UNIT 1 INTRODUCTION TO NC MACHINE

TOOLS

Introduction to
NC Machine Tools

Structure
1.1

Introduction
Objectives

1.2

NC Machines
1.2.1

Types of NC Machine

1.2.2

Controlled Axes

1.2.3

Basic Components of NC Machines

1.2.4

Problems with Conventional NC

1.3

Principles of NC Machines

1.4

Summary

1.5

Answers to SAQs

1.1 INTRODUCTION
NC machines, advantages of NC machines, Types of NC systems, Controlled axes, Basic
Components of NC Machines, Problems with Conventional NC and Principles of NC
Machines are described in this Unit.

Objectives
After studying this unit, you should be able to understand

, and

1.2 NC MACHINES
Controlling a machine tool by means of prepared program, which consists of blocks, or
series of numbers, is know as numerical control (NC). In manufacturing of more
complicated parts, the system has to calculate automatically additional data points,
which is done by means of an interpolator. Numerical Control (NC) refers to the method
of controlling the manufacturing operation by means of directly inserted coded
numerical instructions into the machine tool. It is important to realize that NC is not a
machining method; rather, it is a concept of machine control. Although the most popular
applications of NC are in machining, NC can be applied to many other operations,
including welding, sheet metalworking, riveting, etc.
NC machines are method of automation, where automation of medium and small volume
production is done by some controls under the instructions of a program. Various
definitions of NC are :
A system in which actions are controlled by direct insertion of Numerical Data at some
point. The system must automatically interpret at least some portion of this data by
Electronic Industries Association (EIA).
Numerical Control is defined as a form of software controlled automation, in which the
process is controlled by alphanumeric characters or symbols.
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CNC Machines

According to these definitions, a programme is prepared which consists of blocks, blocks

consisting of combination of characters and numbers in sequence describing the position
of the tool and job, the cutting speed and feed. The data converted into coded
instructions which are called a Part Programme. As the job changes, the instructions of
part program are also changed. The other instructions which can be included may be for
tool changing or coolant on and off. It is easy to encode a new programme than to
change the machinery for flexibility, thus arising the need of an NC machine tool.

Figure 1.1 : Numerical Control (NC) Machine Tool

Advantages of NC
The major advantages of NC over conventional methods of machine control are as
follows :
Higher Precision
NC machine tools are capable of machining at very close tolerances, in
some operations as small as 0.005 mm.
Better Quality
NC systems are capable of maintaining constant working conditions for all
parts in a batch thus ensuring less spread of quality characteristics.
Higher Productivity
NC machine tools reduce drastically the non machining time. Adjusting the
machine tool for a different product is as easy as changing the computer
program and tool turret with the new set of cutting tools required for the
particular part.
Multi-operational Machining
Some NC machine tools, for example machine centers, are capable of
accomplishing a very high number of machining operations thus reducing
significantly the number of machine tools in the workshops.
Low Operator Qualification
The role of the operation of a NC machine is simply to upload the work
piece and to download the finished part. In some cases, industrial robots are
employed for material handling, thus eliminating the human operator.
Less Time
An easy adjustment of the machine, adjustment requires less time.
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1.2.1 Types of NC System

Introduction to
NC Machine Tools

Machine controls are divided into three groups:

(a)

Traditional numerical control (NC);

(b)

Computer numerical control (CNC);

(c)

Distributed numerical control (DNC).

The original numerical control machines were referred to as NC machine tool. They
have hardwired control, whereby control is accomplished through the use of punched
paper (or plastic) tapes or cards. Tapes tend to wear, and become dirty, thus causing
misreading. Many other problems arise from the use of NC tapes, for example the need
to manual reload the NC tapes for each new part and the lack of program editing
abilities, which increases the lead time. The end of NC tapes was the result of two
competing developments, CNC and DNC.
CNC refers to a system that has a local computer to store all required numerical data.
While CNC was used to enhance tapes for a while, they eventually allowed the use of
other storage media, magnetic tapes and hard disks. The advantages of CNC systems
include but are not limited to the possibility to store and execute a number of large
programs (especially if a three or more dimensional machining of complex shapes is
considered), to allow editing of programs, to execute cycles of machining commands,
etc.
The development of CNC over many years, along with the development of local area
networking, has evolved in the modern concept of DNC. Distributed numerical control is
similar to CNC, except a remote computer is used to control a number of machines. An
off-site mainframe host computer holds programs for all parts to be produced in the DNC
facility. Programs are downloaded from the mainframe computer, and then the local
controller feeds instructions to the hardwired NC machine. The recent developments use
a central computer which communicates with local CNC computers (also called Direct
Numerical Control).

1.2.2 Controlled Axes

NC system can be classified on the number of directions of motion they are capable to
control simultaneously on a machine tool. Each free body has six degree of freedom,
three positive or negative translations along x, y, and z-axis, and three rotations
clockwise or counter clockwise about these axes.
Commercial NC system is capable of controlling simultaneously two, two and half,
three, four and five degrees of freedom, or axes. The NC systems which control three
linear translations (3-axis systems), or three linear translations and one rotation of the
worktable (4-axis systems) are the most common.

Figure 1.2 : Coordinate System (Milling and Drilling Operations)

CNC Machines

Figure 1.3 : Coordinate System (Turning Operations)

Figure 1.4 : Coordinate System (Milling and Drilling Operations)

1.2.3 Basic Components of NC Machines

Software
The programmes or set of instructions, languages, punched cards, magnetic tape,
punched paper tape and other such information processing items are referred to as
software. This software controls the sequence of movement of an NC. That is why
these numerical controls are sometimes called software controlled machines by
NC lies entirely in the programming. The programmer plans the operations and
their sequence from seeing the drawing and writes instructions in tabulated blocks
of information, known as Part Programme on a programme manuscript. Then these
instructions are punched on the control tape. Tape reader reads the codes and
sends it to Machine Control Unit, which conversely converts them into the
machine movements of machine tool.
Machine Control Unit (MCU)
NC machine tool has a main unit, which is known as Machine Control Unit,
consists of some electronic hardware that reads the NC programme, interprets it
and conversely translates it for mechanical actions of the machine tool.
A typical Machine Control Unit may consist of the following units :
Input or Reader Unit

This unit consists of electro-mechanical devices used to collect the input

from punched tape, cards, magnetic tape and disk. Then drive it through the
system under a reading head, interpret the coded information and collect it
again for reuse.

Memory
A block of information, consisting of words, is read from tape and stored
into temporary memory called buffer. One block may contain one complete
set of instruction words in sequence. The function of this memory is to keep
on storing the next block of words when the machine is doing processing of
previous block.

Introduction to
NC Machine Tools

Processor
The function of the processor is to coordinate and control the functions of
other units, by giving ready signals to them at appropriate point of time.
Output Channels
The data stored in the memory is converted into actuation signal and
supplied through output channels in the form of pulses.
Control Panel
The control panel has the switches, indicators, Manual Data Input (MDI)
and dials for providing information to the operator.
Feedback Channels
Feedback channel is to check whether the operations are done in the way we
want to, the feedback is sent through feedback channels by position and
velocity.
The MCU may be of three types :
Housed MCU
Machine Control Unit may be mounted on the machine tool or may be built
in the casing of the machine.
Swing Around MCU
Machine Control Unit is directly mounted on the machine, which can swing
around it and can be adjusted as per requirement of the operators position.
Stand Alone MCU
Machine Control Unit is enclosed in a separate cabinet which is installed at
some remote or same place near to the machine.
Machine Tool
Machine tool is the main components of a numerical control system, which
executes the operations. It may consist of worktable, cutting tools, jigs and
fixtures, motors for driving spindle and coolant and lubricating system. The latest
development in the numerical control machine tool is the versatile machining
center. This is a single machine capable of doing a number of operations such as
milling, boring, drilling, reaming, and tapping by Automatic Tool Changer (ATC)
under the control of tool selection instruction.

1.2.4 Problems with Conventional NC

The problems arise in the conventional NC system are the following :
Punched Tape
It is an unreliable NC component for repeated use in the shop because of paper
tape is especially fragile and its susceptibility to wear and tear.

Figure 1.5 : Punched Tape

CNC Machines

Tape Reader
Tape reader is the least reliable hardware components of the machine while any
breakdown is occurred on an NC machine.

Figure 1.6 : Tape Reader

Controller
The hard-wired controller cannot be easily altered to incorporate improvements
into the unit.

Figure 1.7 : Controller

Management Information
The machine tool manufacturers have been continually improving NC technology
by redesigning the systems to provide timely information such as piece counts,
machine tool change, etc. to the management.
Part Programming Mistakes
When preparing the punched tape, part programming mistakes are common and to
achieve the best sequence of processing steps.
Non-optimal Speed and Feed
The control system does not provide the provision to change the speed and feed
during the cutting operation.

1.3 PRINCIPLES OF NC MACHINES

The basic elements and operation of a typical NC machine in numerical control and the
components basically involved of data input, data processing and data output. For data
input, numerical information is read and stored in the tape reader or in computer
memory. In data processing, the programs are read into machine control unit for
processing. For data output, this information is translated into commands, typically
pulsed commands to the motor. The motor moves the table on which the work piece is
placed to specified positions, through linear or rotary movements, by the motors, ball
screw, and others devices.
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A NC machine can be controlled through two types of circuits, which is open loop and
closed loop. In the open loop system, the signals are given to the motor by the processor,

but the movements and final destinations of the worktable are not accurate. The open
loop system cannot accurate, but it still can produce the shape that is required. The
closed loop system is equipped with various transducers, sensors, and counters that
measure the position of the table accurately. Through feedback control, the position of
the worktable is compared against the signal. Table movements terminate when the
proper coordinates are reached. For the close loop system normally servomotor is
utilized. For open loop system normally the stepper motor is utilized. The closed loop
system is more complicated and more expensive than the open loop.

Introduction to
NC Machine Tools

There are two basic types of control systems in numerical control, point-to-point and
contouring. In point-to-point system, also called positioning, each axis of the machine is
driven separately by ball screw, depending on the type of operation, at different
velocities. The machine moves initially at maximum velocity in order to reduce
nonproductive time, but decelerates as the tool reaches its numerically defined position.
Thus in an operation such as drilling or punching, the positioning and cutting take place
sequentially. The time required in the operation is minimized for efficiency.
Point-to-point systems are used mainly in drilling, punching, and straight milling
operations.
In the contouring system, also known as the continuous path system, positioning and
cutting operations are both along controlled paths but at different velocities. Because the
tool cuts as it travels along the path, accurate control and synchronization of velocities
and movements are important. The contouring system is used on lathes, milling
machines, grinders, welding machinery and machining centers.

1.4 SUMMARY

1.5 ANSWERS TO SAQs

Refer the preceding text for all the Answers to SAQs.

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