NC Machine Tools

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.
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.”
In short, a programme is prepared which consists of 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 (Part Programme). The machine control unit then reads the part programme, interprets it
and conversely translates it for mechanical actions of the machine tool. 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. Need of an NC – easy and flexible to encode a new programme than to change the machinery.

Advantages of NC:
Higher Precision: NC machine tools are capable of machining at very close tolerances, as small as 0.005 mm.
Better Quality: NC systems are capable of maintaining constant working conditions for all parts in a batch, hence
better quality of materials.
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 (machine centres) 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.
Types of NC System: Machine controls are divided into three groups:
(a) Traditional numerical control (NC): referred to as NC machine tool, they have “hardwired” control whereby
control is accomplished through use of punched paper or plastic tapes or cards. Disadvantages are – tapes tend to
wear/get dirty causing misreading, manually reloading the tapes, lack of program editing abilities etc.
(b) Computer numerical control (CNC): has a local computer to store all required numerical data using magnetic
tapes and hard disks. Advantages are – ability to store/execute large programs (esp. 3 or more dimension
machining of complex shapes), allow program editing, execute cycles of machining commands etc.
(c) Distributed numerical control (DNC): CNC along with the development of local area networking has evolved in
the modern concept of DNC. DNC uses a remote computer 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.
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.

Basic Components of NC Machines

1. 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.
2. 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.
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 operator’s 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.
3. 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.
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.

Tape Reader: Tape reader is the least reliable hardware components of the machine while any breakdown is
occurred on an NC machine.
Controller: The hard-wired controller cannot be easily altered to incorporate improvements into the unit.

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.
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.
 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.
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 non-productive 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.