Misr International Technological University

Faculty of Industry and Energy Technology in Fayoum

Bachelor of Technology in Industrial Automation

Programming of manufacturing cells

(TP_11)

Lecture 03
Dr. Sabry Said Youssef
Assistant professor
Mechanical Engineering Department
Faculty of Engineering
Fayoum University
 Introduction to CNC Machine tools.

 Introduction to DNC Machine tools.

 Difference Between NC, CNC and DNC machine

tools.
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 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.
 Functions of CNC
There are a number of functions which CNC is designed to perform. Several of these
functions would be either impossible or very difficult to accomplish with conventional
NC. The principal functions of CNC are:
1. Machine tool control
2. In-process compensation
3. Improved programming and operating features
4. Diagnostics
 Components of CNC machine tool system
The main components of CNC machine tools are as follows :
 Input / Output Console.
 Microprocessor Based control unit.
 Memory.
 Feedback unit.
 Machine Tool.
 Interfaces.
 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.
 Classification of CNC Machine tool systems
(a) According to type of Feedback (d) According to type of controller
systems 1. Hybrid controller CNC systems.

1. Open loop type CNC machine. 2. Straight controller CNC systems.

2. Closed loop type CNC machine. (e) According to axis & type of
operations
(b) According to type of tool motion
control 3. CNC horizontal machining centre.

4. CNC vertical machining centre.

3. Finite positioning control CNC machines.
5. CNC turning centre.
4. Continuous path control CNC machines.
6. CNC milling centre.
(c) According to program methods

5. Absolute Programming CNC machine systems.

6. Incremental Programming CNC machine

systems.
Classification based on type of feedback systems

1. Open-Loop type CNC Machine

Input Microcompute
Program r
• It does not have any feedback
mechanism.

• It only has motion control but do not

CNC
Drive motor
controller
have any provision for feedback,
which is needed to be compared with
input for better control & correction of
Machine tool
Gear box slide
drive system.
displacement
 Classification based on type of feedback systems

2. Closed-Loop type CNC Machine

Input Program • It has a feedback mechanism.

Measuring
unit
Microcompute
r
• It has the motion control with a provision

of feedback .

• Which can be used for accurately

Machine tool
slide CNC controller controlling the drive system by comparing
displacement
it with the input information until the

required or desired position is achieved.

Gear box Drive motor
 According to type of tool motion control

1. Finite position control CNC machine

• In point to point CNC machines, the movement of cutting

tool from one predefined position to another predefined
position is important, while the path along which this tool
moves is irrelevant. Commonly used in drilling & punching
operations.

• Straight cut line control mode is the extension version of

point to point method, straight cut is obtained controlling
the movement of tool with controlled feed rate in one of the
axis direction at a time. Commonly used in Face milling,
pocket milling and step turning operations.
 According to type of tool motion control
2. Continuous path control CNC machine
• The continuous path control system is used
for continuous, simultaneous & coordinated
motions of cutting tool & work piece along
different axes.

• Such motion enables machining of different

contoured profiles & curved surfaces.

• Types : 2 axis, 2 ½ axis, 3 axis, Multi axis

countering.
 According to programming Methods

1. Absolute programming CNC machine systems

X Y
In Cartesian coordinate geometry
0 0
0 4 system using absolute measurement,
2 4 each point is always specified using
2 5 same zero established for a given
4 6
coordinate system.
4 7
6 6
8 8
8 4
5 4
 According to programming Methods

2. Incremental programming CNC machine systems

X Y
In Cartesian coordinate geometry
0 0
0 4 system using incremental
2 0 measurement , each point is
0 1 specified using the path differential
2 1
from the preceding point position. So
0 1
2 -1 in such programming , controller
2 2 must store and process additional
0 -4 path measurement.
- -
 According to type of controllers

1. Hybrid controller CNC systems

• Hard wired logic circuits : It
Minicomputer Hard-Wired logic performs those functions for which
Circuits
they are best suited, such as feed
rate generation and interpolation.
Interface
• Soft wired computer : The computer
performs the remaining control
functions plus other duties not
Feedback
normally associated with a
conventional hard-wired controller.
 According to type of controllers

2. Stage controller CNC systems

• It uses a computer to perform all the

Minicomputer functions.

• The interpolation, feed rate generation

and all other functions are performed by
Interface the computer with the help of software.

• The only hard-wired elements are those

required to interface the computer with
Feedback
machine tool and operator’s console.
Advantages & Limitations of CNC machine tools

Advantages Limitations

• Ease of program input. • Higher investment cost.

• Multiple program storage. • Higher maintenance cost.

• Online part programming and editing. • Requires specialised operators.

• Use of advanced interpolation.

• Automatic tool compensation.

• Auto generation of part program for

existing components.

• Change in system of units.

 Direct Numerical Control (DNC)

• DNC is a manufacturing system in which a number of machines are controlled by a

computer through direct- connection and in real time.

• Also, defined as a system connecting a set of NC machines to a common memory for

part program or machine program storage with provision for on- demand distribution

of data to machines.

• The tape reader is omitted.

• Involves data connection and processing from the machine tool back to the computer.
 Components of DNC
• Central computer

• Bulk memory which stores the NC part programs.

• Telecommunication lines

• Machine Tools.
 Direct Numerical Control (DNC)
• A central computer connected to a number of machine tools and control them

• Part program of all machine tools are stored in the memory of the central
computer and transmitted on direct transmission lines on demand

• Two way information flow take place in real time

• Various machine tools can communicate with the computer in real time

• Programs in full or segment can be transferred to NC machines

• Computer can be used for program editing

• No tape readers are used

• No limitation for the number or size of programs stored

 Two types of DNC
Behind-the-tape reader (BTR)

The computer is linked directly to the regular NC controller unit. The replacement of
the tape reader by the telecommunication lines to the DNC computer is what gives
the BTR configuration its name
The operation of the system is very similar to conventional
NC. The controller unit uses two temporary storage
buffers to receive blocks of instructions from the DNC
computer and convert them into machine actions. While
one buffer is receiving a block of data, the other is
providing control instructions to the machine tool.
 Two types of DNC
Special machine control unit (MCU)
The other strategy in DNC is to eliminate the regular NC controller altogether and replace it
with a special machine control unit.

This special MCU is a device that is specifically designed to facilitate communication

between the machine tool and the computer.
• The special MCU is soft-wired, while the conventional NC
controller is hard-wired. The advantage of soft-wiring is its
flexibility.
• The advantage of the BTR configuration is that its cost is less,
since only minor changes are needed in the conventional NC
system to bring DNC into the shop.
 Functions of DNC
The functions which a DNC system is designed to perform:
1. NC without punched tape.

One of the original objectives in direct numerical control was to eliminate the use of
punched tape.

2. NC part program storage.

A second important function of the DNC system is concerned with storing the part programs.

3. Data collection, processing, and reporting.

Another important function of DNC involves, the transfer of data from the machine tools
back to the central computer. DNC involves a two-way transfer of data.

4. Communication

Communication among the various subsystems is a function that is central to the operation
of any DNC system
 Advantages of DNC

Elimination of punched tapes and tape readers

Convenient storage of NC part programs in computer files

Greater computational capability and flexibility

Reporting of shop performance.

Convenient editing and diagnostic features.

Comparison between NC, CNC and DNC machine tools
 Comparison between NC, CNC and DNC machine tools
NC Machine Tool CNC Machine Tool System DNC Machine Tool System
System
1. The part program is fed to the 1. In CNC machine tool system, the 1. The part program is fed to the
machine through the tapes or other program is fed to the machine machine through the Main
such media. through the computer. computer

2. The programs can be easily 2. In order to modify the program,

2. In order to modify the program, the
modified with the help of computer.
tapes have to be changed. single computer is used
3. The microprocessor or
3. In NC machine tool system, tape 3. Large memory of DNC allows it
minicomputer forms the machine
reader is a part of machine control to store a large amount of part
control unit. The CNC machine does
unit.
program.
not need tape reader.

4. It has memory storage ability, in 4. Same part program can be run

4. System has no memory storage
which part program can be stored. on different machines at the
and each time it is run using the
same time.
tape. 5. System can import CAD files and
convert it to part program. 5. The data can be processed using
5. It can not import CAD files.
the MIS software so as to
6. The system can use feedback
6. It can not use feedback system.
effectively carry out the
system.
Production planning and
7. They are not software driven. 7. The system is software driven. scheduling.
Thanks

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