Numerical Control

OBJECTIVES
understand the following concepts:
After reading this chapter, the reader will be able to

Numerical control
machine control unit, NC machine
Numerical control elements: Program of instructions,
tools, and NC cutting tools
NC coordinate system
methods
NC tool positioning
and straight-cut NC mode
Numerical control modes: Point-to-point NC mode

Contouring NC mode
Numerical control applications
control
Advantages of numerical
Limitations of NC

11.1 INTRODUCTION
and enadie
Conventional machine tools have developed over aperiod of more than 160 years ped
machine tools are develop
movements. The metal-cutting
tool to cut metal by power-assisted
with two kinematic systems. These are:

1. Based on the displacement of the workpiece.

2. Based on the displacement of the cutting tool.

308
 Numerical Control 309

The linear displacements are associated with slideways. The rotary displacements take pla
solt spindl
about Spindle axes. 1ne geometriC shapes are machined by controlling the relative movements

the workpiece and the tool.

etween
With the advent of new materials and requirements for tolerances of precision, skilled human
eators have reached the limit of their ability. There is also a huge demand for a variety of
opera
dcts in
products in view
view of the varying tastes of the consumer and global competition. Hence, the need
for flexible and just-in-time manufacturing is felt. These requirements have led to a form of
automatic machine control known by the generic name numerical control (NC).
By 1957.the first successful NC machines were used in production. Initially, the part programs
were prepared manually and input into the machine controller through the tape reader. In order to
solve the difficulty in generating part programs manually, a computer-based part programming
resc

language called APT (automatically programmed tools) was introduced.

The development of NC technology has taken place on the following two platforms:

1. Hardware development to improve control systems and machine tools.

2. Software development to generate computer-aided part programming.

11.2 NUMERICAL CONTROL

in which various
Numerical control may be defined as a method of programmable automation
In NC, the numbers
functions of machine tools are controlled by numbers, letters and symbols.
instructions may be:
form a program of instructions. The
1. To start or stop the machine tool spindle
2. To control the spindle speed
3. To change the tool
4. To change the feed rate
5. To switch the coolant on/off
6. To position the tool at a desired position.
of an NC machine is
shown in Figure 11.1. The program of
Theprinciple of operation tool serves
nstructions in terms of part geometry, cutting process
parameters and type ofcutting
machine tool to
control unit (MCU), which, in turn, commands the
45 the
input to the machine
work under the
a k e the product. The machine axes are
connected to servomotors, which
tool with respect to
of the MCU. The servomotors control
the movement of the cutting
ro
the workpiece.
11.2. It is a closed loop positioning
NC machine is shown Figure
in
ne control ofan axis in an
the feedback transducer
signal until the signal returned from
i.The MCU generates a pulse movement. The comparator
required to execute the
of pulses
ces with the original number
number, and the error signal
is the output
pulses with the original
r e s the count of feedback The feedback transducers are linear/rotary
encoders
reaches the desired position.
neto table or velocity feedback.
d
obtain the appropriate position
310 CADICAM: Concepts and Applications

Z-axis drive

Spindle Data flow

Cutting tool

X-axis drive-
Machine control unit

Y-axis drive

of operation of an NC machine.
Fig. 11.1 Principle

Spindle

Comparator
Servomotor Transducer

Amplifier
Table

Fig. 11.2 Control of an axis in an NC machine tool.

11.3 NUMERICAL CONTROL ELEMENTS

The basic elements of an NC machine system are:

1. Program of instructions
2. Machine control unit (MCU)
3. NC machine tool
4. NC cutting tools

11.3.1 Program of Instructions

The program of instructions is the detailed step-by-step set of operations, which are to De
implemented by the machine control unit. The program is coded in alphanumerical form on an
input medium to the MCU. The input medium, in general, is a punched tape or a magnetic lape
Two methods are used to program for NC. They are
 311
Numerical Control

Manual part programming

Computer-aided part programming

Machine Control Unit

11.3.2
unit (MCU) consists of the electronics and hardware that read and interpret
The
The machine control tool. The
nart program of instructions and convert them into mechanical actions ofthe machine
the p
tw main units: data processing unit (DPU) and control loops
unit (CLU). The
consists of two
MCU the
the instructions available on the tape, and to provide
fnction of the DPU is to read and decode control the drives atached to the axes
and
iecoded data to the CLU. The function of the CLU is to
from the machine tool. CLU also prompts a signal that
the previous
the feedback signals
to receive and that the DPU can read the next block of the part program.
data segment is completed
The DPU consists
of the following elements:
reader
Input device, e.g., tape
Reading circuit
Parity checking logic
Decoding circuits
Interpolator
The CLU consists of the following:
feedback device such as a linear encoder
.Positional control unit with a encoder
feedback device such as a rotary
Velocity control unit with a circuits
Acceleration, retardation
and backlash correction
coolant on and off, etc.
Auxiliary function control unit for

11.3.3 NC Machine Tools

when conventional machine
demands the use of expensive tooling
The quality of the product impact on the cost of
each component in proportion
a considerable
tools are employed, and there is is a high-cost area of production.
and medium quantities
to the tooling cost. The machining ofsmall of production, to improve the quality
of
The prime objective of NC machines
is to reduce the cost tool set-up time and the
manufacturing lead
times by saving the
the product, and to decrease the
material handling time. machine tools in the manufacturing
The general characteristics for the implementation of NC

industry are manufactured by the conventional

machine
that cannot be
The part geometry is so complex
tools.
but frequently.
. Parts are produced in small lots,
. Products demand high accuracy and precision.
on the part.
4. Many operations must be performed
removed.
5. A lot of metal needs to be
machined.
Hard materials need to be changes.
. to frequent engineering design
Parts are subjected
8. Parts 100 per cent
inspection.
require
 312 CAD/CAM: Concepts and Application
The machine tool performs the machining operation on the work. The
machine tool con
work table. spindle. cutting tools. jigs and fixtures, motors with the onsists of a
necessary controls to
them and other auxiliary equipment needed in the machining
The NC machine drive
operation. The
may be used for turning, drilling, milling. boring. grinding,
welding, etc. Some practical tool
machines are illustrated in Figures 11.3 to 11.6. NC

Fig. 11.3 NC milling machine (Courtesy: Bridgepot Machines, Textron Inc.).

Fig. 11.4 Four-axis NC turning machine (Courtesy: Cincinnati Milacron).

 Numerical Control 313

Fig. 11.5 Wire EDM (Courtesy: Mitsubishi Electric Corp., Tokyo).

UPMC-CARAT, Tokyo Seimitsu).

machine (Courtesy:
Fi . 11.6
Coordinate
measuring
314 CADICAM Concepts and Applications
11.3.4 NC Cutting Tools
The ISO procedure is adopted for the designation of NC cutting tools. A power-operated draw

Figure l1
is shown in
may be used
The
pull the tooling at the retention knob. A typical end mill
to
programmer obtains the history of the tools such as tool number, cutter compensation
etc.
from the tool files, which are updated periodically.
Adapter
End mill
H Retention knob

MO025

Fig. 11.7 NC end mill cutter.

11.4 NC COORDINATE SYSTEM

A Cartesian coordinate system consists of three axes positioned at 90 degrees from each other.
The nomenclature ofthe tree main axes (x, y and2) is based on the 'right hand rule'. The r-, y- and
z-axes are represented by the thumb, index and middle fingers of the rght hand, respectively
(Figure 11.8). The right-hand rule is used to define the positive direction ofthe coordinate axes as
shown in Figure 11.9.The three rotational axes defined in NC arethe a, b- and c-axes.
For turning operations, two axes are normally required to control the movement of thetoo
relative to the rotating workpiece. The z-axis is the axis of rotation of the workpiece, and the
r-axis is the radial location of the cutting tool. The arrangement is shown in Figure 11.10. For
drilling operations, the NC machiningtool axis system is shown in Figure 11.11. Two axes, x- and
y-, are defined in the plane of the table and the z-axis is perpendicular to this plane and movement
in the z direction is controlled by the vertical motion of the spindle.
An NC milling machine use an axis system similar to that of a drilling machine. In addition to
three linear axes, the milling machine may use one or more rotational axes i.e. the a-, b- or c-axes.

+y

+X

Fig. 11.8 Cartesian coordinate system.

 Numerical Control 315

+X, +y or +Z

+a, +bor +C

Fig. 11.9 Right hand rule.

+X

Fig. 11.10 NC machine tool axis system for turning operation.

for drilling operation.

machine tool axis system
Fig. 11.11 NC
 316 CADICAM: Concepts and Applications

11.5 NC TOOL POSITIONING METHODS

The positioning of the NC cutting tool can be accomplished by using two distinct meh
first method. calledabsolute positioning'. fixes the reference system and enables hods. The
the a
, and z-coordinates to be specified with respect to a fixed origin. The absolute Dosis dual
illustrated in Figure I.12a.
The incremental positioning uses incremental movement that the next tool location i
ositioning is
with respect to the previous tool location. The incremental positioning is shown in Fiosened
re l1.12h.

(1,3) 2(-2,-1), 3 ,3)

(-1,22 ---

(-3.75, .5) 1 3(-2.75, 1.5)

42TT24 4(0.75, -1.5)

-3,-1) A
2 7 2 , 05
B (3,-2) 5(-1,-1)
(4,-3) 36(5,-0.5)
(75,-3.5) 4
y
(a) (6)
Fig. 11.12 NC positioning methods.

11.6 NUMERICAL CONTROL MODES

The NC modes are broadly classified into the following categories:
. Point-to-point cut mode
2. Straight cut mode
3. Contouring cut mode

11.6.1 Point-to-Point NC Mode

The point-to-point (PTP) NC mode is used to move the cutting tool to a pre-defined position
(Figure 11.13a). The machining operation is performed at that position. The speed or
too
path is not important in the PTP NC mode. An NC drilling machine is the best example or d
PTP NC.
 Numerical Control 317
Straight Cut NC Mode
11.6.2

straig cut NC mode, the cutting tool is moved

parallel to one of the
In
In a
major axes(x ory
)acontrolled
rate as
controlle shown in Figure 11.136. Pocket
or
cut NC mode.
at a
milling is an example of the straignt

11.6.3 Contouring NC Mode

. thic mode, the tool motion in more than one axis is controlled continuously and simultaneously
In
11.13c).
Figure 11.13c). This
Thi mode facilitates two-dimensional or three-dimensional profiles to be contour
machined, and is used in milling turning and grinding machines.

Tool Tool
path

Starting
point Tool path
Starting point Tool
(a) PTP NC mode (b) Straight cut NC mode

Too Tool path

PA 2
,

(c) Contouring NC mode

Fig. 11.13 Numerical control modes.

NUMERICAL cONTROL APPLICATIONS

Numerical control machines are widely used for:
. Material removal processes:
Turning
Drilling
318 CADICAM Concepts and Applications

Boring
Milling
Grinding
2. Welding and cutting processes
Spot welding
Arc welding
Laser beam welding
Plasma arc cutting
3. Automatic drafting
4. Assembling of parts
5. Automatic riveting
6. Plastic moulding processes

Injection moulding
Blow moulding
7. Tube bending
8. Cloth cutting
9. Automated knitting

11.8 ADVANTAGES OF NUMERICAL CONTROL

NC machine tools have manifold

advantages over conventional machines. These are listed
below
1. The
manufacturing lead time in NC machines is less. This is
owing to fewer set-us
reduced work handling time, automatic tool changes, etc.
2. Close tolerance can be maintained
on the
products.
3. Parts can be
produced more accurately.
4. Parts can be
processed in small batches.
5. NC fixtures are
simple and less costly. Since the part program can take care
generated, the need for expensive fixtures is minimised. of the geomeu
6. Operator
fatigue is highly reduced, because the
of part if very less. operator involvement is the manutacu
7. The
manufacturing flexibility is highly improved in view
can perform a
variety of machining of the
fact that machining
entres

etc. operations and alterations of the productionchedule

8. Floor space
requirements are reduced because one NC omplish
the production of several machine centre can acu
9. The quality
conventional machines.
of the products is improved because of automation and the inter
related human factors. abseno
10. Cutting tools can be used
at
11. The inventory is reduced optimum speeds and feeds.
due to shorter lead times and
fewer set-ups.
 Numerical Control 319

11.9 LIMITATIONS OF NCc

Along with the advantages, NC machines also have certain limitations, which must be considered
for their implementation. The limitations are as follows:
1. The initial cost is high.
2. The maintenance cost is high on account of its complex and sophisticated technology.
and training
3. NC machines require part programmers. There is a problem finding, hiring
of
the programmers.