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Chapter-01

Computerized Numerical Control

CNC
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Numerical Control (NC)

• Numerical control(NC): is a system in which

actions are controlled by the direct insertion of
numerical data at some point.
• The system must automatically interpret at
least some portion of the data
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What Is Numerical Control

• An automated manufacturing process in which

a machine tool is controlled;
– In an ordered sequence
– Along a predetermined path
– To require dimensions
– At a specific feed and speed rate
– Done through a group of alphanumeric instructions
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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
• Increased accuracy on duplicate parts
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Advantages of Numerical
Control
• Reduces time for • Reduces storage
delivery of part problems
• Reduces scrap rate of • Less setup time
material • Reduces actual
• Reduces tooling costs machining time
• Reduces layout time • Allows rapid design
• Increases machine and changes in part
tool life • 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
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Industries Most Affected by

Numerical Control
• Aerospace
• Machinery
• Electrical
• Fabrication
• Automotive
• Instrumentation
• Mold making
 Define Geometry

Create Tool Path

Post Process to Create

Code
Read Code To Controller
Interpolate Code Into
Drive Input
System

Finished Part
Basic Elements of a CNC
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Types of Numerical Control

• Numerical Control (NC)
• Computer Numerical Control (CNC)
• Direct Numerical Control (DNC)
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Numerical Control (NC)

• Data is sent to the machine tool by means of
punch cards or tapes.
• The reader at the machine performs no
calculations or interpolations.
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Computer Numerical Control

(CNC)
• The idea of computer numerical control is to
position a computer right at the machine tool.
• Most, if not all machine tools that are
numerical the controlled are CNC machine
tools.
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Direct Numeric Control

(DNC)
• Is a method where a single computer controls
many numerical control machine tools. These
machine tools may or may not be of a similar
nature
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Computer Aided Design / Computer Aided Manufacturing

CAD/CAM
• The idea behind CAD CAM is the use of a
single technical database by a both design a
manufacturing personnel during the product
development and production stages.
– CAD systems are used to define part geometries
– CAM systems are used to create cutter paths that
can be used by the machine tool.
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Types
1. Lath machine

The main axes of a lathe or turning center. (Emco Maier Corp)

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Lathe machine

• Most lathes are programmed on two axes.

• The X axis controls the cross motion of the cutting
tool.
• Negative X (X-) moves the tool towards the spindle
• positive X moves the tool away from the spindle
• The Z axis controls the carriage travel toward or
away fromthe headstock.
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2. Milling machine

Z axis

X axis

Y axis

The main axes of a vertical machining center. (Denford Inc.)

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Milling machine

The milling machine can be programmed on three axes:

• The X axis controls the table movement left or right.
• The Y axis controls the table movement toward or away from
the spindle.
• The Z axis controls the vertical (up or down) movement of
The spindle.
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Programming Systems

Two types of programming modes are used for CNC:

1.The incremental system.

2.The absolute system.

•Most controls on machine tools today are capable of handling either

incremental or absolute programming.
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The incremental programming system

• Incremental program locations are always

given as the distance and direction from the
immediately preceding point .
• Command codes which tell the machine to
move the table and spindle are explained here
using a vertical milling machine as an
example:
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The incremental system

A workpiece dimensioned in the incremental system mode.

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• A “X plus” (X+) command will cause the cutting tool to be located to
the right of the last point.
• A “X minus” (X-) command will cause the cutting tool to be located
to the left of the last point.
• A “Y plus” (Y+) command will cause the cutting tool to be located
toward the column.
• A “Y minus” (Y-) will cause the cutting tool to be located away from
the column.
• A “Z plus” (Z+) command will cause the cutting tool or spindle to
move up or away from the workpiece.
• A “Z minus” (Z-) moves the cutting tool down or into the workpiece.
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The absolute programming system

• Absolute program locations are always given from

a single fixed zero or origin point
• The zero or origin point may be a position on the
machine table, such as the corner of the
worktable or at any specific point on the
workpiece.
• In absolute dimensioning and programming, each
point or location on the workpiece is given as a
certain distance from the zero or reference point.
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The Absolute system

A workpiece dimensioned in the absolute system mode. Note: All dimensions are given
from a known point of reference. (Icon Corporation)
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• A “X plus” (X+) command will cause the cutting tool
to be located to the right of the zero or origin point.
• A “X minus” (X-) command will cause the cutting
tool to be located to the left of the zero or origin point.
• A “Y plus” (Y+) command will cause the cutting tool
to be located toward the column.
• A “Y minus” (Y-) command will cause the cutting
tool to be located away from the column.
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Point-to-Point or Continuous
Path
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Programming Format

• Word address is the most common programming

format used for CNC programming systems.
• This format contains a large number of different
codes (preparatory and miscellaneous) that transfers
program information from the part print to machine
servos, relays,micro-switches, etc., to manufacture a
part.
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• These codes, which conform to EIA (Electronic

Industries Association) standards, are in a logical
sequence called a block of information.

• Each block should contain enough information to

perform one machining operation.
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• Every program for any part to be machined, must be

put in format that the machine control unit can
understand.
• The format used on any CNC machine is built in by
the machine tool builder and is based on the type of
control unit on the machine.
• A variable block format which uses words (letters) is
most commonly used.
• Each instruction word consists of an address
character,such as X, Y, Z, G, M, or S. Numerical data
follows this address character to identify a specific
function such as the distance, feed rate, or speed value.
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Example G90
• The address code G90 in a program, tells the
control that all measurements are in the absolute
mode.
• The code G91, tells the control that measurements
are in the incremental mode.
•
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Codes

• The most common codes used when programming

CNC machines tools are G-codes (preparatory
functions), and M codes (miscellaneous functions).

• Other codes such as F, S, D, and T are used for

machine functions such as feed, speed, cutter
diameter offset, tool number, etc.
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G-codes
• G-codes are sometimes called cycle codes because they
refer to some action occurring on the X, Y, and/or Z
axis of a machine tool.
• The G-codes are grouped into categories such as Group
01,containing codes G00, G01, G02, G03. which cause
some movement of the machine table or head.
• Group 03 includes either absolute or incremental
programming, while Group 09 deals with canned cycles.
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The functions of a few common G-codes. (Deckel Maho, Inc.)

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G-codes cont’d

The G01, G02, and G03 codes move the axes at a

controlled feedrate.
• G01 is used for straight-line movement (linear
interpolation).
• G02 (clockwise) and G03 (counterclockwise) are
used for arcs and circles (circular interpolation).
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M or miscellaneous codes

• M or miscellaneous codes are used to either turn ON or OFF

different functions which control certain machine tool
operations.
• M-codes are not grouped into categories, although several
codes may control the same type of operations such as M03,
M04, and M05 which control the machine tool spindle.
• M03 turns the spindle on clockwise
• M04 turns the spindle on counterclockwise
• M05 turns the spindle off
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The functions of a few common M-codes. (Deckel Maho, Inc.)

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Some of the most common M-codes used in CNC programming.

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Block of Information

A complete block of information consists of five words. (Kelmar Associates)

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Programming for Positioning
Before starting to program a job, it is important to become familiar
with the part to be produced.
• From the engineering drawings, the programmer should be capable
of planning the machining sequences required to produce the part.
• Visual concepts must be put into a written manuscript as the first
step in developing a part program.
•The programmer must first establish a reference point for aligning
the workpiece and the machine tool for programming purposes.
•The manuscript must include this along with the types of cutting
tools and work-holding devices required, and where they are to be
located.
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From the drawing to final product
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Machine Zero Point

The machine zero point can be set by three

methods:
1.Manual setting
2.Absolute zero shift
3.Work Coordinates
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MANUAL SETTING

The operator can use the MCU to locate the spindle

over the desired part zero and then set the X and Y
coordinate registers on the console to zero.
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The relationship between the part zero and the machine system of coordinates.
(Deckel Maho, Inc.)
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ABSOLUTE ZERO SHIFT
• The absolute zero shift can change the position of the
coordinate system by a command in the CNC program.
• The programmer first sends the machine spindle to
home zero position by a G28 command in the program.
• Then another command (G92 for absolute zero shift)
tells the MCU how far from the home zero location, the
coordinate system origin is to be positioned.
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• The sample commands may be as follows:

•
• N1 G28 X0 Y0 Z0 (sends spindle to home
zero position)
• N2 G92 X4.000 Y5.000 Z6.000 (the position
the machine will reference as part zero)
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Work Coordinates

• In absolute positioning, work coordinates are

generally set on one edge or corner of a part and all
programming is generally taken from this position.

• In the following fig., the part zero is used for all

positioning for hole locations 1, 2, and 3.
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Work Coordinates example

In absolute programming, all dimensions must be taken from the XY zero at the top left-hand
corner of the part. (Kelmar Associates)
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Work Coordinates example inc

In incremental programming, all dimensions are taken from the previous point. (KelmarAssociates )