Introduction to

Numerical Control
(NC) Machines

Dr.Deepesh patidar
Assistant Professor
Department of Mechanical Engineering
DIT University
Conventional Lathe
machine
Conventional Milling
machine
Numerical Control
machine
 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 cutting tool and
a work part.
Program Machine
Instructions Control Unit

Transformation
Process
P
o
w
e
Difference between
Conventional m/c & NC
m/c Convention NC
Item
al machine
machine

1. Movement Acme screw Ball screw

2. Feed manual motor

3.measureme manual Linear scale

nt
Control System
Open and Closed loop
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
DNC – contd.,
Central
Computer NC Prgrm

Computer Network

Machine Machine Machine

Control Unit Control Unit Control Unit
1 2 3

Transformation
Process
 Computer
Numerical Control
(CNC) Machines
Basic CNC Principle
Photography of CNC
turner
Photography of CNC
miller
Motion Control methods
Point-to-Point systems
 Also called position systems
 System moves to a location and
performs an operation at that location
(e.g., drilling)
 Also applicable in robotics

Continuous path systems

 Also called contouring systems in
machining
 System performs an operation during
movement (e.g., milling and turning)
 Interpolation methods
1. Linear interpolation
– Straight line between two
points in space
2. Circular interpolation
– Circular arc defined by starting
point, end point, center or
radius, and direction
3. Helical interpolation
– Circular plus linear motion
4. Parabolic and cubic interpolation
– Free form curves using higher
order equations
Absolute vs. Incremental
Positioning
 Absolute positioning
Move is: x = 40, y =
50

 Incremental
positioning
Move is: x = 20, y =
30
Coordinate Systems
For flat and prismatic (block-like) parts:
 Milling and drilling operations
 Conventional Cartesian coordinate
system
 Rotational axis about each linear axis

For rotational parts:

 Turning operations
 Only x- and z-axis
Axes on Lathe machine
tool
Contd.,
Axes on Milling machine
tool
Contd.,
Classifications
 Based on Machine centre:
Turn mill centre / Vertical mill
centre
 Based on Motion Type:
Point-to-Point / Continuous
path
 Based on Control
Loops: Open loop /
Closed loop
 Based on Input
power:
Electric / Hydraulic /
Constructional features of
CNC
 The tool / work part (table) moves
 Tools can operate in 1-5 axes
 Larger machines have a machine control unit
(MCU) which manages operations
 Movement is controlled by servo motors
(actuators)
 Feedback is provided by sensors (transducers)
 Tool magazines are used to change the
 tools automatically
Relative movementof tool with
the workpiece or respect to
vice versa can be guided
controlled by a Part and
program
Feed control system
Machine Control Unit
Components and its
Functions
 On board computer
 Feed drive
 Measuring system
 Work spindle / Work
table
 Cooling system
 Tool magazine (Turret)
On board computer
Feed drive
Tab
L e a d s c re le
E n c o dwe A / C M o to
r r ~

S e rv o C o n tro
lle r
C o u n te C o m p a ra
r to r

In p u t ( c o n v e r fro m a n a lo g to d ig ita l v a
te d lu e )
Recirculating ball
mechanism
Measuring System
 Direct Position
measuring
Contd.,
 Indirect Position
measuring

 Rotary encoder
Work Spindle
Work table
Cooling System
Tool Magazine

 Single Turret

 Chain Turret
CNC Part Programming
 Part program is a sequential
set of instructions
 Storage of more than one part
program
 Various forms of program
input
 Program editing at the machine
tool (on board computer )
 Fixed cycles and programming
subroutines
 Communications interface
Benefits of
CNC
 Cycle time reduction
 Nonproductive time
reduction
 Greater accuracy and
 repeatation
Reduced parts and
 Lower scrap
inventory rates
space floor
 Operator skill-level
reduced
Limitations of CNC
 High machine cost
 Complicated maintenance
 Skill & training are required
for programming and maintenance
 High tooling cost
 Temperature, humidity & dust
must be controlled
CNC Application
Characteristics
 Batch and High Volume
production
 Repeat and/or Repetitive orders
 Geometry and dimensional
accuracy
 Good surface finish
 Complex part geometries
 Many separate operations on one
part
Applications of CNC
 CNC PART
PROGRAMMING
Introduction
 Part Programme is a set of instructions
which instructs the machine tool about
the processing steps to be performed for
the manufacturing a component
 Part programme is an important part of
the CNC system
 The shape of manufactured
components will depends on how
correctly the programme has been
prepared
 The part programme is transferred to as
one of the input medium which
instruct the CNC machine
Types of programming
 NC coding
 Manual part
programming
 Automatic Part
Programming

 Languages:
– APT
– UNIAPT
– COMPACT II
– FORTRAN
Manual Part
Programming
 Binary code decimal system (BCDS)
 Bit - 0 or 1 => absence or presence of
hole in the tape which is in MCU
 Character - row of bits across the
tape (smallest unit / digit)
 Word - sequence of characters
(combination of alpha-numerical
characters)
 Block - collection of words to form one
complete instruction (logical order of
processing)
 Part program - sequence of
Block Format
 The organization of words within a block in
NC part program
 Word address format - used on all modern
CNC controllers
– Uses a letter prefix to identify each type of
word
– Spaces to separate words within the block
– Allows any order of words in a block
– Words
change fromcanthe be
previous
omitted if their values
do
blocknot between
– A new blocks can two
be inserted existing blocks
Example Format
Instruction
Codes
A part program consists the following words:
N, G, X, Y, Z, I, J, K, F, S, T, R, M
N - sequence number prefix (to identify the
block) G - preparatory functions (to prepare
the controller)
– Example: G00 - rapid transverse move
X, Y, Z - prefixes for x, y, and z-axes (position &
motion ) I, J, K – Interpolation parameters
F - feed rate (to specify the feed)
S - spindle speed (to specify the seed)
T - tool selection (for ATC only)
R – arc radius (to specify the tool radius in drill
cycles)
M - miscellaneous functions (to specify auxiliary
Elements of Part
program
 Preparatory functions: which unit, which
interpolator, absolute or incremental
programming, which circular interpolation
plane, cutter compensation, etc.,
 Coordinates: 3 translational and 3 rotational
axis
 Machining parameters: feed, and speed
 Tool control: next tool number, tool change
 Cycle functions: canned cycle, drill cycle,
ream cycle, bore cycle, mill cycle
 Miscellaneous functions: coolant on/off,
spindle on/off, programme rewind, spindle
rotation direction, etc.,
G-Codes
M-Codes
Machine and Tool offset
 Difficult to place a vise in the exact same
position on the machine each time
 The distance from home to the WCS is
usually not known until the vise is set and
aligned with the machine
 Different tools extend out from the machine
spindle with different lengths
 If the tool wears or breaks, tool must be
replaced, it is almost impossible to set it the
exact length out of the tool holder each time
 Therefore, there must be some way to relate the
(MCS) machine coordinate system to the WCS
and take into account varying tool lengths
 This is done using reference points
Reference Points
 Machine Origin
 The machine origin is a fixed point set
by the machine tool builder
 Usually it cannot be changed

 Any tool movement is measured from this

point
 The controller always remembers
tool distance from the machine origin
Contd.,
 Program Origin
 It is also called home position of the tool

 Program origin is point from where the tool

starts for its motion while executing a
program and returns back at the end of
the cycle
 This can be any point within the workspace
of the tool which is sufficiently away from
the part
Contd
., Part Origin
 The part origin can be set at any point
inside the machine’s electronic grid
system
 Establishing the part origin is also known
 as zero shift, work shift, floating zero or
Usually part origin needs to be defined eac
datum h
for new setup
 Zero shifting allows the relocation of
the part
 Sometimes the part accuracy is affectedby
the location of the part origin
Contd.,
Contd.,
Tool Pre-setter
Structure of program
Exercise: 1 (Drilling)
 Write a CNC part program to drill
two holes of diameter 10 mm in a
30 mm
5mm thick mild steel plate as
shown in fig.

30 mm
(Diagram not to scale)

90 mm
30 mm
30 mm

90 mm
Location of Reference
point
Process plan
Part Program
Block 1: O0001;
Block 2: N01 G17 G21 G80 G90 G94;
Block 3: N02 G00 X0, Y0, Z10;
Block 4: N03 X30, Y30;
Block 5: N04 G01 X70 Y30 S800 M03;
Block 6: N05 Z-7 F0.3 M08;
Block 7: N06 Z2;
Block 8: N07 G00 Y60;
Block 9: N08 G01 Z-7 F0.3;
Block 10: N09 Z2;
Block 11: N10 G00 X0 Y0 Z10 M05 M09;
Block 12: N10 M02;
Canned Cycle
Cutter Offset
 Cutter path must
be offset from
actual part outline
by a distance
equal to the
cutter radius
Write the part program for drilling holes in the mild steel plate of
thickness 20 mm as shown in figure 1 (diagram not to scale)
and assume the parameters such as speed, feed, depth of cut
etc.
Exercise 2

 Write an efficient CNC

part program to drill 35
holes of diameter of
0.5 inch each in a
machine component as
shown in the figure.
 The raw material to
be employed is mild
steel plate of 0.4 inch
thickness.
Part Program
Explanation
Block 1:
It indicates the start of the program.

Block 2:
It specifies the program number and ID. It is usually a alpha-
numerical code and always start with an alphabet ‘O’.

Block 3:
It sets the entry of dimensional units in Imperial format.

Block 4:
G17: It selects the plane of operation as X-Y plane
G40, G80, G49 are used to cancel all usual cycle that might
have left in on-mode during the execution of last CNC code.
G90 selects the method of specifying dimensions between
features as ‘absolute’.
Contd.,
Block 5:
 It sets the program zero on the work part.
 There are three major environments in programming that
require an established mathematical relationship.
Machine: machine tool and control
system Part: Workpiece + Drawing +
material Tool: Holder + Cutting tool

 The location coordinates of the program zero with respect to

the machine reference zero must be communicated with the
MCU so that the MCU will convert the part program in to
required signals to control the machine tool.
 This can be achieved by using a Preparatory code ‘G92’. The
syntax of G92 is as follows:

G92 X… Y… Z…
Contd.,
 Block 6:
Replace the existing cutting tool with tool number 1.

 Block 7:
Rapid travel of tool from home position to a reference
position: hole with coordinates X1.7 Y2.4.
Switch on the spindle rotation with speed of about 900
rpm.

 Block 8:
Approach to a safe position at Z = 1.0 rapidly.
Meanwhile the tool length compensation is activated by
using G43. It is used to communicate the length of tool
registered in register number H01 to the MCU. Switch
on the coolant flow.
Contd.,
Block 9:
 In the given task, number of holes is to be drilled.
 For this purpose a special function or cycle is used. It
is called as drilling canned cycle.
 Its syntax and meaning are shown below.
 The number of motions/action elements of drilling
operations is specified only at once.
 Later only the locations of holes to be drilled are
given to the MCU.
Contd.,
 Block 10:
It suggests the distance of next location of the
hole. It is also suggested to carry out the same
drilling operation 6 times along the Y-axis with an
increment of 2.1.

 Block 11:
Drill the hole at increment of 1.8 along X-
direction.

 Block 12:
Carry out the drilling operation 6 times along
the Y-axis with decrement of 2.1.

 Block 13:
Drill the hole at increment of 1.8 along X-
Contd.,
Block 14:
Carry out the drilling operation 6 times along the Y-axis with
increment of 2.1.

Block 15:
Drill the hole at increment of 1.8 along X-direction.
Block 16:
Carry out the drilling operation 6 times along the Y-axis with
decrement of 2.1.
Block 17:
Drill the hole at increment of 1.8 along X-direction.
Block 18:
Carry out the drilling operation 6 times along the Y-axis with
increment of 2.1.
Block 19:
Cancel the canned cycle and switch off the coolant flow.
Contd.,
Block 20:
Stop the spindle and go to safe position along
Z direction at 0.0.
Block 21:
Go to home position via X= 0 and Y=0.
Block 22:
Stop the program from execution.
Block 23:
End the program.
Exercise 3 (Turning)
Part program
Automatic part
programming
Define
Tool

CNC
data

Make 3D model

Simulate
cutting
*** All the best
***