NUMERICAL CONTROL

CHAPTER 1

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What Is Numerical Control?

An automated manufacturing process in which a machine tool is controlled; In an ordered sequence Along a predetermined path To require dimensions At a specific feed and speed rate Done through a group of alphanumeric instructions
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A Definition:
Numerical Control is a system in which actions are controlled by the direct insertion of numerical data at some point. The system must automatically interpret at least some portion of the data

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Numerically Controlled Machine Tools

Functionally the same as a conventional machine tool. The difference is in the way in which the various machine functions and slide movements are controlled.

The functions and motions such as;

turning setting setting

the spindle on and off

cutting speeds feed rate coolant on and off tool with respect to work part

turning moving

are performed by Machine Control Unit (MCU) in NC machine tools.

NUMERICAL DATA (NC CODE)

MANUFACTURING OPERATOR

NUMERICAL CONTROLLER
Drive Control

PROCESSED PART MACHINE UNIT

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Objectives
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2.
3. 4. 5.

6.
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Increased production Reduced labor costs Make production more economical Make production jobs easier Do production jobs that are impossible without numeric control Increased accuracy on duplicate parts
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Brief History of Machine Tool

Basic machining, as early as 700 B.C. 15th century - Metal machining, 18th century - industrialization, production-type machine tools. early 20th century - Invention of high speed steel, First two decades of 20th century - Automated machine controlled by mechanical devices, Screw machines Transfer lines Assembly lines using cams and preset stops 1955 - John Parsons and US Air Force define a need to develop a machine tool capable of machining complex and close tolerance aircraft parts with the same quality time after time (repeatability). MIT is the subcontractor and builds the machine for the project.
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Brief History of Machine Tool

1959 - MIT announces Automatic Programmed Tools (APT) programming language 1960 - Direct Numerical Control (DNC). This eliminates paper tape punch programs and allows programmers to send files directly to machine tools 1968 - Kearney & Trecker machine tool builders market first machining center 1970s - CNC machine tools & Distributed Numerical Control 1980s - Graphics based CAM systems introduced. Unix and PC based systems available 1990s - Price drop in CNC technology 1997 - PC- Windows/NT based Open Modular Architecture Control (OMAC) systems introduced to replace firmware controllers.

Types of Numerical Control

Conventional Numerical Control (NC) Direct Numerical Control (DNC) Computer Numerical Control (CNC)

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Conventional Numerical Control (NC)

Data is sent to the machine tool by means of punch cards or tapes. The reader at the machine performs no calculations or interpolations.

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Features of NC system

The part cannot produce without a tape being run through the m/c
The tape has to be run repeatedly depending on the number of components to be produced. The modification in the design of components is not possible, the tape is discarded and new tape with changed program has to be produced.

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Features of NC system
The control system does not provide the opportunity to make the changes in speeds and feeds. There are always chances of part programming mistakes on the running tape. The storage of these input media is also one problem.

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Computer Numerical Control (CNC)

The idea of computer numerical control is to position a computer right at the machine tool. Most, if not all machine tools that are numericaly controlled are CNC machine tools.

Basic Elements of a CNC System

DEFINE GEOMETRY

COMPUTER
CREATE TOOL PATH POST PROCESS TO CREATE CODE READ CODE TO CONTROLLER INTERPOLATE CODE INTO DRIVE FINISHED PART

MACHINE CONTROL UNIT

MACHINE TOOL

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Additional features available in CNC machine

Some of additional features available in CNC machine tools are given below: 1.The part program can be input to controller unit through keyboard or the tape reader in the control unit can read the paper tape. 2.The part program once entered into the computer memory can be used again and again. 3.The part program can be edited and optimized at the machine tool itself. 4.The part program can be changed according to the design requirements of the component produced on the machine tool.
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Additional features available in CNC machine

5. The input information can be reduced to a great extent with the use of special sub-programs developed for repetitive machining operations. 6. The CNC systems have facility for providing the part program without actually running it on the machine tool.

7. The CNC control unit allows compensation fro any changes in the dimensions of the cutting tool.
8. The CNC system also provides the facility to obtain information on machine utilisation, which is useful to the management.

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Computer Numerical Control (CNC)

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Direct Numeric Control

Is a method where a single computer controls many numerical control machine tools. These machine tools may or may not be of a similar nature

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Distributed Numerical Control (DNC)

The central computer downloads complete programs to the CNC machines, which can be workstations or PCs, and can get the information for the machine operations.

The speed of the system is increased, large files can be handled and the number of machine tools used is expanded.

Distributive Numerical Control

Because CNC machine tools have the ability to run multiple programs without being attached to a centralized computer this enables a centralized computer to perform many different tasks. Line balancing Scheduling Monitoring Quality

Role of the Operator

Execute Machine Control Unit (MCU) or Console Setups Start and Stop Machines Load and Unload Workpieces

Maintain High- Level Machine Tool Performance Standards

Change NC Inputs as Necessary (As Per Engineering)

Feedback Information to Programmer/Engineer

Advantages

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The various Advantages of CNC system are:

Reduces time for delivery of part Reduces scrap rate of material Reduces tooling costs Reduces layout time Increases machine and tool life Reduces storage problems Less setup time Reduces actual machining time Allows rapid design changes in part Less jigs and fixtures are needed
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Advantages of Numerical Control

Greater operator safety Reduced lead time for production Fewer chances for human error Maximal accuracy and interchangeability of parts Increased productivity Minimal spare parts inventory Greater machine tool safety Fewer man hours for inspection Greater machine utilization

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Limitations
o High initial investment Machine tools cost $30,000 - $1,500,000 o High maintenance requirements Maintenance personnel must have both mechanical and electronics expertise o Not cost-effective for low-level production on simple parts As geometric complexity or volume increases CNC becomes more economical o Retraining and recruitment of staff o New support facilities
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Industries Most Affected by Numerical Control

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Aerospace Machinery Electrical Fabrication Automotive Instrumentation Mold making

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APPLICATIONS OF NC MACHINES
Chip producing machines:

Drills, Mills, Lathes, Bores, Saws, Etc.

Chipless machining:

Flame Cutting, Punches, Wire EDM, Welding,

Non machining: Paint Spraying, Tube Bending, Assembly, Etc.

CNC TURNING

CNC MILLING

CNC LASER CUTTING

CNC PLASMA CUTTING

CNC PRESS

CNC RAPID PROTOTYPING

Circumstances best suited to NC

Mass production quantities Complex geometries Tight tolerances

Replacement parts
Parts subject to modification

SAMPLE PRODUCTS OF CNC MANUFACTURING

AUTOMOTIVE INDUSTRY Engine Block

AUTOMOTIVE INDUSTRY(Contd) Different Products

AEROSPACE INDUSTRY Aircraft Turbine Machined by 5-Axis CNC Milling Machine

CNC MOLD MAKING

ELECTRONIC INDUSTRY

RAPID PROTOTYPING PRODUCTS