CHAPTER FOUR

INTRODUCTION TO COMPUTER NUMERICAL

Compiled by Abubeker Omer

12/03/23
August 2021 1
Numerical control
• Numerical control(NC) refer to control of a machine
or a process using symbolic codes consisting of
characters and numerals.
• It is a programmable automation in which process is
controlled by Numbers ,Letters and symbols.
• CNC Machining is a process used in the
manufacturing sector that involves the use of
computers to control machine tools like lathes, mills
and grinders, etc.

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 Numerical Control (NC) refers to the method of
controlling the manufacturing operation by means of
directly inserted coded numerical instructions into
the machine tool.
 It is important to realize that NC is not a machining
method, rather, it is a concept of machine control.
 Although the most popular applications of NC are in
machining, NC can be applied to many other
operations, including welding, sheet metalworking,
riveting, etc.

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The Functions and Motions such as:
- Turning the spindle on and off
- Setting cutting speeds
- Setting feed rate
- Turning coolant on and off
- Moving cutting tools with respect to work piece are
performed by Machine Control Unit (MCU) in NC
machine tools.

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Objectives of Numerical Control
Increased production
Reduced labor costs
Make production more economical
Make production jobs easier
Do production jobs that are impossible without
numeric control
Make production processes repeatable

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 Components of traditional NC systems

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Advantages of NC 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; increase machine & tool life
Better production planning and placement of machining
operations in the hand of engineering.
Less setup time; Reduces actual machining time
Allows rapid design changes in part
Less jigs and fixtures are needed
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Limitations of Numerical Control
High initial investment
Machine tools cost $30,000 - $1,500,000
High maintenance requirements
Maintenance personnel must have both mechanical
and electronics expertise
Not cost-effective for low-level production on
simple parts
As geometric complexity or volume increases CNC
becomes more economical
Retraining and recruitment of staff
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The two major types of NC systems are:-
1. point-to-point (PTP) system:- PTP is a NC system, which
controls only the position of the components. In this system,
the path of the component motion relative to the workpiece is
not controlled.
The travelling between different positions is performed at the
traverse speed allowable for the machine tool and following
the shortest way.
2. Contouring:- NC systems are capable of controlling not
only the positions but also the component motion, i.e., the
traveling velocity and the programmed path between the
desired positions:

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 Schematics of point-to-point contouring NC systems

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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 soft-wired 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.
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Components of modern CNC systems

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Why CNC Machining is necessary?
•To manufacture complex curved geometries in 2D or
3D was extremely expensive by mechanical means
(which usually would require complex jigs to control
the cutter motions).
•Machining components with high Repeatability and
Precision.
•Unmanned machining operations.
•To improve production planning and to increase
productivity.
•To survive in global market CNC machines are must
to achieve
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close tolerances. 14
Advantages of CNC
High Repeatability and Precision e.g. Aircraft parts.
Volume of production is very high.
Complex contours/surfaces can be easily machined.
Flexibility in job change, automatic tool settings,
less scrap.
More safe, higher productivity, better quality.
Less paper work, faster prototype production,
reduction in lead times.
High Productivity & quality of product is possible
Reduced inventory
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better production management control
Disadvantages of CNC
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.
It requires Computer programming knowledge.
Investment in CNC machines can lead to
unemployment.
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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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12/03/23 DNC systems 18
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.
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 DNC systems
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CNC System Elements
 A typical CNC system consists of the following six
elements
1. Part program
2. Program input device
3. Machine control unit
4. Drive system
5. Machine tool
6. Feedback system

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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.
The machines controlled by CNC can be classified into the
following categories:
CNC mills and machining centres,
CNC lathes and turning centres
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)
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CNC welding machines
Classification of CNC Machines
1.Classification based on the motion type.
2.Classification based on the control loops.
3.Classification based on the number of axes.
4.Classification based on the power supply.

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1. Classification based on the motion type
I. Point-to-Point Systems
It is used in some CNC machines such as drilling, boring
and tapping machines…etc.
The control equipment for use with them are known as
point-to-point control equipment.
Feed rates need not to be programmed.
In theses machine tools, each axis is driven separately.

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II. Contouring Systems (Continuous Path Systems)
It is used in CNC machine tools such as milling machines.
These machines require simultaneous control of axes.
Contouring machines can also be used as point-to-point
machines, but it will be uneconomical to use them unless the
work piece also requires having a contouring operation to be
performed on it.

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2. Classification based on the control loops
I. Open Loop Systems
Programmed instructions are fed into the controller
through an input device.
These instructions are then converted to electrical
pulses (signals) by the controller and sent to the servo
amplifier to energize the servo motors.
The primary drawback of the open-loop system is
that there is no feedback system to check whether the
program position and velocity has been achieved.

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 The open -loop system is generally used in point-to-
point systems where the accuracy requirements are
not critical.
 Very few continuous-path systems utilize open-loop
control.

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II. Closed Loop Systems
The closed-loop system has a feedback subsystem to
monitor the actual output and correct any discrepancy
from the programmed input.
These systems use position and velocity feed back.
The feedback system could be either analogue or
digital.

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 The analogue systems measure the variation of physical
variables such as position and velocity in terms of voltage
levels.
 Digital systems monitor output variations by means of
electrical pulses.
 Closed-loop systems are very powerful and accurate
because they are capable of monitoring operating conditions
through feedback subsystems and automatically
compensating for any variations in real-time.

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3. Classification based on the number of axes
2&3 axes CNC Machines
CNC lathes will be coming under 2 axes machines.
There will be two axes along which motion takes
place.
The saddle will be moving longitudinally on the bed
(Z-axis) and the cross slide moves transversely on the
saddle (along X-axis).
In 3-axes machines, there will be one more axis,
perpendicular to the above two axes.
By the simultaneous control of all the 3 axes,
complex
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Importance of higher axes machining are:
Reduced cycle time by machining complex
components using a single setup.
In addition to time savings, improved accuracy can
also be achieved as positioning errors between setups
are eliminated.
Improved surface finish and tool life by tilting the
tool to maintain optimum tool to part contact all the
times.
Higher axes machining has been widely used for
machining sculptures surfaces in aerospace and
automobile
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industry. 32
Improved access to under cuts and deep pockets. By
tilting the tool, the tool can be made normal to the
work surface and the errors may be reduced as the
major component of cutting force will be along the
tool axis.

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4. Classification based on the power supply
Mechanical power unit refers to a device which
transforms some form of energy to mechanical power
which may be used for driving slides, saddles or
gantries forming a part of machine tool.
The input power may be of electrical, hydraulic or
pneumatic.

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