Computer Numerical Control

Machines

Contents
What is NC?
Brief History of NC
Basic Components of NC System
NC ~ CNC
Advance Elements in MCU of CNC
System
Classification of CNC Machines
CNC Part Programming
Example of a Part Programming
Computer Aided Part Programming
Advantages of CNC
Disadvantages

What is NC?
NC stands for Numerically Controlled
The

word NUMERICAL is defined as the

expression of something by NUMBERS.

CONTROL

is defined as the exercise of directing,

guiding or restraining power over something.

Numerical

Control is a form of programmable

automation in which the mechanical actions of an
equipment are controlled by alphanumeric data
instructions.

The

set of data instructions, which is required to

produce a part is called as a part program.

The

program is translated into appropriate electrical

signals for input to motors that run the machine.

Brief History of NC
1947:

The concept was credited to John

Parson, who was able to control the position
of machine tool, using punch cards, in an
attempt to machine helicopter blades.

Layout of Punched Cards NC Machine

Part
Drawing
Equipment for
part programming

Punch
Tape

MCU, that converts part programming

into electric signals
Machine
Tool

Brief History of NC
1947:

The concept was credited to John

Parson, who was able to control the position
of machine tool, using punch cards, in an
attempt to machine helicopter blades.

1949:

US Air Force teamed up with MIT to

develop a programmable milling machine.

1952:

A three axis milling machine was

demonstrated, that used punched cards and
electromechanical controller. The term
Numerical Control (NC) was originated.

1980s:

A digital computer was linked directly

to the controller, upgrading NC to CNC.

Why NC machines were

developed?
To achieve
Flexibility to manufacture complex or impossible jobs at
lesser cost
Improvement in the accuracy and quality of
manufactured parts
Automation and repeatability
Reduction of non-cutting time in the machining cycle

Prototype of NC Milling Machine Developed

By MIT
Controller

Machine
Tool

Basic Components of NC System

An NC system consists of three basic
components,
a) Program of Instructions
b) Machine Control Unit (MCU)
c) Processing Equipment
Machine Control Unit

Processing Equipment

Program

Basic Components of NC System

a) Program of Instructions:
The part program is the set of detailed step-bystep commands that directs the actions of the
processing equipment.
The program is coded on a suitable medium for
submission to the machine control unit.
1-inch wide punched tape was first used as
medium for many years.
Now, the punched tapes has largely been replaced
by newer technologies that include magnetic tape,
diskettes, and electronic transfer of part program
from a computer.

Basic Components of NC System

b) Machine Control Unit (MCU):
MCU of NC system reads and interprets the
program of instructions and convert them
to electrical signals to control the
mechanical actions of processing
equipment.
It consists of following elements,

Program Reader
Signal output channel to processing equipment
Feedback channel from processing equipment
Sequence Controllers

Basic Components of NC System

c) Processing Equipment:
The third basic component of NC system is
the processing equipment that performs
the actual productive work, such as,
Machining Processes (Drilling, Milling etc.)
Sheet Metal Processes (Punching, Bending etc.)
Welding Processes (Spot and arc welding
processes)
Thermal cutting
Tube bending
Assembly work
Inspection work (CMM etc.)

NC ~ CNC
Since

the introduction of NC in 1952, there have

been dramatic advances in digital computer
technology.
The significant reduction of size and cost of digital
computers and the introduction of microcomputers,
urged the makers of NC system to incorporate
these advances in their products.
Thus, in 1980s, NC was transformed into CNC.
CNC, Computer Numerical Control, is an NC system
whose MCU is based on dedicated microcomputer
rather than on a hard-wired controller.
Todays CNC feature high-speed processors, large
memories, solid-state flash memory, improved
servos, and bus architectures.

Advance Elements in MCU of CNC

System
The MCU is the hardware that distinguishes CNC from conventional
NC. MCU consists of following components and sub-systems,
1)

Central Processing Unit (CPU)

2)

Memory

3)

I/O Interface

4)

Machine Tool Controls

5)

Sequence Controls

Memory
ROM Operating System
RAM Part Programs

Central
Processing Unit
(CPU)

Input/output Interface
Operator panel
Tape reader

System Bus
Machine Tool Controls
Position Control
Spindle Speed Control

Sequence Controls
Coolant
Fixture Clamping

Advance Elements in MCU of

CNC System
1) Central Processing Unit (CPU):
It is the brain of Machine Control Unit
that manages other components of MCU.
CPU can be divided into three sections,
a) Control Section: It retrieves commands and
data from memory and generates signals to
activate other components in MCU.
b) Arithmetic Logic Unit: It performs various
calculations, counting and logical functions
required by the software.
c) Immediate Access Memory: It provides a
temporary storage for data being processed
by CPU.

Advance Elements in MCU of

CNC System
2) Memory:
A storage capacity is required to store
various programs and data. Memory
can be divided into two categories;
a) Main Memory: It consists of ROM and RAM
devices. Operating system software and
machine interface programs are stored in
ROM and part programs are stored in RAM.
b) Secondary Memory: High capacity
secondary memory stores large programs
and data files that can be transferred to
main memory. Hard disks are the common
secondary memory storage devices.

Advance Elements in MCU of

CNC System
3) Input/output Interface:

The I/O interface transmits and receives

data and signals to and from external
devices.
The operator control panel is the basic
interface by which the machine operator
communicates to the CNC system.
It may include alphanumeric
keypad, keyboard or even a
display screen, to indicate
current status of program
as it is being executed.

Advance Elements in MCU of

CNC System
4) Machine Tool Controls:

These are hardware components that control the

position and velocity of each machine axis as well
as the rotational speed of spindle.
The control signal generated must be converted to
a form and power level suited to the particular
position control system used to drive the machine
axes.

5) Sequence Controls:

They control additional auxiliary functions such as

coolant control, tool changer, fixture clamping etc.
To avoid overloading of CPU, PLC may also be used
to control these functions.

Classification of CNC System

CNC machines can be classified on the basis of
the following;
Motion Control System

Point-to-point
Continuous path

Control Loop System

Open Loop Control System

Closed Loop Control System

Positioning System

Absolute Positioning
Incremental Positioning

Classification on the basis of

Motion Control System

Point-to-point Systems:
It controls the motion of the worktable to
programmed location without regard for the path
taken to get to that location.
Once the move has been completed some
processing action is accomplished by the
workhead at that location, such as drilling or
punching a hole.

Classification on the basis of

Motion Control System

Continuous path System:

This system is capable of controlling continuous
simultaneous control of two or more axes.
The tool performs the process while the
worktable is moving, thus creating angular
surfaces, 2D curves, or 3D contours.
This control mode is required in many milling
and turning operations.

Classification on the basis of

Motion Control System
Interpolation Methods:

The paths that a contouring type CNC system

is required to generate, consist of circular
arcs or non-linear shapes, which are defined
by mathematical expressions or by
approximations.
To cut along a circular path, the curve must
be divided in to a series of straight lines that
approximate the curve.
The interpolation module in the
MCU performs the calculation
and directs the tool along the path.

Classification on the basis of

Motion Control System
Interpolation Methods:
Following are the interpolation methods for various
cases,
a) Linear Interpolation: it is used when a straight line path is
to be generated. The programmer specifies the start and end
point of the straight line and the feed rate.

b)

Circular Interpolation:

c)

Helical Interpolation:

d)

Parabolic and cubic interpolation:

It is used for circular curves. Start

point, end point, radius of arc and direction of cut needs to be
specified.
It combines the circular interpolation
for two axes with the linear movement of the third axis.
It is used for
approximating free form curves using high order equations. Most
applications are in the aerospace and automotive industries.

Classification on the basis of

Control Loop System

Open Loop Systems:

In an open loop control system, the electrical
motor drives the slides as per the input signal
or command. There is no monitoring of the
actual displacement of the machine slide.

Classification on the basis of

Control Loop System

Closed Loop Systems:

In a closed loop system the displacement of
slide is achieved to very high degree of
accuracy by using a monitoring devices. This
feedback is compared with the input info &
the slide position is regulated to agree with
the desired positions.

Classification on the basis of

Positioning System

Absolute Positioning:
In this positioning system, the workhead locations
are always defined with respect to the origin.

Incremental Positioning:
In incremental positioning, the next workhead
position is defined w.r.t the present location.

B (20,
35)
A (10, 20)

Move from A to B is
specified as,
Absolute:
X = 20 Y
= 35
Incremental: X = 10 Y
= 15

CNC Part Programming

CNC part programming contains geometric data

about the part and movement commands of the
cutting tool with respect to the work piece.
The machine receives instructions as a
sequence of blocks containing commands to set
machine parameters such as tool paths, feed,
spindle speed, etc.
Preparatory functions (G-Codes) are associated
with tool movements.
Miscellaneous functions (M-Codes) are
associated with other auxiliary machine
functions, such as coolant on/off function,
fixture clamping, etc.

Common G-Codes
Code

Function

G00

Rapid Movement

G01

Linear Interpolation, controlled feed

G02

Circular Interpolation, clockwise

G03

Circular Interpolation, counter clockwise

G04

Dwell for programmed duration

G17

Select x-y Plane

G18

Select y-z Plane

G19

Select x-z Plane

G70

Inch units

G71

Metric units

G90

Absolute dimensions

G91

Incremental dimensions

Common M-Codes
Code

Function

M00

Program Stop

M01

Optional Stop

M02

End of Main Program

M03

Spindle CW

M04

Spindle CCW

M05

Spindle Stop

M06

Tool Change

M07

Flood Coolant ON

M08

Mist Coolant ON

M09

Coolant OFF

M17

End of Subprogram

M30

End of Program

Other Symbols in part

Programming
the program number
N the block sequence address letter
F the feed address letter
O

the spindle speed or cutting speed address

letter
T the tool address letter
X X-axis identification letter
S

Y-axis identification letter

Z Z-axis identification letter
Y

Example of Manual Part

Programming
To move the tool to four points using rapid
positioning command.
Program:
Ooo1
N001 T0101;
N002 S1000 M03;
N004 G00 Z10;
N005 G00 X12 Y20;
N006 G00 X62 Y20;
N007 G00 X62 Y50;
N008 G00 X12 Y50;
N009 G28 X0 Y0 Z0;
N010 M30;

Steps involved in part

Programming
1.
2.
3.
4.
5.
6.
7.
8.

Read the part drawing

Make a process flow sheet
Select cutting parameters
Mount the raw material block
Select datum/origin on work piece
Mount all tools required
Enter the part program according
to the process flow sheet
Start cycle

Computer Aided Part

Programming

CNC part programming can also be done using

CAD/CAM Technology.
Develop or obtain the 3D geometric model of
the part, using CAD.
Decide which machining operations and
cutter path directions required.
Choose the tooling required.
Run CAM software to generate the CNC part
program.
Download the part program to appropriate
CNC Machine.
Verify and edit the program if necessary.
Run the program and produce the part.

Advantages of CNC

More complex part geometries are possible

Greater accuracy, repeatability and flexibility
Shorter manufacturing lead times
Nonproductive time is reduced
Inspection requirements are reduced
Simpler fixtures are needed
Scrap reduction
Operator skill-level requirements are reduced

Disadvantages of CNC

Higher investment cost

Higher maintenance effort
Only feasible for higher utilization.