NUMERICAL CONTROL

NC

CH 7 NUMERICAL
CONTROL
Sections:
1. Fundamentals of NC Technology
2. Computer Numerical Control (CNC)
3. DNC
4. Applications of NC
5. Engineering Analysis of NC Positioning Systems
6. NC Part Programming

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 containing coded alphanumeric
data
The alphanumeric data represent relative positions
between a workhead (e.g., cutting tool) and a workpart
When the current job is completed, a new program can be
entered for the next job

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

BASIC COMPONENTS OF AN NC
SYSTEM

NC COORDINATE SYSTEMS
For flat and prismatic (block-like) parts
Milling and drilling operations
Rotational axes about each linear axis

COORDINATE AXIS SYSTEM

FOR FLAT AND PRISMATIC
PARTS

NC COORDINATE SYSTEMS
For rotational parts:
Turning operations
Conventional Cartesian coordinate system, but only x- and
z-axes
y-axis not needed in turning

COORDINATE AXIS
SYSTEM FOR
ROTATIONAL PARTS

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
systems in machining
System performs an operation during movement (e.g.,
milling and turning)

POINT-TO-POINT CONTROL IN NC
DRILLING OF THREE HOLES IN FLAT
PLATE

CONTINUOUS PATH CONTROL IN NC

PROFILE MILLING OF PART OUTLINE

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 AND INCREMENTAL

POSITIONING
Absolute positioning
Locations defined relative to origin of axis system
Incremental positioning
Locations defined relative to previous position
Example: drilling

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 = 30.

COMPUTER NUMERICAL CONTROL

(CNC)

Is defined as an NC system whose MCU is based on a

dedicated microcomputer rather than on a hard-wired
controller

COMPUTER NUMERICAL
CONTROL (CNC) FEATURES

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

MCU

CNC software
There are three types of software programs:
1) Operating system software
2) Machine interface software
3) Application software

DNC
DIRECT NUMERICAL CONTROL (DNC)
CONTROL OF MULTIPLE MACHINE TOOLS
BY A SINGLE (MAINFRAME) COMPUTER
THROUGH DIRECT CONNECTION
Distributed numerical control network consisting of
central computer connected to machine tool MCUs,
which are CNC
Present technology
Two way communication

General Configuration of a Direct

Numerical Control System

Connection

to MCU is behind the tape reader

(BTR). In distributed NC, entire programs are
downloaded to each MCU, which is CNC rather
than conventional NC

Distributed Numerical Control

Configurations
Switching network

Distributed Numerical Control

Configurations

Local area network (LAN)

APPLICATIONS OF NC
Machine tool applications:
Milling, drilling, turning, boring, grinding
Machining centers, turning centers, mill-turn centers
Punch presses, thermal cutting machines, etc.
Other NC applications:
Component insertion machines
Drafting machines
Electrical wire wrap machines
Tape laying machines
Filament winding machines

COMMON NC MACHINING
OPERATIONS

Turning

COMMON NC MACHINING
OPERATIONS

Milling
Drilling

2008 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved. This material is protected under all copyright laws as they currently exist.
No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

CNC HORIZONTAL MILLING

MACHINE

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 workpart
5. Many separate machining operations on the part
6. The part is expensive

ADVANTAGES OF NC

Nonproductive time is reduced

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
Reduce parts inventory
Operator skill-level requirements are reduced

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
Repeat orders are easy because part program is
already available
Higher utilization is required

NC POSITIONING SYSTEM

Typical motor and leadscrew arrangement in an NC

positioning system for one linear axis
For x-y capability, the apparatus would be piggybacked on
top of a second perpendicular axis

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:
1. Control resolution
2. Accuracy
3. Repeatability

OPEN-LOOP MOTION CONTROL

SYSTEM

Operates without verifying that the actual position

achieved in the move is the desired position

CLOSED-LOOP MOTION CONTROL

SYSTEM

Uses feedback measurements to confirm that the final

position of the worktable is the location specified in
the program

OPTICAL ENCODER

Device for measuring rotational position and speed

Common feedback sensor for closed-loop NC control

PRECISION IN NC POSITIONING
Three measures of precision:
1. Control resolution - distance separating two adjacent
addressable points in the axis movement
2. Accuracy - maximum possible error that can occur
between the desired target point and the actual position
taken by the system
3. Repeatability - defined as 3 of the mechanical error
distribution associated with the axis

NC PART PROGRAMMING
NC part programming consists of planning and documenting
the sequence of processing steps to be performed on an NC
machine. The NC programming methods are:
1.
2.
3.
4.

Manual part programming

Computer-assisted part programming
Part programming using CAD/CAM
Manual data input

MANUAL PART
PROGRAMMING
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

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)

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

Example: Word Address Format

N001 G00 X07000 Y03000 M03
N002 Y06000

COMPUTER-ASSISTED PART
PROGRAMMING
Manual part programming is time-consuming, tedious,
and subject to human errors for complex jobs
Machining instructions are written in English-like
statements that are translated by the computer into
the low-level machine code of the MCU
APT (Automatically Programmed Tool)
The various tasks in computer-assisted part
programming are divided between
The human part programmer
The computer

COMPUTER-ASSISTED PART
PROGRAMMING

Sequence of activities in computer-assisted part

programming

PART PROGRAMMER'S JOB

Two main tasks of the programmer:
1. Define the part geometry
2. Specify the tool path

CUTTER OFFSET
Cutter path must be
offset from actual
part outline by a
distance equal to
the cutter radius

NC PART PROGRAMMING USING

CAD/CAM
Is a computer interactive graphics system equipped with
software to accomplish certain tasks in design and
manufacturing and to integrate the design and manufacturing
functions
Geometry definition
If the CAD/CAM system was used to define the original
part geometry, no need to recreate that geometry as in
APT
Automatic labeling of geometry elements
If the CAD part data are not available, geometry must
be created, as in APT, but user gets immediate visual
feedback about the created geometry

TOOL PATH GENERATION

USING CAD/CAM
Basic approach: enter the commands one by one (similar
to APT)
CAD/CAM system provides immediate graphical
verification of the command
Automatic software modules for common machining
cycles
Profile milling
Pocket milling
Drilling bolt circles

EXAMPLES OF MACHINING CYCLES IN

AUTOMATED NC PROGRAMMING
MODULES
Pocket milling

Contour turning

EXAMPLES OF MACHINING CYCLES

IN AUTOMATED NC PROGRAMMING
MODULES

Facing and shoulder facing

Threading (external)

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

QUESTIONS
1.
2.
3.
4.

Type three of the NC advantages?

What are the Basic Components of an NC System?
What are The NC programming methods?
What is the Computer Numerical Control (CNC)?

ANSWERS
Type three of the NC advantages?
Simpler fixtures
Shorter lead times
Reduce parts inventory

What are the Basic Components of an NC System?
Program of instructions
Machine control unit
Processing equipment

What are The NC programming methods?
Manual part programming
Computer-assisted part programming
Part programming using CAD/CAM
Manual data input

What is the Computer Numerical Control (CNC)?
Is defined as an NC system whose MCU is based on a dedicated microcomputer rather
than on a hard-wired controller