GROUP MEMBERS:

Chapter 7 Afifa Akter – 1808027

Azim Miah - 1808028
Bishowjit Paul – 1808029
CNC : Computer
A. K. M. Mohibur Rahman – 1808030
Numerical Control
Abu Bakar Siddik - 1808031
Enamul Hasan – 1808032

1
 Fundamentals of NC Technology
Theory
❑ Numerical control (NC) is a form of programmable automation in which the mechanical
actions of a machine tool or other equipment are controlled by a program containing coded
alphanumeric data.
❑ The alphanumeric data represent relative positions between a work head and a work part as
well as other instructions needed to operate the machine.
❑ The work head is a cutting tool or other processing apparatus, and the work part is the object
being processed.
❑ It is much easier to write new programs than to make major alterations in the processing
equipment.
❑ Numerical control can be applied to a wide variety of processes. The applications divide into
two categories: (1) machine tool applications, such as drilling, milling, turning, and other
metal working; and (2) other applications, such as assembly, rapid prototyping, and
inspection. The common operating feature of NC in all of these applications is control of the
work head movement relative to the work part

25 Nov 2023 2
 The Evolution of NC
1. Numerical Control Origin (1947):
1. Challenge: John C. Parsons faced difficulties making helicopter rotor blade templates quickly.
2. Innovation: He combined computer equipment with a jig borer, creating the first Numerical
Control (NC) system.
3. Implementation: Punched cards were used to control the digit Ron system.
2. U.S. Air Material Command (1949):
1. Need for Speed: The U.S. Air Material Command urgently required faster production of
complex plane and missile parts.
2. Parsons Corporation's Role: Parsons Corporation received a contract to address design
changes and improve production speed.
3. MIT Involvement: MIT's Servo-Mechanisms Laboratory served as a subcontractor.
3. Transition to MIT (1951-1952):
1. MIT Takeover: MIT assumed full control of the project in 1951.
2. Prototype Demonstration (1952): MIT successfully demonstrated the prototype using a
modified Cincinnati Hydrogel Milling Machine.
4. Origin of "Numerical Control" Term:
1. Coined at MIT: MIT introduced the term "Numerical Control."
2. Significance: MIT played a crucial role in formalizing and advancing the concept.

25 Nov 2023 3
 Basic Components of an NC System
An NC system consists of three basic components:

(1) A part program of instructions: The part program is

the set of detailed step-by-step commands that direct
the actions of the processing equipment.

(2) A machine control unit: The machine control unit

(MCU) is a microcomputer and related control hardware
that stores the program of instructions and executes it by
converting each command into mechanical actions of the
processing equipment, one command at a time.

(3) Processing equipment: The third basic component of

an NC system is the processing equipment that performs
the actual productive work (e.g., machining).

25 Nov 2023 4
 NC Coordinate Systems

Basic CNC Principles: All computer controlled machines are able to accurately and repeatedly
control motion in various directions. Each of these directions of motion is called an axis. Depending
on the machine type there are commonly two to five axes. Additionally, a CNC axis may be either a
linear axis in which movement is in a straight line, or a rotary axis with motion following a circular
path.

25 Nov 2023 5
 Motion Control Systems
Point-to-Point Versus Continuous Path Control

• Point-to-point systems, also called positioning systems, move the worktable to a programmed location
without regard for the path taken to get to that location.
• Continuous path systems are capable of continuous simultaneous control of two or more axes.

25 Nov 2023 6
 Motion Control Systems
CNC Interpolation

CNC Interpolation: CNC interpolation is how a computer-controlled machine calculates and moves
a cutting tool smoothly between points to create precise shapes during machining. It involves linear
movement for straight lines and circular movement for curves.

There are two main types of CNC interpolation:

➢ Linear interpolation: Linear interpolation involves moving the tool in a straight line between
two specified points. Linear interpolation is commonly used for straight cuts and contouring.

➢ Circular interpolation: Circular interpolation involves moving the tool in an arc or circular
path. This is particularly useful for machining curves, circles, and other rounded shapes

25 Nov 2023 7
 Motion Control Systems
CNC Interpolation

End Point End Point

Start Point Start Point

Fig: Linear interpolation. Fig: Circular interpolation.

25 Nov 2023 8
 Computers and Numerical Control (CNC)
➔ CNC is a technology that utilizes computerized systems to control machine tools and manufacturing
processes. Instead of manually operating machines, CNC systems use programmed instructions to
dictate the movement and operation of the machinery. These instructions are encoded in numerical
form, and the CNC machine interprets and executes them.

➔ In CNC machining, a computer program is created with the specific instructions for the tool or
machine. This program includes details about toolpaths, speeds, feeds, and other parameters
necessary for the manufacturing process. The CNC machine then reads and executes these
instructions, resulting in the automated and precise production of parts and components.

➔ CNC is widely used in various industries, including manufacturing, aerospace, automotive, and
more. CNC machines can be applied to a range of tools and equipment, such as milling machines,
lathes, routers, plasma cutters, and 3D printers. The advantages of CNC include precision,
repeatability, and the ability to produce complex parts with high efficiency.

25 Nov 2023 9
 NC to CNC
➔ Since the introduction of NC in 1952, there have been dramatic advances in digital
computer technology.
➔ The physical size and cost of a digital computer have been significantly reduced at the
same time that its computational capabilities have been substantially increased. The
makers of NC equipment incorporated these advances in computer technology into
their products, starting with large mainframe computers in the 1960s and followed by
minicomputers in the 1970s and microcomputers in the 1980s.
➔ Today, NC means computer numerical control (CNC), which is defined as an NC
system whose MCU consists of a dedicated microcomputer rather than a hardwired
controller.
➔ The latest computer controllers for CNC feature high-speed processors, large
memories, solid-state memory, improved servos, and bus architectures.

25 Nov 2023 10
 OPERATIONAL FEATURES of CNC MACHINES

25 Nov 2023 11
 Motion Control Systems

CNC Coordinates System

CNC (Computer Numerical Control) machining relies on a coordinate system to define the
position of the tool and workpiece.

Absolute and Incremental Coordinates:

● Absolute coordinates define positions relative to the origin point.

● Incremental coordinates define positions relative to the current tool position.
● Most programs use absolute coordinates for clarity and precision.

25 Nov 2023 12
 Motion Control Systems
CNC Coordinates System

Fig: Linear interpolation. Fig: Circular interpolation.

Absolute coordinates Incremental coordinates
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25 Nov 2023
 The CNC Machine Control Unit
CPU
● Control section
The MCU is the hardware ● Arithmetic logic unit
● Immediate access memory.
that distinguishes CNC
from conventional NC. The
general configuration of
the MCU in a CNC system
is illustrated in Figure.

The MCU consists of the components and subsystems:

(1) Central Processing Unit (2) Memory,
(3) I/O interface (4) Controls for machine tool axes and
spindle speed, and
(5) Sequence controls for other machine tool functions.
These subsystems are interconnected by means of a system bus, which communicates data and signals
among the components of the network
25 Nov 2023 14
 TYPES OF CNC MACHINE
There are many different types of CNC Machines used in industry,
Such as:
•Mills and Machining Centers
•Lathes and Turning Centers
•Drilling Machines
•EDM Sinker and wire cut Machines
•Flame and Laser-Cutting Machines
•Water Jet Profilers

25 Nov 2023 15
 CNC Lathe
➔ Automated version of a manual lathe.
➔ Programmed to change tools automatically.
➔ Used for turning and boring wood, metal and plastic.

❖ How CNC Lathe Works:

➢ Controlled by G (Geometric codes) and M (Miscellaneous codes) codes.
➢ These are number values and co-ordinates.
➢ Each number or code is assigned to a particular operation.
➢ Typed in manually to CAD/CAM by machine operators.
➢ G & M codes are automatically generated by the computer software.

25 Nov 2023 16
 CNC Lathe

25 Nov 2023 17
 Features of CNC Lathe

➔ The tool or material moves.

➔ Tools can operate in 1-5 axes.
➔ Larger machines have a machine control unit (MCU) which manages operations.
➔ Movement is controlled by a motors .
➔ Feedback is provided by sensors.
➔ Tool magazines are used to change tools automatically.

25 Nov 2023 18
 Tools

➔ Most are made from:

◆ High Speed Steel (HSS),
◆ Tungsten carbide or
◆ Ceramics.
➔ Tools are designed to direct waste away from the material.
➔ Some tools need coolant such as oil to protect the tool and work.

25 Nov 2023 19
 Tool Paths, Cutting and Plotting Motions
➔ Tool paths describes the route that the cutting tool takes.
➔ Motion can be described as point to point, straight cutting or contouring.
➔ Speeds are the rate at which the tool operates e.g. rpm.
➔ Feeds are the rate at which the cutting tool and workpiece move in relation to each other.
➔ Feeds and speeds are determined by cutting depth, material and quality of finish needed,
e.g. harder materials need slower feeds and speeds.
➔ Rouging cuts remove larger amounts of material than finishing cuts.
➔ Rapid traversing allows the tool or workpiece to move rapidly when no machining is taking
place.

25 Nov 2023 20
 NC Application Characteristics
➔ Batch Production.
➔ Repeat Orders.
➔ Complex part Geometry.
➔ Much metal needs to be removed from the work part.
➔ Many separate machining operations on the part.
➔ The part is Expensive.

25 Nov 2023 21
 Advantages of NC
➔ Nonproductive time is reduced.
➔ Greater accuracy and repeatability.
➔ Lower scrap rates.
➔ Operator skill requirements are reduced.
➔ Less floor space.
➔ Reduced parts inventory.
➔ Shorter manufacturing lead times.
➔ Simpler Fixtures.
➔ Inspection requirements are reduced.
➔ More complex part geometries are possible.
➔ Engineering changes can be accommodated more gracefully.

25 Nov 2023 22
 Disadvantages of NC

➔ Higher investment cost.

➔ Higher maintenance effort.
➔ Part programming.
➔ Higher utilization of NC equipment.

25 Nov 2023 23
 CNC programming

● CNC programming (Computer Numerical Control Programming) is a method for

creating computer program instructions to control machine tools.
● It consists of planning and documenting the sequence of processing steps to be
performed by an CNC machine.
● CNC instructions are called part program commands.
● When running, a part program is interpreted one command line at a time until all
lines are completed.
● A word specifies a detail about the operation, such as x-position, y-position,
feed rate, or spindle speed.
● Out of a collection of words, a block is formed. A block is one complete NC
instruction.

25 Nov 2023 24
 Types of CNC programming

1. Manual part programming

2. Computer-assisted part programming
3. CAD/CAM part programming
4. Manual data input

25 Nov 2023 25
 CNC programming

Important things to know:

● Coordinate System
● Units, incremental or absolute positioning
● Coordinates: X,Y,Z
● Feed rate and spindle speed
● Coolant Control: On/Off, Flood, Mist
● Tool Control: Tool and tool parameters

25 Nov 2023 26
 Coding For Manual Part Programming
Common Word Prefixes Used in Word Address Format

Word Prefix Example Function

N N001 Sequence number

G G21 Preparatory word; prepares controller for instructions given in the block.

X, Y, Z X31.0 Coordinate data for three linear axes.

R R100 Radius of arc; used in circular interpolation.

F F40 Feed rate per minute or per revolution in either inches or millimeters

S S0800 Spindle rotation speed in rev/min, expressed in four digits.

T T14 Tool selection

M M03 Miscellaneous command

25 Nov 2023 27
 Table of Important G codes
G-word Function

G00 Point-to-point movement (rapid traverse)

G01 Linear interpolation movement. Block must include x–y–z coordinates of end position.

G02 Circular interpolation, clockwise.

G17 Selection of x–y plane in milling.

G21 Input values specified in millimeters.

G28 Return to reference point.

G90 Programming in absolute coordinates.

G91 Programming in incremental coordinates.

G92 Specify location of coordinate axis system origin relative to starting location of cutting tool

G94 Specify feed per minute in milling and drilling.

25 Nov 2023 28
 Table of Important M codes

M-word Function
M00 Program stop

M01 Optional program stop

M02 Program end

M03 Spindle on clockwise

M04 Spindle on counterclockwise

M05 Spindle stop

M06 Tool change

M08 Coolant on

M30 Program stop, reset to start

25 Nov 2023 29
 Programming example - 1

Define the origin at X = 0, Y = -50, Z = 10

G92 X0 Y-050.0 Z010.0

Programming example - 2

Define the origin at X = 0, Y = -50, Z = 10 and coordinate values are in millimeters

G21 G92 X0 Y-050.0 Z010.0

25 Nov 2023 30
 Programming example - 3

N001 G00 X07000 Y03000 M03

N002 Y06000

25 Nov 2023 31
 Programming example - 4

G02 G17 X088.0 Y040,0 R028.0 F30

25 Nov 2023 32
 Programming example - 5

25 Nov 2023 33
 Programming example - 5

25 Nov 2023 34
 Solution:

25 Nov 2023 35
 Analysis of Positioning System
An NC positioning system helps move the tool and work part during machining based on the coordinates given
in the program.

Gear Mechanism-
Gear Reduction
Servo/

Machine Control Unit (MCU) 1 Revolution= worktable moves a distance= 1 Pitch

P (mm/Thread)
Velocity of worktable ∝ Rotational speed of the
Screw
⮚ The worktable moves in a straight line using a rotating leadscrew or ball screw, driven by a stepper motor or
servo motor—a common set up in a one-linear-axis NC positioning system.
⮚ To make it move in both the horizontal (x) and vertical (y) directions, put another part on top that goes the
other way, like a second floor on a building- piggybacked.

36
 Classification
Two types of control systems are used in positioning systems:
1. Open loop system:
operates without verifying that the actual position (worktable) achieved in the move is the same
as the desired position.
❖ Advantage: cheaper and suitable, little resistance to motion
❖ Disadvantage: Metal waste, Higher Energy Consumption

2. Closed Loop Control:

A closed-loop system double-checks the worktable's final position by using feedback measurements to ensure
it matches the programmed location. Used in continuous path operations such as milling or turning.
❖ Advantage: Positioning accuracy.
❖ Disadvantage: Pricier, substantial forces oppose the
cutting tool's forward motion.

37
 Basic Stepper Motor System Configuration

Programs in the PLC are converted into pulse signals in the controller, then converted into motor controlling
electrical current in the driver.
4 Phase Stator
C

B D

e
ngl
pA
D1 B1

Ste
C1

38
 Open Loop Positioning System
❖ Uses Stepper Motor
❖ Driven by series of Electrical Pulses (Generated in MCU)

The angle through which the motor shaft

rotates, Am = angle of motor shaft rotation, °
np = number of pulses received by the
motor
a = step angle, °/pulse.
The angle of the screw rotation must take the gear ratio into account,
As = angle of screw rotation, °;
rg = gear ratio, defined as the number of turns of the motor for each
single turn of the screw

Nm,Ns = rotational speed of the motor and screw, rev/min

39
 Open Loop Positioning System
The linear movement of the worktable is given by the number of full and partial rotations of the screw
multiplied by its pitch, x = x axis position relative to the starting position, mm (in);
p = pitch of the screw mm/rev (in/rev); and
As>360 = number of screw revolutions.

The number of pulses required to achieve a specified x-position increment in a point-to-point system can be
found using combinations of Equations 1, 3 and 5…

Control pulses are transmitted from the pulse generator at a certain frequency, which drives the worktable at a
corresponding velocity or feed rate in the direction of the screw axis. The rotational speed of the screw depends
on the frequency of the pulse train as Ns = screw rotational speed, rev/min;
fp = pulse train frequency, Hz;
ns = steps per revolution or pulses per revolution
The table travel speed in the direction of screw axis is determined by the rotational speed as
vt = table travel speed, mm/min (in/min);
fr = table feed rate, mm/min (in/min);
Ns = screw rotational speed, rev/min; and
p = screw pitch, mm/rev (in/rev)
40
 Open Loop Positioning System
The required pulse train frequency to drive the table at a specified linear travel rate

Example 7.1: NC Open-Loop Positioning

The worktable of a positioning system is driven by a ball screw whose pitch = 6.0 mm. The screw is connected to
the output shaft of a stepper motor through a gearbox whose ratio is 5:1 (five turns of the motor to one turn of the
screw). The stepper motor has 48 step angles. The table must move a distance of 250 mm from its present
position at a linear velocity = 500 mm/min. Determine (a) how many pulses are required to move the table the
specified distance and (b) the required motor speed and pulse rate to achieve the desired table velocity.

41
 Servo Motor System Configuration

Optical Encoder

❖ Device for measuring rotational position and speed

❖ Common feedback sensor for closed-loop NC control

42
 Closed-Loop Positioning Systems
❖ Uses servo motor
❖ Feedback measurement sensor – optical encoder
❖ a gear reduction between the servomotor and the screw driving the worktable
In the basic optical encoder, the angle between slots in the disk must satisfy the following requirement
a = angle between slots, °/slot; and
ns = number of slots in the disk, slots/rev.

For a certain angular rotation of the encoder shaft, the number of pulses sensed by the encoder is given by
np = pulse count emitted by the encoder
As = angle of rotation of the encoder shaft, °
a = angle between slots, which converts to °/pulse.

The pulse count can be used to determine the distance moved by the worktable along the x-axis (or y-
axis
∆x = distance moved along the axis, mm (in)
p = screw pitch, mm/rev (in/rev).

43
 Closed-Loop Positioning Systems
The velocity of the worktable, which is normally the feed rate in a machining operation, is determined by
the rotational speed of the screw, which in turn is driven by the servomotor
vt = worktable velocity, mm/min (in/min);
fr = feed rate, mm/min (in/min);
Ns = screw rotational speed, rev/min;
Nm = motor rotational speed, rev/min;
rg = gear reduction ratio.

At the worktable velocity or feed rate given by Equation (7.15), the pulse frequency emitted by the encoder
is the following:
fp = frequency of the pulse train, Hz
the constant 60 converts worktable velocity or feed rate from
mm/sec (in/sec) to mm/min (in/min).

44
 Closed-Loop Positioning Systems
Example 7.2 NC Closed-Loop Positioning
An NC worktable operates by closed-loop positioning. The system consists of a servomotor, ball screw, and optical
encoder. The screw has a pitch of 6.0 mm and is coupled to the motor shaft with a gear ratio of 5:1 (five turns of the
drive motor for each turn of the screw). The optical encoder generates 48 pulses/ rev of its output shaft. The table
has been programmed to move a distance of 250 mm at a feed rate = 500 mm/min. Determine (a) how many pulses
should be received by the control system to verify that the table has moved exactly 250 mm, (b) the pulse rate of
the encoder, and (c) the drive motor speed that corresponds to the specified feed rate

45
 Precision in Positioning Systems
❖ an NC positioning system - a high degree of precision
❖ Three measures of precision can be defined for an NC positioning
system:
(1) Control resolution,
(2) Accuracy,
(3) Repeatability.

46
 Precision in Positioning Systems
1. Control Resolution:
Defined as the distance separating two adjacent addressable points in the axis movement
❖ Addressable points are locations along the axis to which the worktable can be specifically directed to go.

❖ Desirable: CR as small as possible

❖ Location of addressable points depend on the limitations
imposed by:
1. The Electromechanical components of positioning system
2. The number of bits used by the controller to define the axis
coordinate location

❖ Electromechanical components: Screw pitch, Gear ratio, Step

angle or angle between slots
❖ For an open-loop and close loop,

CR1 = control resolution of the electromechanical components,

mm (in);

47
 Precision in Positioning Systems

❖ Number of bits: If B = the number of bits in the storage register for the axis, then the number of control points
into which the axis range can be divided = .

Assuming the control points are equally spaced,

CR2 = control resolution of the computer control system, mm (in)

L = axis range, mm (in)
❖ The control resolution of the positioning system is the maximum of the two values; that is

❖ Nearly all of the mechanical errors (99.73%) are contained within of the control point.

2. Accuracy:
The maximum possible error that can occur between the desired target point and the actual position taken by
the system
Ac = accuracy, mm (in);
CR = control resolution, mm (in); and
σ = standard deviation of the error distribution.
48
3. Repeatability:
The ability of the positioning system to return to a given addressable point that has been previously programmed.

❖ The repeatability of any given axis of a positioning system is standard deviations of the mechanical error distribution
associated with the axis. This can be written as,
Re = repeatability, mm (in).

49
 Example 7.3 Control Resolution, Accuracy, and Repeatability in NC
Suppose the mechanical inaccuracies in the open-loop positioning system of Example 7.1 are described by a
normal distribution with standard deviation = 0.005 mm. The range of the worktable axis is 1,000 mm, and there
are 16 bits in the binary register used by the digital controller to store the programmed position. Other relevant
parameters from Example 7.1 are the following: pitch = 6.0 mm, gear ratio between motor shaft and screw = 5.0,
and number of step angles in the stepper motor = 48. Determine the (a) control resolution, (b) accuracy, and (c)
repeatability of the positioning system

50
Thank You

51