Numerical Control ( NC) Programming

Submitted By, Group 4 Jibin Jose (1020015) Arani Ukil (1020106) R Manju Pargavi (1020147) Sherin Sunny (1020230) Dony Jose (1020311) Sandeep Pandita (1020328)

Introduction

Numerical Control (NC) refers to the method of controlling the manufacturing operation by means of directly inserted coded numerical instructions into the machine tool. (example : cutter, milling machine) NC augmented with analog & digital computers - creating Computer Numerical Control (CNC) NC systems comprises of (1) Machine tool [milling machine, drilling machine ] and (2) Controller to control the motion of the machine Program Machine tool
Instructions Control Unit

Transformatio n Process

Power

Types of NC machines
Punched Card NC machines
Used in the late 1940s

APT (Automatically Programmed Tools)

The main aim of APT language was to provide the means to the programmer by which they can communicate the machining instructions to the machine tools in easier manner using English like statements.

Computer Numerical Control machines

CNC Grinders
A program is entered, which includes the various passes that the wheel will make, and hit start. It is one of the easiest types of CNC machines to work with as they often only contain a single grinding wheel.

CNC Lathe

CNC Vertical Spindle Milling machine

It is basically a vertical milling machine that has an onboard computer to control its motion.

Types of Control Systems

There are two types of control systems used on NC machines: point-to-point systems and continuous-path systems. Point-to-point machines move only in straight lines. A continuous-path machine can move its drive motors at varying rates of speed while positioning the machine. Each controller is manufactured with a standard set of built-in codes. Other codes are added by the machine tool builders

NC MOTION-CONTROL
NC Program Execut ion Sy st em Dim ensio n s Com m ands

Int erpolat or & Se r v o - c o n t r o l Mec hanism

T r an sl at o r

Cont rol

Logic

Po w e r

Re la y

Linear

Mot ion

So len o id

NC MACHINE CLASSIFICATIONS
1. Motion control: point to point (PTP) continuous (contouring) path

2. Control loops: open loop closed loop

3. Power drives: hydraulic, electric,or pneumatic 4. Positioning systems: incremental absolute positioning 5. Hardwired NC and softwired Computer Numerical Control (CNC)

CONTROL LOOPS
Open loop - No position feedback.
table pulses motor

Use stepping motor.

CLOSED LOOP
_
Up-down counter DAC Amp

Differential amplifier

Shaft

DC Motor

Tachometer

Encoder

+
Reference pulses

Closed-loop control mechanism

What Moves--The Cutter or the Work piece?

The function of an N/C program is to direct the motion of a cutting tool around a work piece. N/C programs for milling machines must be written as though the work piece were stationary, except for rotary motion, and the cutting tool did all the moving--right, left, in, out, up, down--even though in fact most N/C milling machines use a stationary cutter (except for rotary and axial motion) and move the workpiece around the cutter

The Four Essential N/C Program Elements

The 1st Essential Element - Where to Go

To tell the controller where to send the cutter (its destination). This positioning information will be specified either incrementally (from the cutter's last position) or absolutely (from the origin).

E.g., G70 G90 X0.045 Y-3.980

G70 sets the controller to accept inch units. the cutter will move to a point 0.045 inches along the X axis and -3.980 inches along the Y axis. G90sets the controller for positioning in terms of absolute

The 2nd Essential Element - How to Get There

Commands are given that will cause the cutter to move along one, two, or three axes. In order to machine surfaces that are not parallel to one of the N/C machine's axes, the motion of two or more axes must be "timed" or coordinated to with other.

The 3rd Essential Element - How Fast to Get There

Rapid travel usually "wide open," as fast as the axes can go, usually 100 to 400 inches per minute. too fast for cutting operations. used for positioning moves, when the cutter is "cutting air. Feedrate travel The rate of feed for N/C mills is usually stated in terms of how far the cutter moves per minute. The units are inches per minute (IPM) and millimetres per minute (MMPM). The feedrate on some N/C machines, particularly lathes, can be stated in terms of how far the cutter advances per revolution of the spindle. The units are inches per revolution (IPR) or millimetres per revolution (MMPR).

The 4th Essential Element - What to do When It Arrives

Possibilities: 1. It could be told to send the cutter somewhere else--to its next destination. 2. It could be told to drill a hole. 3. It could be told to stop and wait while a clamp was being repositioned 4. It could be told that the program is finished and to return the cutter to the origin or some other "home" point and to rewind the tape or memory in preparation for making the next part.

Information required by an N/C controller

Preparatory commands to establish the desired operating conditions. Axis commands to move the cutter a certain distance in a certain direction. Feed rate commands to control cutter linear velocity. Spindle speed commands to control cutter rotational velocity. Miscellaneous commands to take care of the odds and ends, such as stop, turn off the coolant, change cutting tools, and rewind the memory. Identification commands, such as assigning a number to each block so the N/C operator can tell which command in a program is being executed, and assigning tool identification numbers so the controller knows which cutting tool to use.

Types of Words
N - sequence number prefix G - preparatory words
Example: G00 = PTP rapid traverse move

X, Y, Z - prefixes for x, y, and z-axes F - feed rate prefix S - spindle speed T - tool selection M - miscellaneous command
Example: M07 = turn cutting fluid on

Example
NC part program code N001 G21 G90 G92 X-050.0 Y-050.0 Z010.0; N002 G00 Z-020.0 S1989 M03; N003 G01 G94 G42 Y0 D05 F398; N004 G01 X075.0; N005 G01 X150.0 Y043.02; N006 G01 Y070.0; N007 G01 X080.0; N008 G17 G02 X050.0 Y100.0 R030.0; N009 G01 Y125.0; N010 G01 X0; N011 G01 Y0 N012 G40 G00 X-050.0 Y-050.0 Z010.0 M05; N013 M30; Comments

Define origin of axes. Rapid to cutter depth, turn spindle on. Bring tool to starting y-value, start cutter offset. Mill lower horizontal edge of part. Mill angled edge at 35 degrees. Mill vertical edge at right of part. Mill horizontal edge leading to arc. Circular interpolation around arc. Mill vertical step above arc. Mill top part edge. Mill vertical edge at left of part. Rapid move to target point, cancel offset, spindle stop. End of program, stop machine.

Feeding the Controller

Loading a program into CNCs memory

Keying in the program directly into the controller through the controller's keyboard.

Connect the controller to a computer or a network that contains a previously written program.
Connect the CNC controller to a data storage peripheral device such as a paper tape punch/reader, magnetic tape recorder or magnetic floppy disk drive through the serial port.

What is interpolation?

interpolation is a method of constructing new data points within the range of a discrete set of known data points. For example, suppose we have a table like this, which gives some values of an unknown function f.

Plot of the data points as given in the table.

X 0 1 2 3 4 5 F(x) 0.8415

0.9093 0.1411 -0.7568 -0.9589 -0.2794

Interpolation provides a means of estimating the function at intermediate points, such as x = 2.5. There are many different interpolation methods, some of which are described below. Some of the concerns to take into account when choosing an appropriate algorithm are: How accurate is the method? How expensive is it? How smooth is the interpolant? How many data points are needed?

Interpolation Methods
1. 2.

3.

4.

Linear interpolation Straight line between two points in space Circular interpolation Circular arc defined by starting point, end point, center or radius, and direction Helical interpolation Circular plus linear motion Parabolic and cubic interpolation Free form curves using higher order equations

Advantages of NC

Higher precision Machining of complex three-dimensional shapes: Better quality: Higher productivity: Multi-operational machining: Low operator qualification:

Disadvantages
Increase in electrical maintenance High initial investment Higher per-hour operating cost than traditional machine tools Retraining of existing personnel

Cost-Benefits of NC
Costs High investment cost High maintenance effort Need for skilled programmers High utilization required Benefits Cycle time reduction Nonproductive time reduction Greater accuracy and repeatability Lower scrap rates Reduced parts inventory and floor space Operator skill-level reduced

Applications
Traditional machining Turning, boring, milling, grinding etc. Sheet metal manufacture Turret punch press, pipe bending, flow forming etc. Non-traditional machining Wire-EDM, water-jet cutting, electron beam machining, laser beam machining, plasma cutting etc. Coordinate Measuring Machines Drafting machines Robots Rapid Prototyping (RP) machines

Applications of NC

Thank You