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
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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(through punched tape) containing coded alphanumeric data The alphanumeric data represent relative positions between a work head (e.g., cutting tool) and a work part When the current job is completed, a new program can be entered for the next job
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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
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Basic Components of an NC System

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1.Program: Is a set of detailed step by step command that direct the action of the processing equipment. A person who prepare the program is called part programmer. Individual commandrefer position of cutting tool relative to w/p.

Older days the part program was punched in 1 inch wide punched tape.
But now, magnetic tape, diskettes and electronic transfer . 2.Machine control unit: Is a micro computer and related control hardware that stores the program of instruction and execute it by converting each command into mechanical action.

The term CNC is used that all MCU are based on computer technology. MCU includes control system software, calculation algorithm, and translation software. 3.Processing equipment: That perform the actual productive work(e.g.machining). Its operation directed by MCU. The processing equipment consist of worktable, and spindle as well as motor and controls to drive them. NC coordinate system:

First define standard axis system(x,y,z), three rotational axis(a,b,c).

In most m/c application x,y axis are used to move and position the work table. And z axis for controlling the tool movement.

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
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NC Coordinate Systems
For rotational parts: Turning operations Conventional Cartesian coordinate system, but only x- and z-axes y-axis not needed in turning
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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 Continuous path systems Also called contouring(when continuous path control is used for simultaneous control of two or more axes) systems in machining 2008 Pearson Education, Inc., System performs an operation during movement (e.g., Upper Saddle River, NJ. All rights reserved. This material milling and turning) is protected under all copyright
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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

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Free form curves using higher order equations

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 2008 Pearson Education, Inc.,
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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 2008 Pearson Education, Inc., curve Upper Saddle River, NJ. All
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Absolute and Incremental Positioning

Another aspect of motion control is concern with whether position are defined relative to the origin or relative to previous location of the tool. 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 Education, 2008 Pearson = 30. Inc.,
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Computer Numerical Control (CNC) Additional Features

CNC is defined as an NC system whose MCU is based on micro computer rather than on a hard wired controller. Features of CNC: Storage of more than one part program Various forms of program input(punched,magnetic,floppy diskettes,RS 232 communication) Program editing at the machine tool Fixed cycles and programming subroutines Interpolation Acceleration and deceleration computations 2008 Pearson Education, Inc., Upper Saddle River, NJ. All Communications interface rights reserved. This material is protected under all copyright as they currently exist. laws Diagnosticsmalfunction sign
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Machine control unit for CNC

The MCU consists of the following components and subsystems: (I) central processing unit (2) memory (3) l/O interface (4) controls for machine tool axes and spindle speed. And (5)sequence controls for other machine tool functions.

These subsystems are interconnected by means of a system bus. which communicates data and signals among the components of network. indicated in the figure,

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Central Processing Unit

The central processing unit (CPU) is the brain of the MCU. It manages the other components in the MCU based on software contained in main memory. The CPU can be divided into three sections: (1) control section, (2) arithmetic-logic unit, and (3) immediate access memory. control section retrieves commands and data from 2008 Pearson Education, Inc., memory and generates signals to activate other Upper Saddle River, NJ. All rights reserved. This material components in the MCU. In short, it sequences. is protected under all copyright laws as they currently exist. coordinates. and regulates all of the activities of the MCU No portion of this material may be reproduced, in any form or computer. by any means, without
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 Arithmetic logic unit (ALU) consists of the circuitry to perform various calculations (addition, subtraction, multiplication), counting. and logical functions required by software residing in memory. Immediate access memory provides a temporary storage for data being processed by the CPU. It is connected to main memory by means of the system data bus.
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Configuration of CNC Machine Control Unit

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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

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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 Configurations

Switching network

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Applications of NC
Machine tool applications: Milling, drilling, turning, boring, grinding Machining centers(almost any CNC milling and drilling machine that includes an automatic tool changer and a table that clamps the workpiece in place), 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 2008 Pearson Education, Inc., Tape laying machines for polymer composites Upper Saddle River, NJ. All rights reserved. This material Filament is protected under all copyrightwinding machines for polymer composites
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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
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Advantages of NC
Nonproductive time is reduced(e.g.set up time) 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 2008 Pearson Education, Inc., Reduce Upper Saddle River, NJ. All parts inventory and less floor space rights reserved. This material is protected under all copyright Operator skill-level requirements are reduced laws as they currently exist.
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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
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Higher utilization is required

NC Positioning System

Typical motor and leadscrew arrangement in an NC positioning system for one linear axis Pearson Education, 2008Saddlex-y NJ. All Inc., For River, capability, the apparatus would be piggybacked Upper on top material rights reserved. Thisof 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:

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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
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Optical Encoder

Device for measuring rotational position and speed 2008 Pearson Education, Inc., Upper Saddle River, NJ. All rightsCommon feedback sensor for closed-loop NC control reserved. This material is protected under all copyright
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NC Part Programming
NC part programming consists of planning and documenting the sequence of processing steps to be performed on an NC machine. The part programmer must have a knowledge of machining (or other processing technology for which the NC machine is designed) as well as geometry and trigonometry. The documentation portion of par! programming involves the input medium used to transmit the program of instructions to the NC machine control unit (MCU). The traditional input medium dating back to the first NC machines in the 1950s is linch wide punched rape. More recently the use of magnetic tape and floppy disks have been used for NC due to their much higher data density. Part programming can he accomplished using a variety of procedures ranging from 2008 Pearson Education, Inc., highly manual Upper Saddle River, NJ. Allto highly automated methods. rights reserved. This material 1. protected underpart programming Manual all copyright is laws Computer-assisted part programming 2. as they currently exist. No portion of this material may be Part programming 3. reproduced, in any form or using CAD/CAM by any means, without 4. Manual data input permission in writing from the

1.Manual Part Programming

In manual part programming, the programmer prepares the NC code using the low-level machine language previously described. The coding system is based on binary numbers This coding is the low level machine language that can be understood by the MCU. Whenever higher level languages are used , such as APT, the statements in the program are converted to this basic code NC uses a combination of the binary and decimal number system, called BCD system. In this coding scheme , each of the ten digits (0-9) in the decimal system is coded as a four digit binary number, and these binary number are added in sequence as in the decimal number system. Conversion of the ten digits in the decimal system into binary numbers Exe: decimal value 1250 would be coded in BCD Number sequence binary number decimal value First 0001 1000 Second 0010 200 Third 0101 50 Fourth 0000 0 Sum 1250

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)
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Types of Words
N - sequence number prefix G - preparatory words
Example: G00 = PTP rapid traverse move

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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

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:
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Other Functions in ComputerAssisted 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
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4.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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Computer Tasks in ComputerAssisted 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 2008 Pearson Education, Inc., Upper Saddle River, NJ. All that can be interpreted by the MCU rights reserved. This material
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