ME 473

Computer-Aided Design/Manufacturing
Lecture 3

F. NYARKO
fnyarko.coe@gmail.com // 0261807208
Jan 2014
 Unit 3
FUNDAMENTALS OF NUMERICALLY CONTROLLED (NC) AND
COMPUTER NUMERICALLY CONTROLLED (CNC) MACHINES

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 Introduction
Conventional power driven machines (machine tools) are capable of
generating high forces required for machining, but to use the tool, one needs
to;
• determine the location on the work-piece where machining is to be done
• control the path followed during the motion of the tool or work-piece
• and control the rate at which the path is traversed.

Further problems associated with the use of conventional power driven

machines includes;
• a highly skilled operator is required even for a simple job,
• inconsistency in results,
• much longer time required depending on knowledge and skill of operator,
• difficulty in manufacturing complex products and low productivity.
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 Numerically Controlled (NC) Machines have the same technological
capabilities as of conventional machines in terms of machining, but differ
in control of machine functions.

NC machines are used to manufacture complex curved geometries which

is extremely expensive by mechanical means (which usually would require
complex jigs to control the cutter motions). NC machines are capable of
machining components with repeatable accuracy since machining
operations are carried out with little or no human intervention.

In this Unit we shall study how NC machines are classified, types of

control systems and some basic programming commands for CNC
machining operations.

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 Learning Objectives

After studying this unit you should be able to:

• Define NC and explain the various NC classification.
• List and explain the types NC control systems, their
advantages and drawbacks.
• List advantages of NC, CNC &CAD/CAM versus
(Manual Machining)
• List the major phases of a CNC part programme.
• Explain the basic CNC programming commands.

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 Unit content
• Session 1-3: NC MACHINES AND TYPES OF CONTROL SYSTEMS
• 1-3.1 Classification of NC Machines
• 1-3.1.1 NC: Numerically Control
• 1-3.1.2 DNC: Distributed Numerical Control
• 1-3.1.3 CNC: Computer Numerical Control
• 1-3.1.4 CAD/CAM (fully integrated system)

• 1-3.2 Types of (NC) and (CNC) Machines

• 1-3.2.1 Types of NC control systems
• 1-3.2.1.1 Open Loop System.
• 1-3.2.1.2 Closed Loop System.
• 1-3.2.2 Types of CNC machines
• 1-3.2.2.1 Based on Motion Type
• 1-3.2.2.2 Based on Control Loops
• 1-3.2.2.3 Based on ‘Power Supply’
• 1-3.2.2.4 Based on Positioning System
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 Unit content
Session 2-3: FUNDAMENTALS OF CNC MACHINES

• 2-3.1 Machine coordinate system

• 3-3.1 Manual Part Programming (G-Code)
• 3-3.1.1 CNC Codes (G – Codes)
• 3-3.1.2 CNC Codes ( M – Codes)
• Session 3-3: NC PART PROGRAMMING
• 3-3.2 The Major Phases of a CNC Program
• 3-3.3 Programming CNC Machines
• 3-3.3.1 Preparing a CNC Program
• 3-3.3.2 Sample Program

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 1-3 NC MACHINES
Numerical Control (NC) is the use of coded numerical
information in the automatic control of equipment positioning.
The term ‘NC’ is used to describe the control of the various
functions of a machine using numeric data. Generally, there are
three basic components of an operational NC namely;
• Programme of instruction.
• A machine control unit.
• Machine tool.

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 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 Machine control unit (MCU)

• 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.

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 Capabilities of Machine control unit (MCU) of a NC machine
include:
• Positioning the tool
• Turning the spindle ON/OFF
• Setting cutting speeds/feed rates
• Turning coolant ON/OFF
• Direction and rate of slide motion, spindle rotation, etc.

The machine tool

• performs the mechanical work and deals directly with the
part being machined.

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A TYPICAL NC MACHINE
 1-3.1 Classification of NC Machines
NC machines can classified into four main types namely; Numerical Control
(NC), Distributed Numerical Control (DNC), Computer Numerical Control
(CNC) and CAD/CAM (fully integrated system)

1-3.1.1 NC Numerical Control

Refers to the automation of machine tools that are operated by abstractly
programmed commands encoded on a storage medium. Electric control based
on paper tape, hard wired CPU.

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 1-3.1.2 DNC Direct/Distributed Numerical
Control
• This is where an off-site single, fast mainframe computer
holds the tool motion command for all the parts to be
produced.
• This computer centrally controls each NC machine (time
sharing). The off-site computer and the NC machines are
linked through a local area network (LAN).
• The information is downloaded only when the machine that
will do the work has been determined. Production stops if
Central CPU goes down.

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 1-3.1.3 CNC Computer Numerical
Control
• CNC refers to a computer that is joined to the NC
machine to make the machine versatile.
• The programme is read from a storage medium such as
the punched tape or magnetic medium (tape or disk) and
retrieved to the memory of the CNC computer.
• CNC machines with magnetic medium (tape or disk) for
storing programs have the flexibility for editing or saving
CNC programs Each CNC has its own CPU, may be
retrofitted.
• Production continues if central CPU goes down

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 1-3.1.4 CAD/CAM (fully integrated system)

• Computer-Aided Design / Computer-Aided Mfg

• Stronger design / manufacturing database
• Enhanced knowledge (CPU), off-line error-checking
• More productive, flexible; less tedious and error-prone

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 1-3.2 TYPES OF CONTROL SYSTEMS FOR (NC) AND (CNC) MACHINES

1-3.2.1 Types of NC control systems

Two basic types of control unit are used with NC machines: Open-loop
control and Closed-
1-3.2.1.1 Open-loop Control loop control.

• Stepper motor is used, having a predefined amount of revolution.

• Current pulses are send from MCU to individual motors.
• Movement/rotation depends on number of pulses send.

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 Advantages of Open-loop Control:
 Position is maintained just by keeping track of number of revolutions.
 Can produce a movement of 1/1000th of an inch, for a single pulse.
 Cheap and less complex.
 Easy to maintain.
Drawback:
 Assumption: Motor movement is precise, i.e. motor is moving the exact amount
depending on the number of pulses.
 No way to correct errors, because no feedback.

• This control is not suitable for large machines requiring greater power
because of limitation of stepper motor to generate high torque.

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 1-3.2.1.2 Closed-loop Control

• Direct current (DC) motors are used.

• Can generate high levels of torque.
• Can be reversed.
• Unlike stepper motors, it cannot achieve very precise
movement.
• Separate positions sensors are required.
• Position information is fed back as a signal to the controller

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Major advantage of Closed-loop Control:
• because of feedback and servo motors formed a closed loop reversible
feature, errors can be corrected, by comparing with target position.
• Higher accuracy than open loop systems because of feedback.
Applications:
• Larger NC machines because of higher loads.
• For greater accuracy, any kind of load.
Drawback
Expensive and complex.

1-3.2.2 Types of CNC machines

• CNC machines can be classified into four main types based on the following;
• Based on Motion Type
• Based on Control Loops:
• Based on ‘Power Supply’:
• Based on Positioning System

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 -3.2.2.1 Based on Motion Type:
1(a)- Point- to-point

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 1(b) Continuous Path (Angles and Arcs)
Linear path interpolation
Incremental path approximation
Interpolation using circular or other equations

• 1-3.2.2.2 Based on Control Loops:

• Open loop or Closed loop ( as discussed in NC control systems
types)
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 1-3.2.2.3 Based on ‘Power Supply’:
Electric or Hydraulic or Pneumatic
1-3.2.2.4 Based on Positioning System:
Incremental or Absolute ( To be discussed in later
session)
1-3.2.3 Advantages of NC, CNC &CAD/CAM (vs. Manual)
• Flexibility
• Easily reprogrammed
• Capability for complex work pieces
• Control more than two axes simultaneously (vs. manual)
• Programmed for sequences of operations
• Tool changing capability
• Single head accepting multiple tools from a magazine
• Reduced fixturing costs
• More axes, more tools fewer machine setups
• Repeatability (Quality)
• Reduced number of variability sources (vs. manual)

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 1-3.2.4 Impact on Labour (vs. manual production)

Skills change
• Manual capability vs. Knowledge capability
• Increased wages
• Doing away with Seniority tradition
• Not just a labor union tradition
• Increased operator responsibility
• Put the best people where the money is
• Increased productivity
• Fewer people needed to achieve output
• Lower cost for the product when produced in volume

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 • Self-Assessment 1-3

•
1.Define NC and list the various types of NC machines.

2.With the aid of labelled sketches explain briefly the two types of NC control systems.

3.List the four types of CNC machines.

4.List five advantages of NC, CNC &CAD/CAM systems.

5.Explain briefly the impact of CNC machines on labour comparing with manual machining.

• Answer tips

•Please refer to notes

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 2-3 FUNDAMENTALS OF CNC MACHINES

2-3.1 Machine coordinate system designation

• The direction of each finger represents the positive direction of motion.
• The axis of the main spindle is always Z, and the positive direction is into the
spindle.
• On a mill the longest travel slide is designated the X axis and is always perpendicular
to the Z axis.
• If you rotate your hand looking into your middle finger, the forefinger represents the
Y axis.
• The base of your fingers is the start point or (X0, Y0, Z0).

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 • The right-hand rule for determining the correct axis on a CNC
machine may also be used to determine the clockwise rotary
motion about X, Y, and Z.
•
• To determine the positive, or clockwise, direction about an axis,
close your hand with the thumb pointing out.
•
• The thumb may represent the X, Y, or Z direction and the curl
of the fingers may represent the clockwise, or positive, rotation
about each axis.
• These are known as A, B, and C and represent the rotary
motions about X, Y, and Z, respectively.

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 2-3.1.2 Axis and motion nomenclature – CNC mill
 On this gantry mill the spindle travels along the X Axis.
 The travel direction of the table designates the Y Axis.
• The Z Axis is designated by the stationary vertical
column.

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 2-3.1.3 Axis and motion nomenclature – vertical CNC knee
mill
On a common vertical knee CNC mill the spindle is stationary
while the rest of the components move according to their axis
designations (X, Y, and Z).

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 2-3.1.4 Axis and Motion Nomenclature – 5-axis CNC Contour Mill
 On this five-axis horizontal contour milling machine, note the
orientation of the X and Y axes in relation to the Z Axis.
 The rotary axes for both the X and Y axes are designated by the
A and B rotary tables.

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 2-3.1.5 Axis and motion nomenclature – CNC lathe
On most CNC lathes the Z Axis is parallel to the spindle and longer than the X
Axis.

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 2-3.1.6 CNC Milling Fundamentals – The three Cartesian planes

The three planes in the Cartesian coordinate system are

XY, XZ, and YZ. These are referred to as G17, G18,
and G19, respectively, on the mill.
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 •2-3.1.7 Part Reference Zero (PRZ)
All CNC machine tools require a reference point from which to base
coordinates.
It is generally easier to use a point on the work-piece itself for reference,
thus the PRZ designation.
The PRZ is defined as the lower left-hand corner and the top of the
stock of each part.
2-3.1.8 The Cartesian Graph
•Most Cartesian graphs for milling and turning use a three-axis coordinate
system denoted by the X, Y, and Z axes. These coordinates are used to
instruct the machine tool where to move on the work-piece.

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 2-3.1.9 CNC Milling Fundamentals – Absolute Coordinates

• Absolute coordinates use the

origin as the reference point.

• This means that any point on

the Cartesian graph can be
plotted accurately by
measuring the distance from
the origin to the point, first in
the X direction, then in the Y
direction, and then, if
applicable, in the Z direction.

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 2-3.1.10 CNC Milling Fundamentals –
Incremental Coordinates
• Incremental coordinates use
the present position as the
reference point for the next
movement.
•
• This means that any point in
the Cartesian graph can be
plotted accurately by
measuring the distance
between points, generally
starting at the origin.

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 2-3.1.11 CNC Turning Fundamentals
• Primary, or horizontal, axis and
Secondary, or vertical, axis
• The Z axis is usually the longer.

• The X axis is perpendicular to

the Z axis (or vertical).
• When measuring X and Z
coordinates, use a central
reference point. Start all
measurements at this reference
point, the origin point (X0, Z0).
For all our examples the origin
is located at the center right-
hand endpoint of the
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 2-3.1.12 CNC turning fundamentals –
Diameter programming
• Diameter (or diametrical)
programming relates the X axis
to the diameter of the work
piece.
•
• For example, if the work piece
has a 5-in. outside diameter
and you want to command an
absolute move to the outside,
you would program X5.0.

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 2-3.1.13 CNC turning fundamentals –
Radial programming
 Radius (or radial)
programming relates
the X axis to the
radius of the
workpiece.
•
 For example, for the
same 5-in. outside
diameter workpiece,
you would program
X2.5 to move the tool
to the outside.
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 2-3.1.14 CNC turning fundamentals – Absolute
coordinates
 When plotting points using
absolute coordinates, always
start at the origin (X0, Z0). Then
travel along the Z axis until you
reach a point directly below the
point that you are trying to plot.
•
 Write down the Z value and then
go up until you reach your point.
Write down the X value. You
now have the XZ (or ZX)
coordinate for that point.
•
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 2-3.1.15 CNC turning fundamentals –
Incremental coordinates
 The second method for
finding points in a
Cartesian coordinate system
is by using incremental
coordinates.
•
 Incremental, or relative,
coordinates use each
successive point to measure
the next coordinate. Instead
of constantly referring back
to the origin, the
incremental method refers
to the previous point
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  Self-Assessment 2-3

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 Self-Assessment 2-3
• What is the value in X and Y for each hole in ABSOLUTE G90 positioning when each move
• is defined from a single fixed part zero point of an X0 Y0 origin point.
1. PT1 = X______ Y______
2. PT2 = X______ Y______
3. PT3 = X______ Y______
4. PT4 = X______ Y______
5. PT5 = X______ Y______
6. PT6 = X______ Y______
7. PT7 = X______ Y______
8. PT8 = X______ Y______
•
• What is the value for each hole in INCREMENTAL G91 positioning when each move is
• defined from the previous position and the zero point shifts with the new position.
•
1. From PT8 to PT9 = X______ Y______
2. From PT9 to PT10 = X______ Y______
3. From PT10 to PT11 = X______ Y______
4. From PT11 to PT12 = X______ Y______
4 5. From PT12 to PT13 = X______ Y______
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 Thank You

For any concerns, please contact

elearning@knust.edu.gh
elearningknust@gmail.com
0322 191132
Jan 2014