Unit 5 Numerical Control

Sections:
1. Fundamentals of NC Technology
2. Computer Numerical Control
3. Distributed Numerical Control
4. Applications of NC
5. NC Part Programming

History of CNC
1949
US Air Force asks MIT to develop a "numerically controlled"
machine.
1952
Prototype NC machine demonstrated (punched tape input)
1980CNC machines (computer used to link directly to controller)
1990DNC: external computer drip feeds control programmer
to machine tool controller

Numerical Control (NC) Defined

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
Program
Instructions
Instructions

Machine
Machine
Control
Control Unit
Unit

Transformation
Process
Power
Power

NC PROGRAM CONSISTS OF
FOLLWING CRITERIA

METHODOLOGY OF MANUFACTURE
THE MOVEMENT OF M/C TOOL
WHAT TOOL IS TO BE USED?
AT WHAT SPEED?
AT WHAT FEED?

NC Coordinate Systems
For flat and prismatic (block-like) parts:
Milling and drilling operations
Conventional Cartesian coordinate system
Rotational axes about each linear axis
For rotational parts:
Turning operations
Only x- and z-axes

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)

POINT TO POINT
Moving at maximum rate from point to point.
Accuracy of the destination is important but not the path.
Drilling is a good application.

IE550

CONTINUOUS PATH

IE550

Controls both the displacement and the velocity.

Machining profiles.

Precise control.

Use linear and circular interpolators.

MAJOR COMPONENTS OF
AN NC MACHINE TOOL
Position
transducer

Controller

Machine table

Gear Tachometer
box
Motor

Leadscrew
Servo
drive

Magnetics control
cabinet

IE550

NC MACHINE RATING
Accuracy
Repeatability
Spindle and axis motor horsepower
Number of controlled axes
Dimension of workspace
Features of the machine and the controller.

IE550

REPEATABILITY
Programmed position
Repeat abilit y
Avg. error

T est result

IE550

INTERPOLATION
Control multiple axes simultaneously to move on a
line, a circle, or a curve.
Y

(10,5)

(10,5)
(3,2)
X

Point-to-point control path

Vx =6
Vy =6
IE550

(10-3)
(10-3)2+ (5-2)2
(5-2)
(10-3)2+ (5-2)2

(3,2)
X

Linear path

=6

7
= 5.5149
49+ 9

=6

3
= 2.3635
49+ 9

INTERPOLATORS
Most common interpolators are: linear and circular
Since interpolation is right above the servo level,
speed is critical, and the process must not involve
excessive computation.
Traditional NC interpolators: Digital Differential
Analyzer (DDA)
Higher order curves, such as Bezier's curve, use offline approximation algorithms to break the curves
into linear or circular segments.
IE550

Interpolation Methods
1.

2.

3.
4.

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

Absolute vs. Incremental Positioning

Absolute positioning
Move is: x = 40, y = 50
Incremental positioning
Move is: x = 20, y = 30.

OPEN LOOP SYSTEM

CLOSED LOOP SYSTEM

Computer Numerical Control (CNC)

Storage of more than one part program

Various forms of program input
Program editing at the machine tool
Fixed cycles and programming subroutines
Interpolation
Acceleration and deceleration computations
Communications interface
Diagnostics

Machine Control Unit

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

Distributed Numerical Control

Central
Central
Computer
Computer

NC Pgms

Computer Network

Transformation
Process

BTR

BTR

BTR

Machine
Machine
Control
Control Unit
Unit

Machine
Machine
Control
Control Unit
Unit

Machine
Machine
Control
Control Unit
Unit

Applications of NC

NC Application Characteristics
(Machining)

Batch and High Volume production

Repeat and/or Repetitive orders
Complex part geometries
Mundane operations
Many separate operations on one part

Cost-Benefits of NC
Costs
High investment cost
High maintenance effort
Need for skilled programmers
High utilization required
Benefits
Cycle time reduction
Nonproductive time reduction
Greater accuracy and repeatability
Lower scrap rates
Reduced parts inventory and floor space
Operator skill-level reduced

Precision

NC Part Programming
1.
2.
3.
4.

Manual part programming

Manual data input
Computer-assisted part programming
Part programming using CAD/CAM

YouTube

CNC Milling
CNC Punching
CNC Adhesive Bonding
CNC Drug Insertion
CNC Bioprocessing
CAD/CAM
Etc.