roller bearings also called tychoways
– Needs hardened machine bed surface or
hardened steel guides with special guide
forms may be attached
• Guiding surfaces are covered with low
friction material
– As a coating for e.g. with
Polytetraflouroethylene (PTFE)
– As replaceable strips of low friction material
 Spindle
• Due to high speeds and feeds spindle should be:
– Short and stiff
– Drive located as close to the front bearing as possible
• Spindle Drive:
– Requires large speed variations needs infinitely
variable speed system
– Uses electrical or fluid motors
 Drive Units: Spindle Drive
• Electrical motors
– Drive may be direct from motor or through belts or
gears
– Both A.C. and D.C.
• A.C Induction motors
– Used to drive the main spindle directly
– Easy speed variation
– More reliable low maintenance and cost
• D.C motors are used for step-less speed variation by
changing input voltage
• Fluid Motors: Use pressurised oil or air directed
on the rotor blades gives very high speeds
 Drive Units: Axis Drive
• Each axis is controlled by a separate
servomotor or stepper motor
• Servomotor gives accurate control of velocity
and position
• Stepper motor drive
– Does not need feedback systems
– They are simpler and cheaper
– Suitable only for light duty machines
 Swarf Removal
• High volume of swarf
• May interfere with operations like tool
changing, loading and access to machine tool
• Methods of swarf removal:
– Slant or vertical beds are used in turning centres
– Multiple cooling jets around the cutting tool inject
cutting fluid at high pressure
– Compressed air jets
– Linear or rotating conveyer belts
 Tooling for CNC Machines
• Cutting time for CNC machines is 70-80%
(Conventional machines approx. 25%)
• Tooling Used in CNC should be
– Rigid: to withstand high MRR
– Capable of being preset and reset
– Accurate
 Cutting Tools for CNC
• CNC’s use preset and qualified tools
• Tool preset: Tools are preset a known
dimension away from the machine tool
• Tools are preset with the tool held in the tool
holder
• Qualified tools: position of the cutting edge is
guaranteed( to high accuracy) relative to a
datum on the tool holder
 Qualified Tools
• Position of the cutting edge is
guaranteed (to high accuracy)
relative to a datum on the tool-
holder
• Hard metal inserts are suited for
qualified tooling as their
dimensions are known
• Semi-qualified tools can be
adjusted to the required
dimension and may be used on
different machines
 Indexable Inserts
• Indexable carbide inserts are used due to their lower
tool changing time
• Hard and special grade carbides give high MRR:
Tungsten carbide inserts are coated with titanium
carbide or titanium nitride for better wear resistance
• Chip-breakers: grooves on the insert or tool-holders
• Coolant fed tools (coolant fed through shank)are used.
Interlocks are provided to avoid cutting without
coolant
• Tool overhang should be minimum
 Work Holding Devices
A tool-holder for CNC machines must:
• Restrict linear and rotary motion of component
• Facilitate quick loading and unloading
• Permit multiple operations simultaneously
• Not allow the component to deflect under cutting
forces
• Be adaptable to automation
• Allow easy swarf removal
• Be fool proof