Numerical Control 1

Prepared by Ravi Vayeda Modified by Louis McDaniels ENTC 380

CHAPTER 6: NUMERICAL CONTROL

Topics covered : {# 11} 6.1.1 Basic Components of an NC System 6.2.2 The Machine Control Unit for CNC 6.1.2 NC Coordinate Systems 6.1.3 Motion Control Systems 6.2.1 Features of CNC 6.4.3 Advantages and Disadvantages of NC 6.4.1 NC Application Characteristics 6.5.1 NC Coding System 6.5.2 Manual Part Programming 6.5.5 NC Part Programming Using CAD/CAM

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Computer Numerical Control {# 6}

Difference between NC & CNC
Numerical Control is a form of programmable automation in which the machine tool is controlled by a punched tape. A narrow paper tape is punched at a teletype machine and then fed into a tape reader on an NC machine. Each possible combination of eight holes or lack of holes across the tape represents a letter, a number or a symbol which forms the NC code making a program of instructions. In CNC the program in stored in computer memory.

Tape Writer
{# 5}

Punched Tape
{# 5}
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Basic Components of an NC System {# 11}

Part Program: Contains positions of tool or worktable, speed, feed rate, tool no etc. MCU: Consists of a micro computer, reading device, control system software, calculation algorithms and translation software. Processing Equipment: Consists of worktable, spindle, motors and controls to drive them.
Haas VF-2 Mill {# 2}
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The Machine Control Unit for CNC {# 11}

It consists of the following components and subsystems : Central processing unit: Control Section, Immediate access memory, Arithmetic-Logic-Unit (ALU). Memory: Primary storage; ROM stores system software & machine interface programs while RAM stores the part programs. Secondary storage includes Hard disks and floppy diskettes to store macros & other software. Input / Output interface: Operator panel, Tape reader. Machine tool controls: Position, Spindle speed control. Sequence controls: Coolant, Fixture clamping, Tool Changer, Emergency stop, Loading/Unloading, Counter. System bus: Connects all the above subsystems.
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NC Coordinate Systems {# 11}

Flat & Prismatic work parts: 3 linear axes (x, y, z) in Cartesian coordinate system, plus 3 rotational axes (a, b, c). Generally 3 linear + 1 or 2 rotational axes are used. Righthand-rule gives +ve rotation. Rotational work parts: X axis is the radial location of tool while Z axis is parallel to the axis of rotation. Origin can be at the center or at corner of the work part.
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Linear Axes {# 1}

X+

Z+

Rotational Axes {# 1}

Haas VF-1 Mill 3-Axis Coordinate Sys.

X-axis travel : 20", Y-axis travel : 16", Z-axis travel : 20" Smallest increment of each axis equals .0001 inches. Number Of Tools : Up to 20

Coordinate Axis {# 2}
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Quadrants {# 2}
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Haas SL-20 Lathe 2-Axis Coordinate Sys.

Bar Capacity : 2.0", Max RPM : 4,000 X-Axis travel : 8.45" Z-Axis travel : 20.0" Number Of Tools : Up to 10

{# 2}

Quadrants {# 2}

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Setting Work Zero {# 2}

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Different types of 5-axis machines {# 10}

Broad classifications of 5-axis machines are head rotation type, table rotation type, and mixed type (head/table rotation type). Used to machine complex surfaces like turbine-blades, impellers, aircraft or automobile parts, dies etc. with complex free-form surfaces.

Head Rotation Type {# 10}

Table Rotation Type {# 10}

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Head/Table Rotation Type {# 10}

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5-Axis Examples
Simultaneous 5 axis VMC from John Hart for machining of aluminum aerospace components using a tilting spindle and side of ball nose end mill. Machining capability up to 50 HP spindle motor and spindle speed of 10,000 rpm. {# 8} A 5 axis impeller cut on a Haas VF- 4 VMC with a 10,000 rpm spindle using a Haas TRT 210 tilting rotary table for fully interpolated 4th and 5th axis motion. {# 2}
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5-Axis Examples Continued

Machining an Impeller

Double-spindle lathe with 5-axis unit {# 7}

5-Axis CNC Turn-Milling Center, Mazak Co. {# 3}

5 Axis Rotary Table Mill, ENTC 380 Fujicon Engg. Ltd. {# 4}

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Motion Control Systems {# 11}

Point-to-Point Control: Worktable moves to programmed location without regard for the path taken to get to that location. Used for drilling, boring, reaming, tapping and punching.

{# 6}

{# 6}

{# 6}

Continuous Path Control: Commonly known as the Contouring System. Simultaneous control of 2 or more axes. Can control its drive motors independently at various speeds as the tool moves towards the specified position. toolpath_contour.wmv {# 6}
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Motion Control Systems Continued

Interpolation Methods: Interpolation is a method of constructing new data points from a discrete set of known data points. Linear, Circular, Helical, Parabolic and Cubic interpolation modules are available in MCU.

Bad Finish, 0.00033 Cut Tolerance {# 2}

Linear Interpolation {# 9}

Circular Interpolation {# 2}

Absolute Vs Incremental Positioning

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Good Finish 0.00002 Cut Tolerance {# 2}

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Features of CNC {# 11}

Storage of more than one part program Various forms of program input Program editing on computer as well as machine tool Fixed cycles and programming subroutines Various types of Interpolation Positioning work part axis with m/c axis for setup Cutter length and size compensation Acceleration and deceleration calculations Communications interface Diagnostics
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Advantages of NC

{# 11}

Nonproductive time is reduced Greater accuracy and repeatability Lower scrap rates Inspection requirements are reduced More complex part geometries are possible Changes can be accommodated easily Simpler fixtures are needed Shorter manufacturing lead times Reduced parts inventory Less floor space is required Operator skill-level requirements are reduced Bar feed 300.wmv {# 2} VF-4 Dual APC.wmv {# 2}
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Disadvantages of NC {# 11}
Higher investment cost Higher maintenance effort Part programming Higher utilization of NC equipment

NC Application Characteristics {# 11}

For Batch production Repeat Orders Complex part geometry High metal removal from work part Different machining operations on the same part Cost concern
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SOURCES
1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) http://www.cnc-connect.com/vized.html http://www.haascnc.com/ http://www.aps-tech.com/services/mfg.htm http://www.fujicon.com.sg/page05.html http://users.bergen.org/jdefalco/CNC/punched_tape.html http://www.jjjtrain.com/vms/lessons_cnc.html http://www.sylviexpert.com/en/logiciel/fao/sylviexpert.php http://www.johnhart.com.au/products/machine_tools/ http://en.wikipedia.org/wiki/Linear_interpolation http://www.fanuc.co.jp/en/product/cnc/15i150i/5axis/5axis.html Automation, Production Systems and Computer Integrated Manufacturing by Mikell P. Groover

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