CAD/CAM

NC, CNC, DNC Technologies

Numerical Control (NC)
Numerical Control can be defined as a
form of programmable automation in
which the process is controlled by
numbers, letters and symbols.
In NC, the numbers form a program of
instructions designed for a particular part
or job.
Numerical Control
NC programs are quite flexible and easy to
change and hence boosts productivity.
NC technology is applied to a variety of
operations like, machining, drafting,
assembly, inspection, sheet metal working,
welding and such.
NC is been existence for over 125 years now!
NC History
 The need of the U.S. Air Force for templates more precise than could
be obtained by state-of-the-art methods of the late 1940s inspired
John Parsons, President of the Parsons Works of Traverse City,
Michigan, to propose that a by-the-numbers technique (commonly
used by machinists of that era) be placed under servo control with
positional data generated by a computer, thereby providing much
more data than would be practical by means of hand calculations.
Later, MIT demonstrated the first ever NC machine tool to a select
group from the military, the aerospace industry, the machine tool
industry and the technical media in September, 1952.
 Basic components of a NC
system
A functional Numerical Control system consists of
following three basic units,
 Program of Instructions
 Controller Unit (MCU, Master Control Unit)
 Machine tool or operating unit

Program or
Instructions Machine Tool
Controller Unit
 Program Of Instructions
 It is a step by step set of directions which tell the
machine tool what to do.
 Written using numerical and symbols, which can
be interpreted by the controller unit.
 These instructions use 1” paper tape, magnetic
disks, cassettes, punched cards as input media.
 Other way to input data to the controller is
manually and is called Manual Data Input (MDI).
 MDI is used for relatively simple programmable
jobs which need not be stored or repeated.
Master Controller Unit (MCI)

 This consists of electronics and hardware that read and

interpret the program and convert into mechanical actions
of the machine tool.
 Typical parts of the MCI are a tape reader, data buffer,
signal output channels to the machine tool, feedback
channels from machine tool and a sequence controller to
control overall operations.
 Recent controllers include on-board computer to
effectively manage these activities. They are referred to as
Computer Numerical Control (CNC).
Machine tool or Operating Unit

 This unit is responsible for directly

producing the end job
 Consists of machine table, spindle, ball
screws, drive motors and necessary
controllers.
 Additional equipments like tool holders,
work holders, rotary tables can be part of
the tool.
NC process
NC manufacturing process involves,
 Process Planning: Depending upon the job to be
machined, a Route sheet is made ready. Route sheet lists
the sequence of operations which must be performed to
get to the final product. It also lists variety of machines on
which the part must progressively machined and hence
the name Route sheet.
 Part Programming: A part programming is the process
of making NC instructions /programs for the machines
which are Numerically controlled.
Part programs can be done manually or Computer
Assisted.
NC Process, contd…
•Tape Preparation: Part program information is now put
on a media of choice. If a paper tape is to be punched, the part
program is fed to a paper tape-punching machine. Or else
magnetic media can also be used.

•Tape verification: The paper tape prepared has to be

checked for correctness and possible errors. The tape reader is
an optical device which reads the tape and validates it.
Sometimes, foam or soft metal can be cut as a test run using
the punched tape.

•Production: Final step in the NC process uses the machine

tool to produce the part in consideration. Typically involves,
machine tool, raw blanks, cutting tools, coolants etc.
 NC Co-ordinate Systems
 In order for the part-programmer to plan the sequence of
positions and movements of the cutting tool relative to the
work piece, it is necessary to establish a standard axis
system by which the relative positions can be specified.
This axis is referred to as co-ordinate system. This is the
X0 Y0 Z0 for the NC program or “home” +Z location.
Axis system for Milling c
and drilling
-Z
+Y
+X
b -Y -X
a
NC Co-ordinate Systems
Axis system for
turning tools
-Y

-X

+Z
-Z

+X
+Y
NC Motion Control Systems
In order to accomplish the machining process,
the cutting tool and the work piece must be
moved relative to each other. There are 3
basic types of motion control systems.
1. Point – to –point (PTP)
2. Straight Cut
3. Contouring
Point-to-point Cut (PTP)
Point-to-point is also called as positioning system, the
objective of the the machine tool control system is to
move the cutting tool to a predefined position. The speed
or the path by which the movement is accomplished is not
important.
Once the tool reaches the desired location, the machining
operation is performed in that location. In between two
locations, no cutting takes place. Hence it is point-to-point
system. These are the least expensive control systems.
Examples: NC Drill presses
Straight Cut
Straight cut control systems are capable of moving the cutting
tool along one major axis at a controlled rate suitable for
machining. However, it will not be able to control the
movement of tool in more than one major axis. Thus it is
called a straight cut control system.
This systems enables milling along major axis one at a time.
It can also perform PTP positioning also.

Example: NC Milling Machine

Contouring NC
This is the most complex and most flexible motion systems of all.
Expensive compared to the other two systems.
It is capable of doing PTP, straight and contour cuts. In essence, the NC
control will have the tool to move in more than one major axis
simultaneously, thus performing contour machining.
The path of the cutter is continuously controlled to generate the desired
geometry of the work piece. These are also called continuous path NC
systems.
This system can machine any circular, conical or for that matter, any
shape that can be mathematically definable.
Ex: NC contouring Milling Machine, Turning Machines
Suitability of NC Systems
Typically NC Machines are most suitable for a Batch Type
manufacturing. Especially when,
1. Parts are processed frequently and in small lots
2. The part geometry is complex
3. Machining involves variety of operations
4. Engineering design changes quickly
5. Close tolerances are to be held
6. Wherever 100% inspection otherwise would be needed
Advantages of NC Systems
1. Reduced Non-productive time
2. Reduced fixturing
3. Reduced manufacturing lead times
4. Greater manufacturing flexibility
5. Improved quality control
6. Reduced Inventory
7. Reduced Inspection requirements
8. Less wastage and scrap
Disadvantages of NC Systems

1. Higher initial investment cost

2. Higher running costs and maintenance cost
3. Finding trained manpower could be a challenge
4. Breakdowns can be expensive
5. Elaborate accessories like programming and tape
punch/reader systems adds to the cost
 Computer Numerical Control (CNC)

With the development of digital computers,

the design of NC systems has changed
dramatically and has paved to,
 Computer Numerical Control (CNC)
 Direct Numerical Control (DNC)
 Adaptive Control
 CNC
A computer Numerical Control is a NC system
that utilizes a dedicated computer to perform all
basic numerical control functions.

Data Flow Memory

Computer

MCU

Feedback

Position,
Velocity,
Diagnostics
Vertical Machining Center
Functions of CNC
Many functions which are almost
impossible to achieve using NC, can be
accomplished by CNC, they are,
1. Machine tool control
2. In-process compensation
3. Improved programming and operating
features
4. Diagnostics
 Machine Tool Control

The primary function of the CNC system is to control

machine tool. This involves conversion of part
program instructions into machine tool motions
through the computer interface and servo system.
Some of the complex functions like, tool
compensation, circular interpolation, 3D contouring,
scaling and off setting can now be accomplished
using CNC system.
In-process Compensation
A function which is closely related to machine tool
control is in-process compensation. This involves
dynamic correction of the machine tool motions for
changes or errors which occur during processing. Some
of the in-process compensation are,
1. Adjustments for errors sensed by in-process gauges and inspection
probes.
2. Re-computation of axes positions
3. Offset adjustment for tool radius and length
4. Adaptive control adjustment for speed and feed
5. Computation of tool life and selection of alternate tooling
6. Temperature compensation
7. Chatter and vibration compensation
Improved Programming and
Operating Features
Enhanced user experience by having an on-board,
dedicated computer is the major advantage of a
CNC system.
Some of these are,
1. Editing of the part programs at the machine. On the fly corrections
and optimization
2. Graphic display of the cutting tool path- less machining glitches
3. Various types of interpolation, circular, parabolic, cubic…
4. Metric and Non-Metric support
5. Specially developed canned routines
6. Manual Data Input (MDI) through pulse generator
7. Local storage of more than one part program
Diagnostics
CNC systems are often equipped with a diagnostic
capability to assist in maintaining and repairing
the system.
Many systems track the down time and uptime to
help computer productivity. Many have graphical
diagnostic tools to pin-point the problem area and
repair it quickly.
Many systems can disconnect the faulty system and
let the machine continue without hampering the
outcome or the safety.
 Advantages of CNC
 Preparation of Part programming data intuitive and easy:
As there is little or no need of punched tape, data can be
transferred through electronic media quite reliably. Many
systems let the programming done on the machine itself.
 Unit independence: Can work in Metric or non-Metric
and convert data as needed
 Greater operational flexibility
 MACRO ability cuts down on programming time and
skill needed
 CNC provided, Total manufacturing system
Direct Numerical Control (DNC)

Direct Numerical Control (DNC) can be

defined as a manufacturing system in
which a number of machines are controlled
by a computer through direct connection
and in real time.
Typically one large computer can manager
few to hundred machine tools.
 Components of DNC
Four basic components are,
1. Central computer
2. Bulk memory to store part programs and instructions
3. Communication lines between computer and machines
4. Machine tools

Central Computer System Memory

Machine tools
Functions of DNC
Typical functions served by a DNC are,
1. Communication
2. Part program storage
3. Ancillary functions
Communication
Focus is on the communication between DNc computer and
the Machine tool. They are,
1. Sending part programs to CNC machine tools
(downloading)
2. Receiving part programs from CNC machines are
editing, optimizing for archival purposes (uploading)
3. Serve as a buffer to store large part programs
4. Download tool offsets and length information
5. Control the CNC machine remotely as required
Part Program Storage
There are large number of functions that can be carried out by a
DNC computer that can not be done on the MCU,
1. It can store all programs as the storage is quite large
2. It can input, edit, copy and delete programs much faster than MCU
3. Editing can be done on multiple lines (blocks) of program rather
than a line feed as in MCU
4. After editing, re-numbering of program lines takes quite a time.
DNC computers can do this automatically.
5. Many functions like, calculating machining parameters, syntax
checking can be done with much ease
6. Complete tool management functions like tool offset, length, life,
wear can be embedded into the DNC computer
Ancillary Functions

DNC systems can help accomplish,

1. Integrating with CAD/CAM systems for latest design updates,
changes.
2. Integration with shop floor systems for better machine utilization,
throughput, worker safety, load distribution…
3. Constant control over the performance of the machine tools and
diagnosing the possible problems before they lead to machine
shutdown
4. Keeping track of production performance like number of
components machined, machines used and such
Advantages of DNC
 DNC eliminates local data input like tape reader and punched cards
 Because of large storage, many part programs can be stored and
managed
 As DNC computer feeds the programs to the machine tools, many
machines working on the same job, duplication of part on each
machine is eliminated.
 Better management of part programs, I.e editing, storing, deleting,
copying and such
 Integration with CAD/ CAM and shop floor systems, eliminate
manual intervention, thus less errors and problems
 Factory integration could be a reality with DNC implementation
Adaptive Control
Originated in 1960’s sponsored by the US Air force at the
Bendix Research Labs.
It is defined as a control system that measures certain output
process variables and uses these to control speed, feed or
some other attributes.
Some of the process variables that have been used in
Adaptive Control are spindle deflection, force, torque,
cutting temperatures, vibration amplitude, horse power,
power consumption and such.
The motivation for developing an AC is to operate a process
for efficiently.
Where is AC used?
 When in-process time consumes a significant
portion of the total machining cycle time. Rule of
thumb, when cutter is engaged for 40% of the
cycle time, AC is recommended
 Where most of the variable factors can be
measured effectively and utilized to control speed
and feed.
 The cost of operating and machine is high,
including the initial investment
 Typically where jobs involve machining of steel,
titanium alloy, high strength alloy etc.