COMPUTER NUMERICAL CONTROL

OF MACHINE TOOLS
Laboratory for Manufacturing Systems and Automation
Department of Mechanical Engineering and Aeronautics
University of Patras, Greece

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Chapter 1:
An Introduction to Numerical Control
Machinery

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Objectives of Chapter 1

Describe the difference between direct and distributive

Numerical Control (NC)

Describe the difference between a numerical control tape
machine and a Computer Numerical Control (CNC) machine

Describe four ways that programs can be entered into a
computer numerical controller

Explain two tape code formats in use with CNC machinery

Give the major objectives of Numerical Control

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Objectives of Chapter 1

Numerical Control (NC) helps solve the problem of making
Manufacturing Systems (MFG) more flexible

“A Numerical Control machine is a machine positioned

automatically along a pre
pre--programmed path by means of
coded instructions”

Manual Part Programming

Programming:: Manual programming of the
machines

Computer Aided Programming (CAP): (CAP): Programming done
by a computer

Manual Data Input (MDI):
(MDI): A manual program is entered into
the machine’s controller via its own keyboard

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Objectives of Chapter 1

Computer is used as the Control Unit (CU) of the modern
Numerical Control machinery

Computer replaced the Tape Reader found on earlier NC
machines

Program is loaded into and executed from the machine’s
computer

Computer Numerical Control (CNC) machines are the NC

machines of today

FOCUS on
on:: MDI programming of CNC machinery

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 The History of NC

1947
1947:: J. Parsons (Parsons Corporation) began
experimenting for using 3-axis curvature data to control
machine tool motion for the production of aircraft
components

1949:: Parsons awarded a US Air Force contract to build the
1949
first NC machine

1951:: MIT was involved in the project
1951

1952:: NC achieved when MIT demonstrated that
1952
simultaneous 3-axis movements were possible using a
laboratory--build controller and a Cincinnati HYDROTEL
laboratory
vertical spindle

1955:: after refinements NC become available to industry
1955

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 The History of NC

Early NC machines run off punched cards and tape

Due to the time and effort for editing and changing tapes
Computers where introduced for programming

Computers’ Involvement

Computer Aided Programming Direct Numerical Control

Languages

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 The History of NC

Computer Aided Programming Languages:

Languages:

Allow the development of an NC program using a set of
universal “pidgin English” commands

Computer translate commands into machine codes

Machine codes are punched into the tapes

Direct Numerical Control

Control::

A computer is used as a partial or complete controller of one
or more NC machines

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 The History of NC

Direct Numerical Control (DNC):

(DNC):

Expensive mainframe or mini mini--
computers were required in the past

Due to cost the use of DNC was

limited to large companies

Powerful PCs given rise to affordable

PC-
PC-based DNC systems

Most of PC-
PC-based DNC systems
running on MS Windows OS

FIGURE 1-
1-1: Direct numerical control

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 The History of NC
Distributed Numerical Control (DNC):
(DNC):

A network of computers is used to
coordinate the operation of a number
of CNC machines

Ultimately an entire factory can be

coordinated in this manner

Alternative System 1: NC program is

transferred in its entirety from a host
computer directly to machines
controller

Alternative System 2: NC program is

transferred from a mainframe or a
host computer to a PC on the Shop
Floor, stored and used when needed
FIGURE 1-
1-2: Distributed numerical control  transferred to machine controller

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

A CNC machine has more programmable features than

older NC tape machinery

A CNC machine may be used as stand
stand--alone unit in a
network of machines – Flexible Machining Centers or
Machining Cells

CNC machines are easier to program by more than one
method::
method

On board computer keyboard

Tape reader / electronic connector to transfer a
program to CNC machine

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

A CNC machine is a softsoft--wired controller

Once the CNC program is loaded into the computer’s
memory no HW is required to transfer the NC codes to the
controller

The controller uses a permanent resident program –
EXECUTIVE PROGRAM – to process the codes into
electrical pulses to control the machine

EXECUTIVE Program is called “executive software” or
“executive firmware”

EXECUTIVE program resides in ROM (Read Only
Memory)

NC code resides in RAM (Random Access Memory)
Firmware:: Routines of SW including low-
Firmware low-level instructions stored in ROM only for
reading
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
 CNC Machines

ROM (Read Only Memory)

Is an electronic chip which can be accessed by a computer but not
altered (erased or written) without special equipment

The EXECUTIVE program can not be erased

The EXECUTIVE program is always active when machine is on

RAM (Random Access Memory)

RAM can be altered by the computer

NC code is written into RAM by keyboard or other outside source

The content of RAM is lost when the controller is turned off

Battery backup system is used for saving the program in the event
of power loss

CMOS (Complementary Metal
Metal––Oxide
Oxide––Semiconductor) memory
special type of RAM which retains the information content in the
case of power loos

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

FIGURE 1-3 A high speed 4-axis vertical machining FIGURE 1-4 A high speed 4-axis horizontal
center machining center

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

FIGURE 1-5 A FIGURE 1-6

31/2 axis horizontal machining center A Tsugami ‘’lightning’’ 3 ½ axis horizontal
machining center

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

FIGURE 1-
1-7 A precision NC lathe FIGURE 1-
1-8 A NC lathe

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

FIGURE 1-9
A horizontal machining center equipped with an eight-
eight-pallet automatic work
work--change (Photo courtesy of
Cincinnati Machine)

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

FIGURE 1-10
A CNC centerless grinding machine with an epoxy
granite bed, (Photo courtesy of Cincinnati
Machine)

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Input Media
Input Media for the NC code into the Controller

Are used to electronically or mechanically store the NC programs

An NC program is read from the input medium when it is loaded into the
machine

Old NC machinery could only read programs from punched tape or DNC

CNC machines may process multiple means of program input
Punched Tape

The oldest medium for program storage

Made from paper or Mylar plastic (stronger than paper)

The NC program code is entered into the tape by tape puncher in a form
of a series of holes representing the NC codes

A tape reader by electrical, optical or mechanical means senses the
holes and transfers the coded information into the machine computer

The NC code is entered into CAM or Word Processor program and
punched into tape

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Input Media

Magnetic Tape

Early experiments were not successful due to machine shop environment

High quality tapes of today can be used with reasonable care in handling

The most commonly used format is ¼ - inch computer cassette tape

Standards for tape format and coding have been developed by the
Electronics Industries Association (EIA)

Floppy Diskette

Popularized by the use of PCs in NC programming

The NC program is transferred into the CNC control by means of a
portable diskette drive attached to the communication port of the CNC
machine

The most common used port is RS232
RS232 (serial communication port)

Floppy diskettes are cheaper than other program storage options

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Binary Numbers
How controller processes information?

It is important in learning to program CNC machinery

Computers and Computer
Computer-- Controlled machinery do not deal in Arabic
symbols or numbers

All of the internal processing is done by calculating or comparing binary
numbers

Binary numbers contain only two digits
digits:: ZERO (0) and ONE (1)

Within CNC controller
controller::

Each binary digit “1” may represent a “positive charge” or

A binary digit “0” may represent a “negative charge” or

A “1” may be the “ON” or

A “0” may be the “OFF”

The CNC program code in binary form must be loaded into the computer

Programming formats and languages allow the NC code to be written
using alphabetic characters / base
base--ten decimal numbers

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Binary Numbers

When the NC program is

punched or recorded on
tape or other storage media
the information is
translated to binary form

FIGURE 1-
1-11 Binary numbers compared to Arabic numbers

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Tape Formats

General

Toady punched tape is not often used for NC program storage

Formats used in NC programming are still referred as Tape Formats

Computer files containing the NC programs are referred as “tape files”,
“punch files” or “tape image files”

Old machinery is still used in machine shops

RS-
RS-274 Format

Follows Electronics Industries Association (EIA) standard

Program information is contained in program lines called “Blocks”

“Blocks” are punched into the tape in one or two tape code standards

RS-
RS-274 is a “variable block coding” format

The information contained in a block may be arranged in any order

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Tape Formats
RS-
RS-244 Binary Coded Decimal (BCD)

The EIA RS-
RS-244 standard is one of the two tape codes used for NC tapes

Became a standard early in the development of NC – limited punctuation

Each hole represents the digit “1” while each blank the digit “0”

The tape code allows alphabetic characters and base
base--ten numbers to be
translated into the binary code the controller requires (Binary Coded
Decimal – BDC)
RS-
RS-358 Format

Government, telephone and Computer industries required tape code
containing upper and lower case letters

The existing tape coding formats were sufficient only for machining

The standard accepted was American Standard Code for Information
Interchange (ASCII)

EIA RS-
RS-358 was adopted

EIA RS-
RS-358 is also as ISO and ASCII is a subset of the ASCII code used
in other applications – Today is dominant over RS-
RS-244
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
 Tape Formats

FIGURE 1-
1-12, 1-
1-13 EIA RS
RS--244 tape code

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Objectives of Numerical Control

Numerical control (NC) was developed with these goals in mind:

mind:

To increase production

To reduce labor costs

To make production more economical

To do jobs that would be impossible or impractical without NC

To increase the accuracy of duplicate parts

Before deciding to utilize an NC or CNC machine for a particular job the

requirements and economics must be weighted against the advantages
and disadvantages of the machinery

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Objectives of Numerical Control

Advantages

Increased productivity

Reduced tool/fixture storage and cost

Faster setup time

Reduced parts inventory

Flexibility that speeds changes in design

Better accuracy of parts

Reduction in parts handling

Better uniformity of parts

Better quality control

Improvement in manufacturing control

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Objectives of Numerical Control

Disadvantages

Increase in electrical maintenance

High initial investment

Higher per
per--hour operating cost than traditional machine tools

Retraining of existing personnel

NC is a general term used for Numerical Control. CNC refers

specifically to COMPUTER NUMERICAL CONTROL. CNC machines are
all NC machines but not all NC machines are CNC machines

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Applications in Industry

Originally developed for use in Aerospace industries

Widespread in manufacturing
manufacturing::

Aerospace

Defence

Automotive

Electronic

Appliance

Tooling industries

Advances in microelectronics have lowered the cost of acquiring CNC

equipment

Bending, Forming, Stamping and Inspection Machines have been
produced as NC systems

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Summary 1/2

An NC machine is a machine positioned automatically along a

preprogrammed path by way of coded instructions

DNC involves a computer that acts as a partial or full controller to

one or more NC machines

Distributive NC is a network of computers and NC machinery

coordinated to perform some task

CNC machines use an on

on--board computer as a controller

Offline programming is the programming of a part away from the

computer keyboard - usually done with a micro-
micro-computer
computer..

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Summary 2/2

There are four ways to input programs into CNC machinery

machinery::

MDI (Manual Data Input)

Punched Tape

Magnetic Tape

DNC (Direct Numerical Control / Distributive Numerical Control)

The CNC program must be loaded into the controller in binary form

RS-
RS-244 and RS-
RS-358 tape codes used to place information on punched
tape information being punched into the tape in binary form

Before deciding on a NC machine for a specific job, the advantages

and disadvantages of NC must be weighed in view of the primary
objectives of numerical control

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 Vocabulary Introduced in this chapter

ASCII

Binary coded decimal (BCD)

Computer Aided Programming (CAP)

Computer Numerical Control (CNC)

Direct Numerical Control (DNC)

Distributive numerical control

Input media

Manual Data Input (MDI)

Manual part programming

Numerical control (NC)

Random Access Memory (RAM)

Read
Read--only Memory (ROM)

Word address format

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis