Dr.K.

Balamurugan, ASP/MECH, IRTT

COMPUTER NUMERICAL CONTROL (CNC)

Computer Numerical Control (CNC) - A numerical control system in which

the data handling, control sequences, and response to input is determined by
an on-board computer system at the machine tool.

Conventionally, an operator decides and adjusts various machines parameters like

feed , depth of cut etc depending on type of job , and controls the slide movements
by hand. In a CNC Machine functions and slide movements are controlled by
motors using computer programs.

For a CNC machine control unit (MCU) decides cutting speed, feed, depth of cut,
tool selection , coolant on off and tool paths. The MCU issues commands in form
of numeric data to motors that position slides and tool accordingly.

Numerical Control Machines

A numerical control, or NC, system controls many machine functions and

movements which were traditionally performed by skilled machinists.

Numerical control developed out of the need to meet the requirements of high
production rates, uniformity and consistent part quality.

Programmed instructions are converted into output signals which in turn

control machine operations such as spindle speeds, tool selection, tool
movement, and cutting fluid flow.

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Dr.K.Balamurugan, ASP/MECH, IRTT

CNC

By integrating a computer processor, computer numerical control, or CNC

as it is now known, allows part machining programs to be edited and stored in
the computer memory as well as permitting diagnostics and quality control
functions during the actual machining.
All CNC machining begins with a part program, which is a sequential
instructions or coded commands that direct the specific machine functions.
The part program may be manually generated or, more commonly, generated
by computer aided part programming 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.

Motion control - the heart of CNC

The most basic function of any CNC machine is automatic, precise, and
consistent motion control.

Rather than applying completely mechanical devices to cause motion as is

required on most conventional machine tools, CNC machines allow motion
control in a revolutionary manner.

All forms of CNC equipment have two or more directions of motion, called
axes. These axes can be precisely and automatically positioned along their
lengths of travel.

The two most common axis types are linear (driven along a straight path) and
rotary (driven along a circular path).

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Dr.K.Balamurugan, ASP/MECH, IRTT

Three Basic Categories of Motion Systems

l Point to Point - No contouring capability

l Straight cut control - one axis motion at a time is controlled for machining
l Contouring - multiple axiss controlled simultaneously

Absolute Coordinate System Incremental Coordinate

System

Each axis consists of a mechanical component, such as a slide that moves, a

servo drive motor that powers the mechanical movement, and a ball screw to
transfer the power from the servo drive motor to the mechanical component.

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Dr.K.Balamurugan, ASP/MECH, IRTT

These components, along with the computer controls that govern them, are
referred to as an axis drive system.

Using a vertical mill machining

center as an example, there are
typically three linear axes of motion.
Each is given an alphabetic
designation or address. The machine
table motion side to side is called the
X axis. Table movement in and out
is the Y axis, while head
movement up and down the column
is the Z axis.

If a rotary table is added to the machine table, then the fourth axis is
designated the b axis.

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Dr.K.Balamurugan, ASP/MECH, IRTT

Control Systems

Open-Loop Control
Stepper motor system
Current pulses sent from control unit to motor
Each pulse results in a finite amount of revolution of the motor001 is
possible
l Open-Loop Limitations
Control unit assumes desired position is achieved
No positioning compensation
Typically, a lower torque motor
l Open-Loop Advantages
Less complex, Less costly, and lower maintenance costs

Closed-Loop Control

Variable DC motors - Servos

Positioning sensors -Resolvers
Feedback to control unit
Position information compared to target location
Location errors corrected
l Closed-Loop Advantages
DC motors have the ability to reverse instantly to adjust for position
error
Error compensation allows for greater positional accuracy (.0001)
DC motors have higher torque ranges vs. stepper motors
l Closed-loop limitations
Cost

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Dr.K.Balamurugan, ASP/MECH, IRTT

Interpolation

The calculation of successive increments in slide position to reach the programmable

point is called interpolation. Common methods of interpolations are linear, circular,
polar and cylindrical.

Linear Circular Parabolic

CNC systems classification

1. CNC Machining centres

2. CNC lathe and turning centres
3. CNC for special applications like grinding machines, EDM, EBM etc.

CNC Machining Centers

A machining center can be defined as a machine tool capable of:

Multiple operation and processes in a single set-up utilizing multiple
axis
Typically has an automatic mechanism to change tools
Machine motion is programmable
Servo motors drive feed mechanisms for tool axiss
Positioning feedback is provided by resolvers to the control system

CNC Lathe

Automated version of a manual lathe.

Programmed to change tools automatically.
Used for turning and boring wood, metal and plastic

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Dr.K.Balamurugan, ASP/MECH, IRTT

CNC Milling machine

Has 3 to 5 axes.
Used for wood, metal and plastic.
Used to make 3D prototypes, moulds, cutting dies, printing plates and signs.
How CNC Works

Controlled by G and M codes.

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

Features of CNC Machinery

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 (actuators).
Feedback is provided by sensors (transducers)
Tool magazines are used to change tools automatically.

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.

Tool Paths, Cutting and Plotting Motions

Tool paths describes the route 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 work piece 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 work piece to move rapidly when no
machining is taking place.

CNC controllers

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Dr.K.Balamurugan, ASP/MECH, IRTT

The CNC controller is the brain of a CNC system. A controller completes the
all important link between a computer system and the mechanical components
of a CNC machine.
The controller's primary task is to receive conditioned signals from a computer
or indexer and interpret those signals into mechanical motion through motor
output. There are several components that make up a controller and each
component works in unison to produce the desired motor movement.

The word controller is a generic term that may refer to one of several
devices, but usually refers to the complete machine control system.

This system may include the protection circuitry, stepper or servo motor
drivers, power source, limit switch interfaces, power controls, and other
peripherals.

Commercial CNC controls

Fanuc
Sinumerik (Siemens)

Heidenhain

Haas

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Dr.K.Balamurugan, ASP/MECH, IRTT

Direct/Distributed Numerical Control (DNC)

Direct numerical control (DNC), also known as distributed numerical control

(also DNC), is a common manufacturing term for networking CNC machine tools.

Direct Numerical Control

Direct numerical simultaneously control the operations of a group of NC

machine tools using a shared computer. Programming, editing part
programs and downloading part programs to NC machines are main
responsibilities of the computers in a NC system.

Distributed Numerical Control (DNC)

In early 1980s, with advancement in computers and communication technologies,
engineers realized that in a network of computers there must be a proper co-ordination for
operations of a group of CNC machine tools. Hence, Distributive numerical control
(DNC) comes into picture. Now, many CNC machines together with robots,
programmable logic controllers, and other computer-based controllers have been
integrated into DNC systems to make automated manufacturing systems possible.

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Dr.K.Balamurugan, ASP/MECH, IRTT

On some CNC machine controllers, the available memory is too small to

contain the machining program (for example machining complex surfaces), so
in this case the program is stored in a separate computer and sent directly to
the machine, one block at a time.
If the computer is connected to a number of machines it can distribute
programs to different machines as required.

Usually, the manufacturer of the control provides suitable DNC software.

However, if this provision is not possible, some software companies provide
DNC applications that fulfill the purpose.

DNC networking or DNC communication is always required when CAM

programs are to run on some CNC machine control.

Uses a few methods,

- the oldest methods used modems, and a mainframe which emulated a tape
reader, to control the NC machine (no storage)
- a more recent advance used a local computer which acts as a storage buffer.
Programs are downloaded from the main DNC computer, and then the local
controller feeds instructions to the hardwired NC machine, as if they have
been read from tape.

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Dr.K.Balamurugan, ASP/MECH, IRTT

- the newer methods use a central computer which communicates with local
CNC computers (also called Direct Numerical Control)

DNC controllers came before CNC machines, but as computer technology improved
it became practical to place a computer beside the NC machine, and DNC changed in
form.

Characteristics of modern DNC systems are,

- uses a server (with large storage capacity) to store a large number of part
programs
- the server will download part programs on demand to local machines
- may have abilities to,
- display and edit part programs
- transmit operator instructions and other data needed at the machines
- collect and process machine status information for management purposes

Advantages are,
- eliminates the need for NC tapes (the advantages are obvious)
- design changes are immediate
- NC programs may be edited quickly
- can be used to support an FMS system
- increase efficiency of individual machine tools
- more shop up-time than with stand alone machines
- simplifies implementation of group technology, computer aided process
planning, and other CIM concepts
- reduces peripheral costs with NC tapes

Disadvantages,
- high cost of computer hardware
- the number of machines which could be controlled by one computer was limited
- computer software was limited for maintenance, scheduling, control, and data
collection
- a backup computer was usually required
- was hard to justify on the basis of downloading parts programs

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