Chapter 1

NC Technology
1.

Introduction:
Conventional machines used for operations like Turning, Drilling, Milling were commonly
used and operated manualy. the worker had to use a detailed working drawing sheet of the
workpart that included dimensions, tolerances, surface roughness,.
He also had to use process sheet, which includes production steps, cutting speed, feed,
feedrate, revolutions,..
This sheet was used to develop the NC coded program.

2.

Basic Components of NC Machine System:

NC Machine

Program
Instruction

Machine
Control
Unit (MCU)
(Computer
)

Machine Tool

To produce the program instruction we use the process sheet and convert it to NC coded
program.
The NC coded program is then punched into a tape to be transferred to the machine
control unit.
The machine control unit (MCU) contains a tape reader, it also has register and buffer,
they are used to convert the data from the punched tape into electric signals that are sent
to the machine tool.

3.

Flow Diagram of the Steps in Processing NC Program:

4. Program of Instructions :
It is the detailed step by step commands that direct the actions of the processing
equipment. In machine tool applications ,the program of instruction is called part
program ,and the person who prepare the program is called a part programmer.
The program is coded on a suitable medium for submission to the machine control
unit. The most common input mediums used are punched tape , punched cards and
magnetic tape .
a. Punched Card:
Punched card is a plastic / paper card which is having holes . It can
accommodate only few sentences of the program so there is restriction on the
size . The advantage of using card is that sequence of operation can be changed
because each operation is on separate card .,program readers and
transportation devices for punched cards are more complicated than for
punched tape.
b. Punched Tape :
Different materials have been used for punched tape . These materials are
paper and foil . The following figure shows the shape and dimensions of the
punched tape

The following tables shows the standard EIA and ISO (ASCII) codes for
numerical control programming originally designed for punched tape.

c. Magnetic Tape :
Magnetic tape is a plastic tape coated with iron oxide and is similar to the tape
Used in tape recorders (but small size).magnetic tape can store much more
information per unit length as compared to punched cards or magnetic tapes .Also
Information can be easily stored and erased .This is the least preferred in
machining because of the following reasons :
1. electrical and magnetic fields can easily distort program signals
2. any damage of the magnetic tape is not easy detectable because no visual
examination is possible.
3.tape gets damaged in dust in the shop floor.

5.Machine Control Unit :

Information is passed from the NC tape to the machine control unit by means of
the tape reader in the machine control unit (MCU) . After the tape has been read
by the tape reader ,the coded information ,now in the form of signals ,is passed on
to the control. Registers within the control accept the information which consists
of proper coordinates , preparatory functions and miscellaneous functions..This
information is transmitted to the respective register sections where actuation
signals are relayed to the machine tool drives. A fundamental sketch of this process
is illustrated in the following figure .

Tape Reader

Information Read
& Decode
Machine
Actuating
Registers

Machine Table

Machine Control
Unit (MCU)

Most modern NC and CNC machine controls are equiped with buffer storage shown
in the following figure ,this feature allows the control to accept information into the
buffer registers while an operation is being performed from the active machine
registers.when the operation is complete the information is transferred from the buffer
storage to the machine actuation registers.
Tape Reader

Information
Read
Decode&

X
Y

1
5

0
8

7
9

6
2

4
4

Machine Table

Information Passed
Directly
Machine
Actuating
Registers

X
Y

Machine Control
Unit (MCU)

Tape reader types:

a.Mechanical Type: as shown in following figure
Consists of pins that read holes in the tape, such that a hole is read as 1 or
signal, tape is red as 0 or no signal.
It is commonly used in point to point motion (like in drilling)
It is slow, reads only about 60 chr/sec
It is reliable, inexpensive, and easy maintainance.

b. Photo-electric reader: as shown in the following figure

Consists of a light beam and photo electric cell that gives a signal when light
falls upon it, such that a hole is read as 1 or signal, tape is red as 0 or no signal.
It is commonly used in contouring motion.
It is fast, reads 300-500 chr/sec
It is very expensive
It has high sensitivity to dust

C. Pnumatic reader : as shown in the figure

Their principle is similar to that of electromechanical tape reader . Here pressure on
the moving contact is exerted by compressed air . If there is punched hole in front of
nozzle , the compressed air passes and no pressure builds up at the opening of nozzle
.this pressure is utilized to obtain an electric signal . these readers are relatively cheap
.They have the advantage that the dirt particales in the reading zone are automatically
blown off thus providing more reliability .

6. .Axis Relationships:
For Milling/Drilling
+
Z

-Y

-X

+
X

+
Y

8
-Z

a
c

 for Turning:
+
X

-Z

+
Z

-X
Once the NC tape has been read ,decoded and the machine actuation registers loaded ,the
Machine responds with its appropriate coordinate axis movements and other commands
Machines with only X and Y position capability are known as two axis machines. On
Machines of this type distance in Z direction is controlled by the operator or by preset
Stops similar to that of a conventional drill press.
The three basic motions are designed by the electronic industries association (EIA) are the
X,Y,Z , the X motion is parallel to the longest dimension of the machine table,the Ymotion
Is normally parrel to the shortest dimension of the machine table.The Z motion becomes
Complicated by the fact that the NC macines are made with vertical and horizontal spindle
so it can be said that the line through the centre of the machine spindle is actually the Z
axis ,it is only when the actual depth of cut Z axis is controlled by the tape ,the macine is
considered a true three axis NC machine. Machine / axes relationships can be seen in
figures :

Vertical Milling Machine

Horizontal Milling Machine

Turning Machine

10

7. Types of Motion Control:

1. Point to Point Motion (PTP):
Tool moves to the defined points with only feed back at the specific point.
Used in drilling operations.

2. Contouring Motion:
X,Y,Z motion are always controlled and they have constant feedback.
Used in milling or turning operations.

11

3. Straight Cut:
Only one coordinated is monitored at a time.
Used in simple straight cutting operations.

8.Rectangular Coordinates : Absolute and Incremental

8.1. Cartesian Coordinate System :
The system of cartesian is illustrate in figure , the X axis is the horizontal (left
And right ) and the Y axis is vertical (up and down) and the Z is perpendicular
To the paper with its point at the location where the X and Y lines cross each
Other ,the intersection of the two axes X and Y is called orign or Zero point.
Four quadrant are formed when the X and Y axes cross as shown in the figure

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8.2 incremental System :

An incremental system works according to the same principle , it positions the
Work or cutter in increments from the immediately preceding point. Calculations
Are made from the location of the tool or table to where it is going. As shown in
figure the use of plus and minus signs involves a new aspect when used in the
incremental mode , a x move directs the tool to the left . Similarly a +Y move
positios the cutter up from the present location and Y is a command to move
down . a + Z directs the cutter away from the workpiece,while a Z is a move
toward or into the workpiece.

8.3 Absolute Systems :

An absolute system operates similar to the absolute dimensioning. All positions
are figured and punched in the tape relative to the same zero or reference point.

One advantage of absolute systems over incremental systems concerns

positioning errors .if a positioning error occurs in an incremental system ,all

13

subsequent positions are affected and all the remaining moves are incorrect, but
when a positioning error occurs in an absolute system a particular location is in
error but subsequent positions are not affected.

Zero Shift System :

They define the origin of the coordinate axis. They have three types:
1. Fixed Zero:
It is where the machine manufacturers define the origin; normally at the corner of the
table, (X & Y are always positive).

+
Z

-X

+
X

+
Y
-Z

2.Floating Zero:
The origin point is left for the operator to define using a special tool, which is lowered
until it touches the desired point with no restrictions.
(X & Y can take positive or negative values)
+
Z

-Y
-X

+
Y

+
X

-Z

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9. Engineering Analysis of NC Positioning Systems :

The NC positioning system converts the coordinate axis values in the NC part
program into relative positions of the tool and work part during the processing .
Let us consider the simple positioning system shown in figure .The system consists of
A cutting tool and worktable on which a work part is fixed .The table is designed to
move the part relative to the tool . The worktable moves linearly by means of a
rotating leadscrew ,which is driven by stepping motor or servomotor .For simplicity,
We show only one axis in our sketch .To provide x-y capability ,the leadscrew has a
certain pitch P (in/thread , mm/thread). Thus the table moves a distance equal to the
pitch for one revolution. The velocity of the work table ,which corresponds to the feed
Rate in a machining operation is determined by the rotational speed of the leadscrew.

There are two types of positioning systems used in NC system : shown in figure
a. open loop system operates without verifying that the actual position achieved
in the move is the same as the desired position.
b. Closed loop control system uses feedback measurements to confirm that the
final position of the worktable is the location specified in the program .
Open loop cost less than closed loop systems and are appropriate when the force

15

Resisting the actuating motion is minimal , closed loop systems are normally
specified for machines that perform continuous path operations such as milling or
Turning in which there are significant forces resisting the forward motion of the
cutting tool.

16

Chapter 2

CNC Machines
1.Introduction:

Punched tape, Punched

Card, Magnetic tape

Computer as input data

2.Features of CNC Machines:

1. Storage of more than one part program.
2. Various form of program input
Manual data input
Floppy diskette
Communiction with external computer
3.
4.
5.
6.
7.
8.
9.

Program editing at the machine tool

Fixed cycles & programming subroutines
Interpolation
Cutter length and size compensation
Acceleration and deceleration calculation
Communication interface
Diagnostics

17

Program
performs
interpolation
calculations

3.

Machine Control Unit of CNC:

Memory
1.Main Memory:
.ROM: Operating
Sys.
RAM: Part
Program
2.Secondary
Memory:
Removable
storage

CPU
1.Control Section
2.Arithmetic Logic
Unit (ALU).
3.Immediate Access
memory

System
Bus

Machine Tool Controls

Position Control (X,Y,Z)
Spindle Speed Control

4.

I/O Interface
1.Operator Panel
(Keyboard, CRT,)
2.Tape Reader

Sequence Controls
Coolant
Fixture Clamping
Tool Changer

CNC Software:
1. Operating system software: is to interpret the NC part program and generate the
corresponding control signals to derive the machine tool axes ,it is installed by the
controller manufacturer and is stored in ROM in the MCU. The operating system
software consists of the following :
Editor: which permits the machine operator to input and edit NC part programs
Control program: which decodes the part program instructions,perform
interpolation and acceleration/deceleration calculations ,and accomplishes
other related functions to produce the coordinate control signals for each axis.
Executive program: which manage the execution of the CNC software as well as
the I / O operations of the MCU.
2. Machine interface software: is used to operate the communication link between the
CPU and the machine tool to accomplish the CNC auxiliary functions (coolant
control ,tool changer ,fixture clamping device ,timers ),as previousely indicated ,the
I / O signals associated with the auxilliary functions are sometimes implemented by
means of a programmable logic controller interfaced to the MCU ,and so the machine
interface software is ofthen written in the form of ladder logic diagram

18

3. Application software: consists of the NC part programs that are written for
machining.
5.

Direct Numerical Control (DNC):

Central
Computer

MC
U

MC
U

Bulk Memory
NC
Programming

MC
U

DNC can be used for up to 256 machines.

It has two systems:
1. Load:
It's where the machine is directly controlled from the central computer
2. Download:
It is where the MCU attached to the machine downloads the NC code from the central
computer

6.

Distributed Numerical Control (DNC):

Data Switching
Box

MCU

MCU

Switching 19
Network

MCU

DNC Computers

Satellite
Computer

MC
U

MC
U

LAN Key system

7. Applications of NC & CNC:
1. Machine tool applicatioin:
NC lathe
NC boring mill
NC drill press
NC milling machine
NC cylindrecal grynding
Non-machine tool application:
Welding machining
Thermal cutting machine
8. Part characteristcs to be Suited to Applications of NC & CNC:
1. Batch production of small to medium lot size (1-100 products)
2. Repeated order
3. Complex part geometry
4. Much metal needs to be removed
5. Part is expensive
9. Advantages of using NC,CNC:
1. Greater accuracy
2. Lower scrap rates
3. More complex part geometry
4. Less floor space is required
5. Operator skill level is redued
6. Inspection requirement is reduced
10.Disadvantages of using NC, CNC:
1. Higher investment cost
2. Higher maintainance effort

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Chapter 3

NC Coding System
1.Format of NC Coded Program:
Punched tape, Punched
Card, Magnetic tape

Computer as input data

Word Adress Format:

1. Sequence Number (N-Word)
2. Preparatory word (G-Word)
3. Coordinates (X,Y,Z Word)
4. Feed Rate (F-Word)
5. Spindle Speed (S-Word)
6. Tool Selection Word (T-Word)
7. Miscellaneous Command (M-Word)
8. End-Of-Block (EOB Symbol)

2. NC coded Program in milling and drilling operations :

The following figure shows the axes convention for the vertical milling machine (VMC)
And Horizontal milling machines(HMC). While the tables indicate a summary of the
G- codes,M- codes used in milling and drilling operations .The remaing part of this
section explains the method of using G codes .

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3. NC coded Program in Turning operations :

The following figure shows the axes convention for turning operations . While the
tables indicate a summary of the G- codes,M- codes used in turning operations .The
remaing part of this section explains the method of using G codes .

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Chapter .4

NC

Part Program

NC part programming consists of planning and documenting the sequence of processing

Steps to be performed on an NC machines, the part programmer must have a knowledge
Of machining as well as geometry . The documentation portion of the part programming
involves the input medium used to transmit the program of instructions to the NC machine
Control unit (MCU).
The traditional input medium (1950) to the NC machines is 1-inch wide punched tape .
more recently ,the use of magnetic tape and floppy disks have been growing in popularity as
storage technologies for NC .
Part programming can be accomplished using a variety of procedures ranging from highly
Manual to highly automated methods. These methodes are :
1.
2.
3.
4.

Manual Part Programming

Computer Assisted Part Programming
Part Programming Using CAD/CAM
Manual Data Input

The following are explanations of the different methods of part programming with some
. Examples

:Manual part programming .1

In manual part programming ,the programmer prepares the NC code using the low level
machine language .the program is either written by hand on a form from which a
punched tape or other storage media is subsequently coded ,or it is entered directly into
A computer equipped with NC part programming software ,which writes the program onto
the storage media .In any case ,the part program is a block by block listing of the
machining instructions for the given job ,formatted for the particular machine tool to be
.used
Manual part programming can be used for both point-to-point and contouring jobs. It is
Most suited for point to-point machining operations such as drilling . It can also be used
.for simple contouring jobs, such as milling and turning when two axes are involved
However ,for complex three dimensional machining operations ,there is an advantage in
.using computer assisted part programming

45

The following are some exercises in drilling ,milling and turning machine operations
: using the Boxford CNC machines
: a. Drilling and Milling Exercises

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: b. Turning Exercises

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: Computer Assisted Part Programming .2

86

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95

96

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100

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: NC Part Programming using CAD/CAM .3

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103

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: Manual Data Input .4

Chapter .5
105

Exercises and Previous Examinations

Higher Technological Institute
10 th of Ramadan
Mechanial Engineering
Department

Midterm Examination
Term: JAN./MAY 2007
Course
: Control of
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:1 Hour

Problem ONE :
[10]
?What are the basic components of NC System .1
? Explain the different zeros of NC machine tool .2
? Explain the NC Procedure .3
Problem TWO:
[10]
? Explain briefly the Function controlled by NC .1
?Explain the preparatory functions .2
Write a simple part program for the following .3
:component
Drilling and taping two holes with diameter 10 ..
mm with
.depth 20 mm ,using manual Z control
Higher Technological Institute
10 th of Ramadan
Mechanial Engineering
Department

Midterm Examination
Term: JAN./MAY 2007
Course
: Control of
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:1 Hour

1.Explain briefly the Function controlled by

NC ?

?How to adjust the R- work plane ? Give an example .2

Write a simple part program for the following .3

106

Material : Plastic
Tool changed at : X0,Y0,Z25

: Required
Mill the steps [8 mm diameter slot drill] .1
Drill the holes [ 4 mm diameter slot drill ] .2
Mill the 30 mm diameter pocket [ 8 mm diameter slot .3
drill ]
Higher Technological Institute
10 th of Ramadan
Mechanial Engineering
Department

Midterm Examination
Term: MAY/AUG. 2007
Course
: Control of
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:1 Hour

Problem ONE :
[10]
?What are the basic components of NC System .1
? Explain the different zeros of NC machine tool .2
?Explain the NC Steps .3

107

Problem TWO:
[10]
Describe the usage of punched tape as input medium for NC .1
? machine
Compare between the punched tape readers operations ?
.2
3.Explain the functions of the following : Decoder Buffer
storage
interpolator Drive unit
? 4.Explain the basic types of motion control system
? Draw block diagram of NC system .5

108

Higher Technological Institute

10 th of Ramadan
Mechanial Engineering
Department

Final Examination
Term: JAN./MAY 2007
Course: Automatic control in
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:1.5 Hour

Problem ONE :
[5]

? Explain the basic components of NC system .1

With drawing,explain machine registers and buffer storage .2
?operations
? What are the types of NC system .3
Problem TWO:
[10]
Using sketches ,explain how the Z-axis control can be done in .1
? drilling
?Compare between different zeros used in milling and drilling .2
? What are the functions controlled by NC in milling and drilling .3
Problem THREE:
[5]
Explain with examples the different G-codes canned cycle used .1
?in drilling and milling
? Draw sketch and indicate the machine axes .2
?Explain the canned cycles used in turning .3
Problem Four:
[20]
Practical

109

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111

Higher Technological Institute

10 th of Ramadan
Mechanial Engineering Department

Final Examination
Term: Oct./Jan.2008
Course: Automatic control in
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:30 min.

Write the G,M- coded program and simulate the production

steps on
Computer

Select the suitable tool , feed rate and cutting speed

112

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114

Higher Technological Institute

10 th of Ramadan
Mechanial Engineering Department

Final Examination
Term: Oct./Jan.2008
Course: Automatic control in
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:1.5 Hour

Problem ONE :
[10]
1. What are the steps of NC system ?
?Briefly , compare between NC,CNC, DNC machines .2
? Explain briefly the components of NC system .3
? sketch and explain the NC coordinate system .4
? Compare between the types of Zero points .5
Problem TWO:
[10]
?What are the types of motion control system 1
? Compare between the different input media in NC machine .2
?What are the types of punched tape readers .3
Explain with sketches ,the difference between open and closed .4
loop
? control systems
Problem Three: [Practical]
[20]
Write the G,M- coded program and simulate the production
steps on
Computer

Select the suitable tool , feed rate and cutting speed

115

Higher Technological Institute

10 th of Ramadan
Mechanial Engineering Department

Final Examination
Term: Jan./May 2008
Course: Automatic control in
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:1.5 Hour

Problem ONE :
Compare between the
?machine controlunit of NC and CNC machines
:Explain the following using sketch .2
NC coordinate system Zero point .The G81 , G82 ,G84 , G85 ,G97 -

[5]
.1

Problem TWO:
[15]
? Explain the Tasks in computer assisted part programming .1
Write the APT program to produce the following shown .2
: component

: the required

a. drilling 4 holes with feed rate 120 mm/min. ,cutting tool

speed 2000 rpm
b.milling the outer surface with cutting tool diameter 8 mm
,feed rate 120 mm/min. and cutting tool speed 2000 rpm

116

Problem Three: [Practical]

[20]
Higher Technological Institute
10 th of Ramadan
Mechanial Engineering Department

Final Examination
Term: Jan./May 2008
Course: Automatic control in
manufacturing
Code
: MTE203
Examiner :Dr.Ibrahim Nasr
Time
:1.5 Hour

Problem ONE :
?How NC collect informations .1
:Explain the following using sketch .2
motion control system -.flow diagram of NC -.interpolation G-codes -Problem TWO:
[15]
?Explain the APT language statements ?give examples .1
Write the APT program to produce the following shown .2
: component

: the required

a. drilling the hole with feed rate 120 mm/min. ,cutting tool
speed 2000 rpm

117

[5]

b.milling the outer surface with cutting tool diameter 8 mm

,feed rate 120 mm/min. and cutting tool speed 2000 rpm
Problem Three: [Practical]
[20]

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