Ch 7 Numerical Control

Numerical control can be defined as a form of

programmable automation where process is
controlled by numbers, letters and symbols.
 Basic Components of an NC System

1. Program of instructions
▪ Part program in machining using punched cards
2. Machine control unit
▪ Tape reader
▪ Data buffer
▪ Signal output channels
▪ Feedback channels
▪ Sequence control
3. Machine tool or other controlled process
▪ Worktable
▪ Spindle
▪ Fixtures
▪ Cutting tools etc.
Basic Components of an NC System
 NC Procedure

➢Process planning(route sheet)

➢Part programming
➢Tape preparation
➢Tape verification(acid test)
➢Production
 NC Coordinate Systems

➢Fixed Zero and Floating Zero

➢Absolute Positioning and Incremental
Positioning
 Absolute and Incremental Positioning

Absolute positioning
▪Locations defined relative to origin of
axis system Incremental positioning
▪ Locations defined relative to
previous position
▪ Example: drilling
 Absolute vs. Incremental Positioning

The workhead is presently

at point (20, 20) and is to be
moved to point (40, 50)
▪In absolute positioning,
the move is specified by x =
40, y = 50
▪In incremental positioning,
the move is specified by x =
20, y = 30.
 NC Motion Control Systems
1. Point-to-Point systems
▪ Also called position systems
▪ System moves to a location and performs an operation at
that location (e.g., drilling)
2.Straight cut systems
▪ Capable of moving the cutting tool parallel to one of the
major axis at a controlled rate.
3.Continuous path systems
▪ Also called contouring systems in machining
▪ System performs an operation during movement (e.g.,
milling and turning)
Point-To-Point Control in NC
Drilling of Three Holes in Flat Plate
Straight Cut Control
Continuous Path Control in NC
Profile Milling of Part Outline
 NC Application Characteristics
(Machining)

Where NC is most appropriate:

1. Batch production
2. Repeat orders
3. Complex part geometries
4. Much metal needs to be removed from the starting
workpart
5. Engineering design changes are likely
6. The part is expensive
7. Close tolerances must be held on the workpart.
 Advantages of NC
▪ Nonproductive time is reduced
▪ Greater accuracy and repeatability
▪ Lower scrap rates
▪ Inspection requirements are reduced
▪ More complex part geometries are possible
▪ Engineering changes are easier to make
▪ Simpler fixtures
▪ Shorter lead times
▪ Reduce parts inventory and less floor space
▪ Operator skill-level requirements are reduced
 Disadvantages of NC

▪ Higher investment cost

▪ CNC machines are more expensive
▪ Higher maintenance effort
▪ CNC machines are more technologically sophisticated
▪ Part programming issues
▪ Need for skilled programmers
▪ Time investment for each new part
▪ Repeat orders are easy because part program is
already available
▪ Higher utilization is required
 Problems with conventional NC

➢Part programming mistakes

➢Non optimal speeds and feeds
➢Punched tape
➢Tape reader
➢Controller
➢Management Information
Computer Numerical Control (CNC)
 Functions of CNC

➢Machine tool control

➢In process compensation
➢Improved programming and operating features
➢Diagnostics
 Machine tool control

➢Hybrid CNC
 Machine tool control

➢Straight CNC
 Advantages of CNC

➢Part program tape and tape reader are used only once
➢Tape editing at the machine site
➢Metric conversion
➢Greater flexibility
 DNC(Direct Numerical Control)
DNC can be defined as a manufacturing
system in which a number of machines
are controlled by a computer through
direct connection and real time.
DNC(Direct Numerical Control)
DNC(Direct Numerical Control)
 Components of DNC System

➢Central computer
➢Bulk Memory which stores NC part
programs
➢Telecommunication lines
➢Machine tools
 Two Types of DNC

➢Behind The Tape Reader (BTR) System

 Two Types of DNC

➢Special Machine Control Unit

 Functions of DNC

➢NC without punched tape

➢NC part program storage
➢Data collection, processing and
reporting
➢Communications
 Advantages of DNC

➢Elimination of punched tape and tape

readers
➢Greater computational capability and
flexibility
➢Convenient storage of NC part programs
➢Programs stored as CLFILE
➢Reporting of shop performance
➢Establishes the framework for the evolution
of future computer automated factory
 Disadvantages of DNC

➢DNC uses a central control and in an event

of computer failure, the complete activities of
the machine shop would come to a standstill.

➢DNC is expensive and its use is practical in

areas where high automation is required.

Comparison of NC, CNC, DNC.