Module-III

Numerical Control
 What is CAD ?
 What is CAM ?

 What are the CAD/CAM packages ?

 Where would CAD / CAM be used?

 Why is it an advantage to use CAM?

Types of NC systems Machine controls are
divided into three groups, Œ

1. Traditional numerical control (NC)

2. Computer numerical control (CNC)
3. Distributed numerical control (DNC).
 Numerical control can be defined as
a form of programmable automation
in which process is controlled by
numbers,letters and symbols.

 InNC,the numbers form a programme of

instructions designed for a particular
workpart or job. When job changes the
program of instruction changes. This
capability to change a program for each
new job gives NC its flexibilty.
 In a broad sense, numerical
control converts numerical values
into physical values, such as
quantities and dimensions.
*NC machine tools one or more of the
following functions may be Automatic
-Starting and stopping of machine tool
spindle
-controlling the spindle speed
-Positioning the tooltip at desired locations
-Changing the tools of spindle
-controlling the rate of movement of the tool
tip.
Basic Elements or components of NC
system
An operational numerical control system
consists of the following three basic
components:
1. Program of instructions.
2. Controller unit, also called machine tool
unit.
3. Machine tool or other controlled
process.
Tape
 The program of instruction is a numerical or
symbolic code that is detailed step-by-step to
tell the machine tool what to do.
 The controller unit is the unit that reads the
programme of instructions and converts it to
real movement of a machine tool. Two basic
types of control unit are used with NC
machines: open-loop control and closed-loop
control.
 The machine tool performs the mechanical work
and deals directly with the part being
machined.
 Thetape reader is an electrical-
mechanical device for the winding and
reading the punched tape containing the
program of instructions. The signal output
channels are connected to the servo
motors.

 Theprogram of instructions serves as

input to the controller unit, which in turn
commands the machine tool or other
process to be controlled.
Program of Instructions.

It is coded in numerical or symbolic

form on some type of input medium that
can be interpreted by the controller unit.
The most common one is the 1-inch-wide
punched tape. Over the years, other forms
of input media has been used, including
punched cards, magnetic tape, and even
35mm motion picturefilm.
Machine Control Unit
 MCU consists of electronics and hardware
that read and interpret the program of
instructions and convert it to mechanical
actions of the machine tool.
 The typical elements of the controller unit
include the tape reader, a data buffer,
signal output channels to the machine tool,
and the sequence controls to co-odinate the
overall operation of the foregoing
elements.
 MachineTool

The machine tool consists of the

worktable and spindle as well as the motors
and controls necessary to drive them. It also
includes the cutting tools, work fixtures and
other auxillary equipment needed in
machining operation.
 HOW NUMERICAL CONTROL WORKS
 As the prepared tape passes through the
tape reader head, silicon photo diodes sense
light as it passes through holes in the tape.

 This causes signals to be sent to the

electronic control.

 The number and location of the holes in

each row across the tape conform to a code.
 The code is interpreted by the control
unit. This unit stores all information until a
complete block of information is obtained.

 The control then causes the motors to

make the required number of steps.

 During the tool cycle, the next tape block

will be read and stored.
 The major advantages of NC over
conventional methods

 higher precision
 better quality
 higher productivity
 multi-operational machining
Applications of NC
Machine tool applications:
1. Milling machines.
2. Drilling machines.
3. Boring machines.
4. Turning machines.
5. Grinding machines.

Non- machine tool applications:

1. Welding machines- flame cutting machines.
2. Press-working machines- assembly
machines.
3. Inspection machines- automatic drafting machines
 NC Modes or 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)
 Also applicable in robotics

2. Continuous path systems

 Also called contouring systems in machining
 System performs an operation during movement
 (e.g., milling and turning)
 Point-to-point (PTP) NC
 The cutting tool is moved relative to the work piece
(i.E., Either the cutting tool moves, or the work piece
moves) until the cutting tool is at a numerically
defined position and then the motion is paused.
 The cutting tool then performs an operation.
 When the operation is completed, the cutting tool
moves relative to the work piece until the next point is
reached, and the cycle is repeated.
 The simplest example of a PTP NC machine tool is the
NC drilling machine.

Production Automation
Technologies (Henry C. Co) 30
 Straight-cut NC
 Straight-cut system are capable of moving
the cutting tool parallel to one of the
major axes (X-Y-Z) at a controlled rate
suitable for machining.
 It is appropriate for performing milling
operations to fabricate work pieces of
rectangular configurations.
 Straight-cut NC systems can also perform
PTP operations.
Production Automation
Technologies (Henry C. Co) 31
 Contouring NC
 In contouring (continuous path)
operations, the tool is cutting while the
axes of motion are moving.
 The axes can be moved simultaneously, at
different velocity.
 The path of the cutter is continuously
controlled to generate the desired
geometry of the work piece.
 Interpolation Methods
1. Linear interpolation
– Straight line between two points in
space
2. Circular interpolation
– Circular arc defined by starting point,
end point, center or radius, and
direction
3. Helical interpolation
– Circular plus linear motion
4. 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.

 Controlled Axes
 NC system can be classified on the number of
directions of motion they are capable to control
simultaneously on a machine tool. Each free
body has six degree of freedom, three positive
or negative translations along x, y, and z-axis,
and three rotations clockwise or counter
clockwise about these axes.
 Commercial NC system is capable of controlling
simultaneously two, two and half, three, four
and five degrees of freedom, or axes. The NC
systems which control three linear translations
(3-axis systems), or three linear translations and
one rotation of the worktable (4-axis systems)
are the most common
 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