» DNC is a manufacturing system in which a number of machines are controlled by a computer through direct- connection and in real time. ° Also, defined by EIA as: DNC is a system connecting a set of NC machines to a common memory for part program or machine program storage with provision for on- demand distribution of data to machines. ° The tape reader is omitted. * Involves data connection and processing from the machine tool back to the computer. Components 1. Central computer 2. Bulk memory which stores the NC part programs. 3. Telecommunication lines 4. Machine Tools.———— = a —*A central computer connected to a number of machine tools and control them * Part program of all machine tools are stored in the memory of the central computer and transmitted on direct transmission lines on demand * Two way information flow take place in real time * Various machine tools can communicate with the computer in real time * Programs in full or segment can be transferred to NC machines = Computer can be used for program editing » No tape readers are used * No limitation for the number or size of programs stored— a Advantages of DNC System * Elimination of punched tapes and tape readers * Convenient storage of NC part programs in computer files ° Greater computational capability and flexibility © Reporting of shop performance. ° Convenient editing and diagnostic features.“ef oP ot MANUAL PART PRO@PA nNNG.+ TO prepa. a Yauk Frage Wry He woul Metind , be Prog Pome ite, be onackiniy instruction on & Spal fom ob o Poak Prosramiy erdauaci pt: The WWpkructions Auf be Prepay (BO Way Precise onomnee be Caue A Tyeiae Ceri Jk NO hop de verls fro. fe Moauscript- Honu sexi pts Come jw Vasicus Fons, eperding on He Machine bool Od Tape format: fy he Ute For Braap, Be emonmeitt Form a Tac Any foint-0- Point dilly Machine Would be datfuets Bor one Jor Scanned by CamScanner ipt in @ Linky a. 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TE, He Move | Corplicaked font - to- foint Toba and in Com Fung Fark — ProSvommiy Bete Ae Keanel, Tediow Tork Od Sided fe Crom. | Ta Mere Dabeccey jt ta Muh Moe opprapsiahe fe vp log Yue high Speed digital Corpus fo aaiaty in He faut V0 Sven; “4 Provas. Mong Pak trogen Loy wage Syste have bee developed Peon, Qubbmakicalh most 4 he Col culakory whic, He Progr, Loud Obavise be Forced fe do, Tp Bae Tre And Yeadts ma Hox Altwake Od EY faxk Trosvo.. “Aas Af Popa: Nov Corp A¢FNC Rom, Ocal eee ewe www www urvHEyruy~~ ©7.3 THENC PROCEDURE To utilize numerical control in manufacturing, the following steps must be accom- plished. 1. Process planning. The engineering drawing of the workpart must be interpreted in terms of the manufacturing processes to be used. This step is referred to as process planning and it is concerned with the preparation of a route sheet. The route sheet is a listing of the sequence of operations which must be performed on the workpart. It is called a route sheet because it also lists the machines through which the part must be routed in order to accomplish the sequence of operations. We assume that some of the operations will be performed on one or more NC machines. 2. Part programming. A part programmer plans the process for the por- tions of the job to be accomplished by NC. Part programmers are knowledgeable about the machining process and they have been trained to program for numerical control. They are responsible for planning the sequence of machining steps to be performed by NC and to document these in a special format. There are two ways to program for NC: Manual part programming Computer-assisted part programmingComputer-assisted part programming In manual part programming, the machining instructions are prepared on a form called a part program manuscript. The manuscript is a listing of the relative cutter/workpiece positions which must be followed to machine the part. In computer-assisted, part programming, much of the tedious computational work required in manual part programming is transferred to the computer. This is espe- cially appropriate for complex workpiece geometries and jobs with many machin- ing steps. Use of the computer in these situations results in significant savings in 3. Tape preparation. A punched tape is prepared from the part pro- grammer’s NC process plan. In manual part programming, the punched tape is Prepared directly from the part program manuscript on a typewriterlike device equipped with tape punching capability. In computer-assisted part programming, the computer interprets the list of part programming instructions, performs the necessary calculations to convert this into a detailed set of machine tool motion commands, and then controls a tape punch device to prepare the tape for the specific NC machine. 4. Tape verification. After the punched tape has been prepared, a method is usually provided for checking the accuracy of the tape. Sometimes the tape is checked by running it through a computer program which plots the various tool Movements (or table movements) on paper. In this way, major errors in the tape can be discovered. The ‘‘acid test’’ of the tape involves trying it out on themachine tool to make the part. A foam or plastic material is sometimes used for this tryout. Programming errors are not uncommon, and it may require about three attempts before the tape is correct and ready to use. ; 5. Production. The final step in the NC procedure is to use the NC tape in production. This involves ordering the raw workparts, specifying and preparing the tooling and any special fixturing that may be required, and setting up the NC machine tool for the job. The machine tool operator’s function during production is to load the raw workpart in the machine and establish the starting position of the cutting tool relative to the workpiece. The NC system then takes over and machines the part according to the instructions on tape. When the part is com- pleted, the operator removes it from the machine and loads the next part.74 NC COORDINATE SYSTEMS Tn order for the part programmer to plan the sequence of positions and movements of the cutting tool relative to the workpiece, it is necessary to establish a standard axis system by which the relative positions can be specified. Using an NC drill press as an example, the drill spindle is in a fixed vertical position, and the table is moved and controlled relative to the spindle. However, to make things easier for the programmer, we adopt the viewpoint that the workpiece is stationary while the drill bit is moved relative to it. Accordingly, the coordinate system of axes is esta- blished with respect to the machine table. Two axes, x and y, are defined in the plane of the table, as shown in Figure 7.4. The z axis is perpendicular to this plane and movement in the z direction is controlled by the vertical motion of the spindle. The positive and negative direc- tions of motion of tool relative to table along these axes are as shown in Figure 7.4. NC drill presses are classified as either two-axis or three-axis machines, depending on whether or not they have the capability to control the z axis. A numerical control milling machine and similar machine tools (boring mill, for example) use an axis system similar to that of the drill press. However, in addition to the three linear axes, these machines py possess the capacity to con- +z i FIGURE 7.4, NCima- Lg | ™ Machine table chine tool! axis system ’ for milling and wea yy 2 operations, \+2 FIGURE 7.5 NC me chine tool ads system for tuming operation. ae sta : trol one or more rotational axes. Three rotational axes are defined in NC: the a, b, and c axes. These axes specify angles about the x, y, and z axes, respectively. To distinguish positive from negative angular motions, the “‘right-hand rule’ canbe —__ used. Using the right hand with the thumb pointing in the positive linear axis direc tion (x, y, or 2), the fingers of the hand are curled to point in the positive rotational Srecti = For turning operations, two axes are normally all that are required to com-— mand the movement of the tool relative to the rotating workpiece. The z axis is the axis of rotation of the workpart, and x axis defines the radial location of the cutting tool. This arrangement is illustrated in Figure 7.5. The purpose of the coordinate system is to provide a means of locating the tool in relation to the workpiece. Depending on the NC machine, the part program- mer may have several different options available for specifying this location. I Hl iFixed zero and floating zero The programmer must determine the position of the tool relative to the origin (zero point) of the coordinate system. NC machines have either of two methods for specifying the zero point. The first possibility is for the machine to have a fixed zero. In this case, the origin is always located at the same position on the machine table. Usually, that position is the southwest comer (lower left-hand comer) of the table and all tool locations will be defined by positive x and y coordinates. The second and more common feature on modern NC machines allows the machine operator to set the zero point at any position on the machine table. This feature is called floating zero. The part programmer is the one who decides where the zero point should be located. The decision is based on part programming con- venience. For example, the workpart may be symmetrical and the zero point should be established at the center of symmetry. The location of the zero point is communicated to the machine operator. At the beginning of the job, the operator moves the tool under manual control to some ‘‘target point’’ on the table. The tar- get point is some convenient place on the workpiece or table for the operator to position the tool. For example, it might be a predrilled hole in the workpiece. The target point has been referenced to the zero point by the part programmer. In fact, the programmer may have selected the target point as the zero point for. tool posi- tioning. When the tool has been ar lat the eee point, the machine opera-Hh Wi Nit Wi tor presses a ‘*zero’”. button on the machine | console, where the origin is located for subsequent tool movements. th ‘Another option sometimes available. part programmer is to use either an absolute system of tool positioning or an incremental system. Absolute positioning means that the tool locations are always defined in relation to the zero point. Ifa hole is to be drilled at a spot that'is 8 in. above the x axis and 6 in. to the night of the y axis, the coordinate location of the hole would be specified as x = +6.000 and y = +8,000. By’ contrast, incremental positioning means that the next tool location must be defined with reference to the previous tool location. If in our dril- ling example, suppose that the previous hole had been drilled at an absolute pos- tion of x = +4.000 and'y = +5.000. Accordingly, the incremental position instructions would be specified a3 + =| -+2.000 and y = 3,000 in arder to move the drill to the desired spot, Figure 7,6 illustrates the difference between absolute and incremental positioning,’ | NCA a eeNC MACHINE PART PROGRAMMING METHODS The processing tape used for programming can be prepared using any of the several different methods of NC part programming. NC part programming represents one of the elements in the broader procedure called process planning. Process planning is a function of manufacturing engineering in which the sequence of individual production operations for making a part is planned. The part programming methods include: 1. Manual part programming 4 2. Computer-assisted part programming 3. Manual data input 4.NC programming using CAD /CAM 5. Computer-Automated part programming 6. Voice NC part programming MANUAL PART PROGRAMMING In the more familiar manual part programming, the part processing instructions are written in the form of coded machine language and are documented ona form called the part program manuscript. These instructions describe the positions of the tool relative to the workpiece that the machine must follow in order to perform the processing of the part. On the manuscript, they appear in the form of a tabular listing of data which includes other commands such as speeds, feeds, tooling, and others. A punched tape , magnetic tape or as the case may be, is then prepared from the manuscript directly.MANUAL DATA INPUT (MDI) Manual and computer assisted part programming are methods that require a relatively high degree of formalistic documentation and procedure. Also, substantial time is required to; Write the part program (either using the manuscript or the computer language code) Punch the tape and validate the program. To achieve that, two or more persons will be involved i.e. the programmer and the machine operator.NC PART PROGRAMMING USING CAD/CAM The term CAD/CAM typically refers to a computer interactive graphics system equipped with the software to accomplish certain functions in a geometrical description in design and manufacturing. The term CAD/CAM actually means computer-aided design and computer-aided-manufacturing.In the part programming using CAD/CAM, the system is again equipped with NC_ programming software used to facilitate the part programming tasks. In this method of part programming, the programmer works on a CAD/CAM workstation to enter the machining commands. The actions indicted by these commands are displayed on the graphics monitor, which provides visual feedback to the programmer. Also, certain positions of the programming cycle usually done by the part programmer are automated by the NC programming software, to reduce the total programming time required. Recall that the two tasks of the programmer in computer-assisted programming are: Defining the part geometry and specifying the tool path. Advanced CAD/CAM systems have the capability to automate portions of these two tasks. COMPUTER AUTOMATED PART PROGRAMMING Advertisement In the CAD/CAM approach to NC part programming, several aspects of the procedure had been automated. In the future, it should be possible to automate the complete NC part programming procedure, when this is done, it can be referred to the fully automated procedure as computer-automated part programming. Given the geometric model of a part that has been defined during product design, the computer automated system would possess sufficient logic and decision-making capabilities to accomplish NC part programming with no human assistance. This can most readily be done for certain NC processes that involve well-defined, relatively simple part geometries. Examples are in point to point operation such as drilling, wire-wrap machines , and electronic component assembly machines. In these processes, the design data can be processed to generate NC program for the particular system. VOICE NC PROGRAMMING Voice programming of NC machines, abbreviated VNC. involves vocal communication of the machining procedure to a voice input NC tape preparation system. NC allows the programmer to avoid steps such as writing the program by hand, key-punching or typing and manual verification. To perform the part program process with VNC, the speaker speaks into the headband microphone designed to reduce background acoustical noise. Communication of the programming instructions is done in shop language with such terms as “turn’, “thread”, “mill line’, etc., together with numbers to provide dimensional and coordinate data.CNC System © To overcome the shortcomings of the NC systems, CNC systems are evolved. o CNC machines are the NC machines whose MCU is based on the microcomputer rather than the hardwired controller. o ACNC system consist of the following 1. Input device 2. Machine control unit (MCU) 3. Machine tool 4. Driving system 5. Feedback devices 6. Display unit | Part Programs Gontrolteon pf nit Miscellaneous Function Motion Data Position Feedback Velocity Feedback Feedback System Schematic diagram of'a CNC System Hie S A antl ahiiye tt HQO Working Principle of a CNC System o In CNC systems the part program is fed into the computer. Then the instructions are read and interrupted by the controller to convert it into signals that activate the machine tool. o The signals are sent to the servo control system. This servo control system control the machine tool for performing different operations. o The feed back transducer checks the actual position of the machine tool slide and passes it to CPU. o If there is any difference featicnn given input and actual position achieved, the CPU takes corrective action to achieve the given input values by suitable instructions to the machine tool, © Closed loop CNC system has both velocity and position control loops. o Software of CNC system has three major programs Part Program. It has part dimensions, Spindle speed, Feed rate, etc. Service Program: Used to check , edit, correct the part program. Control Program: Accepts the part program as a input data to produce | signals to drive the axes of motion. HV hacalreiydtuyatty weAdvantages of cNne Machines ' OHigheraccuracy DReduce lead time QO) Higher flexibility: Q Reduce scrap rate Q Reliable operation Q Consistent quality O Reduced manpower Q Increased productivity O Reduced non productive time Q Shorter cycle time Q JIT Manufacture QO Lesser floor space Increased operational safety Q Machining advanced materials Disadvantages of CNC Machines = High machine cost = Complicated maintenance = Parts are imported from abroad = High tool cost = Temperature, humidity and dust must be controlled Applications of CNC System * Parts needed in a hurry * Parts with complicated contours + Parts requiring expensive jigs and fixtures * Parts those have several engineering changes * Cases where human errors can be extremely costly * Parts requiring close tolerance or good repeatabilityU Difference between NC ant CNC Machines Less flexible Machine is not controlled by o Input is given by punched tape Tape reading at the remote place Reliability is less Program editing is not possible | Simulation of part program 1s not possible | Storing the part program is difficult _NCMachines Mh Less capability ek NC Programers are skilled persons De S Gartioueyien, { Highly flexible CNC Machines \ Machine is controlled by computer Inputis directly given through computer Reading and editing at the machine site itself Reliability is more Program editing is possible Simulation of part program is possible Storing the part program is easy High capability Programmer not necessarily a skilled person >HP MGABWARSEAgE ops cace on. Lee SELLERS Sce ies o7 UBL ete pom greeoe teeter Functions automated by NC system - Starting and stopping of machine tool spindle. - Controlling the spindle speed, Advantages - Positioning the tool tip * Reduces non productive time - Guiding the tool in desired paths * Reduces manufacturing lead time * Greater manufacturing flexibility * Improves quality control * Reduced inventory Disadvantages Mactine * High investment cost ‘ol ¢ High maintenance effort. ¢ Part programming * Higher utilization of NC equipments 3 Basic Components of NC Sys Dr.$.CartigueyenAdvantages of CNC Mackties QO Higher accuracy | ) Reduce lead time Oj Higher flexibility ° QO) Reduce scrap rate QO Reliable operation Q Consistent quality QO) Reduced manpower C1 Increased productivity Q) Reduced non productive time Q Shorter cycle time, _ QO JIT Manufacture Qj Lesser floor space Q) Increased operational safety _ Disadvantages of CNC Machines = High machine cost = Complicated maintenance = Parts are imported from abroad _. ™ High tool cost = Temperature, humidity and dust must _ be controlled ' Applications of CNC System + Parts needed in a hurry + Parts with complicated contours * Parts requiring expensive jigs and fixtures * Parts those have several engineering changes * Cases where human errors can be extremely costly | * Parts requiring close tolerance or good repeatability