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”

Programming:: Manual programming of the

Manual Part Programming
machines

Computer Aided Programming (CAP): (CAP): Programming done
by a computer
(MDI): A manual program is entered into

Manual Data Input (MDI):
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
on:: MDI programming of CNC machinery

FOCUS on

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES

Numerical control (NC) has been used in industry for more

than 40 years

NC is a method of automatically operating a manufacturing
machine based on a code of letters, numbers, and special
characters

A complete set of coded instructions for executing an
operation is called a program

The program is translated into corresponding electrical
signals for input to motors that run the machine

Numerical control machines can be programmed manually

If a computer is used to create a program, the process is
known as computer
computer--aided programming

The approach we take is in the form of Manual Programming

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 The History of NC

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
first NC machine

1951: MIT was involved in the project

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

1955: after refinements NC become available to industry

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 The History of NC

1959: MIT announces Automatic Programmed Tools (APT)
programming language

1960: Direct Numerical Control (DNC). This eliminates paper
tape punch programs and allows programmers to send files
directly to machine tools

1968: Kearney & Trecker machine tool builders market first
machining center

1970’s: CNC machine tools & DNC

1980’s: Graphics based CAM systems introduced. Unix and
PC based systems available

1990’s: Price drop in CNC technology

1997: PC Windows/NT based “Open Modular Architecture
Control (OMAC)” systems introduced to replace “firmware”
controllers
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

Languages:
Computer Aided Programming 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

Control::
Direct Numerical 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

(DNC):
Direct Numerical Control (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
(DNC):
Distributed Numerical Control (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

NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES

Numerical control systems’ components:

Tape punch: converts written instructions into a
corresponding hole pattern

The hole pattern is punched into tape, which passes through
this device

Much older units used a typewriter device called a
Flexowriter

Later devices included a microcomputer coupled with a tape
punch unit

Tape reader: reads the hole pattern on the tape and
converts the pattern to a corresponding electrical signal code

Controller: receives the electrical signal code from the tape
reader and subsequently causes the NC machine to respond

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES

machine:: responds to programmed signals from the

NC machine
controller. Accordingly, the machine executes the required
controller.
motions to manufacture a part (spindle rotation on/off, table and
or spindle movement along programmed axis directions, etc etc..).

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES

FIGURE 1-
1-3 Components of traditional NC systems

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 DEFINITION OF CNC AND ITS COMPONENTS

 A computer numerical control (CNC) machine is an NC

machine with the added feature of an on-
on-board computer

 The on-
on-board computer is often referred to as the machine
control unit or MCU

 Control units for NC machines are usu-ally hard wired

wired.. This
means that all machine functions are controlled by the physical
electronic elements that are built into the controller

 The on-
on-board computer, on the other hand, is "soft" wired.
wired.

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 DEFINITION OF CNC AND ITS COMPONENTS

 Thus, the machine functions are encoded into the computer at

the time of manufacture

 They will not be erased when the CNC machine is turned off
off..
Computer memory that holds such infor-mation is known as
ROM or read
read--only memory

 The MCU usually has an al-phanumeric keyboard for direct or

manual data input (MDI) of part programs
programs.. Such programs are
stored in RAM or the random
random--access memory portion of the
computer

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 DEFINITION OF CNC AND ITS COMPONENTS

 They can be played back, edited, and processed by the

control. All pro-grams residing in RAM, however, are lost when
control.
the CNC machine is turned off

 These programs can be saved on auxiliary storage devices

such as punched tape, magnetic tape, or magnetic disk

 Newer MCU units have graphics screens that can display not
only the CNC program but the cutter paths generated and any
errors in the program

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 DEFINITION OF CNC AND ITS COMPONENTS

The components found in many CNC systems are shown in Figure

1- 3.

Machine control unit:

unit: generates, stores, and processes
CNC programs
programs.. The machine control unit also contains the
machine motion controller in the form of an executive software
program.. See Figure 1-4.
program

machine:: responds to programmed signals from the

NC machine
machine control unit and manufactures the part

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 DEFINITION OF CNC AND ITS COMPONENTS
machine:: responds to programmed signals from the

NC machine
machine control unit and manufactures the part

FIGURE 1-
1-4 Components of modern CNC systems

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 1-5 A high speed 4-axis vertical machining FIGURE 1-6 A high speed 4-axis horizontal
center machining center

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 CNC Machines

FIGURE 1-7 FIGURE 1-8

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-
1-9 A precision NC lathe FIGURE 1-
1-10 A NC lathe

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 SPECIAL REQUIREMENTS FOR UTILIZING CNC
Computer numerical control machines can dramatically boost
productivity. The CNC manager, however, can only ensure
such gains by first addressing several critical issues

1. Sufficient capital must be allocated for purchasing quality CNC

equipment
2. CNC equipment must be maintained on a regular basis basis.. This
can be accomplished by obtaining a fullfull--service contract or by
hiring an in-
in-house technician
3. Personnel must be thoroughly trained in the setup and
operation of CNC machines
4. Careful production planning must be studied
studied.. This is because
the hourly cost of operating a CNC machine is usually higher
than that for conventional machines
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
 FINANCIAL REWARDS OF CNC INVESTMENT
Investors are encouraged to look to the CNC machine tool as
a production so-lution with the following savings benefits

1. Savings in direct labor

labor..
2. One CNC machine's output is commonly equivalent to several
conventional machines
2. Savings in operator training expenses
3. Savings in shop supervisory costs
4. Savings due to tighter, more predictable production scheduling
5. Savings in real estate since fewer CNC machines are needed
6. Savings in power consumption since CNC machines produce
parts with a minimum of motor idle time
7. Savings from improved cost estimation and pricing

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 FINANCIAL REWARDS OF CNC INVESTMENT

8. Savings due to the elimination of construction of precision jigs,

and the reduced need for special fixtures Maintenance and
storage costs of these items are also reduced
9. Savings in tool engineering/design and documentation
documentation.. The
CNC's machining capability eliminates the need for special
form tools, special boring bars, special thread cutters, etc
etc..
10.
10. Reduced inspection time due to the CNC machine's ability to
produce parts with superior accuracy and repeatability
repeatability.. In many
cases, only spot checking of critical areas is necessary without
loss of machine time
time..

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 FINANCIAL REWARDS OF CNC INVESTMENT
Using Payback Period to Estimate Investment Efficiency
The Payback Period calculation estimates the number of years
required to re-cover the net cost of the CNC machine tool

Using ROI to Estimate Investment Efficiency

The ROI calculation predicts what percent of the net cost of the
CNC will be recovered each year year.. The ROI calculation accounts
for the useful life of the CNC machine tool

Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis

 EXAMPLE 1 -1
 Given the investment figures in Table 1-1 for implementing a
new CNC machine tool, determine the payback period and the
annual return on investment
investment.. The CNC is conservatively
estimated to have a useful life of 12 years
years..

 This calculation estimates that the investor can expect 57% of

the net cost of the CNC or (.57 x $95,250) = $54,293 to be
recovered each year if the CNC machine's useful life is 12
years
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
 CNC Machines

FIGURE 1-11
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

 Input Media

FIGURE 1-
1-12 CNC input and storage media

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-
1-13 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-
1-14, 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

New functions can be programmed into the MCU as software Less
hardware

Many different CNC programs can be stored in the MCU

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

Several DNC can be networked forming a large distributive NC system

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