An overview of CNC

What is Computer Numerical Control (CNC)

 It is a method of controlling the movements of machine components using

 Numbers, symbols, signals, letters, codes, words, instructions
 In short, a language-based communications with machines to be controlled

How does it happen

Input to the machine

through numbers, letters and codes

The processing of data

through numerical calculations and logic operations

The execution of operations

through generated signals
2
 Difference between NC, CNC and DNC
 Numerical Control (NC)

 In the beginning, only numbers and alphabets were used to achieve control, together with hard-wired
circuitry called integrated circuit (IC) and there was no computer to control the motion of the machine
axes that was achieved only by IC. That is why it is called NC.

 The instructions to the NC machines are fed through paper tape or magnetic tape. The information read
from the tape is stored in the memory of the control system and is processed by the machine step by
step.

 If there is even a minor change in the design of the component, the tape has to be discarded and new
tape with changed program has to be produced.

 Computer Numerical Control (CNC)

 It is the numerical control system in which a dedicated computer is built into the control to perform basic
and advanced NC functions. CNC controls are also referred to as soft-wired NC systems because most of
their control functions are implemented by the control software programs. 3
 Difference between NC, CNC and DNC (contd.)

 It is a computer assisted process to control general purpose machines from instructions generated by a
processor and stored in a memory system.

 It is a specific form of control system where position is the principal controlled variable.

 Direct Numerical Control (DNC)

 In a DNC, a mainframe computer is used to coordinate the simultaneous operations of a number NC

machines. The main tasks performed by the computer are to program and edit part programs as well as
download part programs to NC machines.

 Machine tool controllers have limited memory and a part program may contain few thousands of blocks.
So the program is stored in a separate computer and sent directly to the machine, one block at a time.

4
 Area of application of CNC

 What is meant for mass (high volume) production

 Special purpose machine, automatic machines and transfer lines

 Why

 These machines use fixed automation with automated material handling devices. This helps in reducing
machining time and cyclic idle time.

 Why not CNC

 In mass production, there is hardly any change in part design over extended period of time. Hence CNC,
which possesses flexibility is not necessary in mass production.

 Why not fixed automation for low volume production

 In low volume production, part design changes frequently. Fixed automation is not amenable to frequent
changes.
5
 Area of application of CNC (contd.)

 Advantages of CNC over fixed automation

 But if control is achieved by application of letters, numbers, codes and language, it is easy to change
the part design and that is CNC
 Hence flexibility is the one advantage which makes computer control more suitable than fixed
automation in case of low volume production
 In addition, CNC has the ability to manufacture complex shapes without the use of part-specific tooling

 Motion is controlled by physical devices,

like cams, jigs, templates, tracers, limit
switches, guides, operators etc.

Fig. Fixed automation

6
 How is computer control achieved

 By interfacing the machine with computer

 By modifying conventional machine tool architecture

 By adding devices which permit the control of motion and other actions from computer

 By writing and executing a program from the computer

7
 What is a CNC Program
 A CNC program is a sequence of commands, written in a suitable language , meant for controlling the
operations of a machine

 When executed, it makes a machine tool carry out some motions and auxiliary operations

 As a result, a part is successfully produced from a blank

 There are other operations also, apart from machining, which are successfully controlled by CNC program
execution
N006 G90 G00 X20 Y30
N007 Y50
N008 G01 X100 Y100 F200
N009 G02 X140 R30
N010 M30

Fig. A typical example of a CNC program 8

 How control is achieved in computer controlled machines

 CNC is capable of controlling a machine through

Programmed Instructions  Digital signals, Binary logic and logic gates

 Digital circuitry is employed in almost all aspects of CNC control.

Digital signals Example: data storage, data processing, interpolation, motion
execution, feed back etc.

Rotation of motors

Leading to  Achieving a programmed extent of motion Fig. Logic Gates

 Achieving a programmed ratio of axes velocities

 Achieving a programmed feed velocity along cutter path 9

 Architecture of the control unit
 MCU (Machine control unit) = DPU + CLU

o DPU = Data processing unit

 to read the coded instructions

 to decode the coded instructions
 to implement interpolations (linear, circular, and helical) to generate axis motion commands
 to feed the axis motion commands to the amplifier circuits for driving the axis mechanisms
 to receive the feedback signals of position and speed for each drive axis.
 to implement auxiliary control functions such as coolant or spindle on/off and tool change
o CLU = Control loop unit

 contains all devices for achieving required motion along an axis (example: the motor, the lead screw-
nut, the gear box, the feed back device etc.

 The control signals are augmented to actuate drive motors which in turn rotate the ball lead-screws to
10
position the machine table
 What are the modifications of the conventional machine tool

 More robust and rigid for the same power level

 Backlash elimination, incorporation of recalculating ball screw-nut mechanism

 Gear box elimination-gear boxes limit the ratio axes speeds

 Feed back where necessary

 Simple kinematic chains/structures instead of complex or compound chains/structures

 Motors with lower time constant (faster response)

 Interpolator where necessary

 Control over displacement, velocity, acceleration of the axes in order to avoid overshoots, sluggish response
and resulting inaccuracies in part geometry

11
Is it possible to implement computer control on this machine tool

12
 Simple kinematic chains for CNC machine tools

Fig. Conventional machine tool with Fig. CNC machine tool with individual
one prime mover motors for all axes

13
 Machine axes designation

 Right Hand Rule

 When the thumb of right

hand points in the direction
of the positive X axis, the
index finger points toward
the positive Y axis, and the
middle finger toward the
positive Z axis.
+Z  Z axis is always the axis of
the main spindle of the
machine.

Fig. Right hand rule for vertical and horizontal milling machine

14
 Advantages and Disadvantages of CNC machines
 Advantages
 Reduced Lead time
 Disadvantages
 Elimination of operator errors
 Higher investment cost
 Operator activity
 Higher maintenance cost
 Lower labour cost
 Costlier CNC personnel
 Smaller batches
 Planned support facility
 Longer too life

 Elimination of special jigs and fixtures

 Flexibility in changes of component design

 Reduced inspection

 Less scrap

 Accurate costing and scheduling 15

 Parts suitable for CNC machines
 The number of operations per component are large

 Operations are very complex

 Size of the batches is medium

 Batches are often repeated

 Labour cost for the component is high  Following factors should be

considered while selecting
 The component requires substantial tools components for machining on CNC
machine tools
 Components require 100% inspection

 Set-up and inspection times are high

 Ratio of cutting time to non-cutting time is high

 A large variety of components is produced

 The component requires highly skilled labour 16