Advantages of DNC

Just as CNC had certain advantages over a conventional NC system, there are also advantages
associated with the use of direct numerical control. The following list will recapitulate much of
our previous discussion of DNC:
1. Elimination of punched tapes and reader. Direct numerical control eliminates the least
reliable element in the conventional NC system. In some DNC systems, the hard-wired control
unit is also eliminated, and replaced by a special machine control unit designed to be more
compatible with DNC operation.
2. Greater computational capability and flexibility. The large DNC computer provided the
opportunity to perform the computational and data processing functions more effectively than
traditional and data processing functions more effectively than traditional NC. Because these
functions are implemented with software rather than with hard-wired devices, there exists the
flexibility to alter and improve the method by which these functions are carried out. Examples of
these functions include circular interpolation and part programming packages with convenient
editing and diagnostics features.
3. Convenient storage of NC part programs in computer files. This compares with the more
manually oriented storage of punched tapes in conventional NC.
4. Programs stored as CLFILE. Storage of part programs in DNC is generally in the form of
cutter path data rather than post-processed programs for specific machine tools. Storing of the
programs in this more general format affords the flexibility in production scheduling to process a
job on any of several different machine tools.
5. Reporting of shop performance. One of the important features in DNC involves the
collection, processing, and reporting of production performance data from the NC machines.
6. Establishes the framework for the evolution of the future computer automated factory.
The direct numerical control concept represents a first step in the development of production
plants which will be managed by computer systems.
ADAPTIVE CONTROL SYSTEMS

For a machining operation, the term adaptive control denotes a control system that measures
certain output process variables that have been used in adaptive control machining systems
include spindle deflection or force, torque, cutting temperature, vibration amplitude, and
horsepower. In other words, nearly all the metal cutting variables that can be measured have
been tried in experimental adaptive control systems. The motivation for developing an adaptive
machining system lies in trying to operate the process more efficiently. The typical measures of
performance in machining have been metal removal rate and cost per volume of metal removed.
Where to use adaptive control
One of the principal reasons for using numerical control (including DNC and CNC) is that NC
reduces the non-productive time in a machining operation. This time savings is achieved by
reducing such elements as work piece handling time, setup of the job, tool changes, and other
sources of operator and machine delay. Because these non-productive elements are reduced
relative to total production time, a larger proportion of the time is spent in actually machining the
work part. Although NC has a significant effect on downtime, it can do relatively little to reduce
the in process time compared to a conventional machine tool. The most promising answer for
reducing the in process time lies in the use of adaptive control. Whereas numerical control guides
the sequences of tool positions or the path of the tool during machining, adaptive control
determines the proper speeds and/or feeds during machining as a function of variations in such
factors as work-material hardness, width or depth of cut, air gaps in the part geometry, and so on.
Adaptive control has the capability to respond to and compensate for these variations during the
process. Numerical control does not have this capability.
Adaptive control (AC) is not appropriate for every machining situation. In general, the following
characteristics can be used to identify situations where adaptive control can be beneficially
applied:
1. The in-process time consumes a significant portion of the machining cycle time.
2. There are significant sources of variability in the job for which adaptive control can
compensate. In effect, AC adapts feed and/or speed to these variables conditions.
3. The cost of operating the machine tool is high. The high operational cost results mainly from
the high investment in equipment.
4. The typical jobs are ones involving steel, titanium, and high-strength alloys. Cast iron and
aluminium are also attractive candidates for AC, but these materials are generally easier to
machine.
Two types of adaptive control:
In the development of adaptive control machining system, two distinct approaches to the
problem can be distinguished. These are:
1. Adaptive control optimization (ACO)
2. Adaptive control constraint (ACC)
1. Adaptive control optimization (ACO). In this form of adaptive control, an index of
performance is specified for the system. This performance index is a measure of overall process
performance, such as production rate or cost per volume of metal removed. The objective of the
adaptive controller is to optimize the index of performance by manipulating speed and/or feed in
the operation.
2. Adaptive control constrains (ACC). The systems developed for actual production were
somewhat less sophisticated (and less expensive) than the research ACO systems. The
production AC systems utilize constraint limits imposed on certain measured process variables.
Accordingly, these are called adaptive control constraint (ACC) systems. The objective in these
systems is to manipulate feed and/or speed so that these measured process variables are
maintained at or below their constraint limit values. The following subsection describes the
operation of the most common commercially available ACC system.
Operation of an ACC system:
Typical applications of adaptive control machining are in profile or contour milling jobs on an
NC machine tool. Feed is used as the controlled variable, and cutter force and horsepower are
used as the measured variables. It is common to attach an adaptive controller to an NC machine
tool. Numerical control machines are a natural starting point for AC for two reasons. First, NC
machine tools often possess the required servomotors on the table axes to accept automatic
control. Second, the usual kinds of machining jobs for which NC is used possess the sources of
variability that make AC feasible. Several large companies have retrofitted their NC machines to
include adaptive control. The adaptive control retrofit package consists of a combination of
hardware and software components. The typical hardware components are:

1. Sensors mounted on the spindle to measure cutter deflection (force).

2. Sensors to measure spindle to motor current. This is used to provide an indication of power
consumption.
3. Control unit and display panel to operate the system.
4. Interface hardware to connect the AC system to the existing NC or CNC control unit.
The software in the AC package consists of a machinability program which can be called
as an APT MACRO statement. The relationship of the machinability program in the part
programming process is shown in below Figure:
The inputs to the program include cutting parameters such as cutter size and geometry, work
material hardness, size of cut, and machine tool characteristics. From calculations based on these
parameters, the outputs from the program are feed rates, spindle speeds, and cutter force limits
for each section of the cut. The objective in these computations is to determine cutting conditions
which will maximize metal removal rates. The NC part programmer would ordinarily have to
specify feeds and speeds for the machining job. With adaptive control, these conditions are
computed by the machinability program based on the input data supplied by the part
programmer.
In machining, the AC system operates at the force value calculated for the particular cutter and
machine tool spindle. Maximum production rates are obtained by running the machine at the
highest feed rate consistent with this force level. Since force is dependent on such factors as
depth and width of cut, the end result of the control action is to maximize metal removal rates
within the limitations imposed by existing cutting conditions.
Below figure shows a schematic diagram illustrating the operation of the AC system during the
machining process. When the force increases due to increased work piece hardness or depth or
width of cut, the feed rate is reduced to compensate. When the force decreases, owing to
decreases in the foregoing variables or air gaps in the part, feed rate is increased to maximize the
rate of metal removal.
Above figure also shows an air-gap override feature which monitors the cutter force and
determines if the cutter is moving through air or through metal. This is usually sensed by means
of a low threshold value of cutter force. If the actual cutter force is below this threshold level, the
controller assumes that the cutter is passing through an air gap. When an air gap is sensed, the
feed rate is doubled or tripled to minimize the time wasted travelling across the air gap. When
the cutter reengages metal on the other side of the gap, the feed reverts back to the cutter force
mode of control.
Benefits of adaptive control machining
(1.) Increased production rates.
(2.) Increased tool life.
(3.) Greater part protection.
(4.) Less operator intervention.
(5.) Easier part programming.