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CNC Technology:
• The basic information are given to the. NC system in the form of part drawing
along with the cutting process parameters and the cutting tools used.
• By using these, the part programs are written in the form of letters, numbers and
symbols. This part program is entered in the punched tape.
• The program is then read by the punched tape reader.
• This numerical codes are translated by the Machine Control Unit (MCU) into a
form so that the machine can understand and the motion of the machine tool are
controlled.
• With the availability of powerful computers, the functions of machine control
units are done by the computers.
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• The part programs are written as a software using high level Languages. Since
computer has enhanced memory capacity, the NC m operations are controlled
completely by computer.
• This NC system controlled by the computers are known as Computer Numerical
control (ON Here the punched tapes are replaced by floppy (or) CD ROM disc.
Since the operator can have more free time,. he can look after other machine operations
also.
Disadvantages
1. The price of CNC machine is very high.
2. Maintenance is complicated. Special care should be taken by specially trained people.
3. Well trained software professionals are needed for writing part programs.
• In the CNC system, part program’s which is required for producing part is
maintained in a floppy (or) CD ROM.
• The .separate software — part program — is developed for each part. Once this
part program is loaded in the computer, it will control the operations of the
machines.
• The part program contains all the information needed for processing a segment .of
the work piece. The dimensional information like length, width
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and radii of circles and the profile of linear and circular form will be taken from the part
drawing.
• Instructions are given separately for each axis of rotation (X, Y and Z).
• The cutting speed, feed and auxiliary function like coolant on and off, spindle
direction, gear change etc. are programmed according to surface finish and
tolerance requirements.
• The computer reads the part program and decode it. The decoded instructions
control the machine axis of motion and machine tool actions.
• So the computer interprets the program of instructions and convert it into
mechanical actions of the machine tool.
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• The control loop unit provides signals stating that the previous operation is
completed and the DPU has to read new set of data.
• The control loop unit controls the driving motors of the machine lead screws (or)
any other motion and receives feed back signals about the actual position and
velocity of each one of the axes.
• The control loop unit circuit is shown in figure.
• The cutting tool movement with respect to work piece is known as axis of motion.
• This axis of motion is achieved by the movement of the machine tool slides. The
X, Y and Z are the main three axes of motion.
• The main axes to be designated are the rectangular axes and rotary axes.
• The right handed coordinate, system is shown in fig.
• This is the coordinate system approved by International Standard 150fR841 to
designate the axes of, their machines.
• The Z axis motion is set parallel to the spindle axis in the machines like drilling,
vertical milling boring etc.
• In shapers and planers, the Z axis is set perpendicular to the surface of the work
holding table.
• If the tool is moving away from the workpiece, it is considered as positive Z axis.
So, in case of drilling machine, if the drill moves into the workpiece, then it is
moving the desired path
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in (— Z) negative direction. This set up will reduce the accidents if the part program is
wrongly typed in the coordinate signs.
• For other machines, the positive + Z motion increases the clearance between the
work piece and tool holder.
• The X axis and Y axis are set perpendicular to each other and they both together
are perpendicular to Z axis i.e. X and Y axes are horizontal.
• The X axis is normally parallel to the work holding surfaces wherever possible.
• The X axis is from left to right when operator is facing the ONC machine. The
positive X axis is towards right.
• But for the turning machines like CNC lathe, it is parallel to the cross slide i.e. X
is positive when the tool moves away from the axis of rotation of the work piece.
• The Y axis is set perpendicular to both X and Z axes.
• The Y axis motion is from front to back. The Y axis moving away from the
operator is ± Y direction.
Rotary motions
• Refer Fig. (c) A, B and C are the positive rotary motions about X axis, Y axis and
Z axis respectively.
• These are positive in (— Z) negative direction. This set up will reduce the
accidents if the part program is wrongly typed in the coordinate signs.
• For other machines, the positive + Z motion increases the clearance between the
workpiece and tool holder.
• The X axis and 1’ axis are set perpendicular to each other and they both together
are perpendicular to Z axis i.e. X and Y axes are horizontal.
• The X axis is normally parallel to the work holding surfaces wherever possible.
• The X axis is from left to right when operator is facing the CNC machine.
• The positive (+) X axis is towards right. But for the turning machines like CNC
lathe, it is parallel to the cross slide i.e. X is positive when the tool moves away
from the axis of rotation of the work piece.
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• The Y axis is set perpendicular to both X and Z axes. The Y axis motion is from
front to back. The Y axis moving away from the operator is ± Y direction.
• In CNC machine tools, each axis of motion is rotated by a separate driving motors
which replace the hand wheel in conventional.
• The driving motor can be a dc motor, a stepping motor or operated by hydraulic
system.
Functions of CNC
4. Diagnostics:
• Diagnostics features are used in CNC machines in order to assist in maintaining
and repairing the system. Due to this feature,
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• The down time is minimised. The possible failures are felt.
• Some unreliable components are stacked as spares and these are known as
redundant components.
• When any one of these components fails, the diagnostics will automatically
disconnect the faulty component from the system, and activate the redundant
component in place of faulty one.
• So, repairs can be corrected without any breaks in normal operations of the CNC
machine.
• After getting corrected, the redundant com withdrawn from the system
automatically so that newly installed component can perform its function.
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• The open loop systems are usually of digital type.
• They are the stepping motors to drive the machine slide.
• A stepping motor rotates, through a fixed angle in response to an input signal.
• It converts the digital electrical signals into proportional movement. For each
pulse signal the stepper motor rotates exactly by 1.8 degree. So, 200 ‘electric
pulse signals’ are required to complete one full revolution of motor i.e. 360°.
Since there i no check on the machine slide position, the system accuracy solely
depends on the stepping motor’s ability to step through exact number of steps
provided at the input.
• Applications of open loop control system
• It is best suited for the following applications,
• where light duty machinery is required.
• when less money can be invested.
• when there is no need of much accuracy.
• where ‘less maintenance is required due. to absence of monitoring devices.
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Closed loop control system
• If there is a feed back device to compare and correct the actual position of tool
slide with the desired one, it is known as closed loop control system..
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• In case of contouring system (continuous path system), another feed back
transducer is used to control the velocity of the motor.
• It is required to control the cutter speed and feed so that the cutter follows the
right path to get the required profile.
• These control systems have capabilities of up to 0.0001 mm and speeds up to 10
m/mm.
• So the closed loop control system measures the actual position of slide and its
velocity x compares them it with the desired position and desired velocity
respectively.
• The difference between the actual and the desired values is the error and this
control system eliminates the error.
• This closed loop control system is used for obtaining higher degree of accuracy.
Most of the contouring (continuous path) systems are controlled by this closed
loop.
• Classification based on motion Control system
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2: Flame cutting (or) torching and (3) Fabrication of intricate die templates.
This also known as C-type motion control system.
Interpolators:
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• By knowing ‘end points and centre of arc’ (or) ‘radius and centre of circle’,
calculating the intermediate points of arc (or) circle is known as circular
interpolation.
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• Floating Origin will be useful for symmetrical parts.
• Here, the centre of symmetrical part will be taken as origin and a the right side
and upside measurements are taken as positive and left side and downward
measurements are taken as negative.
• In this absolute coordinate system, the origin O(G,O,O) is stored in the computer
memory and the control system returns the table to origin by simply pressing
‘Zero Reset’ button on the control panel.
• Here all the dimensions are independent of each other. This system is mostly used
in PTP system.
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• This incremental system needs no predetermined datum point. This system is
mostly used in CNC lathes.
CNC controllers
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2, Since computer has got more memory capacity, large part program of more than 1 MB
can be stored.
3. Advanced part programming like ‘English Statements’ can be developed.
4. In case of parabolic and helical (or) even complicated profile defined by mathematical
equation can be done by using complex interpolations.
5. Do loops are used for repetitive part programming;
6. Subroutines and macros are used.
7. Use of parameters in part programming.
8. There are help topics for operators.
9. Special geometric calculation facilities.
10. Better interfaces to outside world with serial and parallel communications.
11. Diagnostic facilitates.
12. Direct Numerical Control (DNC) functions are possible with links to factory
networks.
13. Using Programmable Logic Control(PLC), a better shop floor control is possible.
14. Adaptive control, lead screw pitch error compensation, thermal l are possible proving
enhanced the machine control.
15. Contouring control system with multiple axis machining simultaneously can be easily
controlled.
So the CNC controller — ie CNC Machine Control Unit (MCU) has number ‘of
subsystem to perform the above functions.
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Diagnostics
• It is necessary to check the functions of the machine tool continuously to make the
machine utilization high.
• Hence, a number of sensors are normally inserted in the machine tools. These
sensors will send the information to the controller so that any fault already-
present (or) likely to come in future will be identified and corrective action can be
taken.
• Such diagnosis is communicated as alarms to operator through Video Display
Unit (VDU).
• In some CNC controllers, a built in modem and a telephone line will send such
information to the service people for corrective action.
External Inputs:
• This unit is useful for CNC to have interaction with the outside world.
• The computer in CNC can be linked with DNC to down load part program, to
have remote datum, and to link with Robots and Automated Guided Vehicles
(AGV) etc.
External Outputs
• For sending output from CNC to outside world ie for works is uploading the
generated or corrected programs, sending information to the controller such as
certain PLO register status, diagnostic information etc.
Graphic Proving
• To verify the accuracy of the part generated, the machining process can be
simulated on the ‘video •display unit’ of the MOU. Most modem controls provide
a solid simulation process where the workpiece and the tool are actually shown in
3D shaded image:
• When the tool moves through the work piece, the material is removed layer by
layer.
• The layer removed is shown in different colour to have a realistic, feel of material
removal process.
• This process is able to simulate uncut material at the corners because of tool
radius, burr information etc more realistically.
• By changing speeds and feeds, the surface finish generation process also can be
simulated to get a feel of final surface finish which will be obtained on the
component.
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Advanced Management
• The modern CNC controllers provide additional facilities to carry out the
activities like axis calibration, Adaptive control, thermal compensation and Lead
screw pitch error compensation.
Control Program
• The control program controls the various elements of the CNC machine tool.
• This program is useful for interactions between the control system components,
the machine tool mechanics, tooling, material changes during machining etc.
• This program reads and studies the part program a few lines ahead so that the
speed of tool can be adjusted to cater to the future difficulties in the tool path like
sharp changes in direction.
• This control program is fully integrated with the servo and feed back systems
involved.
• When several CNC machines are used, it is a common practice to use a Central
Computer to connect all the CNC machines for preparing part programs at a
central place and to transfer the same to the CNC system whenever required.
• This feature is called DNC system.
• So Direct Numerical control (DNC) can be defined as a type of manufacturing
system in which several CNC machines are controlled remotely by a main frame
computer. It is similar to many computers are controlled by server. In DNC
system, one large computer can be used to control more than 100 separate CNC
machines In a DNC system, the processing and post processing of part program is
performed in a central computer.
• This enables the programmer to modify and edit the part programs easily.
• The tape reader is eliminated in DNC. Instead, the part program is transmitted to
the machine tool directly from the computer memory. -
• The DNC computer provides instruction to each CNC machines on demand.
• The 2 way communication interface option (11S232C) enables the user to
immediately access any program from the library of programs in the central
computer.
• Also., this link permits transmission of messages and other critical data.
• So DNC also involves data collection and processing from the machine tool back
to the central computer.
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• Feed back data from the machines are also stored in the satellite computer and
then delivered to central computer.
• So, the communication network connects the central computer with the lengthy
cables to the CNC machines’ directly Refer fig (a), (or) it connects the central
computer with each satellite ‘computer at each individual CNC machine. Refer fig
(b).
Types of DNC
There are two types of DNC, depending upon the communication network between the
computer and the CNC machine tool.
1. Special Machine Control Unit
2. Behind— Tape — Reader (BTR) system
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• This type is very much useful in circular interpolation of the cutter path.
• It achieves superior accuracy of interpolation with fast metal removal rates.
• The special MCU is soft wired with flexibility.
• In this system the central computer is directly linked with the GNU controller unit.
• Since the tape reader, is replaced by telecommunication lines, the name BTR has
given to this system.
• The central computer is connected with the CNC controller by by-passing the tape
reader (i.e. without tape reader) - i.e. behind the tape reader;
• The CNC controller has two storage buffers.
• One receives block of instruction from the DNC computer and convert them into
machine actions and another one receives data from the CNC machine and it will
be sent to DNC computer.
• BTR system cost is less since minor changes are enough to convert conventional
NC
• into DNC.
• However, this BTR advantage is not a permanent one.- Because, most of the NC
machines are nowadays CNC machines computer numerical control machines.
• So the CNC controller will serve the same purpose as a special MCU when
incorporated with DNC system.
Advantages of DNC
1. The punched tapes and tape readers are eliminated.
2. Enhanced computational capability and flexibility are possible in DNC. Part
programming can be modified and edited at any time. Heavy computational work and
data processing functions are performed efficiently.
3. Part programmes can be stored as a file in the computer memory.
4. The computer can give commands to many CNC machines simultaneously.
5. The production performance data from the CNC machines can be collected, processed,
analysed and reported for further actions.
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6. The DNC system makes the production• plant fully automated factory with the use of
computers.
7. The central computer can be located any where.
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