Conventional Numerical Control

Zain Shami
Layout
 Introduction
 History Background
 Basic Components of NC Machine
 NC Procedure

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Introduction
 Numerical Control
“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 Machine
Instructions Control Unit

Transformation
Process
Power
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History Background
 Pioneer : John T. Parsons
 Initially used the punched cards containing the coordinate
position data to control the machine tool
 Got funded projects from US Air Force in MIT
 Projects include development of a part programming
language like APT (Automatic Programmed Tooling)

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Basic Components of NC System
 Program of Instructions
 Part program in machining
 Controller Unit, also called a Machine control unit (MCU)
 Controls the process
 Machine tool or other controlled process

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Program of Instructions
 Set of detailed step-by-step instructions for machine
 Two methods to input the data
 MDI (manual data input) appropriated for relatively simple jobs
 By direct link with a computer (Direct Numerical Control)
DNC

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Controller Unit
 Consists of Electronics and hardware
 Read and interpret the program of instructions
 Convert it into mechanical actions of the machine tool
 Elements of Conventional NC controller unit
 Tape reader, data buffer,
 signal output channels to machine tool
 Feedback channels from the machine tool
 In CNC, controller unit consists of a microcomputer

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Tape Reader
 Electromechanical Device for winding and reading the
punched tape containing the program of instructions
 Data contained on the tape are read into the data buffer
 Purpose of this device is to store the input instructions in
logical blocks of information
 A block of information usually represents one complete
step in the sequence of processing element
 One block may contain movement of machine table to a
certain position and drill a hole at that location

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Signal Output channels
 Connected to the servomotor and other controls in the
machine tool
 Through these channels the instructions are sent to the
machine tool from the controller unit.
 To make certain the instructions are sent to the machine tool
from the controller unit.
 To make sure the instructions are properly executed by
the machine,
 Feedback data are sent back to the controller via the feedback
channels

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Sequence Controls
 Coordinates the activities of other elements of the
controller unit.
 Tape reader is actuated to read data into the buffer from
the tape
 Signals are sent to and from the machine tool and so on
 These types of operations must be synchronized and this
is the function of the sequence controls

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NC Machine Tool

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Control Panel
 It contains the control dials and switches by which he
machine operator runs the NC system
 May also contain the display unit
 Operator is required to turn machine ON and OFF
 Change the tools (some NC systems have automatic tool
changer)
 Load and Unload the machine

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Machine Tool
 Consists of
 Worktable
 Spindle
 motors and controls necessary to drive them
 Multifunction machines
 Drilling, tapping, reaming, milling and boring
 Change tools automatically
 Tools are kept in a tool drum or other holding device
 When the changing is required the drum rotates and new tool
is positioned in the spindle
 Position the work piece

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NC Machine

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NC Procedure
 Process Planning
 Part Programming
 Tape Preparation
 Tape Verification
 Production

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NC Procedure
 Process Planning
 Engineering drawing must be interpreted in terms of the
manufacturing processes to be used
 Preparation of Route sheet
 Listing of sequence of processes which must be performed on
the work part
 It also lists the machines to accomplish the sequence of
operations

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NC Procedure
 Process Planning
 Part Programming
 Write the program for give sequence of the operations, tools
required and machines
 Manual part Programming
 Computer assisted part programming

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NC Procedure
 Process Planning
 Part Programming
 Tape Preparation
 A punched tape is prepared from the part programmer’s NC
process plan
 In manual part programming, the punched tape is directly
prepared form the part program manuscript on a type writer
like device equipped with tape punching capability
 In Computer assisted part programming, the computer is used
to convert and create tape for the respective NC machine

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NC Procedure
 Process Planning
 Part Programming
 Tape Preparation
 Tape Verification
 A sample problem is run on the computer to check the errors
in tape
 A sample project of plastic or foam is manufactured on the
machine to verify the tape

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NC Procedure
 Process Planning
 Part Programming
 Tape Preparation
 Tape Verification
 Production
 After verification of the tape, iff successful, the tape is sent for
the production
 Now operator loads the raw object and unloads the fabricated
final object

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NC Coordinate Systems
 For flat and prismatic (block-like) parts
 Milling and drilling operations
 Conventional Cartesian coordinate system
 Rotational axes about each linear axis
 Right hand rule

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Coordinate System for Rotational Parts
 For rotational parts:
 Turning operations
 Conventional Cartesian coordinate system, but only x-and z-
axes
 y-axis not needed in turning

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Fixed Zero and Floating Zero
 Fixed Zero
 Southwest corner of table
 Lower left-hand corner
 Floating zero
 Operator can define zero on his convenience
 ‘Zero’ is used for zero identification

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Absolute vs. Incremental Position
 Absolute positioning
 Locations defined relative to origin of axis system
 Incremental positioning
 Locations defined relative to previous position
 Example: drilling

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Absolute vs. Incremental Position
 The work head is presently
at point (20, 20) and is to be
moved to point (40, 50)
 In absolute positioning,
 the move is specified by
x= 40, y= 50
 In incremental positioning,
 the move is specified by
x= 20, y= 30.

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NC 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)

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Point-To-Point Control in NC
Drilling of Three Holes in Flat Plate

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Continuous Path Control in NC
Profile Milling of Part Outline

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Interpolation Methods
 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

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Circular Interpolation

Approximation of a curved path in NC by a series of

straight line segments, where tolerance is defined on only
the inside of the nominal curve

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Circular Interpolation

Approximation of a curved path in NC by a series of

straight line segments, where tolerance is defined on only
the outside of the nominal curve

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Circular Interpolation

Approximation of a curved path in NC by a series of

straight line segments, where tolerance is defined on both
the inside and outside of the nominal curve

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Applications of NC
 Common Application of NC is for metal cutting machine
tools
 Milling
 Drilling and related processes
 Boring
 Turning
 Grinding
 Sawing

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Appropriate jobs for NC
 Parts are Processed frequently and in small lot size
 The part geometry is complex
 Many operations must be performed on the part in its
processing
 Much metal needs to be removed
 Engineering design changes are likely
 Close tolerances must be held on the work part
 It is an expensive part where mistakes in processing
would be costly
 The parts require 100% inspection

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Advantages of NC
 Reduced Non Productive Time
 Reduced Fixturing
 Reduced Manufacturing lead time
 Greater manufacturing flexibility
 Improved quality control
 Reduced inventory
 Reduced floor space requirement

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Disadvantages of NC
 Higher investment cost
 Higher maintenance cost
 Training NC personnel

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 1 1

1 1

1 1

dx
K1 K1 K2

F2 F1
F3 K2
K2 K1
dx

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