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INTERPOLATION METHODS
 Linear interpolation:
This is the most basic and used method when a straight line path
is to be generated in continuous path NC. The programmer
specifies the beginning point and end point of the straight line
and the feed rate to be used along the straight line. The
interpolator computes the feed rates for each of the two (or three)
axes to achieve the specified feed rate.
 Circular interpolation:
This method permits programming of a circular arc by specifying
the following parameters: (1) the coordinates of the starting
point, (2) the coordinates of the endpoint, (3) either the center or
radius of the arc. The generated tool path consists of a series of
small straight line segments calculated by the interpolation
module.

INTERPOLATION METHODS
 Helical interpolation:
This method combines the circular interpolation scheme for two
axes described above with linear movement of a third axis. This
permits the definition of a helical path in three-dimensional
space. Applications Include the machining of large Internal
threads.
 Parabolic and cubic interpolation:
These routines provide approximations of free form curves using
higher order equations. Most applications are in the aerospace
and automotive Industries for free form designs that cannot
accurately and conveniently be approximated by combining
linear and circular interpolations

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THE COMPUTER’S JOB

Post-Processor
 NC machine systems are different, they have different features
and capabilities
 High-level programming languages are not intended for only
one machine tool type. They are designed to be general
purpose.
 The final task of the computer in computer-assisted part
programming is post-processing, in which the CLFILE file is
converted into low-level code that can be interpreted by the NC
controller.
 The output of post-processing is a part program consisting of
G-codes, x-, y-, and z-coordinates, S,F,M, and other functions in
word address format.
 A unique post-processor must be written fro each machine tool
system.

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NC PROGRAMMING WITH INTERACTIVE GRAPHICS

There are several innovations in NC part programming during the

1980s.
1. Use of CAD/CAM
2. Voice programming
3. Manual data input (MDI)

USE OF CAD/CAM
 The use of interactive graphics in NC programming is an excellent
example of the integration of computer-aided design and computer-
aided manufacturing.

 Using the same geometric data which defined the part during the
computer-aided design process, the programmer constructs the
tool-path using high-level commands to the system.

 In many cases the tool path is automatically generated by the

software of the CAD/CAM system.

 The output resulting from the procedure is a listing of the APT

program, which can be post processed to generate the NC punched
tape.

 All of the major CAD/CAM system vendors offer part programming

packages.

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PROCEDURE

 The CAD/CAM procedure for NC programming begins with the

geometric definition of the part.

 A significant benefit of using a CAD/CAM system is realized when

these geometric data have already been created during design.

 The CAD/CAM systems accomplish the labeling of various surfaces

and elements of the geometry in response to a few simple
commands by the programmer.

 After labeling is completed, the APT geometry statements can be

generated automatically by the system.

 In addition to this facility, the part can be displayed at various

angles, magnifications, and cross sections to examine potential
problem areas in machining.

PROCEDURE

 Also, with the part defined in the computer, the programmer

overlay the outline of the raw work-part to consider the number of
passes required to complete the machining.

 Alternative methods of fixing the part can be explored using the

graphic terminal.

 Tool selection is the next step in the procedure. The CAD/CAM

system typically have a tool library. The part programmer could
either select one of these tools or create a new tool design by
specifying the parameters.

 At this point, the programmer has a geometric model of the work

part and the tools needed to machine the part. The next step is to
create the cutter path.

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PROCEDURE

 The currently available commercial CAD/CAM systems use an

interactive approach, with certain common machining routines
being done automatically by the system (e.g. profile milling around
the part outline, end milling pocket, point-to-point, and surface
contouring).

 As the tool is being moved on the CRT screen, the corresponding

APT motion commands are automatically prepared by the
CAD/CAM system.

 At this stage the postprocessor statements (e.g. feed rate, speed,

and the control of the cutting fluid) can also be inserted.

 The use of color graphics is also very helpful to the programmer.

The part can be displayed in one color, while the tool path would be
shown in a different color.

PROCEDURE

 Another feature which aides visualization of the machining sequence

is dynamic tool path simulation on the screen.

 The simulated tool motion can be displayed in any of several modes:

1. High speed motion, which reduces the time to verify the tool path.

2. Actual speed, which shows the tool feed at the commanded rate.

3. Freeze mode, which stops the tool motion for close inspection.

4. Stepping mode, which displays the tool path in discrete steps.

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ADVANTAGES OF CAD/CAM IN PROGRAMMING

 See from the book page # 206.

VOICE PROGRAMMING

 Voice programming of NC machines (VNC) involves vocal

communication of the machining procedure to a voice-input
NC tape-preparation system.

 VNC allows the programmer to avoid steps such as writing

the program by hand, keypunching or typing, and manual
verification.

 To perform the part programming process with VNC, the

operator speaks into a microphone designed to reduce
background noise.

 Communication of the programming instructions is in shop

language with such terms as, turn, thread, and mill line,
together with numbers to provide dimensional and
coordinate data.

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VOICE PROGRAMMING

 The entire vocabulary for the Threshold system contains

about 100 words.

 Most NC programming jobs can be completed by using

about 30 of these vocabulary words.

 In talking to the system, the programmer must isolate each

word by pausing before and after the word.

 The pause must be only 1/10 of a second or longer.

 Typical word input rates under this restriction are claimed

to be about 70/min.

 As the words are spoken, a CRT terminal in front of the

operator verifies each command and prompt for the next
command.

EXAMPLE
 A typical dialogue between the VNC system (printing on the
CRT screen) and the programmer (speaking) might go as
follows for defining a circle.
Programmer: “Define”
System: DEFINITION TYPE
Programmer: “Circle”
System: CIRCLE # =
Programmer: “Three”
System: CIRCLE PT X =
Programmer: “Five decimal three one, Go”
System: Y=
Programmer: “Two decimal four seven five, Go”
System: RADIUS =
Programmer: “One decimal five, Go”
System: CW/CCW
Programmer: “Counterclockwise”

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VOICE PROGRAMMING

 When all the programming instructions have been entered

and verified, the system prepares the punched tape for the
job.

 ADVANTAGES

1. Saving in the programming time up to 50%

2. Improvement in accuracy

3. Lower computer-skill requirement for the programmer.

MANUAL DATA INPUT (MDI)

 Manual data input involves the entry of part programming

data through a CRT display at the machine site; hence the
use of punched tape is avoided.

 The programming procedure is usually carried out by the

machine operator (not the part programmer).

 NC systems equiped with MDI capability possess a

computer.

 MDI systems are designed to facilitate the part

programming process by using an interactive mode to assist
the operator through the programming steps.

 It queries the operator about the details of the machining

job so that the operator types in the program responding to
the sequence of questions.

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MANUAL DATA INPUT (MDI)

 MDI units use shop language rather than alphanumeric

codes.

 This removes some of the ambiguity, usually surrounding

the programming activity.

 The programmer just needs to be able to read an

engineering drawing and familiar with the machining
process.

 No extensive training is required in NC part programming.

 The great advantage of MDI is its simplicity.

 Since, no punched tape is employed with MDI, the shop is

spared the expense of tape punching equipment normally
associated with NC.

MANUAL DATA INPUT (MDI)

 The limitation on MDI is that the programs should be

relatively short and simple.

 The reasons for this limitation are

1. Since there is no paper copy of the program, there is a limit on the

length and complexity of the program that the operator is capable
of visualization.

2. The CRT can display a total of 22 or 25 lines, which adds to the

operator’s visualization problem.

 One of the biggest disadvantages of MDI is that the machine

tool itself is not productive while programming is being
accomplished.

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MANUAL DATA INPUT (MDI)

 The more complicated the program, the more time is taken

when the machine is not cutting metal.

 One way of overcoming this problem, is for the machine to

be operated in a background mode.

 The particular features of MDI make it suitable for work-

parts which are simpler than usual NC jobs.

PRECISION IN NC POSITIONING
 For accurate machining by an NC system, the positioning system
must possess a high degree of precision.

 Three measures of precision:

1. Control resolution

2. Accuracy

3. Repeatability

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CONTROL RESOLUTION
Control resolution is defined as the distance separating two adjacent
addressable points in the axis movement.

 Addressable points are locations along the axis to which the

worktable can be specifically directed to go.

 It is desirable for control resolution to be as small as possible.

Control
resolution

Bit storage
Electromechanical
capacity of the
components
controller

· Lead-screw pitch
· Gear ratio
· Step angle
· Angle b/w encoder slots

CONTROL RESOLUTION
 Control resolution of the electromechanical system
 For open-loop positioning system:

p
CR1 
ns rg

 For closed-loop system

p
CR1 
ns rg rge

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CONTROL RESOLUTION
 Control resolution of the computer system
 The ability to divide the axis range into individual increments
depends on the bit storage capacity in the control memory

 The number of increments = 2n

n = number of bits in the control memory

 Control resolution

L
CR2 
2 1
B

 Control resolution of the overall positioning system

CR  Max CR1, CR2 

CONTROL RESOLUTION
 A desirable criterion is for CR2 < CR1, meaning the electromechanical
system is the limiting factor.

 The bit storage capacity of modern computer controller is sufficient

to satisfy the requirement.

 Resolutions of 0.0025 mm is within the current state of NC

technology.

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ACCURACY
 The accuracy of any given axis of a positioning system is
the maximum possible error that can occur between the
desired target point and the actual position taken by the
system.

ACCURACY IN IDEAL CASE

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MECHANICAL ERRORS
 The capability of a positioning system to move the
worktable to the exact location is limited by the following
mechanical errors.
1. Play between the lead-screw and the table

2. Backlash in the gears

3. Elastic deflection in the structural members

4. Stretching of pulley cords

ACCURACY IN REAL CASE

 Assumptions

1. Mechanical errors form an normal distribution about

the control point whose mean is 0
2. Standard deviation is constant over the range of the
axis.
 Accuracy is defined under worst case conditions in which
the desired target point lies in the middle between two
adjacent addressable points.
 Since the table can only be moved to one or the other of
the addressable point, there will be an error in the final
position of the work-table.

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ACCURACY IN REAL CASE

 This is the maximum possible positioning error.

 Mathematically

CR
Accuracy   3
2

REPEATABILITY
 Repeatability
refers to the capability of the positioning
system to return to a given addressable point that has
been previously programmed

Re peatability  3

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REPEATABILITY
 Suppose the mechanical inaccuracies in the open-loop
system are described by a normal distribution with
standard deviation 0.005 mm. The range of the worktable
axis is 1000 mm, and there are 16 bits in the binary
register used by the digital controller to store the
programmed positions. Other relevant parameters are;
pitch = 6.0 mm, gear ratio between motor shaft and lead-
screw rg = 5.0, and number of stop angles in the stepping
motor ns = 48. Determine
a. Control resolution
b. The accuracy
c. The repeatability for the positioning system

REPEATABILITY
 Control resolution is the greater of CR1 and CR2

p 6.0
CR1    0.025mm
ns rg 48  5.0
1000
CR2   0.01526mm
216  1
CR  Max 0.025,0.01526  0.025mm
 Accuracy

 0.5(0.025)  3(0.005)  0.0275mm

 Repeatability

 3(0.005)  0.015mm

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