UNIT II

Elements of CNC
Machines
Karthikeyan.N, A.P.,
SRM Univetsity.

Interpolation
The method by which a control system calculates the
intermediate points and the speed of the motor is
called interpolation

Types of interpolation
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 interpolation
5. Cubic interpolation
Free form curves using higher order equations

Circular Interpolation Methods

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

Circular Interpolation Methods

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

Circular Interpolation Methods

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

Classification of CNC machines

Based on Feedback Control
1. Open loop
2. Closed loop
3. Semi-closed loop

Servomechanism : A group of electromechanical, pneumatic or hydraulic or hydraulic

components that control the position or velocity
of a m/c slide.

Open Loop Control

- Where the final value is not directly measured and
checked against the desired value.
- no feedback device to measure actual position of
tool or work table.

Open Loop ControlApplications & Drawbacks

Applications

Light duty machinery <5KW & torque 200 Nm

Economy constraints
Less accuracy required
Less maintenance required

Drawbacks
Backlash errors in leadscrew due to wear and tear
Periodical adjustments required to compensate for tool geometry
or drive mechanism
Less accurate slide movement a few mm short

Closed loop control

Uses feedback measurements to confirm that the final

position of the worktable is the location specified in the
program
Used for higher degree of accuracy
(Differential
Analyzer)

Transducer

Semi-closed loop systems

Gives feedback for displacement, so closed loop
Open as it depends on the accuracy of the lead screw or
gear arrangement
Reduces bulkiness

CNC terminology

Table

Leadscrew

A/C Motor

Encoder

Servo Controller
Counter

Comparator
Input (converted from analog to digital value)

CNC terminology
BLU: basic length unit
smallest programmable move of each
axis.
Controller: (Machine Control Unit, MCU)
Electronic and computerized interface
between operator and m/c
Controller components:
1. Data Processing Unit (DPU)
2. Control-Loops Unit (CLU)

CNC terminology
Data Processing Unit:
Input device [RS-232 port/ Tape Reader/ Punched Tape Reader]
Data Reading Circuits and Parity Checking Circuits
Decoders to distribute data to the axes controllers.

Control Loops Unit:

Interpolator to supply machine-motion commands between data
points Position control loop hardware for each axis of motion

Configuration of CNC machine

control unit

CNC Controllers

CNC Controllers
CNC controller interprets part program instructions and then converts them into two
types of control signals:
Motion control signals
- a series of electric pulse trains that control position and the speed of
machine table and spindle.
- Each pulse activates a motion of one basic length-unit (BLU) which is the
minimum increment size of the NC control system
- number of pulses transmitted to each axis determines the incremental axis
position; frequency of these pulses regulates the axis speed

CNC Controllers
The control signals in CNC systems are in the form of
binary words. Each word contains a fixed number of
bits, 32 bits or 64 bits are commonly used.
Each bit of data produces one BLU motion in the
controlled axis.
A 32-bit word could represent one of up to 232 =
4,294,967,296 different axial positions.
If the system resolution is, for example, BLU =
0.0001 in., this number can represent up to 429,969
in. possible motions, which is more than enough for
all types of applications

CNC Controllers

Miscellaneous control signals

-a set of on/off signals to implement the control of

1. speed and direction of the spindle rotation,
2. control of coolant supply,
3. selection of cutting tool,
4. automatic clamping and unclamping, etc.

Advantages of CNC

Increased productivity
Reduced production costs
Facilitation of complex machining operations
Improved production planning and control
Facilitation of flexible automation
High accuracy and repeatability
Reduced indirect operating costs
Greater flexibility
Lower operator skill requirement

Disadvantages of CNC
High initial cost
Equipment and installation

High maintenance cost

Skilled CNC personnel required
Have to be installed in air-conditioned places
Not suitable for long run applications

Direct Numeric Control

(DNC)
Direct numerical control (DNC) control of multiple
machine tools by a single (mainframe) computer through
direct connection and in real time
1960s technology
Two way communication

Distributed numerical control (DNC) network consisting

of central computer connected to machine tool MCUs,
which are CNC
Present technology
Two way communication

Direct Numeric Control

(DNC)
- Bypasses the need for a MCU
- Processing of part programs are done on a centralized computer
- Program transmitted to the MCU, one block at a time (BTR)
Basic components
Mainframe computer
Connected via satellite computers or lengthy cables

Bulk memory
Communications network
NC machine tools

Direct Numeric Control

(DNC)
Advantages:
Higher reliability than hardwired MCUs
Elimination or error prone tape and tape-reader
Control of multiple machines
Improved computational capability for
interpolations
Part programs stored in a central location
Computers located in an environmentally agreeable
location

Direct Numeric Control

(DNC)
Types of DNC
- based on communication link between machine tool
and computer
1. Dedicated MC
- Similar to a CNC as MCU is hardwired

2. Behind the tape reader (BTR) interface

- cheaper to use
- easily implemented
- receives only the program of the part to be manufactured

Direct Numeric Control

(DNC)

Connection to MCU is behind the tape reader (BTR). In distributed NC,

entire programs are downloaded to each MCU, which is CNC rather than
conventional NC

Distributed Numeric Control

(DNC)

Similar to CNC computers

Improved data collection

Direct Numeric Control

(DNC)

DNC switching network

configuration

Limitations
1. No of machines
2. Frequency of service required for each machine

Direct Numeric Control

(DNC)-LAN configuration

Adaptive Control
to adapt means to change a behavior to conform
to new circumstances.
An adaptive controller
a controller that can modify its behavior in response
to the changes in dynamics of the processes and the
disturbances acting on the process.
A self-correcting form of optimal control

Adaptive Control
In machining, it includes automatic adjustment of
cutting parameters like speeds, feeds, depth of cut, etc.

General
Configuration

Adaptive Control
Adaptive controller performs 3 functions
1. Identification
-

Identifies the current value of performance index

Functions continuously to be dynamic

2. Decision
- decide what changes have to be made to
improve system performance
3. Modification
- implement the decision

Adaptive Control
Two types of Adaptive control
Adaptive Control with optimization (ACO)
Adaptive Control with constraints (ACC)
ACO attempts to maximize IP index of performance
IP = MRR/ TWR
MRR = Metal Removal Rate; TWR = Tool Wear Rate
usually an economic index of performance
eg: Maximum production rate, minimum production cost

Adaptive Control
Adaptive Control with Constraints (ACC)
Machining conditions are maximized within machine
constraints eg: maximum force or torque or power

Two sensors are employed

Tool vibration sensor accelerometer mounted on the
housing
Spindle torque sensor strain gauges mounted on the
machine spindle

The three functions of adaptive

control are:
1. Identification function.
2. Decision function.