IP 710

AUTONOMOUS

 Computer control
Servo axis control
Tool changers
Pallet changers
On-machine programming
Data communication
Graphical interface

1947: J. Parsons (Parsons Corporation) began

experimenting for using 3-axis curvature
data to control machine tool motion for the
production of aircraft components
1949: Parsons awarded a US Air Force
contract to build the first NC machine
Laboratory for Manufacturing Systems and
Automation
1951: MIT was involved in the project
1952: NC achieved when MIT demonstrated
that simultaneous 3-axis movements were
possible using a laboratory-build controller
and a Cincinnati HYDROTEL vertical spindle
1955: after refinements NC become available
to industry

Early NC machines run off punched cards and tape

Due to the time and effort for editing and

changing tapes, computers were introduced for
programming
Computer Aided Programming Languages:

Allow the development of an NC program using a

set of universal English commands

Computer translate commands into machine

codes

Machine codes are punched into the tapes

Direct Numerical Control:

A computer is used as a partial or complete

controller of one or more NC machines

Numerical control (NC) was developed with

these goals in mind:
To increase production
To reduce labor costs
To make production more economical
To do jobs that would be impossible or
impractical without NC
To increase the accuracy of duplicate parts

NC Program

Execution
Syst em
Commands

Dimensions
Interpolator &
Servo- cont rol
Mechanism

Control

Linear

Logic

Motion

T ranslat or

Po wer

Relay

Solenoid

1. Motion control:
point to point (PTP)
continuous (contouring) path
2. Control loops:
open loop
closed loop
3. Power drives:
hydraulic, electric,or pneumatic

4. Positioning systems:
incremental
absolute positioning
5. Hardwired NC and softwired
Computer Numerical Control (CNC)

Increased productivity
Reduced tool/fixture storage and cost
Faster setup time
Reduced parts inventory
Flexibility that speeds changes in
design
Better accuracy of parts
Reduction in parts handling
Better uniformity of parts
Better quality control
Improvement in manufacturing
control

Increase in electrical maintenance

High initial investment
Higher
per-hour
operating
cost
traditional machine tools
Retraining of existing personnel

than

NC is a general term used for Numerical

Control.
CNC refers specifically to
COMPUTER NUMERICAL CONTROL.
CNC machines are all NC machines
But all NC machines are not CNC machines

Conventionally, an operator decides and adjusts various machines parameters like feed , depth of cut
etc depending on type of job , and controls the slide movements by hand.
In a CNC Machine, functions and slide movements are controlled by motors using computer programs.
CNC machine control unit (MCU) decides cutting speed, feed, depth of cut, tool selection , coolant on
off and tool paths.
The MCU issues commands in form of numeric data to motors that position slides and tool accordingly.

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 Pneumatic
Based on Positioning System
Incremental or Absolute

NOTE: this machine uses stepper motor control

Controls both the displacement

and the velocity.

Machining profiles.

Precise control.

Use linear and circular

interpolators.

Position
transducer

Controller

Machine table

Gear
box

Tachometer

Motor
Leadscrew
Servo
drive

Magnetics control
cabinet

Accuracy

Repeatability

Spindle and axis motor

horsepower

Number of controlled axes

Dimension of workspace

Features of the machine and the

controller.

Accuracy = control instrumentation

resolution and hardware accuracy.

Control resolution: the minimum

length distinguishable by the control
unit (BLU).

Hardware inaccuracies are caused by

physical machine errors.

Motor
Motor speed control

lead screw rotation

feedback

table moves
position sensed by encoder

Two types of encoder configurations

a. OPEN LOOP CONTROL

SYSTEM

Does not provide positioning

feedback to the control unit.

Counts tool movement pulses

only

Cannot identify discrepancies

in positioning,

slightly inaccurate.
b . CLOSED LOOP SYSTEM

The electronic movement

pulses are sent from the
control
to
the
servomotor, enabling the
motor movement.
Movements are detected
by a feedback device
(transducer), which can
send a signal to the
control for checking after
each step.

Milling Machine
Operations such as milling, contouring, gear cutting, drilling,
boring, and reaming operations which can be performed on a
milling machine.
The milling machine can be programmed on three axes:
The X axis controls the table movement left or right.
The Y axis controls the table movement toward or away from the
column.
The Z axis controls the vertical (up or down) movement of
the knee or spindle.

All computer controlled machines are able to accurately and

repeatedly control motion in various directions. Each of these
directions of motion is called an axis. Depending on the machine
type there are commonly two to five axes.
Additionally, a CNC axis may be either a linear axis in which
movement is in a straight line, or a rotary axis with motion
following a circular path.

 Machine Zero - Machine zero is a point at the origin of the machines

coordinate measuring system. All the Axis movements and other dimensions are
measured from this point. It is similar to the origin of coordinate measuring
system.
Machine reference point - It refers to the initial point of return for the
purpose of measuring/feedback systems. Whenever a CNC machine is switched
on the feedback system has to be initialized by referring this point on every axis.
Work Zero - This is the origin for the measuring of dimensions of work piece.
The programmer is free to select it anywhere on the drawing.
Absolute measuring system - In this measuring system all the dimensions
are made from the work zero, which defined. The machine control uses work
zero as the reference point to position the tool during program execution. The
main advantage of programming in absolute system is that any point can be
readily changed without affecting subsequent dimensions.

 Incremental measuring system - The movements are based on the change

in position between two successive points. It expresses the relative distance
between the current location and the next position. This type of measuring system
is called Incremental Measuring system. The main advantage of this system is that
sum of the dimensions must always be zero if start point and finishing point is
same at the end of programming which makes it easy to check a program.

Axis designation (conventions) - Axis designation for each type of

machine tool is suggested in the EIA (Electronic Industries Association) RS 274-B

standard. This conforms to ISO Recommendations R831. The nomenclature of the
three main axes (X, Y AND Z) is based on the Left hand rule. The thumb
indicates the orientation of the X-axis; the index finger indicates the Y-Axis, and
the middle finger points in the direction of the Z-axis.

Tool and tool offset - The T function is used to call the particular tool and

tool offset in the program. The tool offset is used to correct the values entered in
the coordinate system preset block. Using the tool offsets, it is easy to set up the
tools and to make adjustments in part size.

 Spindle speed - The spindle speed is the rotational frequency of the spindle of
the machine, measured in revolutions per minute (RPM). The preferred speed is
determined based on the material being cut. Using the correct spindle speed for the
material and tools will greatly affect tool life and the quality of the surface finish.

Feed rate - Feed rate is the velocity at which the cutter is fed, that is, advanced
against the work piece. It is expressed in units of distance per revolution for turning
and boring (millimeters per revolution). For milling it is expressed in units of
distance per time for milling (millimeters per minute).

Cutting Speed - Cutting speed may be defined as the rate (or speed) that the
material moves past the cutting edge of the tool , irrespective of the machining
operation used the surface speed.

HydrostaticSlideWay

Hydrostatics
are
an
improvement over rolling
element and plain slides
because they are a noncontact bearing, resulting in
zero starting friction, zero
wear, error averaging for
straight,
smooth
silent
operation and the highest
possible damping function.

A ball screw is a mechanical linear actuator

that translates rotational motion to linear
motion with little friction. A threaded shaft
provides a spiral raceway for ball bearings
which act as a precision screw. As well as
being able to apply or withstand high thrust
loads they can do so with minimum internal
friction.
They are made to close tolerances and are
therefore suitable for use in situations in
which high precision is necessary.
The ball assembly acts as the nut while the
threaded shaft is the screw.
In a CNC machine, the connection between
the screw and the nut is through an endless
stream of re-circulating steel balls, replacing
sliding friction threads with rolling friction.
Advantages
are
higher
efficiency,
reversibility and reduction in wear and tear.

Control systems
There are two types of control systems on CNC machines:
Open loop (less accurate)
Closed loop (more accurate)

Drive motors

1.
2.
3.
4.

The drive motors control machine slide movement on CNC

equipment. Types used :
Stepper motors (convert a digital pulse into a small rotation,
mostly used in applications where low torque is required )
DC servo motors (rotate in response to the applied voltage, used to
drive lead screw and gear mechanisms, provide higher-torque o/p
AC servo motors (controlled by varying the voltage frequency to
control speed, more power than a DC servo, used to drive a lead
screw and gear mechanism )
Fluid servo motors (variable speed motors, produce more power,
in the case of pneumatic motors, than electric servomotors)

Tool changers
Several different cutting tools are used to produce a part.
The tools must be replaced quickly for the next machining operation.
Majority of NC/CNC machine tools are equipped with automatic tool
changers.
They allow tool changing without the intervention of the operator.
Automatic Tool Changer

Grips the tool in the spindle, pulls it out, and replaces it with another
tool.
Tool changers are equipped for either random or sequential selection.
IN RANDOM TOOL SELECTION
THERE IS NO SPECIFIC PATTERN OF TOOL SELECTION.
IN SEQUENTIAL TOOL SELECTION,
THE TOOLS MUST BE LOADED IN THE EXACT ORDER
IN WHICH THEY ARE CALLED FOR IN THE PROGRAM.

The method by which contouring machine

tools move from one programmed point to the
next is called interpolation.

This ability to merge individual axis points into

a predefined tool path is built into most of
todays MCUs.
There are five methods of interpolation:

Linear, Circular, Helical, Parabolic, And Cubic

All
contouring
controls
provide
linear
interpolation, and most controls are capable of
both linear, circular , helical, parabolic, and
cubic interpolation.

These are used by industries that manufacture

parts which have complex shapes, such as
aerospace parts and dies for car bodies.

To program an arc , the MCU requires only the coordinate

positions (the XY axes) of the circle center, the radius of
the circle, the start point and end point of the arc being
cut, and the direction in which the arc is to be cut
(clockwise or counterclockwise)

Computer Numericalcontrolmachinesareprogrammedbymeansof
a series of coded instructions, commonly entered into the controller using
manual programming. A typical block of instruction is of the following
form:
BlockFormat
N135G01X1.0Y1.0Z0.125F5
SampleBlock
RestrictionsonCNCblocks
Eachmaycontainonlyonetoolmove
EachmaycontainanynumberofnontoolmoveGcodes
Eachmaycontainonlyonefeedrate
Eachmaycontainonlyonespecifiedtoolorspindlespeed
Theblocknumbersshouldbesequential
Boththeprogramstartflagandtheprogramnumbermustbeindependent
ofallothercommands(onseparatelines)
Thedatawithinablockshouldfollowthesequenceshownintheabove
sampleblock

Name of the program

Selection of Working plane, Measuring system ( Absolute or incremental ),
Unit of measurement (mm or inch)
Defining and calling work origin
Tool changing position (Remote area away from work piece), Tool call & Tool change
First position (Movement in working Plane) and Second positioning (Movement in
spindle axis) for working, Spindle start & coolant on
Third positioning for working (for mechanizing, tool movement with tool radius
compensation)
Depth of cut (in feed only)
Definition of geometry/preparation of profile (feeding of CNC drawing data)
Return to second position, spindle stop & coolant off
Cancellation of fixed cycles, Macro instructions, Special commands, Tool Radius
compensation
Return to tool change position
Movement in spindle axis and in working plane
If required, repeat step Nos. to 16 as required.
End of part program

The most common codes used when programming CNC

machines tools are G-codes (preparatory functions), and M codes
(miscellaneous functions).
Other codes such as F, S, D, and T are used for machine
functions such as feed, speed, cutter diameter offset, tool
number, etc.
G-codes are sometimes called cycle codes because they refer to
some action occurring on the X, Y, and/or Z axis of a machine
tool,
The G-codes are grouped into categories such as Group 01,
containing codes G00, G01, G02, G03. which cause some
movement of the machine table or head.
Group 03 includes either absolute or incremental programming,
while Group 09 deals with canned cycles.
A G00 code rapidly positions the cutting tool while it is above the
work piece from one point to another point on a job. During the
rapid traverse movement, either the X or Y axis can be moved
individually or both axes can be moved at the same time. The
rate of rapid travel varies from machine to machine

CODE TYPES
Sequence Number (N-Codes)
This is an identification number for each block of instructions and increases
sequentially through the program.

Preparatory Function (G-Codes)

The G-codes are the codes that position the tool and do the actual work These
codes are largely standardized and can be seen in the provided G-code table.
Many of the preparatory functions can indicate canned cycles.
Co- ordinate Codes
These indicate the co-ordinates for the tool movement. Four to five axis
machines can have the following axes
Cartesian Co-ordinates Angular positions for
the Cartesian axes

Circular Interpolation
about Cartesian axes

Feed rate (F-code)

This specifies the feed rate for the operation. The units
may be mm per minute or mm per revolution (indicated by
the G-code used), with the decimal point implied at a fixed
position from the right.
Spindle speed (s-code)
This specifies the spindle speed to be used for the
operation.
Tool Number
This indicates to the controller which tool is to be used for
the operation. In case of tool adaptors with multiple tool
slots, the machine just switches to the next tool without
removing the earlier one form the adaptor.

G CODES (FANUC MACHINE CONTROL)

G CODE
G00
G01
G02
G03
G04
G17
G18
G19
G20- 21
G28
G40
G41
G42
G43
G44

FUNCTION
Positioning (Rapid traverse)
Linear Interpolation (Cutting feed)
Circular interpolation /Helical cutting CW
Circular interpolation/Helical cutting CCW
Dwell Time
XY plane selection
ZX plane selection
YZ plane selection
Input in inch and mm respectively.
Return to reference point
Cutter compensation cancel
Cutter compensation left
Cutter compensation right
Tool length compensation + direction
Tool length compensation direction

G53
G54 - 59
G71
G73
G76
G78
G81
G82
G83
G90
G91
G92
G94/98
G95/99
G96
G97
G98
G99

Machine coordinates system selection

Work co-ordinate system 1 -6 selection
Stock removal Canned Cycle
Pattern Repeating Canned Cycle
Thread Cutting Canned Cycle
Grooving Cycle Canned Cycle
Drilling cycle, spot boring
Drilling cycle, counter boring
Peck drilling cycle
Absolute command
Incremental command
Programming of absolute zero point
Feed per minute
Feed per rotation
Constant surface speed control
Constant surface speed controls cancel
Return to initial point in canned cycle
Return to R point in canned cycle

MISCELLANEOUS CODE (M-CODE)

CODE
M00
M01
M02
M04
M05
M06
M07
M08
M09
M10
M11
M13
M14
M 20 29
M30
M31
M40-M45
M90
M99

FUNCTION
Program stop, spindle and coolant off
Optional programmable stop
End of program-often interchangeable with M30
Spindle on CCW
Spindle stop
Tool change
Coolant supply No. 1 on
Coolant supply No. 2 on
Coolant off
Clamp
Unclamp
Spindle on, CW + Coolant on
Spindle on, CCW + Coolant on
Unassigned
Program stops at end of tape+ tape rewind
Interlock by-pass
Gear Changes; otherwise unassigned
Reserved for user
(Subroutine call) Reserved for user

The G01, G02, and G03 codes move the axes at a controlled feed
rate.
G01 is used for straight-line movement (linear interpolation).
G02 (clockwise) and G03 (counterclockwise) are used for arcs
and circles (circular interpolation).

MISCELLANEOUS CODES
M03
DIRECTION OF ROTATION
(CLOCKWISE)
M04
DIRECTION OF ROTATION
(COUNTERCLOCKWISE)
M05
SPINDLE STOP
M06
TOOL CHANGE WITH
AUTOMATIC RETRACTION
M30
END OF PROGRAM
AND RETURN TO BEGINNING
OF PROGRAM

Each line of program == 1 block

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

Sequence and format of words:

N3

G2

sequence
no

X+1.4

Y+1.4

destination
coordinates

preparatory function

Z+1.4

I1.4

J1.4

K1.4

F3.2

S4

feed rate
dist to
center of
circle

T4

M2

tool

spindle speed
miscellaneous function

The machine zero point can be set by three methods

By the operator,

Manually by a programmed absolute zero shift, or

By work coordinates, to suit the holding fixture or the part to be

machined.
Manual setting

The operator can use the MCU controls to locate the spindle
over the desired part zero and

Then set the x and y coordinate registers on the console to

zero.
Absolute zero shift

The absolute zero shift can change the position of the

coordinate system by a command in the CNC program.

The programmer first sends the machine spindle to home zero

position by a G28 command in the program.

Then another command (G92 for absolute zero shift) tells the
MCU how far from the home zero location, the coordinate
system origin is to be positioned as shown in the fig.

G33 X Z K
Where,
K = Pitch of the
thread

G42(Radius compensation on
the right side of the profile)

G41(Radius compensation on
the left side of the profile)

U (i d) : depth of cut (radius designation) designation without sign) in x direction

R (e ) : escaping amount/retraction
P
: sequence number of first block for Programming of finishing shape
Q
: sequence number of last block for programming of finishing shape
U (i u) : distance and direction of finishing allowance in X direction (dia /radius)
W (i w): distance and direction of finishing allowance in Z direction

G73 U(i I) W(i k) R(d)

G73 P(-) Q(-) U(i u) W(i w) F(f) S(s) T(t) ;
U(i I) = Maximum Dia of the Work piece-Minimum diameter of the
profile /2
W(i k) = Escape Distance and direction in Z axis
R( d) = U(i I) / Depth of cut = No. of times the cycle is to be repeated

G75(X direction grooving :

Peck drill cycle in turning)
G75 R(e) :
G75 X(u) Z(w) P( i) Q( k) R( d) F :

G76 P (m r a) Q (D) R (d)

G76 X (Root Diameter) Z ( Distance of thread)
P (Depth) Q (First Depth) F (Feed)
The threading cycle in this program is based
on the following parameters:
m= Number of finishing passes = 3,
r = Chamfer distance = 1.5 3.5 = 5.25 mm
(3.5 mm is pitch)
a= Thread angle (tool-tip angle) = 60 degree,
Q= Minimum depth of cut or Finishing
allowance = 150 micron = 0.15 mm
X= Core diameter = 25.706 mm
Z= Axial end of thread = 30 mm in the
negative Zdirection
P= Depth of thread = 2147 micron = 2.147 mm
Q= First depth of cut = 250 micron = 0.25 mm,
F= Lead (= pitch, for single-start) = 3.5 mm
.

There is also a provision for

an R-word for taper threads.