Unit 5 Numerical Control

Sections:
1. Fundamentals of NC Technology
2. Computer Numerical Control
3. Distributed Numerical Control
4. Applications of NC
5. NC Part Programming

Numerical Control (NC) Defined

Programmable automation in which the mechanical actions of a machine
tool are controlled by a program containing coded alphanumeric data
that represents relative positions between a work head (e.g., cutting
tool) and a work part
Program
Program
Instructions
Instructions

Machine
Machine
Control
Control Unit
Unit

Transformation
Process
Power
Power

NC Coordinate Systems
For flat and prismatic (block-like) parts:
Milling and drilling operations
Conventional Cartesian coordinate system
Rotational axes about each linear axis
For rotational parts:
Turning operations
Only x- and z-axes

Motion Control Systems

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
Continuous path systems
Also called contouring systems in machining
System performs an operation during movement
(e.g., milling and turning)

Interpolation Methods
1.

2.

3.
4.

Linear interpolation

Straight line between two points in

space
Circular interpolation

Circular arc defined by starting point,

end point, center or radius, and
direction
Helical interpolation

Circular plus linear motion

Parabolic and cubic interpolation

Free form curves using higher order

equations

Absolute vs. Incremental Positioning

Absolute positioning
Move is: x = 40, y = 50
Incremental positioning
Move is: x = 20, y = 30.

Computer Numerical Control (CNC)

Storage of more than one part program

Various forms of program input
Program editing at the machine tool
Fixed cycles and programming subroutines
Interpolation
Acceleration and deceleration computations
Communications interface
Diagnostics

Machine Control Unit

DNC
Direct numerical control (DNC) control of multiple
machine tools by a single (mainframe) computer
through direct connection and in real time
1960s technology
Two way communication
Distributed numerical control (DNC) network
consisting of central computer connected to machine
tool MCUs, which are CNC
Present technology
Two way communication

Distributed Numerical Control

Central
Central
Computer
Computer

NC Pgms

Computer Network

Transformation
Process

BTR

BTR

BTR

Machine
Machine
Control
Control Unit
Unit

Machine
Machine
Control
Control Unit
Unit

Machine
Machine
Control
Control Unit
Unit

Applications of NC

NC Application Characteristics
(Machining)

Batch and High Volume production

Repeat and/or Repetitive orders
Complex part geometries
Mundane operations
Many separate operations on one part

Cost-Benefits of NC
Costs
High investment cost
High maintenance effort
Need for skilled programmers
High utilization required
Benefits
Cycle time reduction
Nonproductive time reduction
Greater accuracy and repeatability
Lower scrap rates
Reduced parts inventory and floor space
Operator skill-level reduced

Precision

NC Part Programming
1.
2.
3.
4.

Manual part programming

Manual data input
Computer-assisted part programming
Part programming using CAD/CAM

Manual Part Programming

Binary Coded Decimal System
Each of the ten digits in decimal system (0-9) is
coded with four-digit binary number
The binary numbers are added to give the value
BCD is compatible with 8 bits across tape format, the
original storage medium for NC part programs
Eight bits can also be used for letters and symbols

Creating Instructions for NC

Bit - 0 or 1 = absence or presence of hole in the tape
Character - row of bits across the tape
Word - sequence of characters (e.g., y-axis position)
Block - collection of words to form one complete
instruction
Part program - sequence of instructions (blocks)

Block Format
Organization of words within a block in NC part program
Also known as tape format because the original
formats were designed for punched tape
Word address format - used on all modern CNC
controllers
Uses a letter prefix to identify each type of word
Spaces to separate words within the block
Allows any order of words in a block
Words can be omitted if their values do not
change from the previous block

Types of Words
N - sequence number prefix
G - preparatory words
Example: G00 = PTP rapid traverse move
X, Y, Z - prefixes for x, y, and z-axes
F - feed rate prefix
S - spindle speed
T - tool selection
M - miscellaneous command
Example: M07 = turn cutting fluid on

Example: Word Address Format

N001 G00 X07000 Y03000 M03
N002 Y06000

Cutter Offset
Cutter path must be
offset from actual
part outline by a
distance equal to
the cutter radius

Issues in Manual Part Programming

Adequate for simple jobs, e.g., PTP drilling
Linear interpolation
G01 G94 X050.0 Y086.5 Z100.0 F40 S800
Circular interpolation
G02 G17 X088.0 Y040.0 R028.0 F30
Cutter offset
G42 G01 X100.0 Y040.0 D05

Example
NC part program code

Comments

N001 G21 G90 G92 X-050.0 Y-050.0 Z010.0;

N002 G00 Z-020.0 S1989 M03;
N003 G01 G94 G42 Y0 D05 F398;
N004 G01 X075.0;
N005 G01 X150.0 Y043.02;
N006 G01 Y070.0;
N007 G01 X080.0;
N008 G17 G02 X050.0 Y100.0 R030.0;
N009 G01 Y125.0;
N010 G01 X0;
N011 G01 Y0
N012 G40 G00 X-050.0 Y-050.0 Z010.0 M05;
N013 M30;

Define origin of axes.

Rapid to cutter depth, turn spindle on.
Bring tool to starting y-value, start cutter offset.
Mill lower horizontal edge of part.
Mill angled edge at 35 degrees.
Mill vertical edge at right of part.
Mill horizontal edge leading to arc.
Circular interpolation around arc.
Mill vertical step above arc.
Mill top part edge.
Mill vertical edge at left of part.
Rapid move to target point, cancel offset, spindle stop.
End of program, stop machine.

Manual Data Input

Machine operator does part programming at

machine
Operator enters program by responding to
prompts and questions by system
Monitor with graphics verifies tool path
Usually for relatively simple parts
Ideal for small shop that cannot afford a part
programming staff
To minimize changeover time, system should
allow programming of next job while current job
is running

Computer-Assisted Part Programming

Write machine instructions using natural language

type statements
Statements translated into machine code of the MCU
APT (Automatically Programmed Tool) Language

Sample Statements
Part is composed of basic geometric elements and
mathematically defined surfaces
Examples of statements:
P4 = POINT/35,90,0
L1 = LINE/P1,P2
C1 = CIRCLE/CENTER,P8,RADIUS,30
Tool path is sequence of points or connected line and arc
segments
Point-to-Point command: GOTO/P4
Continuous path command: GOLFT/L1,TANTO,C1

NC Part Programming Using

CAD/CAM

YouTube

CNC Milling
CNC Punching
CNC Adhesive Bonding
CNC Drug Insertion
CNC Bioprocessing
CAD/CAM
Etc.