cea eda INTRODUCTION TO COMPUTER NUMERICAL CONTROL Objectives Computer numerical contral has revolutionised the manufacturing automation during the last 40 years. The movernent of the tool and the operation of the various components of a machine tool through a program brings in the kind of ‘lexisility to manufacturing which is not possiole by means of hard automation. After completing the study of this chapter, the reader should be able to + Learn the historical development of numerical control technology + Understand the principle of numerical control + Explore the various modes of operation of numerical contral + Know about the elements that are required for the successful operation of ‘numerical control + Discuss the application of numerical contral in the industry + Understand the advantages and disadvantages of adopting numerical control *+ Look at a few of the practical NC machines 24 || wrropucrion Competition between manufacturing firms is increasingly dictated by quality, cost, variety and servicing, ach one ofthese atributes ofa successful product can only be produced by achieving the highest possible efficiency in manufacturing. ‘The variety being demanded in view of the varying tastes of the consumer calls for very small batch sizes, Small batch sizes ate not able to take advantage of mass-production techniques such as special-purpose machines or transfer lines. Hence, the need for flexible automation where you get the benefits of rigid automation but also be able to vary the products manufactured thus bringing in the flexibility, Numerical control fits the bill perfectly, and we can predict that future manufacturing would increasingly be dependent on Numerical Control or NC to be short,Ber al a Re 2, cavrcante Princites nd Appt ‘Numerical Control (NC), or control by numbers, is the concept which has revolutionised the manufac turing scene that is partially due tothe rapid advancement in microelectronics that has taken place since late 1960's. The key factor responsible forthe popularity of numerical conto isthe flebily it offers in manufacturing Towaids the end ofthe Second World War, there was increased activity in aerospace manuficarng in UUSA. John Parsons of Parsons Conporation, wi was one ofthe subcontractors to USAF (United States Ait Fores), wae toying withthe idea of utilising the digital compute, to reduce the drudgery of computation, ‘which were just then becoming popular. Machining (milling) of complex curvature is «highly skilled job, He Proposed thatthe coordinate points ofa complex tee-dimesioual profile may be wilised for contoling the miling- machine table so that accurate jobs could be produced, The USAF accepted his proposal and & contrac wat awarded to him to develop such atachin, The project was ten awarded tothe Servomectanistn Laboratory of Massachusetts Tasiute of Technology in 1951, who finally demonstrated a working ming machine in 1952 This was a 2%-in, Cincinnati Hyrdo-Tel vertial-spindle contour milling machine which was extensively modified. ll the motion elements nthe ming machine were removed and were replaced by three vatiable- speed hydraulic transmissions and connected to the thee lead screws of the table, The retoltion of the thachine was 0.0005-in. A feedback control system involving syachros was provided to make sue the tnachine was moving tothe comectpostlons as programnued The first control system was developed usin electronic valves. Bendix Corporation produced the fist commercial production-based NC unit in 1954 after purchasing the patent rights from MIT. In 1960, the first controller with transistor technology was introduced, These systems were able to contol machines with three, four, and five axes and had new featres sucha circular and parabolic interpolation cutter compensation and dial input. Integrated ciruits (ICs) appeared on the scene in 1967. These permitted a 80% reduction inthe numberof components as wells an 80% reduction in wring. These systems were much more reliable. ‘Though the concept was demonstrated the actual avalbilty of sucha machine forthe aerospace indutry was around 1955 after avery lage numberof reGnetmest tothe basic controller demonstrated in 1952. Later tn, machine-tool builders serving a variety of applications introduced several commetial NC units nto the market. Since then, rapid strides ave taken place in NC technology parallel withthe developments in electronics and microelectronics, 2.2 |] NUMERICAL CONTROL ‘Numerical control of machine tools may be defined as a method of automation in which various functions of | machine tools are controlled by letters, numbers and symbols. Basically, an NC machine runs on a program fed to it, The program consists of precise instructions about the methodology of manufacture as well as the movements, for example, what tool to be used, at what speed, at what feed and to move from which point to which point in what path. Since the program is the controlling point for product manufacture, the ‘machine becomes versatile and can be used for any part. All the functions of an NC machine tool are therefore controlled electronically, hydraulically or pueumatically. InNC machine tools, one or more of the following functions may be automatic: (@) starting and stopping of machinestool spindle (b) controlling the spindle speed (©) positioning the tool tip at desired locations and guiding it along desired paths by automatic control of the motion of slidesLa eta el Introduction to Computer Numerical Control BOE (4) controlling the rate of movement of the tooltip (Le. feed rate) () changing of tools inthe spindle The principle of operation of an NC machine tool is shown in Fig. 9.1. The basic information that has to be input into the system consists of the part geometry, culting-process parameters followed by the cutting tools ‘used. This part program is then entered into the controller of the machine, which in turn runs the machine tool to make the part. Each of the machine axes is connected to a servomotor which works under the control of the Machine Control Unit (MCU) as shown in Fig. 9.2. The movement of the cutting tool with respect to the ‘workpiece is given in terms of the coordinates, which are used to control the motion of the servomotor which drives the individual axes. ol j cov Motor TD Tn Leadeerew a Fig. 91 Principle of operation of an _Fig. 9.2 Principle of operation ofthe control of axis motion in NC machine too! ‘an NC machine too! ‘The general structure of the operation of a typical numerical control system is shown in Fig. 9.3. The part program consists of instructions written in the numerical codes that constitute the basic operations to be carried out in machining of the part. These instructions are then entered into an input medium such as a standard I-inch paper tape, The program is then read by the paper-tape reader. The controller translates these ‘numerical codes into the machine actuatioa details, which are then used to control the individual machine functions such as the movement of the axes. ‘The system shown in Fig, 9.2 is working in an open-loop control, where the checking for the actual position reached is not carried out, Most of the NC machine tools are controlled with a feedback control system wherein the feedback information is provided to the machine control unit as shown in Fig, 9.4 t0 ensure that the programmed instructions are accurately carried out. The feedback provided consists of the positional as well as velocity data, The feedback for the actual motion achieved is obtained generally with the help of an encoder as shown in Fig. 9.5. ‘The axis-motion control system operates in a feedback loop with suitable transducers such as linear scales and/or rotary encoders to get the appropriate position or velocity feedback as shown in Fig. 9.5. Most of these systems have a very high response with good resolution of the order of 1 jim (micron) ot less. ‘The NC machines developed in the early days had the total control system developed using the hardware So the control system is actually implemented as hardware logic using a variety of SSI and MST integrated circuits, This is sometimes called hardwired numerical control. These are characterised by a part program input media such as magnetic or paper tape. Typically, these had very little part program memory, often only a single block.bore aceite ER Avice Principtes and applications en - Part raving ar program 6@ . Paper tape reader Program tape & Tec Contater Fig. 93 Elements of NC machine-tool operation Slide movement Motor Feedback device ofa mm CO Motor signal sam 08)" Feedback signal Fig. 94 The data processing ina CNC mac- Fig, 9.5 The data processing in a CNC machine hine tool in closed-loop contro! {00I in closed-loop controlThe McGraw-Hill Companies troduction to Computer Numerical Controt 23 Introds Computer Numerical Contro! 2&3 With the availability of microprocessors in the mid-70s, al controller technology has made a tremendous progress. The new control systems are termed as Computer Numerical Control (CNC) which are characterised by the availability uy of an embedded computer and enhanced memory in the 7 oe controller as shown in Fig. 9.6. These also may be termed — softwired numerical contr. [itt ‘There are many advantages to be derived from the use of | Fonte iu \ UL tseseagt TT iz ENC compared to NC. Some of them are + Part program storage memory = = + Part-program editing ee + Partprogram dowaloading and uploading + Par program simolaton sing fol path + Toolset data and tole management + Adktonal pa-programming facilities + Backgromnd tape preparation + Drip feeding of par pronrams fo agesized par programs + Loca storage sucha tached hard disks .6 Typical CNC machine-too! operation + Additional support software for diagnostics and maintenance + Using standard operating systems such as Windows 9S for easier interfacing with other components of manufacturing systems In realty, the controls with the machine tools nowadays are all CNC and the old NC control do not exist anymore, As a result, the terms NC and CNC become almost synonymous, 4.3 |] NUMERICAL CONTROL MODES ‘The controllers have a number of modes in which to operate, There could be 4 possible modes in which the controller can function as shown in Fig. 9.7 in relation to a machining centre, The first shows atypical drilling ‘machine operation, termed point-to-point mode. Inthis, the control has the capability to operate all the 3 axes, but not necessarily simultaneously, As a result, it would be possible to move the tool to any point (in. and axes) in the fastest possible speed and carry out the machining operation in one axis (Z-axis) at that point This is useful for drilling and punching machines. The second type is an improvement over this in which in addition to the point-to-point mode, the machine tool has the capability to carry out a continuous motion in cach of the axis direction, This helps in obtaining the milling ina straight line along any of the axes. In the thitd type is shown a control system, which improves the previous type by adding the simultaneous ‘motion capability in any 2 axes, This is what is requited in most ofthe cases. Any 3D profiles to be machined can be completed using the concept of 2.5D mode, in view of the limitation of the machine. ‘The last one is the highest form of control that is generally found in most of the current-day control systems. This gives the capability of simultancous 3 or more axes motion. This would be useful for machining ‘most of the complex 3D profiles encountered in industrial practice such as aerospace components, moulds and dies.Br acl a Re ' Y Frame miling 2-axls contouring with switchable plane 3-axis contouring 2 Z-axis contour 2 continuous path ; ming [pf exes corteur y CADICAM: Principles and Applications = vee Pointto-point Point-to-point straight ine a Dating and bering iz miling 9.7 Types of control systems possible in CNC operation 94 |] NUMERICAL CONTROL ELEMENTS 9.4.1 Machine Control Unit Every NC machine tool is fitted with a Machine Control Unit (MCU) which performs the various controlling functions under the program control. The MCU may be generally housed in a separate cabinet-like body or ‘may be mounted on the machine itself. When separately mounted, it may sometimes be like a pendant which could swing around for convenient handling by the operator. Appearance-wise it looks like a computer with a display panel generally of small size (9 inches), and a number of buttons to control the machine tool along with a keyboard. This control unit controls the motion of the cutting tool, spindle speeds, feed rate, tool changes, cutting-fluid application and several other functions of the machine tool. A typical machine control ‘unit is shown in Fig. 9.8, 9.4.2 Part Program Part program is a very important software element in the NC manufacturing system, It is a detailed plan of ‘manufacturing instructions required for machining the part as per the drawing. It is similar to a computer program containing a number of lines/statementslinstructions (called NC blocks) following a specified format, Tae format is standardised by ISO which is followed by many a controller manufacturers with minor variations, Some typical NC blocks written in the word address format as per ISO are shown belowee ec na err Introduction to Computer Numerical Control BES N30 G00 X120.0Y 45.0 2.85.0 N40 G90 N50 G03 X200.0 Y200.0 1-100.0 10 F200 Noo GOI X120.0 1100 ‘The program can also be written in higher-level languages such as APT, UNIAPT, COMPACT Il, etc. These [programs have to be converted into the earlier mentioned ‘machine-tool-level program with the help of processors and post-processors. It is similar to the practice by which ‘computer programs written in high-level languages such as FORTRAN are converted into the relevant computer machine language with the aid of a suitable compiler ‘This is termed as computer-aided part programming and discussed later. ‘The programs can also be developed directly using CADICAM systems such as Unigraphics, Pro Engineer, Euclid, and SDRC FDEAS or CAM systems such as MasterCAM, SmartCAM, SurfCAM, Duct, ete. These also require a post-processor like the earlier discussed computer-aided part-programming systems. 9.4.3 Program-Coding Systems 9.8 Machine too! control unit (Heidenhain ‘The human readable characters as seen in the manuscript of TNC410} formachining centres the part program cannot be directly entered into the machine control unit. They need to be converted into some form of code and entered. The numbering system that we use for normal algebra function utilises a base-10 decimal system. However, computers utilise a binary system, which is of base 2, A binary system has only two states, 0 and 1, Sometimes other forms such as octal (base 8) and hexadecimal (base 16) systems ate widely used in computer applications, Its a very straightforward manipulation to convert one system of numbering system to the other. For ‘example, the number 365 in base 10 format can be represented as 365 =3 x 10? +6 10 +5 x 10° Ifthe same number is to be represented in binary format, we need far more number of digits. 365 = LOLLO1101= 1 x 2°40 27+ 1x 241x294 0x24 1x2 41x 2+ OKI + 1x2" ‘A pure binary system is of course rarely used for NC input. Instead a mote sophisticated BCD (Binary Coded Decimal) system is usually employed. It is an encoding for decimal numbers in which each digit is represented by its own binary sequence. To encode decimal number in BCD format we may use the common ‘encoding, where each decimal digit is stored in a four-bit nibble. Decimal 0 1 2 3 4 5 6 7 8 9 BCD 0000 00010010 0011-0100 101-110-1000 1001 ‘The number 365 in BCD format is 365 = 0011 0110 0101 te main advantage is the easy conversion to decimal digits, and thus it allows for faster decimal calculations.ra eet a he 266 CADICAM Principles and Applications ran e ee 9.4.4 Part-Program Input Part program after preparing, needs to be entered into the machine-tool control unit for the purpose of execution, For this puspose a variety of methods are used: + Paper tape (now obsolete) + Manual Data Input (MDI) + Direct Numerical Control (DNC) ‘The punched paper tape is a I-inch wide tape with 8 tacks of holes that are used for characters along with 2 set of sprocket holes, The punched tape as per the standard code represents the program characters on its eight twacks. It can be observed that BCD coding specifies the numerals 0 through 9 on the first four tracks while other characters are represented by using additional tracks 5 to 8 to get a wider range. A row of feeding holes is present between the third and fourth tracks. It extends through the length of the tape and is used to engage ‘with the teeth of a sprocket which transports the tape. These feed holes have no relationship with the holes which have been punched according to the code, ‘Although the tape-punching equipment is reliable, there is always a possibility that some holes may not be detected or some holes may be spuriously added, To help detect this error, the standards prescribe either odd sumer of holes or even number of holes for each character. Thus, the BIA (Blectronic Industry Association) code specifies an odd number of holes, while the ISO code and ASCII codes prescribe even number of holes. For example, with EIA coding using odd parity, when in a particular row even number of holes are present, eg, formumber 3 (0011), then the punching system adds a hole in the party track to make the total number ‘of holes in that row to be odd. The codes thus use one of the tracks (for example, the fifth track in the EIA. ccode for odd parity) to add a hole to bring the BCD based holes to the desired parity. In the case of manual data input, the machine control unit (Fig. 9.8) provides a keyboard to directly enter the program into the main memory of the MCU, Since most of the present-day MCUs have large memory, it is possible to store a number of programs in the memory as well as edit them as required, Also, most of the modern-day MCUs are provided with a USB port or Ethernet port as part of the communication facility. The past programs can be entered in ASCII mode using any simple text editor in a personal computer and then transferred to MCU through the USB port or over the LAN connection, Direct Numerical Control or DNC refers to a system where a Personal Computer (PC) is connected to the MCU through a serial port (RS 232C). More details of DNC are given in Chapter 20, 9.4.5 NCTooling ‘The operator gathers, or is supplied with, the relevant tooling for the part to be machined. A distinctive deviation of the NC tooling from the conventional one is that each cutting tool is set in a different adapter (Fig. 9.9). The configuration suggested by ISO is now generally followed. A power-operated drawbar may bbe employed to pull the tooling at the retention knob. This helps eliminate any clearance between the mating surfaces of the spindle and tooling shank. It is not uncommon to set apart an allocation of 20 to 30% of total budget for tooling during the buying of new NC machine tools, A preset tool has adjustable locating faces as shown in Fig. 9.10, It enables the dimensions between the tool-cutting edges and location faces to be preset to a close tolerance using a presetting device. The preset tool usually needs to be removed from the machine for adjustments required during batch production. The tools may be stored on a drum, which is operationally an integral part of the machine itself. In the latter case, the tools are automatically replaced or changed in the spindle,The McGraw-Hill Companies 267 Introduction to Computer Numerical Control - — Gs Retention knob << — Adopter End mil Fig. 9.9 Typical spindle tooling Fig. 9.10 Typical preset tooling used in CNC turing holding an end mill, ‘machines ‘These inform the operator about the deviation the tool tip ofthe actually supplied tool has with the one taken into account by the part programmer. The programmer gets the information from the tool files that are updated periodically. In spite ofthe ‘updating’, the position of the tooltip when supplied to the operator may be different (from what is mentioned in the tool file) because of wear and tear, resharpening or setting of a new cuiting tool du to breakage. 4.5 || Nc mAcHINE Toots ‘The basic objective behind the development of NC machine tools continues to remain the reduction of cost of production and improvement in product quality. The major emphasis is directed towards the avoidance of xnon-productive time which is mainly due to the number of set-ups, set-up time, workpiece-bandling time, tool change time and lead time. 9.5.1 NC Machine-Tool Applications [NC machines have been found quite suitable in industries such as the following: 1. For the parts having complex contours that cannot be manufactured by conventional machine tools. 2. For small lot production, often for even single (one-off) jab production, such as for prototyping, tool ‘manufacturing, et, 3. For jobs requiting very high accuracy and repeatability For jobs requiring many set-ups and/or the set-ups that are very expensive ‘The parts that are subjected to frequent design changes and consequently requite mote expensive manufacturing methods, 6. ‘The inspection cost is a significant portion of the total manufacturing cost One or more of the above considerations would justify the processing of a part by an NC machine tool. 9.5.2 Advantages of NC [NC is superior to conventional manufacturing in a number of ways. The superiority comes because of the programmability. These are as follows:ra eet a he 268 CADICAM Principles and Applications ran e ne 1 Parts can be produced in less time and, therefore, are likely to be less expensive. The idle (non= ‘cuting) time is reduced to absolute minimum. This, of course, depends on the way the part program for the part is written. The endeavour of the machine-tool builder is to provide facility whereby the non-cutting time can be brought to the barest minimum possible. It is possible to reduce the non productive time in NC machine tools inthe following ways: + by reducing the number of set-ups, + by reducing set-up time, + by reducing workpiece-handling time, and + by reducing tool-changing time, ‘These make NC machines highly productive Parts can be produced more accurately even for smaller batches. In the conventional machine tools, precision is largely determined by human akill. NC machines, because of automation and the absence of interrelated human factors, provide much higher precision and thereby promise a product of ‘consistent quality for the whole of its batch, ‘The operator involvement in part manufacture is reduced to a minimum and as a result, less scrap is ‘generated due to operator errors. No operator skill is needed except in setting up of the tools and the ‘work. Even here the set-up has been simplified to a very great extent. Since the part program takes care ofthe geometry generated, the need for expensive jigs and fixtures is reduced or eliminated, depending upon the part geometry. Even when the fixture is to be used, itis very simple compared to a conventional machine tool, Itis far easier to make and store part programs (tapes) Inspection time is reduced, since all the parts in a batch are identical provided proper care is taken about the tool compensations and tool wear in part-program preparation and operation. With the use of inspection probes in the case of some advanced CNC controllers, the measurement function also becomes part of the program, ‘The need for certain types of form tools is completely eliminated in NC machines, This is because the profile to be generated can be programmed, even ifit involves 3 dimensions, Lead times needed before the job can be put on the machine tool and can be reduced to a great extent depending upon the complexity of the job. More complex jobs may requite fixtures or templates if they are to be machined in the conventional machine tools, which can be teduced to a large extent. ‘ONC machining centres can perform a variety of machining operations that have to be carried out ‘on several conventional machine tools, thus reducing the number of machine tools on the shop floor. ‘This saves the floor space and also results in less lead-time in manufacture. This results in the overall reduction in production costs. ‘Many times the set-up times are reduced, since the set-up involves simple location of the datum surface and position, Further, the number of se-ups needed can also be reduced. All this translates into lower processing times. Many times, a component could be fully machined in a single machining centre for turning centre, each of which has wider machining capabilities. In conventional manufacture, if the part has to be processed through a number of machine tools which ate located in different departments, the time involved in completion and the resultant in process inventory, i large, This is ‘greatly eliminated by the use of NC machine tools, ‘Machining times and costs are predictable to a greater accuracy, since all the elements involved in ‘manufacturing have to be thoroughly analysed before a part program is prepared.ra eet a he Inoducion 0 Computer Numer! Contrah Bs 11, Operator fatigue doesnot come ino picture in the manufacturing of pat, The NC machine ool can be used continuously since these ae more rigid than the conventional machine ool 12, Tools can be wilted at optimum feeds and speeds tht can be programed 13, The moificaion to part design canbe very easily translated ino manufacture bythe simple changes in prt programs without expensive and tine-vonsuming changes in jigs, fixtures and fooling, This adds tothe fenblty of manufacture 14, The capability (metal removal of NC machined is generally high because ofthe very rigid onstruction ployed in tvchine fol detign compared to tbe Gouveationalimchins tol, 9.5.3 Limitations of NC ‘Though the NC machines have a range of advantages, there are certain limitations one should take care of While making a choice of them. 1, The cost of an NC machine tool is much high compared to an equivalent conventional machine tool, The cost is often 5 to 10 times. Also, the cost of tooling is high. This isa very high initial investment. All this makes the machine hourly rate high. As a result, itis necessary to ulilise the machine tool for a large percentage of time. Cost and skill of the people required to operate an NC machine is generally high in view of the complex and sophisticated technology involved. The need is for part programmers, tool setters, ‘punch operators and maintenance staff (electronics and hydraulics) who have to be more educated and trained compared to the conventional machine operators, 3. Special training needs to be given to the personnel manning the NC machine tools. NC manufacturing requires training of personnel both for software as well as hardware. Part programmers are trained to write instructions in desired languages for the machines on the shop floor. They need also to be acquainted with the manufacturing process. Similarly, machine operators have to be prepared for the new NC culture. These factors are important for the successful adoption and growth of NC technology. 4. AsNCis acomplex and sophisticated technology, italso requires higher investments for maintenance in terms of wages of highly skilled personnel and expensive spares. The need for maintenance engineers trained in all the sub-systems present such as mechanical, hydraulic, pneumatic and electronics makes the job more difficult. Though the latest machines are equipped with a large number of diagnostic facilites, still maintenance is one of the major limitations 5. The automatic operation of NC machines implies relatively higher running costs. Moreover, the requirements of conditioned environment for operating NC technology adds further to the running costs 9.5.4 Practical NC Machines ‘The earliest development in NC machines, as discussed earlier, started with the milling machines in view of their application in aerospace industry. The typical first-generation NC milling machine which was basically a tooleroom milling machine was converted by the addition of numerical control is shown in Fig. 9.11. These ‘machines typically combined the functionality of drilling and milling machines. ‘The NC milling machines have been successfully improved with a variety of options to improve their productivity and flexibility. As a result, these are now called machining centres to reflect that versatility, and it is possible to do all the milling and hole-making operations to the highest possible accuracy, thereby reducing the other finishing operations. A typical CNC machining centre is shown in Fig, 9.12Br Cae Ee 270 CADICAM Principles and Applications = . te Fig. 9.11 Early form of CNC miling machines: Fig. 9.12 Present-day production horizontal axis EZ-TRAK DX II milling machine ‘CNC machining centre Makino ASS (Courtesy, Bridgeport Machines Inc., (Courtesy, Makino Miling Machines Co. Bridgeport, USA) Lt, Tokyo, Japan) The reduction in the idle time in the case of machining centres is done with the help of a number of automatic options. The main options with machining centres are the Automatic Tool Changer (ATC) used for changing the tool in the spindle in the shortest possible time of the order of 3 to 6 seconds. Similarly, ‘an Automatic Pallet Changer (APC) is used to change the workpieces automatically in the shortest possible time of the order of 10 seconds. A typical CNC machining centte equipped with ATC and APC are shown in Fig. 9.13 with the safety guards removed In addition to these conventional machine tools, the copy milling machines are also provided with CNC control to provide better copying with more transformation flexibility as shown in Fig. 9.14. 13. High production horizontal axis CNC ‘machining centre Makino AGO with automatic tool changer and automatic Fig. 9.14 CNC copy miling machine Makino pallet changer (Courtesy, Makino Miting FD NG-128 (Courtesy, Makino Miling Machines Co. Ltt, Tokyo, Japan) Machines Co, Ltd, Tokyo, Japan)The McGraw Hill compani Irrducton 0 Compute Nemec Cont A Similar to the milling machines, the lathes are also proved with CNC contols. The major imovaton provided in the CNC Ines is the provision of slant bed to help remove the chips ftom the machining zone Ihore efficient, whlea large variety of software functions to machine the mest complex axisymmetric ‘Shapes. typical CNC taming cente is shown in Fig. 9.15 Anotier cigs of CNC turing machine isthe chucker-ype shown in Fig, 9.16 which ie with a flat bed and is ideally suited for turning chucking components. The machine has the advantages of quick cycle time, high. rapid rates and easy chip disposal “The CNC taming centes are normally provided with gantry robos for work and tool handling as shown inFig. 9.17 Fig. 9.15 CNC Tuming centre with Fig. 9.18 CNC Chucker (Turing) Fig. 8.17 CNC tuming centre slant bed GF NDM-16 LC16 (Courtesy, ACE with a gantry loader (Courtesy, George Fischer, Designers) for workpiece handling ‘Switzerland (Courtesy, George Fischer, Switzerland) Another important class of CNC machines used in the industry are the Electric Discharge Machines (EDM). In particular, the CNC wire-cut EDM machines are very common in which the relative motion of the ‘workpiece with respect to the EDM wire is controlled in 2 or 4 axes for machining a variety of complex die shapes used in sheet-metal industries. A typical wire EDM machine is shown in Fig. 9.18 Sheet-metal components are produced by means of blanking and forming dies, For short-volume production, the cost of shect-metal dies becomes uneconomical. Hence, in CNC turret punch presses the ability to quickly change the dic and punch set along with the coordinate movement can be obtained using a ‘CNC control. typical CNC turret punch press is shown in Fig. 9.19. Fig. 9.18 EDM wire-cut machine DWC 110HA Fig. 9.19 CNC turet punching press (Courtesy, Mitsubishi Electric Corp., ‘Amada Vipros 255 (Courtesy, Tokyo) ‘Amada, Japan)ete me 272 CADICAM Principles and Applications = i“ - Another class of CNC machines that are being very common are the CNC coordinate machines which are used | fe oe dae as Sa ne ae =e typical example is shown in Fig. 9.20. In addition to the applications, as explained above, a makita glance. Ie machine tools as follows: Grinding machines Fig. 9.20 CNC Coordinate Measuring ‘Gear-generating machines Machine Mitutoyo Super RV304 Press brakes (Courtesy, Mitutoyo Asia Pacific Flame cutting machines Pre. Lta,, Singapore) Laser cutting machines Pipe-bending and forming machines Folding and shearing machines Filament winding machines ‘Assembly machines ‘Numerical control of machine tools which was first demonstrated in 1952, has Summary been rapidly adopted and applied to a large number of manufacturing applica- tions, with machining accounting for a major share of these applications. PBR ~ urmeviat contro (Nc) has been conceived with the developments in digital computers in the mid 20" century. ‘© Numerical control utilises numbers and words to control the various functions of machine tools Machining instructions are translated from the part drawing through the use of numbers to auto- matically run the machine tool For the successful operation of an NC machine tool, it is necessary to understand the various com- ponents in NC manufacturing. The developments in microprocessors have changed the NC to CNC by incorporating a computer inside the machine-tool control unit. This provides a number of benefits to the user. Numerical-control machine tools can be operated in point-to-point mode ar contour mode. In the contour mode, it is possible to have simultaneous control of multiple axes in order to get complex part geometries. NC tooling is an important element in achieving proper geometry. The application of NC machine tools is mast appropriate for complex contours, small-volume production, high accuracy, and frequent design changes. There are a number of advantages to be gained by the proper application of NC machine tools. The principal advantage is the reduction in processing time because of the reduction in set-ups, simpli- fying or eliminating jigs and fixtures, and reducing idle times. Machining accuracy of NC machining is improved without involving any operator skill Most of the operations can be completed by the use of general-purpose cutting tools, thereby reducing the need for special form tools for complex shapes.ee me ee Inout Compt Numeral Cont 2, ‘* In spite of the advantages, care has to be taken to provide appropriate support facilities for main- tenance and special operator training. ‘© Though machining is a major application for NC, a large number of other metal-forming applications a well as other forms of manufacturing are successfully utilising NC. Questions 1, Explain what you understand by the term “numeral contol"? 2, What ate the factors that contibuted to the development of numerical contol? 3. Briefly explain the functions that are expected to ‘be served by numerical contol in machine tools 4, Explain the principle of numerical coatel 5, Show schematically the different forms of numerical control, viz, open-loop and closed- loop conteol systems What ate the applications where numerical control is most suitable? Give the advantages and disadvantages of numerical contol of machine tools, ‘What isthe difference between NC and CNC? Explain the advantages to be gained by using CNC compared to NC.