Compiled & Presented By

Ashutosh Singh
7th Semester
B.Tech
B.H.E.L -A Brief
Introduction
1st unit- Bhopal in August 1956
B.H.E.L. is the largest engineering and manufacturing
enterprise in India in the energy/infrastructure sector
with strong man force of 82000 people.
B.H.E.L. manufacture over 180 products under thirty
major product groups and caters to core sectors of the
Indian Economy viz., Power Generation and
Transmission, Industry, Transportation,
Telecommunication, Renewable Energy, etc.
Contd…
Certification acquired by B.H.E.L are Systems- ISO
9001, Environmental Management Systems-ISO
14001 and Occupational Health and Safety
Management Systems-OHSAS 18001 and has also
adopted the concepts of Total Quality
Management.
B.H.E.L. has installed equipment for over 90,000
MW of power generation- for Utilities, Captive, and
Industrial users.
MANUFACTURING UNITS OF
B.H.E.L.
 First Generation Units
 BHOPAL Heavy Electrical Plant
 HARDWAR Heavy Electrical Equipment Plant
 HYDERABAD Heavy Electrical Power Equipment Plant
 TIRUCHY High Pressure Boiler Plant
  
 Second Generation Units
 JHANSI Transformer and Locomotive Plant
 HARDIWAR Central Foundry and Forge Plant
 TIRUCHY Seamless Steel Tube Plant
  
 Unit Through Acquisition and Merger
 BANGALORE Electronic Division
 Electro Porcelain Division
  
 New Manufacturing Units
 RANIPAT Boiler Auxiliaries Plant
 JAGDISHPUR Insulator Plant
 RUDRAPUR Component and Fabrication Plant
 BANGALORE Industrial System Group
Mission, Vision & Values of
B.H.E.L
VISION:
A world class engineering enterprise committed to
enhancing stakeholder value.
Mission:
To be an Indian Multinational Engineering Enterprise
providing total business solution through quality products,
system and services in the fields of energy, industry,
transportation, infrastructure and other potential areas.
Contd..
VALUES:
Zeal to Excel Zest for change.
Integrity and fairness in all matters.
Respect for dignity and potential of every
individual.
Strict adherence to commitments.
Ensure speed of response.
Faster learning, teamwork and creativity.
Loyalty and Pride in the Company.
What Makes B.H.E.L So
“Special”
The quality and reliability of its products .
The emphasis on design, engineering and
manufacturing to international standards .
Quality Management Systems- ISO 9001.
Environmental Management Systems-ISO
14001 .
Occupational Health and Safety Management
Systems-OHSAS 18001.
INTRODUCTION OF CNC
MACHINE
CNC machine tools have been widely accepted as time
proven manufacturing technique all over the globe.
Numerical control turns machine tools into a flexible
production unit with a multitude of possible application.
Modern day computerized numerical control system (CNC)
is the result of advancement and sky rocketing
microelectronics .
Flexibility as inherent feature of minicomputer and
microcomputer gave new technology –“Software Oriented
System”.
HISTORY OF CNC
US Air Force asks MIT to develop a "numerically controlled" machine
(1949).
Prototype NC machine demonstrated (punched tape input) (1952).
CNC machines (computer used to link directly to controller) (1980).
DNC: external computer “drip feeds” control programmer to
machine tool controller (1990).
MOTIVATION
To manufacture complex curved geometries
in 2D or 3D was extremely expensive by
mechanical means (which usually would
require complex jigs to control the cutter
motions)
Machining components with repeatable
accuracy
Unmanned machining operations
Conventional milling
machines

Vertical milling machine

SPECIAL FEATURES OFFERED BY CNC
MACHINE

Thermal stabilization
Axis calibration
Lost machine compensation
WORKING PRINCIPLE OF
CNC M/C
Electronic industries association defines
numerical control as “A system in which
action is controlled by direct insertion of
numerical data. The system must
automatically interpret at least some potion of
data.”
In NC machine tools the main function is to
control the displacement and positioning of
slides, spindle, speed, feed rate, selection of
tool and many other auxiliary functions.
Contd…
The major elements that comprises NC machine
tools are :-
Control system – CNC
The machine tool
Servo drive units
Feedback devices
Operator control
Electrical cabinet
Contd…
Motion control is done by: servo-controlled
motors
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CNC terminology
BLU: basic length unit 
smallest programmable move of each axis.

Controller: (Machine Control Unit, MCU) 

Electronic and computerized interface between operator
and m/c

Controller components:
1. Data Processing Unit (DPU)
2. Control-Loops Unit (CLU)
Controller components

Data Processing Unit:

Input device [RS-232 port/ Tape Reader/ Punched Tape Reader]
Data Reading Circuits and Parity Checking Circuits
Decoders to distribute data to the axes controllers.

Control Loops Unit:

Interpolator to supply machine-motion commands between data poin
Position control loop hardware for each axis of motion
Types of CNC machines
Based on Motion Type:
Point-to-Point or Continuous path

Based on Control Loops:

Open loop or Closed loop

Based on Power Supply:

Electric or Hydraulic or Pneumati

Based on Positioning System:

Incremental or Absolute
Open Loop vs. Closed Loop controls
Open loop control of a Point-to-Point NC drilling mach

NOTE: this machine uses stepper motor control

Components of Servo-motor controlled CNC

Motor lead screw rotation table moves

Motor speed control feedback position sensed by encoder

Two types of encoder configurations

Motion Control and feedback

Encoder outputs: electrical pulses (e.g. 500 pulses per revolution)

Rotation of the motor  linear motion of the table: by the leadscrew

The pitch of the leadscrew: horizontal distance between successive threads

One thread in a screw  single start screw: Dist moved in 1 rev = pitch

Two threads in screw  double start screw: Dist moved in 1 rev = 2* pitch
Manual NC programming
Part program: A computer program to specify

- Which tool should be loaded on the machine spindle;

- What are the cutting conditions (speed, feed, coolant ON/OFF etc)

- The start point and end point of a motion segment

- how to move the tool with respect to the machine.

Standard Part programming language: RS 274-D (Gerber, GN-code)

 Contd…
The RS274-D is a word address format

Each line of program == 1 block

Each block is composed of several instructions, or (words)

Sequence and format of words:

N3 G2 X+1.4 Y+1.4 Z+1.4 I1.4 J1.4 K1.4 F3.2 S4 T4 M2

sequence no destination coordinates

dist to center of circle tool

feed ratespindle speed

preparatory function
miscellaneous function
Manual Part Programming Example
5”
2.5”
p4
p2 p3 p5

1”

Tool size = 0.25 inch,

5” Feed rate = 6 inch per minute,
Cutting speed = 300 rpm,
Tool start position: 2.0, 2.0
Programming in inches
45°

(4, 4)
p1 Motion of tool:
p0  p1  p2  p3  p4  p5  p1  p0
p0 (2, 2)
1. Set up the programming parameters

5”
2.5”
p4
p2 p3 p5

1”

Programming in inches
5”
Use absolute coordinates

Feed in ipm
45°
N010 G70 G90 G94 G97 M04
(4, 4)
p1
Spindle speed in rpm
p0 (2, 2)
Spindle CCW
2. Set up the machining conditions

5”
2.5”
p4
p2 p3 p5

1”
Machine moves in XY-plane

Use full-circle interpolation

5”
Feed rate

Spindle speed
45°
N020 G17 G75 F6.0 S300 T1001 M08
(4, 4)
p1
Tool no.
p0 (2, 2)
Flood coolant ON
3. Move tool from p0 to p1 in straight line

5”
2.5”
p4
p2 p3 p5

Linear interpolation
1”
target coordinates

5” N030 G01 X3.875 Y3.698

45°

(4, 4)
p1

p0 (2, 2)
4. Cut profile from p1 to p2

5”
2.5”
p4
p2 p3 p5

1”

Linear interpolation
5” target coordinates

N040 G01 X3.875 Y9.125

45°
or
(4, 4)
p1 N040 G01 Y9.125

p0 (2, 2)

X-coordinate does not change  no need to program it

5. Cut profile from p2 to p3

5”
2.5”
p2 p3
p4
p5 Linear interpolation

target coordinates
1”

N050 G01 X5.634 Y9.125

5”

y = 9 + 0.125 = 9.125
(6.5 - x)2 + 0.1252 = (1 - 0.125)2
x = 5.634
45° p3
(x, y)
(4, 4)
p1 (6.5, 9)
.125

p0 (2, 2)

1”
6. Cut along circle from p3 to p4

5”
2.5”
p4
p2 p3 p5

1”

circular interpolation, CCW motion

5”
target coordinates

45° N060 G03 X7.366 Y9.125 I6.5 J9.0

(4, 4)
coordinates of center of circle
p1

p0 (2, 2)
7. Cut from p4 to p5

5”
2.5”
p4
p2 p3 p5

1”

5”

Linear interpolation

45° target coordinates (Y is unchanged)

(4, 4) N070 G01 X9.302

p1

p0 (2, 2)
8. Cut from p5 to p1

5”
2.5”
p4
p2 p3 p5

1”

5”
Linear interpolation

target coordinates (see step 3)

45°
N080 G01 X3.875 Y3.698
(4, 4)
p1

p0 (2, 2)
9. Return to home position, stop program

5”
2.5”
p4
p2 p3 p5

1”

Linear interpolation

5” target coordinates (see step 3)

N090 G01 X2.0 Y2.0 M30

45°
end of data
(4, 4)
N100 M00
p1

p0 (2, 2) program stop

Automatic Part Programming
Software programs can automatic generate CNC
data

Define Tool

CNC data

Make 3D model
Simulate
cutting
Automatic part programming and DNC
Very complex part shapes  very large NC program

NC controller memory may not handle HUGE part program

computer feeds few blocks of

NC program to controller

When almost all blocks executed,

controller requests more blocks
ADVANTAGES OF CNC
MACHINES

Productivity
Flexibility in design and production
Inspection
Floor space
Inventory
Material Handling
 Tooling
Operator’s Skill
Scrap and Rework
Costing
Better Management Information and Control
 THANK YOU !!

Go Green….