MODULE OUTLINE

Aims
This module is designed to provide students with:

1. Capability of CNC Machines.

2. Coded instructions (programs).
3. Focus on NC, CNC, and DNC
4. Concepts, terminology, and functions of CNC.
5. CNC machines programming.
 Assessment pattern

• Class Participation 5%
• Assignments 10%
• Tests and Quizzes 15%
• Term Project 10%
• Unseen Mid-Term Exam 20%
• Unseen Final Exam 40%

Total 100%
 INTRODUCTION
CAD - CAM

CAD : Computer-aided design, defined

as the use of computer system to assist
in the creation, modification, analysis
or optimization of a design.
 INTRODUCTION
CAD - CAM

CAM : Computer-aided manufacturing;

defined as the use of computer system
to plan, and control the operations of a
manufacturing plant through either:
 1. Direct computer interface

Direct computer interface with the

plant production for computer
monitoring and control for observing
and controlling the process and
associated equipment and collecting
data from the process.
 2. Indirect computer interface

Indirect computer interface for

manufacturing support applications for
supporting operation in the plant.
1. Conventional Numerical Control

Numerical control is defined as a form

of programmable automation in which
the process is controlled by numbers,
letters, and symbols.
 Basic components of NC system

The basic components of NC system are:

1. Program of instructions
2. Controller unit
3. Machine tool or other controlled process
 1. Program of instructions

The program of instructions is the

detailed step-by-step set of directions,
which tell the machine tool what to do.
It is coded in numerical or symbolic form
of some type of input medium that can
be interpreted by the controller units.
 The forms of input medium is:

1. Punched card.
2. Magnetic tape.
3. Picture film.
4. Manual data input, MDI.
5. Direct numerical control, DNC.
 2. Controller unit

It consists of the electronics and hardware

that read and interpret the program of
instructions and convert it into mechanical
actions of the machine tool.
The elements of conventional NC controller
unit are:

1. Tape reader.
2. Data buffer.
3. Signal output channels to the machine
tool.
4. Feedback channels from the machine tool.
5. Sequence control to coordinate the overall
operation.
 The NC procedure
The NC procedure is:
1. Process planning.
2. Part programming.
a. Manual programming
b. Computer-assisted part programming
3. Tape preparation.
4. Tape verification.
5. Production.
 NC drill press
For the NC drill press X, Y defined the
plane of the table, while Z (if present) is
perpendicular to the plane of the table
as shown in fig 1.1.

Fig. 1.1 The coordinate system for NC drill press.

 Numerical milling machine
The numerical milling machine is as the
NC drill press with one or more
rotational axis.

Fig. 1.1 The coordinate system for NC drill press.

 For turning operation
Two axes are needed for the movement of
the tool relative to the rotating workpiece as
shown in fig. 1.2.

Fig. 1.2 The coordinate system for NC turning operation.

 For turning operation
Z : is the axis of rotation of the workpiece.
X : is the radial location of cutting tool.

Fig. 1.2 The coordinate system for NC turning operation.

 Fixed zero and floating zero

The programmer must determine the

position of the tool relative to the
origin (zero point) of the coordinate
system. NC machines have either of
two methods for specifying the zero
point.
 1. Fixed zero

The origin always located at a defined

position known for each machine.
 2. Floating zero

It is the commonly used where the user

sets the zero point at any position.
 1. Absolute positioning

The tool location is always defined in

relation to the zero point.
 2. Incremental positioning

The next tool location must be defined

with reference to the previous tool
location.
 NC motion control systems

The NC motion control systems are:

1. Point -to- point

2. Straight cut
3. Contouring
 Advantages of NC

1. Reduced non-productive time.

2. Reduced fixuring.
3. Reduced manufacturing load time.
4. Greater manufacturing flexibility.
5. Improved quality control.
6. Reduced inventory.
7. Reduced floor space requirement.
 Disadvantages of NC

1. Higher investment cost.

2. Higher maintenance cost.
3. Finding and/or training NC personal.
 Manual part programming

The programmer writes the machining

instruction in a part programming
manuscript form.
Computer assisted part programming

The computer used to assist the more

complicated applications.
The part programmer needs to define:
1. Work geometry
2. Operation sequence & tool path.
The computer’s job:

1. Input translation.
2. Arithmetic calculations.
3. Cutter offset Computation.
4. Post processor.
 NC part programming languages

APT - ADAPT - EXAPT - UNIAPT - SPLIT -

COMPACT II - PROMPT-CINTURN II.
 Computer Controls in NC

Three NC-related control topics:

1. Computer numerical control (CNC).

2. Direct numerical control (DNC).
3. Adaptive control.
Computer NC involves the replacement
of the conventional hard-wired NC
controller unit by small computer,
which perform some or all of the basic
NC functions by stored programs.
CNC: is the use of one computer to
control one machine tool.

DNC: is the use of a large computer to

control a number of separate NC
machine tools.
Adaptive control: It does not require a
digital computer but it uses a control
system that measure one or more
process variables (such as cutting force,
temperature, horse power, etc.) &
manipulates feed &/or speed in order
to compensate for undesirable changes
to optimize the machining process.
 Problems with conventional NC

1. Part programming mistakes.

2. Nonoptimal speeds and feeds.
3. Punched tape.
4. Tape reader.
5. Controller.
6. Management information.
 Computer numerical control (CNC)

CNC is an NC system that utilizes a

dedicated, stored computer program
to perform some or all of the basic
numerical control functions.
CNC is similar to conventional NC machine.
Part programs are initially entered in a
similar manner. However, with
conventional numerical control, the
punched tap is cycled through the reader
for every workpiece in the batch. With
CNC, the part program is entered once and
the data are originally loaded & additional
flexibility of computational capability is
offered by the CNC system.
Two alternative controller design in CNC:
1. Hybrid CNC: it consists of soft wired
plus hard-wired logic circuits. The hard-
wired components perform those
functions as feed rate generation and
circular interpolation. The computer
performs the remaining functions.
2. Straight CNC: The computer performs
all NC functions.
 Advantages of CNC

1. The part program is used only once.

2. Tape editing at the machine site.
3. Metric conversion.
4. Greater flexibility.
5. User-written programs.
6. Total manufacturing system.
 CNC performance
• Accuracy
• Reliability
• Repeatability
• Productivity
 Direct numerical control ( DNC)

DNC: is a manufacturing system in

which a number of machines are
controlled by a computer through
direct connection.
The components of a DNC system are:

1. Central computer.
2. Bulk memory.
3. Telecommunication lines.
4. Machine tools.
 Advantages of DNC
1. Elimination of punched tape & tape reader.
2. Greater computational capability and flexibility.
3. Convenient storage of NC part programs in
computer files.
4. Programs stored as CLFILE
5. Reporting of shop performance.
6. Establishes the framework for the evaluation of
the future computer automated factory.
Computer Process Interfacing

Manufacturing process data: Considering the

nature of the data that must be communicated
between the manufacturing process and the
computer, these data can be classified into
three categories:
1. Continuous analog signals.
2. Discrete binary data.
3. Pulse data.
Computer Process Control

Process control strategies:

1. Feedback control.
2. Regulatory control.
3. Feedforward control.
4. Preplanned control.
5. Steady-state optimal control.
6. Adaptive control.
Computer Aided Quality Control

The objectives of computer-aided quality control

are:

1. To improve product quality.

2. To increase productivity in the inspection
process.
3. To increase productivity and reduce leadtimes
in manufacturing.
Computer Integrate Manufacturing Systems (CIMS)
Computer- integrate manufacturing systems (CIMS)
incorporate many of the individual CAD/CAM
technologies and concept which we have discussed.
These include:
1. Computer numerical control (CNC).
2. Direct numerical control (DNC).
3. Computer process control.
4. Computer-integrate production management.
5. Automated inspection methods.
6. Industrial robotics.
Types of Manufacturing Systems
1. Special manufacturing system
2. Manufacturing cell
3. Flexible manufacturing system (FMS)
A computer-integrated manufacturing system
consists of the following basic components:
1. Machine tools and related equipment.
2. Materials handling system.
3. Computer system.
4. Human labor.
 CNC Lathes

In manual programming using Word

Address format, the manual control unit
(MCU) has several buffers. Each buffer has
an address (N, X, Y, Z, I, J, K, M, F, S, T)
N : block number.
I, J, K : circular motion.
F : feed.
S : speed.
T : tool number.
X, Y, Z : cartesian coordinate.
Several functions are used:

1. Preparatory functions
They are functions describing the
motion. They are defined by G and a
number ranges from 0 to 99.
 CNC Program construction

Code grouping
The G codes are divided into groups. The
reason for that is that the only one code
from the same group may be used in the
same block of instructions otherwise the
last one will be executed.
 CNC Program construction
Modal codes
There are two types of G codes in terms of
volatility. The modal codes will stay in effect
until another code from the same group
replaces it.
The non-modal code will take effect during the
current code block then the machine will reset
back to the default settings
 Code Group Modal Meaning
G0/G00 A Yes Rapid moves
G1/G01 A Yes Linear Interpolation
G2/G02 A Yes CW Interpolation
G3/G03 A Yes CCW Interpolation
G4/G04 B No Dwell
G17 C Yes X,Y Plane of Interpolation
G18 C Yes X,Z Plane of Interpolation
G19 C Yes Y,Z Plane of Interpolation
G28 I Yes Return to Machine zero
G40 D Yes CRC cancel (Cutter Radius Compensation)
G41 D Yes CRC left
G42 D Yes CRC right
 Code Group Modal Meaning
G43 J yes Tool length comp. +
G44 J yes Tool length comp. -
G49 J yes Tool Length comp. Cancel
G54-G59 O Yes Set Local Coordinate Systems
G70/G20 M Yes Rough turning canned cycle
G71/G21 M Yes Finishing turning canned cycle
G73 E Yes Drill CHPBRKR
G80 E Yes Canned Cycle cancel
G90 F Yes Absolute Programming
G91 F Yes Incremental Programming
G92 I Yes Set Program Zero
 CNC Program construction
Program structure
1- Program Start
The program start is the program number. The
program number begins with character/letter O.
2- Program Contents
NC blocks
3- Program End
M30 for a main program
M17 for a sub-program
G00 : Rapid traverse
G01 : Linear interpolation
G02 : Circular interpolation (clockwise)
G03 : Circular interpolation (counterclockwise)
G22 : End of program
G84 : Canned cycle
 2. Auxiliary functions

They describe the feed, speed and the

tool used.
F: feed (mm/min)
S: spindle speed (rpm)
T: tool number
3. Miscellaneous functions
 3. Miscellaneous functions

They specify some particular actions in

the program.
M02: End of program.
M03: Spindle speed CW.
M04: Spindle speed CCW.
 Machine and work coordinates
Tool offsets:
1- Tool length compensation
 Machine and work coordinates
Tool offsets:
1- Cutter radius compensation
 Machine and work coordinates
Tool offsets:
1- Cutter radius compensation
 Machine and work coordinates
Tool offsets:
1- Cutter radius compensation
Tool offsets:
1- Cutter radius compensation
 Answer the Following Questions
1) Define CAD, CAM.
2) Discuss with details the basic components
of a NC system.
3) Mention the NC motion control system and
differentiate between them.
4) What are the advantages and disadvantages
of NC.
5) What are the two Categories of the CAM.
6) Explain the NC – Procedure.
7) Give a brief explanation about the NC
coordinate system.
8) Explain the following CNC programming codes
(G00, G01, G02, G03, G22, G84).
9) Compare between:
- Fixed zero and floating zero.
- Absolute positioning and incremental
positioning.
- Point-to-point and straight cut.
- CNC and DNC and Adaptive control.
 Answer the Following Exercises
1. Write a CNC program using word
address to manufacture the workpiece
shown in figure. The work material is
brass (70/30), the tool material is carbide,
the spindle speed is 1000 rpm, the feed is
100 mm/min and the maximum depth of
cut is 0.3 mm. The workpiece is clamped
over the left hand stem (22 mm diameter)
which would not be machined.
2. Write a CNC program using word
address to manufacture the workpiece
shown in figure. The work material is
brass (70/30), the tool material is
carbide, the cutting speed is 1 m/sec,
the feed is 0.1 mm/rev and the
maximum depth of cut is 0.3 mm. The
workpiece is clamped over the left
hand stem (22 mm diameter) which
would not be machined.
3. Write a CNC program using word address
to manufacture the workpiece shown in
figure. The work material is brass (70/30),
the tool material is carbide, the cutting
speed is 0.8 m/sec, the feed is 0.15 mm/rev
and the maximum depth of cut is 0.4 mm. A
finishing path is required allover the contour
of the workpiece with depth of cut of 0.2
mm, feed 0.08 mm/rev. and cutting speed of
1.5 m/sec. The workpiece is clamped over
the left hand stem (22 mm diameter and 25
mm length) which would not be machined.
4. Write a CNC program using word
address to manufacture the workpiece
shown in figure. The work material is
brass (70/30), the tool material is
carbide, the cutting speed is 1 m/sec,
the feed is 0.1 mm/rev and the
maximum depth of cut in straight paths
is 0.4 mm. And in circular paths is 0.3
mm. The workpiece is clamped over the
left hand stem (22 mm diameter) which
would not be machined.
5. Write a CNC program using word address to
manufacture the workpiece shown in figure.
The work material Aluminum alloy, the tool
material is carbide, the cutting speed is 1 m/sec
for roughing and 1.8 m/sec for finishing, the
feed used is 0.2 mm/rev for roughing and 0.08
mm/rev for finishing. A finishing path is
required allover the outline of the workpiece
with depth of cut of 0.2 mm. The maximum
allowable depth of cut in roughing paths is 1
mm. The workpiece is clamped over the left
hand stem (22 mm diameter) which would not
be machined.