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CNC Unit1 PDF
CNC Unit1 PDF
ME453
UNIT 1
1
Unit 1
Numerical Control:
Basic concepts
NC components
Point to point and controlling concepts
Axis standards
Programme control
Testing
2
Machine tool - Historical developments and
their role in control of machine tools
3
History of Machine Tools
4
History of Machine Tools
• Machine age (~300 years ago)
– Explored new sources of energy (water)
• Industrial age began when James Watt produced
first steam engine (1776)
– Steam engine provided power to other areas
– Machines improved
• Steam/steel in ships, railroads, steam tractors
• New power – electricity produced by generators
• Diesel and gasoline engines
5
History of Machine Tools
• Progress continued slowly during first part of 20th
century
– Spurts during the two world wars
• Since 1950s, progress rapid
• Now in space age
– Atom harnessed: nuclear power
– Journey to moon and outer space
– Calculators, computers, robots common place
– Can mass produce parts to millionths of an inch
6
History of Machine Tools
NC History
– 1725-Knitting machine in England used punched cards
to form various patterns in cloth.
8
– 1990 - DNC: external computer control
programmer to machine tool controller
9
• Numerical Control
– Basic concepts
– Need of NC Machine tools
10
Numerical Control (NC) Defined
12
Schematic of an NC machine tool
Program Machine
Instructions Control Unit
Transformation
Process
Power
13
Schematic of an NC machine tool
• MCU – machine control unit
– Controls the motion of the NC machine tool.
• DPU – data processing unit
– Reads and interprets the part program; sends immediate commands
to CLU.
• CLU – control loop unit
– Reads positions sensors and sends control signals to motors.
14
Applications of NC
NC used to
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• NC machines have been found quite suitable where:
– The components have complex shapes.
– The parts are to be made in small batches.
– Set-ups are numerous and costly.
– A repetition of close tolerances/accuracy is
desired.
– The parts are subjected to design changes.
– The inspection cost is a significant portion of the
total cost.
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NC components
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NC COMPONENTS
• Part program
• Program input device
• Machine control unit
• Drive system
• Machine tool
• Feedback system
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NC Components
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20
NC Components: Part Program
• It is an important software element in the NC
manufacturing system.
• It is the plan proposed for machining the part .
• It is written by keeping in view various standard words,
codes and symbols.
• It is dependent on the machine tool hardware an the
machine control unit.
• The program can be written in a high level language
such as APT, UNIAPT, COMPACT etc.
• These programs have to be converted into machine
level program with the help of processors.
• The program is translated into the appropriate electrical
signals for input to motors that run the machine.
21
NC Components: Program Input Device
• The program input device is the mechanism for part
programs to be entered into the NC control.
• The most commonly used program input devices are:
punched cards,
magnetic tapes,
punched tapes,
diskette drivers
serial ports and
networks.
22
Program Input Device
23
Program Input Device
1. Punched cards
• Punched cards were once used as a medium for data
input in all numerical control systems.
• The data once stored can be erased and new data saved
on the magnetic tape or disk.
• A standard tape is 25 mm
wide.
26
• There are 8 tracks on the tape, which are used for
punching the information in coded form.
• The edge adjacent to track 1 is called reference edge.
• A row of small holes between track 3 and track 4 is
used for feeding the tape into the tape reader.
• The information required to machine the component
is punched on the tape by a tape punching device.
27
NC Coding
29
• ISO Numerical Control
Code:
• The ISO-7 bit code for
numerical control suggested
by International Standard
Organization is shown in
figure.
• The figure shows the
decimal equivalent and
binary representation of
various characters as it
appears on the punched
tape.
30
• The ISO Code is a 7-bit code and uses
7 track for coding and 8th track is
reserved for error checking called
parity check.
• The vertical stream of holes between
track 3 and track 4 are feed holes and
do not form a part of coding system.
• The ISO numerical code, the digits 0-
9 have a hole punched in track 5 and
6.
• In addition, hole (s) is/are punched
according to the binary equivalent of
the decimal number.
• For all alphabet characters A-Z , a
hole is punched in track 7.
• Then the alphabet follow the
ascending binary count from 1 to 26.
• A DELETE character is recognized by
the presence of holes in all the tracks
.
31
• EIA Numerical Control
Code:
• The EIA is also a 7-bit
code in a 8- track
format with track 5
reserved for parity
check.
32
• The vertical stream of holes
between track 3 and track 4 are
feed holes and do not form a
part of coding system.
• A DELETE character is
recognized by the presence of
33
holes in all the tracks .
Parity check
34
NC Components: Machine Control Unit (MCU)
The machine control unit (MCU) is the heart of a NC
system. It is used to perform the following functions:
36
•Mechanical Tape Reader
•The principle of a simple mechanical device for reading the
punched tape is shown in the figure below.
•If there is no hole in the tape the contacts remain open but
when a hole is present in the tape, its presence is detected by a
probe and bending of flexible strip cause the contacts to close.
37
•The presence of holes in the tape causes the switches to
close.
38
•Optical of Photo-electrical Readers
•The operation of an optical photo electrical tape reader is based
upon the principle that if a beam of light falls on a photoelectrical
cell, the latter generates an electric signal.
39
•Whenever a hole is present in the tape, light from the light
source passes through the hole and energies the corresponding
photo-cell which converts the light energy and electrical energy
to produce a pulse i.e. ON position.
•The pulse is amplified and processed into a form suited to the
control circuit.
•When there is no hole, the light from the light source does not
reach the photo-cell, hence no signal is produced and the
position is recorded as OFF.
40
•Pneumatic Tape Reader
•The tape is fed between a series of air jets covering the complete
pattern of holes which is possible to be punched in a block of
information on the tape and tape support plate.
•The compressed air jets are directed through specially designed
tubes which have two openings. The first opening called, main outlet,
is near the tape and second opening is connected to a signal
detector.
41
•If there is no hole in the tape, the tape covers the main outlet and the free
escape of air is restricted and the a back pressure is developed in the supply
tube. This back pressure is sensed by the signal detector and position is recorded
as ‘0’ i.e. OFF.
•But if a punched hole in the tape comes in front of the main outlet, the air is
allowed to escape freely and no back pressure is built up in the supply tube. This
loss of back pressure is detected and position is recorded as ‘1’ i.e. ON.
•The support plate prevents the tape from being blown away by the compressed
air coming from main outlet.
42
Classification of NC systems
43
Based on motion type
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
• Moving at maximum rate from point to
point.
• Accuracy of the destination is important
but not the path.
• Drilling is a good application.
44
Straight line system
• Straight cut control - one axis motion at a time is controlled
for machining.
• It is an extension of point-to-point control system with the
provision of machining along a straight line in case of milling
and turning operations.
• This is obtained by providing movement at controlled feed
rate along the axis in the line of the motion.
• It is possible to machine along diagonal lines with movement
in two axis at a controlled feed rate.
• However, in such cases the control system must be capable
calculating and displacing the slides simultaneously at suitable
feed rates to reach the desired points because in this case the
feed rates along different axis will have to be different.
45
Continuous path systems
• Also called contouring systems in machining
• System performs an operation during movement (e.g., milling and
turning)
• Controls both the displacement and the velocity.
• Machining profiles.
• Precise control.
• Use linear and circular
interpolators.
• Contouring - multiple axis’s
controlled simultaneously
46
47
Axes of NC machine
48
Work Positioning
50
One could use his right hand to arrive at these alternate variable positions
of the same right hand coordinate system (see figure 2).
53
Machine Tool Types
• It is convenient in the context of standard, to classify the NC
machines in the following groups.
• Group I: Machine tools with the rotating cutting tools
– I (a): These machines may have a vertical spindle; e.g. vertical knee,
milling machine, drilling machines, vertical boring machines etc. These
could be of single column type (I(a-i) or gantry type I(a-ii)
54
I (b): These machines may have horizontal spindle e.g. horizontal boring
machines etc.
55
• Group II: Machines tools with rotating work pieces e.g. lathes
and grinding machines
56
• Group III: Machine tools with non-rotating work pieces and non-rotating
tools e.g. shaper, slotter and planer
57
Z-Axis and Motion
Location:
The Z-axis motion is either along the spindle axis or parallel to the
spindle axis (Group I: Machine tools with the rotating tools. Group
II: Machines tools with rotating work pieces e.g. lathes and
grinding machines)
58
Direction:
The principle for the machines of Groups I and II where drilling type
motion can be performed is that for moving a drill into the work
piece, the cutting tool should move in the negative (-) Z direction.
For other machines the positive (+) Z motion increases the clearance
between the work surface and the tool-holder.
59
X-Axis location and direction
The X-motion is the principle motion in the positioning
plane of the cutting tool or the work piece.
Location:
• It is perpendicular to the z-axis and should be horizontal
and parallel to the work holding surface wherever
possible.
Direction:
• For Group I (a-i) machines when looking from the
principal spindle to the column the positive (+) X is to
the RIGHT (Figure 3).
60
Y-Axis location and direction
• Its designation is derived from the already recognized Z and X
axes.
• It is perpendicular to both X and Z axes and +Y is in the direction
which completes with the +X and +Z motions a right hand
cartesian coordinate system.
• In Figure 3 to 7, this has been demonstrated in the columns
under the coordinated system and Y.
• The first two columns under Z and X axes show the designation
of Z and X axes as per the principles mentioned earlier.
61
Programming Control
62
Classification of NC systems
Based on Motion Type:
Point-to-Point or Straight line or Continuous path
63
1. Absolute positioning. In this mode, the desired
target position of the tool for a particular move is given
relative to the origin point of the program.
64
Absolute and Incremental Co-ordinates
• Absolute Co-ordinates
The Z axis is the vertical axis and the datum used is normally
the surface of the work.
65
Absolute Co-ordinate System
66
Absolute Co-ordinate Worksheet
Point Datum A B C D E F G H
X 0 5 10 -4 -9 -7 -4 7 5
Y 0 4 5 5 7 -3 -6 -5 -2
Z 0 0 0 0 0 0 0 0 0 67
Incremental Co-ordinates
• Incremental Co-ordinates
The points on the path to be machined are defined relative to the
previous position.
68
The sequence
specified moving Incremental Co-ordinate Graph
“alphabetically”,
therefore the following
table represents
incremental
movements.
Datum A B C D E F G H
Point
X 0 2 3 -10 -2 0 3 9 -3
Y 0 3 -1 1 2 -9 2 0 -2
70
Zero Points and Reference Point
• In NC/CNC machines tool traverses are controlled by
coordinating systems.
71
a) Machine Origin (M)
• The machine origin is a fixed point
set by the machine tool builder.
• This is the zero point for the
coordinate systems and reference
points in the machine.
• On lathe machine, the machine zero
point is generally at the center of the
spindle nose face.
• Usually it cannot be changed.
• Any tool movement is measured
from this point.
• The controller always remembers
tool distance from the machine
origin.
72
b) Program Origin (N)
• It is also called home position of
the tool.
•
• Program origin is point from where
the tool starts for its motion while
executing a program and returns
back at the end of the cycle.
73
c) Part Origin (W)
• The part origin can be set by
the programmer in the
NC/CNC program or by the
operator manually.
75
Testing of NC/CNC Machines
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• Make sure that the machine is zeroed out.
• This will allow the NC/CNC machine to know its home position.
• NC/CNC machines use air to open and close the tool holder as
well as to keep the tool tight in the spindle for the cutting
process.
77
• If the air pressure or oil pressure for lubrication get too low, the
machine will stop functioning and you may have to restart the
cycle.
• Keeping the machine lubricated and the air flowing will allow for
continuous uninterrupted cutting.
• Check the edges of cutting tools if the part finish looks rough or
out of tolerance.
• This will give the machine the information it needs about the
location of the tip of the tool for accurate cutting, drilling or boring.
78
• Check the coolant flow and fill the reservoir if the tooling is
getting too hot and burning up.
• Make sure that the coolant is in a good general position to hit all
of the various tip lengths of the individual tools.
79
Daily Care and Feeding of Your CNC Machine
• Check the hydraulic pressure.
• Check the hydraulic fluids to make sure they’re at the
right operating level
• Check to make sure the chuck pressure is at the right
operating pressure
• Clean the chips out of the chip pan, and grease any part
that may need to be greased
• Clean off the window of the door and the light so you
can see inside your machine
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• Every Three Months or 500 Hours
• Check and grease the chain on the chip conveyor
• Check and clean the filters on the coolant tank
81
• Have the lubrication unit drained and cleaned out.
• If your machine is equipped with a cooling unit, have
the unit drained and refilled
• Have the leveling of your machine checked and
adjust if necessary
82