BTM 3334
CNC MACHINING
TOPIC 1: INTRODUCTION
LECTURER:
DR. MUSFIRAH ABDUL HADI
Lecture Objectives
• At the end of the lecture, you will be able to:
– Differentiate between numerical control (NC),
computer numerical control (CNC) and distributed
numerical control (DNC).
– Explain what CNC is and what are the basic
component surrounding it.
– Identify the CNC classification.
– Identify the CNC axes.
– State the advantages and disadvantages of CNC
used.
History of NC Machine
1949-
US Air Force asks Massachusetts Institute of Technology
(MIT) to develop a "numerically controlled" machine.
1952-
Prototype NC machine demonstrated (punched tape input)
1980-
CNC machines (computer used to link directly to controller)
1990-
DNC: external computer “drip feeds” control programmer to
machine tool controller
Numerical Control (NC) Defined
Programmable automation in which the mechanical
actions of a ‘machine tool’ are controlled by a program
containing coded alphanumeric data that represents
relative positions between a work head (e.g., cutting tool)
and a work part.
Basic Components of an NC System
The Basic Components of an NC System :
1. Program of instructions
2. Machine control unit
3. Processing equipment
Machine
Program
Control Unit
MCU
Computer Processing
Equipment
(cutting tool)
1. Part Program of Instructions
• It is the set of details step-by-step commands that
direct the actions of the processing equipment.
• “Part Programmer” is the name of the person who
prepares the program.
• The commands refer to positions of a cutting tool
relative to the work part.
• Other program instructions include spindle speed,
feed rate, etc. The program is coded electronically, or
using diskettes.
• Older technologies include magnetic tape and
punched tape.
2. Machine Control Unit (MCU)
•It is a microcomputer and control hardware. The hardware
includes interface components with the processing equipment
and feedback control elements.
•The MCU also includes reading devices to enter the program
into memory.
•MCU installed software include:
Control system software
Calculations algorithms
Translations software, to convert the NC part program
into a usable format for the MCU.
•NC includes hard-wired electronics and CNC.
•CNC: Computer Numerical Control.
2. Machine Control Unit (MCU)
3. Processing Equipment
•It performs the actual productive work (e.g; machining).
•Its operation is directed by program of instructions through
the MCU.
•In machining, the processing equipment consists of:
a worktable,
one or more spindles, motors and controls,
cutting tools,
work fixtures, and
other auxiliary equipment needed in the machining
operation.
NC Coordinate Systems
For flat and prismatic (block-
like) parts:
• Milling and drilling operations
• Conventional Cartesian
coordinate system
• Rotational axes about each
linear axis
For rotational parts:
• Turning operations
• Only x- and z-axes
Axis nomenclature
NC Machine Evolution
NC CNC DNC
Numerical
Control (NC)
Numerical Control (NC)
• NC machine can be programmed manually.
• Data is sent to the machine by means of tapes
punch or tapes reader. The reader at
the machine performs no calculations or
interpolations.
• Conventional machine also one of NC machine.
Numerical Control (NC) System
• Tape punch: convert written instructions into a
corresponding hole pattern. The hole pattern
is punched into tape which is passed through
the tape punch.
• Tape reader: read the hole pattern on the tape
and converts the pattern to a corresponding
electrical signal code.
• Controller: receives the electrical signal code
from the tape reader and subsequently cause
the NC machine to respond.
• NC machine: respond to programmed signals
from the controller.
NC and CNC Machine
Computer
Numerical Control
(CNC)
Computer Numerical Control (CNC)
Computer Numerical Control (CNC) is a numerical control
system that utilizes a dedicated stored programmed.
Computer is used to perform some or all basic function.
Numerical control is a programmable automation in which
process is controlled by Numbers, Letters, and symbols.
(Computer +NC= CNC)
Conventionally, an operator decides and adjusts various
machines parameters like feed , depth of cut, etc. depending
on type of job , and controls the slide movements by hand. In
a CNC Machine functions and slide movements are controlled
by motors using computer programs.
Difference of NC vs CNC
CNC Machine Features
• Storage of more than one part program
• Various forms of program input
• Program editing at the machine tool
• Fixed cycles and programming subroutines
• Interpolation
• Acceleration and deceleration computations
• Communications interface
• Diagnostics
Machine Control Unit of CNC
CNC Software
There are three types of software used in CNC systems:
1. Operating system
2. Machine interface
3. Application
CNC Software (CONT.)
1- Operating system:
It consists of:
1. An editor: which permits the operator to input and
edit NC part
programs.
2. A control program: decodes the part program
instructions performs
calculations.
3. An executive program: manage the execution of the
CNC software.
CNC Software (CONT.)
2- Machine Interface:
Used to operate the communication link between the
CPU and the machine tool
3- Application software:
Consists of the NC part programs that are written for
machining.
Some CNC auxiliary functions such as coolant control,
fixture clamping and counters are often implemented by
a PLC in the MCU.
CNC Input and Storage Media
Modern CNC input and storage methods
Types of CNC machines
1. Based on Motion Type:
Point-to-Point or Continuous path
2. Based on Control Loops:
Open loop or Closed loop
3. Based on Power Supply:
Electric or Hydraulic or Pneumatic
4. Based on Positioning System
Incremental or Absolute
NC vs CNC machines
COMPUTER NUMERICAL CONTROL (CNC)
No. NUMERICAL CONTROL (NC) MACHINE:
MACHINE:
Input method: programs are fed directly into the
Input method: Punched tape, punched card
1 computer by small key board similar to our
and other such media.
traditional key board.
Programs should be changed in punched
2 We can modify the program in computer.
card and then fed to machine.
Operation parameters could not be
3 Operation parameters can be changed.
changed.
We can store programs using the memory
4 It has no memory storage.
storage in computer.
Run off the “Tape” each time of machine It have the facility of running the program
5
cycle. without actually running it ON the machine tool.
6 NC machine cost is less. CNC machine cost is high.
7 Maintenance is less. Maintenance is high.
8 Accuracy is less. It has more accuracy.
9 High skill operator required. High skilled not required.
10 It is less flexible. It is highly flexible.
It required more time to perform a
11 It requires less time.
operation.
Direct &
Distributed
Numerical Control
(DNC)
Direct Numerical Control
• Direct numerical control (DNC) – control
of multiple machine tools by a single
(mainframe) computer through direct
connection and in real time
– 1960s technology
– Two way communication
Direct NC Layout
Distributed Numerical Control
• Distributed numerical control (DNC) –
network consisting of central computer
connected to machine tool MCUs, which are
CNC
– Present technology
– Two way communication
• Two types of DNC:
1. Switching network.
2. Local area network (LAN).
Distributed NC Configurations
Switching network
(Using RS-232-c connection)
Cons = limited number of
machines can be
connected.
Distributed NC Configurations
Local Area Network (LAN)
Hierarchy
Central (host) computer
NC, CNC and DNC
Applications of NC
• Machine tool applications:
• Milling, drilling, turning, boring, grinding
• Machining centers, turning centers, mill-turn centers
• Punch presses, thermal cutting machines, etc.
• Other NC applications:
• Component insertion machines in electronics
• Drafting machines (x-y plotters)
• Coordinate measuring machines
• Tape laying machines for polymer composites
• Filament winding machines for polymer composites
Common NC Machining Operations
Turning
Common NC Machining Operations
Drilling Milling
Example of
CNC Machines
Types of CNC Machine Tools
Mills and Machining centers
Lathes and turning centers
Drilling Machines
Boring Mills and Profilers
EDM Machines
Punch Presses and Shears
Flame/Plasma/Laser Cutting Machine
Routers
Water jet and Laser Profilers
Cylindrical Grinders
Welding Machines
Benders, Winding and Spinning machines, etc.
CNC Turning
CNC Milling
CNC Laser Cutting
CNC Plasma Cutting
CNC Press
CNC Rapid Prototyping
Industries Involved
• Aerospace
• Machinery
• Electrical
• Fabrication
• Automotive
• Instrumentation
• Mold & Die making
SAMPLE PRODUCTS
OF
CNC MANUFACTURING
Engine Block
Different Products
Aircraft Turbine Machined by
5-Axis CNC Milling Machine
CNC Mold Making
Rapid Prototyping Products
Objectives of Numerical Control
•To increase production
•To reduce labor costs.
•To make production more economical.
•To do jobs that would be impossible or impractical without
NC
•To increase the accuracy of duplicated parts.
NC Application Characteristics
(Machining)
Where NC is most appropriate:
1. Batch production
2. Repeat orders
3. Complex part geometries
4. Much metal needs to be removed from the starting
workpart
5. Many separate machining operations on the part
6. The part is expensive
Advantages of NC
• Nonproductive time is reduced
• Greater accuracy and repeatability
• Lower scrap rates
• Inspection requirements are reduced
• More complex part geometries are possible
• Engineering changes are easier to make
• Simpler fixtures
• Shorter lead times
• Reduce parts inventory and less floor space
• Operator skill-level requirements are reduced
Disadvantages of NC
• Higher investment cost
• CNC machines are more expensive
• Higher maintenance effort
• CNC machines are more technologically
sophisticated
• Part programming issues
• Need for skilled programmers
• Time investment for each new part
• Higher utilization is required
Assignment 1
• Choose 1 product (take the picture from the
internet), and discuss the NC/CNC machine
that has been used to produce the product
