Manufacturing Processes-II (ME-317)

Lecture
INTRODUCTION TO NC, CNC, DNC machines

Engr. Muhammad Farooq

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 Lecture Outline
1. Introduction to NC Machine tools.
2. Introduction to CNC Machine tools.
3. Introduction to DNC Machine tools.
4. Difference Between NC, CNC and DNC machine tools.

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 What is NC?
• Numerical control (NC) refer to control of a
machine or a process using symbolic codes
consisting of characters and numerals.
• The word CNC came into existence
when microprocessors and microcomputers
replaced integrated circuit IC based controls
used for NC machines.
• The concept of NC was proposed in the late
1940s by John Parsons who recommended
a method of automatic machine control that
would guide a milling cutter to produce a
curvilinear motion in order to generate
smooth profiles on the work-pieces.
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 Numerical Control (NC) Defined
• NC (numerical control) machine tools are the machine tool, of
which the various functions are controlled by : letters ,numbers
and symbols.
• The NC machine tool runs on a program fed to it; without
human operator. The NC program consist of a set of instruction
or statement for controlling the motion of the drives of the
machine tools as well as the motion of the cutting tool.

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 Components of NC machine tool
system
1. Part program:-
• Using the part drawing and the cutting parameters, the part program
is written.
• The part program is the step-by-step set of instructions that tells the
machines what it has to do. These instructions can tell the machine
to turn the piece of metal to certain diameter, drill the hole of certain
diameter up to certain length, form certain shape etc.
• Method use for part programming
1. Manual part programming
2. Computer-aided part programming
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 Components of NC machine tool
system
2. Program Tape:-
• The part program is entered on the program tape.
• The program is entered on the tape in the form of punched holes.
The holes are punched with the help of punching machine.
3. Machine Control Unit(MCU):-
• The program tape is read by the tape reader.
• The controller takes input from the tape reader.
4. Machine Tool:-
• The machine tool is operated by the controller of the machine control
unit
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Components of traditional NC systems

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 Advantages of NC systems over
manual methods of production
• Better control of the tool motion under optimum
cutting conditions.
• Improved part quality and repeatability.
• Reduced tooling costs, tool wear, and job setup
time.
• Reduced time to manufacture parts.
• Reduced scrap.
• Better production planning and placement of
machining operations in the hand of
engineering.
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 Advantages of NC machine tool
• Cycle time reduction • Greater operation safety
• Complex machining operation • Greater operation efficiency
• High degree of accuracy • Reduction space required
• Less inspection required • Operator skill-level reduced
• Reduction of scrap and
wastage
• Increasing productivity
• Lower tooling cost
• Reduction of human error
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 Limitation of NC machine tool
• High investment cost
• High maintenance effort
• Need for skilled programmers
• High utilization required

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 Introduction to CNC Machine Tools
• In CNC (Computer Numerical Control) machines, a dedicated
computer is used to perform the most of basic NC machine
functions.
• CNC (Computer Numerical Control) machine is a NC machine
which uses a dedicated computer as the machine control unit.
• The entire program is entered and stored in computer memory.
The machining cycle for each component is controlled by the
program contained in the computer memory.
• The stored part program listing can be used for future
production also. 11
 Computer Numerical Control (CNC)
• Computer numerical control (CNC) 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 software
NC systems because most of their control
functions are implemented by the control
software programs.
• CNC is a computer assisted process to
control general purpose machines from
instructions generated by a processor and
stored in a memory system. 12
 Components of CNC machine tool
system
The main components of CNC machine tools are as follows :
1. Input / Output Console.
2. Microprocessor Based control unit.
3. Memory.
4. Feedback unit.
5. Machine Tool.
6. Interfaces.

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Components of CNC machine tool
system

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Components of CNC machine tool system
• Input / Output Console : It is the unit through which part program is fed to
the CNC machine tool system and required output is taken out. It basically
consists of monitor and Keyboard.
• Microprocessor : This controller takes input from Input / Output device,
Feedback from feedback unit and actuates the drives as well as the tool of
the machine tool.
• Memory : It consists of RAM & ROM. The RAM stores part program,
while ROM stores the programs for machine control.
• Feedback unit : The feedback unit takes input from machine tool and
transfers it to control unit for necessary corrections.
• Machine tool : Machine tool is operated by the control unit.
• Interfaces : They are the connections between the different components
of the CNC machine tool system. 15
 Classification of CNC Machine tool systems
(a) According to type of Feedback systems (d) According to type of controller

1. Open loop type CNC machine. 1. Hybrid controller CNC systems.

2. Closed loop type CNC machine. 2. Straight controller CNC systems.

(b) According to type of tool motion control (e) According to axis & type of
operations
1. Finite positioning control CNC machines.
2. Continuous path control CNC machines. 1. CNC horizontal machining centre.
2. CNC vertical machining centre.
(c) According to program methods 3. CNC turning centre.
4. CNC milling centre.
1. Absolute Programming CNC machine systems.
2. Incremental Programming CNC machine systems.

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 Classification based on type of
feedback systems
• Open loop type CNC machine.

• It does not have any feedback

mechanism.
• It only has motion control but do
not have any provision for
feedback, which is needed to be
compared with input for better
control & correction of drive
system.
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 Classification based on type of
feedback systems
• Closed loop type CNC machine.

• It has a feedback mechanism.

• It has the motion control with a
provision of feedback of feedback.
• Which can be used for accurately
controlling the drive system by
comparing it with the input
information until the required or
desired position is achieved

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Components of modern CNC systems

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 Advantages of CNC systems
• CNC machines can be used continuously
and only need to be switched off for
occasional maintenance.
• These machines require less skilled people
to operate unlike manual lathes/milling
machines etc.
• CNC machines can be updated by improving
the software used to drive the machines.
• Training for the use of CNC machines can be
done through the use of “virtual software”. 20
 Advantages of CNC systems
• The manufacturing process can be simulated
virtually and no need to make a prototype or a
model. This saves time and money.
• Once programmed, these machines can be
left and do not require any human
intervention, except for work loading and
unloading.
• These machines can manufacture several
components to the required accuracy without
any fatigue as in the case of manually
operated machines.
• Savings in time that could be achieved with
the CNC machines are quite significant.
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 Disadvantages of CNC systems
• CNC machines are generally more expensive
than manually operated machines.
• The CNC machine operator only needs basic
training and skills, enough to supervise several
machines.
• Increase in electrical maintenance, high initial
investment and high per hour operating costs
than the traditional systems.
• Fewer workers are required to operate CNC
machines compared to manually operated
machines. Investment in CNC machines can
lead to unemployment.
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 Application of CNC Machine Tools
• CNC was initially applied to metal working
machinery: Mills, Drills, boring machines,
punch presses etc and now expanded to
robotics, grinders, welding machinery,
EDM's, flame cutters and also for
inspection equipment etc

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 Application of CNC Machine Tools
The machines controlled by CNC can be classified into the
following categories:
• CNC mills and machining centers,
• CNC lathes and turning centers
• CNC electrical discharge machining (EDM)
• CNC grinding machines
• CNC cutting machines (laser, plasma, electron, or flame)
• CNC fabrication machines (sheet metal punch press, bending machine,
or press brake)
• CNC welding machines
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Application of CNC Machine Tools

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Application of CNC Machine Tools

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Application of CNC Machine Tools

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Application of CNC Machine Tools

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Application of CNC Machine Tools

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Application of CNC Machine Tools

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 Direct Numerical Control (DNC)
• In a Direct Numerical Control system (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.
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 Distributed Numerical Control (DNC)
• Distributed NC is known by the same acronym as
Direct Numerical Control (DNC).
• After the introduction of CNC, the machine tools have
had the capability of storing large amount of
information. Therefore, there have been no need to
have drip feed information system, like, Direct
Numerical Control. Instead, Distributed Numerical
Control is introduced. In such a system, a host
computer communicate with many CNC machine tools
via networks and download or upload programs.
• With Distributed Numerical Control systems, it is
possible to monitor the activities in individual CNC
machine tools on host computer. Therefore, better
shop floor control can be achieved. 32
 Comparison between NC, CNC and DNC machine tools
NC Machine tools CNC Machine tools DNC Machine tools

1. The part program is fed to the 1. In CNC machine tool system, the 1. The part program is fed to
machine through the tapes or program is fed to the machine through the
other such media. the computer. machine through the Main
2. In order to modify the 2. The programs can be easily computer
program, the tapes have to be modified with the help of computer. 2. In order to modify the
changed. 3. The microprocessor or program, single computer is
3. In NC machine tool system, minicomputer forms the machine used
tape control unit. The CNC machine does 3. Large memory of DNC
reader is a part of machine not need tape reader. allows it to store a large
control 4. It has memory storage ability, in amount of part
unit. which part program can be stored. program.
4. System has no memory 5. System can import CAD files and 4. Same part program can be
storage and each time it is run convert it to part program. run on different machines at
using the tape. 6. The system can use feedback the same time.
5. It can not import CAD files. system. 5. The data can be processed
6. It can not use feedback 7. The system is software driven. using the MIS software so as
system. to effectively carry out the
7. They are not software driven. Production planning and
scheduling. 33