OBJECTIVES

Fundamentals of NC systems

Classification of NC systems

Advantages of NC systems
NUMERICAL CONTROL
NC system has been defined by EIA as A system in which
actions are controlled by direct insertion of numerical data at
some point. The system must interpret at least some portion of
this data.
NC milling, drilling & boring machines, NC lathe &turning
centers, NC grinders, NC punches& presses, NC welding machines,
NC inspection machines, NC tube bending machines, NC wirecut
EDM, NC wire wrapping machines, NC gear hobbing machines etc.
PART PROGRAM
The numerical data which is required for producing a part is
maintained in the form of series of instructions on a punched tape
and is called Part program.
Example:
N01G90 G21
N03 M06 T12
N05 GOO X0 Y0 Z.1 F10 S2500 M03
N07 G1Z-.5
N09 G02 X-10. I0J0F20
N13 G01 X0Y10
N17 X10Y0
N19 X0Y-10
N21 X-10Y0
N23 M2
NC VS CONVENTIONAL
In NC machine each axis of motion is controlled by a separate
driving device which replaces the hand wheel of the conventional
machine.
Commonly used driving devices on NC machines are AC & DC
servo motors, Stepped motors, Hydraulic motors.
AXIS OF MOTION
Axis of motion means axis along the cutting tool moves relative to the workpiece.

EIA & ISO recommends right hand co-ordinate system.
ELEMENTS OF NC MACHINE
NC machine tool system consists of MCU & NC machine tool itself.
ELEMENTS OF NC MACHINE
DPU: Decodes the instructions received from the tape, process it and provides
data to the CLU. Such data contains new required positions of each axis, its direction
of motion & velocity, auxillary control signals to relays etc.
CLU: Operates the drives attached to machine lead screws and receives feed
back signal on the actual position and velocity of each axes. It also provides a
signal announcing that the previous segment is completed & the DPU can read
new block of part program.

ELEMENTS OF NC MACHINE
DPU includes the following circuits:
Input device
Reading circuits & Parity checking logic
Decoding circuits
Interpolator circuits
CLU consists of following circuits:
Position control loops
Velocity control loops
Deceleration & Backlash takeup circuits
Auxillary function control
CLASSIFICATION OF NC SYSTEMS
Based on motion type
Point to Point and Contouring systems
Based on structure of the controller
NC and CNC
Based on programming method
Incremental and Absolute systems
Based on type of control loops
Open loop and Closed loop systems
POINT TO POINT SYSTEM
Point to point control system is designed to move the tool to the pre destined location.
No control over the path and velocity while moving from one location to another.
Example: NC drilling machine and Spot welding machines.
STRAIGHT CUT NC SYSTEM
The straight cut NC system can move the cutting tool parallel to one of the major axis
at controlled rate as required for machining operation.
The main limitation with straight cut NC is that it cant perform angular cut.
Example: Shaping machine.
CONTOURING SYSTEM
The continuous path NC can control the movement of more than one axis
simultaneously to generate the desired geometry of the workpiece.
HARDWARE ASPECTS
PTP system would require only Position counters.

L-type NC requires Position counters and velocity control loops.

C-type NC is provided with position loops & position counters for each axis. The
velocity of each axis is decided by interpolation circuits in DPU based on the feed
rate along the given contour.
MATHEMATICAL PERSPECTIVE
P- type NC can position the tool to any point (x,y).
L- type NC can move the tool along x,y axes and can control the feed rates dx/dt &
dy/dt but only one at a time.
C-type can perform L-type and simultaneous control of dx/dt & dy/dt.
NC Vs CNC
NC system use electronic hardware based on digital circuit technology. CNC
machines employ a computer to control the machine tool and eliminates additional
hardware in control cabinet.

NC is Hardware based logic and CNC is Software based logic.
INCREMENTAL AND ABSOLUTE SYSTEM
In incremental system each position is specified with respect to previous one. In
absolute system all tool positions are specified with respect to one fixed zero point.
RELATIVE MERITS AND DEMERITS
In case of interruption it is easy to bring the tool to the beginning of the segment in
which interruption occurred with absolute system. In incremental system operator has
to restart the program and repeat the entire operation prior to interruption point.
It is easy to change the dimensional data in part program with absolute system,
where as in incremental system the part must be re programmed from the point at
which original part program has been changed.
RELATIVE MERITS AND DEMERITS
Error detection is easy with incremental system.

Mirror image programming is facilitated with incremental system.
OPEN LOOP AND CLOSED LOOP SYSTEMS
In Open loop systems there wont be any feed back system to check whether the
programmed position and velocity are achieved or not.
In general open loop system uses stepped motor as a driving device.
OPEN LOOP AND CLOSED LOOP SYSTEMS
The closed loop control system measures the actual position and velocity of each
axis and compares with the desired references. The difference between actual and
desired values is error.
OPEN LOOP AND CLOSED LOOP SYSTEMS
Encoder is used as a feed back device in closed loop control systems.
ADVANTAGES AND DISADVANTAGES OF NC
Advantages:
A full flexibility
Accuracy is maintained through the full range of speeds and feed.
Shorter production time
Possiblity of manufacturing complicated contours
Easy adjustment of machine
No need of highly skilled and experienced operator
Operator will have free time
Disadvantages:
Relatively high cost.
More complicated maintenance
A highly skilled and trained part programmer is needed.
FUNDAMENTALS OF MACHINING
Machining is the manufacturing process in which the size, shape or surface
properties of a part are changed by removing the excess material.
Conventional machining processes vs Uncoventional processes.
The cutting conditions in machining with NC machines are : Cutting speed, feed and
depth of cut.
CUTTING CONDITIONS
Cutting speed (V) is defined as the relative velocity between the cutting tool and
the workpiece material and is expressed as m/min. In NC machines spindle speed is
used rather than cutting speed in programming.
Feed (f) is defined as relative lateral movement between the tool and the
workpiece during machining operation. It is expressed as length units/rev. In NC
machines it is also expressed as units of length per min.
Depth of cut (d) is defined as the distance the cutting tool projects below the
original surface of the work and is expressed in mm.
MRR = Vfd
DESIGN CONSIDERATIONS OF NC MACHINE TOOLS
The reason that stimulated the development of NC were the demand for
better accracy and to increase productivity.
However, it should be noted that the combined characteristics of the control
and machine tool determines the final accuracy and productivity of the NC or CNC
system.
RESOLUTION OF NC SYSTEM
Programming resolution : It is the smallest allowable position increment in part
programs and is referred as the BLU.
Control resolution: It is the smallest change in position that the feedback device
can sense.
For better system efficiency Programming resolution = Control resolution
ACCURACY OF NC SYSTEM
Final accuracy of CNC system depends on
a) Computer control algorithms
b) System resolution
c) Machine inaccuracies
System accuracy = BLU + Machine accuracy
Machine designer tries to ensure that the effect of all inaccuracies associated with
machine tool will be under BLU.
REPEATABILITY OF NC SYSTEM
Repeatability is the statistical term associated with accuracy.
The system repeatability is the positional deviation from the average of the
displacements.
Repeatability is always be better than accuracy.
PRODUCTIVITY VS ACCURACY
High Productivity and Accuracy might be contradictory features.
IMPROVING ACCURACY OF NC SYSTEM
Improved machine tool structure
Use of low friction moving components
Avoiding lost motions and isolating thermal sources
High productivity by improving the efficiency of machine using
machining centers
ECONOMICS
Mass production: SPMs arranged in transfer line.
Low volume production : Conventional machines
Medium volume production: NC machines
RETROFITTED NC MACHINE
Adding MCU
Replacing the conventional screw with ball bearing screw
Adding stepped motors/servo motors and feed back devices
INCREASING PRODUCTIVITY WITH NC MACHINES
The total production time comprises of four time components
i. Actual cutting time
ii. Idle or Traverse motion time
iii. Loading & Unloading time
iv. Tool changing time
Actual cutting time can only be slightly reduced with NC machines however
other three components can be reduced substantially.
IDLE OR TRAVERSE MOTION
Idle or Traverse motion time can be reduced by increasing the traverse velocity
thus idle time is reduced and production time is saved.
LOADING & UNLOADING
Loading & Unloading times can be reduced by using two workholding devices
simultaneously on the machine table.
Using Automatic tool change methods
AUTOMATIC TOOL CHANGE (ATC)
In case of machines with ATC large number of tool are stored in the magazines.

Two types of magazines are very common on CNC machines
i. Chain type tool magazine
ii. Carousel type tool magazine
ROTATING ARM MECHANISM
MACHINING CENTERS
Machining centers are more rigid than conventional machines and equipped
with ATCs and rotary tables.
Capable of machining complex parts with high accuracy. May not be economical
for small parts.
Turning centers.
MCU FUNCTIONS
Various functions on the control panel of the MCU are the direct interface between
machine operator and NC system.
MODE SELECTION
Auto mode for continuous execution of part program.
Manual or Dial mode G-code, M-code, V, f, d and co-ordinate information is
entered and executed block by block.
Jogging mode is used for positioning the slides. Jogging mode is used for
coarse positioning and discrete jogging switches are used for fine positionning.
Block by Block mode is used to read and execute one block of information at a
time.
COMPENSATIONS AND OVERRIDE
Cutter radius compensation: This feature is used to offset actual tool path from
programmed tool path.
Tool length compensation: This feature is suitable in drilling applications
where varying lengths of drills are used.
Feed rate override: This feature is useful to override the programmed feed rate
in case of adverse cutting conditions.
READOUT DISPLAYS
Sequence number readout: Helps to know the location of programming errors.

Present position readout: Electronically display the present position of one or
more axes.
CNC CONTROLLER
Keyboard to edit part program and CRT screen to display messages.