NC, CNC, DNC and Programming

NC ,CNC
CNC and DNC

Programming
Rajeev Agrawal
Senior Lecturer,
rajeevagrawal@bitmesra.ac.in
Conventional Machining
25 FACE-
A
25
50
FACE-B
50
Ф 15
10
Example
Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3
Activities of Operator in Machining the
Components
1. Select a suitable cutting tool
2. Locate the cutting tool in the machine spindle
3 Sec
3. Secure
re the ccutting
tting tool
4. Locate the component in the work holding device
p the component
5. Clamp p
6. Establish a datum in relation to Face-A
7. Determine the amount of slide movement required
8. Determine the direction of slide movement required
9. Move the slide,monitoring the movement on the
graduated slide allowing for lead screw backlash etc
etc.
10. Lock the slide in position

11. Establish a second datum plane in relation to face B
12 Determine
12. D t i ththe amountt off slide
lid movementt required
i d
13. Determine the direction of slide movement required
14. Move
o e the
e sslide,monitoring
de, o o g the e movement
o e e o on the
e
graduated slide allowing for lead screw backlash etc.
15. Lock the slide in position
16. Select a suitable spindle speed
17. Determine the direction of spindle rotation
18 Select a suitable feed rate
18.
19. Switch on the spindle motor
20. Switch on coolant motor

21 E
21. Engage th
the ffeed
d and
d machine
hi ththe h
hole
l
22. Disengage feed and withdraw tool
23. Switch of the coolant
24. Switch off spindle motor
25. Remove the component
26. Verify the accuracy of machine movements by
measuring the component

AUTOMATION IN MANUFACTURING
SYSTEMS
TRENDS IN INDUSTRY
THE OBJECTIVE:
O C
TO BE COMPETITIV THROUGH
INCREASING PRODUCTIVITY AND TOTAL
QUALITY ASSURANCE
2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev 6
COST = COST OF
MANUFACTURING AND
COST OF MATERIAL
HANDLING
EFFICIENCY OF
MANUFACTURIN PRODUCTIVITY =
AVERAGE OUTPUT PER
G MAN-HOUR
PROFIT = INCOME - COST

Rajeev 7
PROFIT increases as COST decreases
and as PRODUCTIVITY increases.
increases
PRODUCTIVITY through AUTOMATION
Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 8

any means of helping
th workers
the k tto perform
f
their tasks more
efficiently
ffi i tl
AUTOMATION
transfer of the skill of

the operator to the
machine

Transferred Results
skill
muscle ppower engine
g driven First industrial
machine tools revolution
manipulating
p g mechanization hard automation
skill
vision skill use of position increase of
transducers, accuracy, part
cameras recognition
brain power cnc machines, industrial second industrial
robots, soft
automation, revolution
computer
t control
t l off
manufacturing
2004Agrawal, Notes on Automation insystems
Rajeev Manufacturing ,Module 2 and 3 10
Utilization of computers in
manufacturing applications has
proved to be one of the most
significant
i ifi t developments
d l t over the
th
last couple
p of decades in helping
p g
to improve the productivity and
efficiency of manufacturing
systems.
Rajeev 11
Th metal
The t l cutting
tti operations
ti ( l
(also
called machining)
g) is one of the
most important manufacturing
processes in industry today (as it
was yesterday).

Rajeev 12
MACHINING IS THE REMOVAL
OF MATERIALS IN FORMS OF
CHIPS FROM THE
WORKPIECE BY SHEARING
WITH A SHARP TOOL.

Rajeev 13
The main function of a machine
tool is to control the workpiece-
cutting tool positional relationship
in such a way as to achieve a
d i d geometric
desired i shape
h off the
h
workpiece
p with sufficient
dimensional accuracy.

Rajeev 14
Machine tool provides:
work holding
tool holding
relative motion between tool
and workpiece
primary motion
secondary motion

Rajeev 15
Pi
Primary motion
ti
Relative motion
between tool and Secondary motion
workpiece
Cutting motion Feed motion
Cutting
g speed
p Feed rate

Rajeev 16
machine control unit
position transducers
work holding device
tool holding device

Rajeev 17
CLASSIFICATION OF THE CHIP REMOVING METHODS
ACCORDING TO THE RELATIVE MOTION

Rajeev 18
CLASSIFICATION OF MACHINE TOOLS
THOSE USING THOSE USING THOSE USING

SINGLE POINT MULTIPOINT ABRASIVE
TOOLS TOOLS TOOLS
lathes drilling m/c’s grinding m/c’s
shapers milling m/c
m/c’ss honing m/c
m/c’ss
planers broaching m/c’s etc.
boring m/c’s hobbing m/c’s
etc.
t etc.
t

Rajeev 19
ISO MACHINE TOOL AXIS DEFINITION

Rajeev 20
ISO MACHINE TOOL AXES DEFINITIONS
AXIS MACHINE TOOL WITH SPINDLE MACHINE TOOL WITH
NO SPINDLE
Z axis of spindle, perpendicular to work

(+Z) as tool goes away from the work piece holding surface, (+Z) as
tool goes away from the
workpiece
p
MACHINE MACHINE TOOL WITH

TOOL WITH ROTATING TOOL
ROTATING
WORKPIECE
HORIZONT VERTICAL
AL AXIS AXIS
X radial and horizontal horizontal parallel to and positive in

parallel to and parallel and parallel the principal direction of
cross slide, to work to the work cutting (primary motion)
(+X) when holding holding
tool goes away surface, surface,
from the axis (+X) to the (+X) to the
of spindle
p right
g when right
g when
viewed viewed
from from
spindle spindle
towards towards
work piece column
Y apply right hand rules

Rajeev 21
RIGHT HAND RULE
Vertical Machine Horizontal Machine
Rajeev Agrawal, Notes on Automation 2004

in Manufacturing ,Module 2 and 3 22
STANDARD LATHE COORDINATE
SYSTEM

STANDARD MILLING MACHINE
COORDINATE SYSTEM

Rajeev 24
41/2 & 5 axes movements
5 Axes
A movement
All the 5 axes viz, X,Y,Z,A & B to move
simultaneously.
41/2 Axes movement
Only 4 out of 5 Axes to move
simultaneouslyy and the 5th axis is for
positioning.

History of numerical Control
The initial development work on
numerical control is credited to John
Parsons and Frank Stulen at the Parsons
Corporate in Michigan in the late 1940s.
Parsons was a machining contractor for
the U.S. Air Force and had devised a
means of using numerical coordinate
data to move the worktable of a milling g
machine for producing complex part for
aircraft.

History of numerical Control
On the basis of Parson’s work, the U.S.
Air Force awarded a contract to the
company in 1949 to study the feasibility
of the new control concept for machine
tools.
The M.I.T lab confirmed that the concept
p
was feasible and proceeded to adapt a
g machine using
three-axis vertical milling g
combined along-digital controls.

Historyy of numerical Control
The name numerical control (NC) was
given to the system
g y byy which the machine
was demonstrated in 1952.
The project was subcontracted to the
Servomechanism Laboratory at the
Massachusetts Institute of Technology to
develop a prototype machine tool that
utilized the new numerical data principle.
principle

THE OBJECTIVES OF NUMERICAL
CONTROL
To increase production
To reduce labour cost
To make production more economical
To do jobs that would be impossible or
impractical without NC
T iincrease the
To h accuracy off duplicate
d li
parts

NUMERICALLY CONTROLLED MACHINE
TOOLS:
A NC machine
An hi tool
t l is
i functionally
f ti ll the
th
same as a conventional machine tool. The
t h l i l capabilities
technological biliti NC machine hi tools
t l
in terms of machining are no different
f
from th
those off conventional
ti l ones. Th
The
difference is in the way in which the
various
i machine
hi functions
f ti andd slide
lid
movements are controlled.

Rajeev 31
Numerical Control
Numerical control is a form of programmable
automation in which a machine is controlled
by numbers (and other symbols) that have
been coded on p punched ppaper
p tape p or an
alternative storage medium.
The initial application of numerical control
was in the machine tool industry, to control
the position of a cutting tool relative to the
work part being machined.
Rajeev Agrawal, Notes on Automation in32

Manufacturing ,Module 2 and 3
Numerical control (NC)
The work-head is a tool or other processing
element,, and the work-part p is the object
j
being processed.
The NC part program represents the set of
machining instructions for the particular
part The coded number in the program
part.
specify x-y-z coordinates in a Cartesian axis
system defining the various positions of the
system,
cutting tool in relation to the work part.

Numerical Control
By sequencing these positions in the

program, the
th machine
hi t l is
tool i directed
di t d tot
accomplish the machining of the part.
A position feedback control system is used in
most NC machines to verify that the coded
instructions have been correctly performed.

Numerical control (NC)
Numerical control
(NC) is a form of
programming automation in which the mechanical
actions of a piece of equipment are controlled by a
program containing coded alphanumeric data.
It representst relative
l ti positions
iti b t
between a work-k
head and a work-part.
Th work-head
The k h d is i a tool
t l or other
th processing
i
element, and the work-part is the object being
processed.
processed

Numerical control (NC) contd..
The operating principle of NC is to control
th motion
the ti off the
th work-head
k h d relative
l ti t
to
the work-part and to control the
sequence ini which
hi h the
th motions
ti are carried
i d
out.
The first application of numerical control
was in machining and this is still an
important application area.

BASIC COMPONENTS OF NC
SYSTEM
The main components of NC machine tool

are:
Program of instructions
Machine control unit
Machine tool or Processing equipment

THE NC MACHINES PROVIDES THE
FOLLOWING ADVANTAGES
Increased productivity
p y
Reduced tool/fixture storage cost
Faster set-up time
Reduced parts inventory
Flexibility that speeds changes in design
Better accuracy off parts
Reduction in parts handling
Better uniformity of parts
Better Quality Control
Improvement in manufacturing control

THE DISADVANTAGES OF
MACHINE TOOLS ARE
Increase in electrical maintenance.
High initial investment
Higher per –hour operating cost than traditional
machine
hi tools
t l
Retraining of existing personnel
A repetition of close tolerances/accuracy (i
(i.e.
e
precision) is desired
The inspection cost is a significant portion of the total
cost.

Types of NC Machines
Point-To-Point: Desired positions of

the tool are programmed, but the tool
path
th iis determined
d t i d by
b the
th controller
t ll
(e.g., spot welding and drilling)
St i ht C t Tool
Straight-Cut: T l movementt iis
constrained to the axis of machine
C t
Contouring:i All
Allows point-to-point
i tt i t
positioning, straight, and oblique cut

The functions and motions such as;
turning the spindle on and off

setting cutting speeds
setting feed rate
turning coolant on and off
moving tool with respect to workpiece
are performed by Machine Control Unit

(MCU) in NC machine tools.

Rajeev 42
Applications
pp of Numerical Control
Many applications of numerical control have
been developed since its initial use to
control machine tools.
Other machine using numerical control
include component-insertion machines used
y drafting
in electronics assembly, g machines
that prepare engineering drawings,
coordinates measuring machines that
accurate
t inspections
i ti off parts,
t and d flame
fl
cutting machines and similar devices.

Applications
pp of Numerical Control contd..
In these applications, the term numerical
control is not always used explicitly but the
operating principle is the same: coded
numerical data are employed to control the
position of a tool or work-head relative to
some object.
object

Alternative applications of Numerical
Control
Co t o
A typical printed circuit board has dozen of
individual components that must be placed on its
surface; in many cases, the lead wires of the
components must be inserted into small holes in
the board,
board requiring great precision by the
insertion machine.
The pprogram
g that controls the machine indicates
which components are to be placed on the board
and their locations.
Thi information
This i f ti isi contained
t i d in
i the
th product-design
d td i
database is typically communicated database
directly from the computer to the insertion
machine.
INTRODUCTION TO CNC

Rajeev 46
Computer based Numerical Control
Today a small computer is used as the
controller in an NC tool, and the program is
actuated from computer memory rather than
punched p
p paper
p tape.
p
However, initial entry of the program into
p
computer memoryy is often still accomplished
p
using punched tape.
Since this form of numerical control is
implemented by computer, it is called
computer numerical control, or CNC.

HISTORY
US Air Force commissioned MIT to develop

the first "numerically controlled" machine in
1949 It was d
1949. demonstrated
t t d iin 1952
1952.
At 1970-1972 first Computer Numeric
Control machines were developed
developed.
Today, computer numerical control (CNC)
machines are found almost everywhere
everywhere, from
small job shops in rural communities to
companies in large urban areas.

DEFINITION
In CNC (Computer Numerical Control),

the instructions are stored as a program
in a micro-computer attached to the
machine. The computer will also handle
much of the control logic of the
machine, making it more adaptable than
earlier hard-wired controllers.

CNC APPLICATIONS
Machining
2.5D / 3D
Turningg ~ Lathes,, Turning
g Centre
Milling ~ Machining Centres
Forming g
2D
Plasma and Laser Cutting
Blanking, nibbling and punching
3D
Rapid Prototyping
SAMPLE
CNC MACHINES

Rajeev 51
CNC TURNING
52
CNC MILLING
53
CNC LASER CUTTING

Rajeev 54
CNC PLASMA CUTTING

CNC PRESS

Rajeev 56
CNC RAPID PROTOTYPING

Rajeev 57
INDUSTRIES MOST AFFECTED
by CNC
Aerospace
Machinery
Electrical
Fabrication
Automotive
Instrumentation
Mold making g

SAMPLE PRODUCTS
OF
CNC MANUFACTURING

Rajeev 59
AUTOMOTIVE INDUSTRY
Engine Block

AUTOMOTIVE INDUSTRY(Cont’d)
Different Products

AEROSPACE INDUSTRY
Ai
Aircraft
ft Turbine
T bi Machined
M hi d byb
5-Axis CNC Milling
g Machine

CNC MOLD MAKING

ELECTRONIC INDUSTRY

Rajeev 64
RAPID PROTOTYPING
PRODUCTS

Rajeev 65
ADVANTAGES of CNC
Productivity
Machine utilisation is increased because
more time is spent cutting and less time
iss ta
taken
e by pos
positioning.
to g
Reduced setup time increases utilisation
too.
too

ADVANTAGES of CNC
Quality
Parts are more accurate.
Parts are more repeatable.
Less waste due to scrap
scrap.

ADVANTAGES of CNC
Reduced inventory
Reduced setup time permits smaller
economic batch quantities. quantities
Lower lead time allows lower stock
levels.
levels
Lower stock levels reduce interest
charges
h and d workingki capital it l
requirements.
ADVANTAGES of CNC
Machining Complex shapes

Slide movements under computer
control.
Computer controller can calculate steps
steps.
First NC machine built 1951 at MIT for
aircraft skin milling.
milling

ADVANTAGES of CNC
Management Control
CNC leads to CAD
Process planning
Production planning

DRAWBACKS of CNC
High capital cost
Machine tools cost $30,000 - $1,500,000
Retraining andd recruitment off staff
ff
New support facilities
High maintenance requirements
Not cost-effective for low-level production on
simple parts
As geometric complexity or volume increases
CNC becomes more economical
Maintenance personnel must have both
mechanical and electronics expertise

CNC SYSTEM ELEMENTS

Rajeev 72
CNC SYSTEM ELEMENTS
A typical CNC system consists of the
following six elements
Part
atp program
og a
Program input device
Machine control unit
Drive system
Machine tool
Feedback system

NC SYSTEM ELEMENTS

OPERATIONAL FEATURES of CNC
MACHINES

PART PROGRAM
A part program is a series of coded instructions required
to produce a part. It controls the movement of the
machine
hi tool
t l andd the
th on/off
/ ff control
t l off auxiliary
ili functions
f ti
such as spindle rotation and coolant. The coded
instructions are composed of letters, numbers and
symbols
b l and d are arranged d in
i a format
f off functional
f i l
blocks as in the following example
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y coordinate (2.5")
Y-coordinate (2.5 )
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number

PROGRAM INPUT DEVICE
The program input device is the

mechanism for part programs to be
entered into the CNC control. The most
commonly used program input devices
are keyboards, punched tape reader,
diskette drivers, throgh RS 232 serial
ports and networks.

MACHINE CONTROL UNIT
The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:
Read coded instructions

Decode coded instructions
Implement interpolations (linear, circular, and helical) to
generate axis motion commands
Feed axis motion commands to the amplifier circuits for
driving the axis mechanisms
Receive the feedback signals of position and speed for
each drive axis
Implement auxiliary control functions such as coolant or
on/off and tool change
spindle on/off,

TYPES of CNC CONTROL
SYSTEMS
Open-loop control
Closed loop control
Closed-loop

OPEN-LOOP CONTROL
SYSTEM
In open-loop control system step motors are
used
Step motors are driven by electric pulses
Every pulse rotates the motor spindle through
a certain amount
By counting the pulses, the amount of motion
can be controlled
No feedback signal for error correction
Lower positioning accuracy

CLOSED-LOOP CONTROL
SYSTEMS
In closed-loop control systems DC or AC
motors are used
Position transducers are used to
generate position feedback signals for
error correction
ti
Better accuracy can be achieved
More expensive
Suitable for large size machine tools

DRIVE SYSTEM
A drive system consists of amplifier

circuits, stepping motors or servomotors
andd ball
b ll lead-screws.
l d Th MCU feeds
The f d
control signals (position and speed) of
each axis to the amplifier circuits
circuits. The
control signals are augmented to
actuate stepping motors which in turn
rotate the ball lead-screws to position
the machine table.

STEPPING MOTORS
A stepping motor provides open-loop, digital
control
t l off th
the position
iti off a workpiece
k i in
i a
numerical control machine. The drive unit
receives a direction input (cw or ccw) and pulse
inputs. For each pulse it receives, the drive unit
manipulates
p the motor voltage
g and current,,
causing the motor shaft to rotate bya fixed angle
(one step). The lead screw converts the rotary
motion
i off theh motor shaft
h f into
i linear
li motion
i off
the workpiece .

STEPPING MOTORS

RECIRCULATING BALL SCREWS
Transform rotational motion of the motor
into translational motion of the nut attached to
the machine table.

RECIRCULATING BALL
SCREWS
Accuracy of CNC
machines depends on
their rigid
construction, care in
manufacturing,g, and
the use of ball screws
to almost eliminate
slop in the screws
used to move portions
of the machine.

Rajeev 86
Rajeev 87
POSITIONING
The positioning resolution of a ball screw

drive mechanism is directly proportional to
the smallest angle that the motor can turn
turn.
The smallest angle is controlled by the motor
step
p size.
Microsteps can be used to decrease the
motor step size.
CNC machines typically have resolutions of
0.0025 mm or better.

MACHINE TOOL
CNC controls are used to control various

types of machine tools. Regardless of
which type of machine tool is
controlled, it always has a slide table
and a spindle to control of position and
speed. The machine table is controlled
in the X and Y axes, while the spindle
runs along the Z axis.

FEEDBACK SYSTEM
The feedback system is also referred to

as the measuring system. It uses
position
iti and d speedd transducers
t d to
t
continuously monitor the position at
which the cutting tool is located at any
particular time. The MCU uses the
difference between reference signals
and feedback signals to generate the
g
control signals for correcting
g position
p
and speed errors.
CNC MACHINES FEEDBACK
DEVICES

Rajeev 91
POTENTIOMETERS

POTENTIOMETERS

ENCODERS
A device used to convert linear or

rotational
t ti l position
iti information
i f ti into
i t an
electrical output signal.

ENCODERS

INDUSTRIAL APPLICATIONS of
ENCODERS

RESOLVERS
A resolver is a rotary
transformer that
produces an output signal
that is a function of the
rotor
t position.
iti

Rajeev 97
SERVOMOTOR with RESOLVER

VELOCITY FEEDBACK
Tachometers:
Electrical output is proportional to rate of
g
angular rotation.
Encoders, Resolvers, Potentiometers:
Number of pulses per time is proportional
to rate change of position.

CNC CUTTERS
Turning
T i center cutters
Machining center cutters

TURNING CENTER CUTTERS
Types of cutters used on CNC turning

centers
Carbides (and other hard materials)
se t tu
insert turning
gaand
d boring
bo g tools
too s
Ceramics
High Speed Steel (HSS) drills and taps

STANDART INSERT SHAPES
V – used for profiling, weakest
insert, 2 edges per side.
D – somewhat stronger, used for
profiling when the angle allows it,
2 edges per side.
T – commonly used for turning
because it has 3 edges per side.
C – popular insert because the
same holder can be used for
turning g and facing.
g 2 edges g p per
side.
W – newest shape. Can turn and
face like the C, but 3 edges per
side.
S – Very strong, but mostly used
for chamfering because it won’t
cut a square shoulder. 4 edges
per side.
R – strongest
t t iinsertt b
butt lleastt
commonly used.
Rajeev 102
TYPICAL TURNING,
THREADING and PARTING TOOLS

MACHINING CENTER CUTTING
TOOLS
Most machining centers
use some form of HSS
or carbide insert endmill
as the basic cutting
tool.
Insert endmills cut
many times faster than
HSS,, but the
HSS endmills leave a
better finish when side
cutting.
tti
Rajeev 104
TOOLS (cont’d)
( t’d)
Facemills flatten
large surfaces
quickly
i kl andd with
ith an
excellent finish.
Notice the engine
block being finished
in one ppass with a
large cutter.

Rajeev 105
TOOLS (cont’d)
( t’d)
Ball endmills (both
HSS and insert) are
used for a variety of
profiling operations
such as the mold
shown
h in the
h
picture.
Slitting and side
cutters are used
when deep, p narrow
slots must be cut.
Rajeev 106
TOOLS (cont’d)
( t’d)
Drills, Taps, and Reamers
Common HSS tools such as
drills, taps, and reamers are
commonly used on CNC
machining centers. Note that
a spot drill is used instead of
a centerdrill. Also,, spiral
p
point or gun taps are used
for through holes and spiral
flute for blind holes. Rarely
are hand taps used on a
machining center.

Rajeev 107
TOOL HOLDERS
All cutting tools must be held in a holder
that
th t fits
fit iin the
th spindle.
i dl These
Th include
i l d end d
mill holders (shown), collet holders, face
mill adapters, etc. Most machines in the
USA use a CAT taper p which is a modified
NST 30, 40, or 50 taper that uses a pull
stud and a groove in the flange. The
machine pulls on the pull stud to hold the
holder in the spindle,
spindle and the groove in
the flange gives the automatic tool
changer something to hold onto. HSK tool
holders were designed a number of years
ago as an improvement to CAT tapers,
but they are gaining acceptance slowly.

Rajeev 108
CNC PROGRAMMING

Rajeev 109
CNC PROGRAMMING
Offline programming linked to CAD

programs.
Conversational programming by the
operator.
MDI ~ Manuall Data Input.
Manual Control using jog buttons or
`electronic
l t i handwheel'.
h d h l'
Word-Address Coding using standard G-
codes and M M-codes.
codes
Basics of NC Part Programming:
During secondary motion, either the tool

moves relative to the workpiece or the
workpiece moves relative to the tool. In
NC programming
programming, it is always assumed
that the tool moves relative to the
workpiece no matter what the real
situation is.

Rajeev 111
The position of the tool is described
by using a Cartesian coordinate
system If (0
system. (0,0,0)
0 0) position can be
described by the operator, then it
is called floating zero.

Rajeev 112
In defining
g the motion of the tool
from one point to another,
either
absolute positioning mode or
incremental positioning mode
can be used.

Rajeev 113
1. Absolute
bso ute pos
positioning
t o g. In tthiss mode,
ode, tthe
e
desired target position of the tool for a
particular move is given
p g relative to the
origin point of the program.
2. Incremental positioning. In this mode,

g position
the next target p for the tool is
given relative to the current tool position.

Rajeev 114
Distinction
Absolute/Incremental
Absolute measuring Incremental
one absolute coordinate measuring
system using (XYZ) from point to point
location
P
–3 left and 2 up
p
P (-1/1); Q (2/-1)
Winter term
x= -3 / y= 2
00/01Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3
Rajeev
St t
Structure off an NC P
Partt P
Program:
Commands
C d are iinputt iinto
t th
the controller
t ll iin
units called blocks or statements.
Block Format:
1. Fixed sequential format
2. Tab sequential format
3. Word address format

Rajeev 116
EXAMPLE:
Assume that a drilling operation is to be
programmed as:
1. The tool is positioned at (25.4,12.5,0) by a

rapid movement.
2. The tool is then advanced -10 mm in the z
direction at a feed rate of 500 mm/min., with the
flood coolant on.
3 Th is
3.The i th
then retracted
t t db backk 10 mm att th
the rapid
id
feed rate, and the coolant is turned off.

Rajeev 117
1 Fixed sequential format
1.
0050 00 +0025400 +0012500 +0000000 0000 00
0060 01 +0025400 +0012500 -0010000 0500 08
0070 00 +0025400 +0012500 +0000000 0000 09
2. Tab sequential format

2
0050 TAB 00 TAB +0025400 TAB +0012500 TAB +0000000 TAB TAB
0060 TAB 01 TAB TAB TAB -0010000 TAB 0500 TAB 08
0070
00 0 TAB 00 TAB TAB TAB -0000000
0000000 TAB 0000 TAB 09
3. Word address format

N50 G00 X25400 Y125 Z0 F0
N60 G01 Z-10000 F500 M08
N70 G00 Z0 M09

Rajeev 118
Modal commands: Commands issued in the
NC program that will stay in effect until it
g byy some other command,, like,,
is changed
feed rate selection, coolant selection, etc.
Nonmodal commands: Commands that are

effective onlyy when issued and whose
effects are lost for subsequent commands,
like,, a dwell command which instructs the
tool to remain in a given configuration for
ag given amount of time.
Rajeev 119
CNC PROGRAMMING

Rajeev 120
Variables in Machining Process
Cutting tools: type, size, and tool material

lead to different feed rates and spindle
speeds
d
Materials: lead to different feed rates and
spindle speeds
Winter in
Rajeev Agrawal, Notes on Automation term 00/01
Manufacturing ,Module 2 and 3
Va iables in Machining Process
Variables P ocess
Work Cutting Speeds in SFPM
Material
End Mills Fly cutters Drills Reamers
HSS Carbide HSS Carbide HSS Carbide HSS Carbide
Aluminum 150 300 600 1200 125 250 60 120
Cast iron
Soft 90 180 450 900 90 180 40 80
Hard 50 100 400 800 70 140 35 70
Stainless
St i l 60 120 400 800 70 140 35 70
Steel
Winter term
00/01Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3
Rajeev
INFORMATION NEEDED by a
CNC
1. Preparatory Information:
f i units,
i incremental
i l or
absolute positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of
rotation stops for part movement
rotation,
This information is conveyed to the machine through a
set
of instructions arranged in a desired sequence –
Program.
BLOCK FORMAT
Sample Block
N135 G01 X1
X1.0
0 Y1.0
Y1 0 Z0.125
Z0 125 F5
Restrictions on CNC blocks

Each may contain only one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feedrate
Each may contain only one specified tool or spindle
speed
The
Th bl blockk numbersb should
h ld be b sequential ti l
Both the program start flag and the program number
must be independent of all other commands (on
separate lines)
The data within a block should follow the sequence
shown
Rajeev in the
Agrawal, above
Notes on Automation 2004
sample block
WORD-ADDRESS
WORD ADDRESS CODING
E
Example
l CNC P
Program
Each instruction to the machine
N5 G90 G20 consists of a letter followed by a
N10 M06 T3 number.
N15 M03 S1250
N20 G00 X1 Y1 Each letter is associated with a
N25 Z0.1
N30 G01 Z-0.125 F5 specific type of action or piece of
N35 X3 Y2 F10 information needed by the machine.
N40 G00 Z1 Letters used in Codes
N45 X0 Y0
N50 M05 N,G,X,Y,Z,A,B,C,I,J,K,F,S,T,R,M
N55 M30

G & M Codes
E
Example
l CNC P
Program
• G-codes: Preparatory Functions
N5 G90 G20 involve actual tool moves.
N10 M06 T3
N15 M03 S1250 • M-codes: Miscellaneous
N20 G00 X1 Y1 Functions – involve actions
N25 Z0.1
N30 G01 Z-0.125 F5 necessary for machining (i.e.
N35 X3 Y2 F10 spindle on/off, coolant on/off).
N40 G00 Z1
N45 X0 Y0
N50 M05
N55 M30

G Codes
G00Rapid
G00R id traverse
G01 Linear interpolation G40 Cutter compensation –
G02 Circular interpolation, cancel
CW G41 Cutter compensation
p – left
G03 Circular interpolation, G42 Cutter compensation-
CCW right
G04 Dwell
G70 Inch format
G08 Acceleration
G09 Deceleration
G71 M Metric
t i format
f t
G17 X-Y Plane G74 Full-circle programming
G18 Z-X Plane
off
G19 Y-Z
Y Z Plane
Pl G75 Full
Full-circle
circle programming
G20 Inch Units (G70)
on
G21 Metric Units (G71) G80 Fixed-cycle cancel
G81-G89 Fixed cycles
G90 Absolute dimensions
G91 Incremental dimensions
Rajeev 127
Modal G
G-Codes
Codes
Most G-codes set the machine in a

mode which stays in effect until it is
“mode”
changed or cancelled by another G-
code These commands are called
code.
“modal”.

Modal G-Code
G Code List
G00Rapid
G00R id T
Transverse G43Tooll llength
G43T h compensation
i
G01Linear Interpolation (plus)
G02Circular Interpolation, CW G44Tool length compensation
G03Circular Interpolation, CCW (minus)
G17XY Pl
Plane G49Tool length compensation
cancel
G18XZ Plane G80Cancel canned cycles
G19YZ Plane G81Drilling cycle
G20/G70 Inch units G82Counter boring g cycle
y
G21/G71 Metric
M t i Units
U it G83Deep hole drilling cycle
G40 Cutter compensation G90Absolute positioning
cancel
G41 Cutter compensation left G91Incremental positioning
G42 Cutter compensation right
G43 Tool length compensation
(plus)

Rajeev 129
M Codes
M00
00 Program stop
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps
p on
M11 Clamps off
M30 Program stop, reset to start

N Codes
Gives an identifying number for each

block of information.
It is generally good practice to

increment each block number by 5 or
10 to allow additional blocks to be
inserted if future changes are required.

X Y and Z Codes
X,Y,
X, Y, and Z codes are used to specify

the coordinate axis.
Number following the code defines the
coordinate
coo d ate at ttheee
end
doof the
t e move
o e
relative to an incremental or absolute
reference
e e e ce po
point.
t

II,J,
J and K Codes
I, J, and K codes are used to specify

the coordinate axis when defining the
center of a circle.
Number following the code defines the

respective coordinate for the center of
the circle.

F S and T Codes
F,S,
F-code: used to specify the feed rate
S-code: used to specify the spindle

speed
T-code:
T d used d to specify if the h tooll
identification number associated with
th ttooll tto b
the be used d iin subsequent
b t
operations.
Application of Some Codes
G01 Linear Interpolation
Format: N_ G01 X_ Y_ Z_ F_
Linear Interpolation results in a straight

line feed move.
U ess too
Unless tool co
compensation
pe sat o iss used, tthe
e
coordinates are associated with the
centerline of the tool.

. As an example, for the motion that occurs in

x-y plane with the same maximum speed for
th x- and
the d y-axis,
i initial
i iti l motion
ti isi att an angle
l
of 45o to the axes until motion in one of
the axes is completed and then the balance

of the motion occurs in the other axis.
axis This is
called point-to-point motion.

25
B C
20
15
10 Positioning motion from A to C

A N10 G00 X30000 Y20000 F0
5
5 10 15 20 25 30

G01 is another preparatory function to specify

that the tool should be moved to a specified
location along a straight line path. It is referred
to as linear interpolation.
This function is typically used to specify

machining of straight features such as turning
a cylindrical surface in turning, cutting a slot in
milling, etc.

Linear interpolation from A to C
25 N10 G01 X30000 Y20000 F2500
C
20
15
10
A
5
5 10 15 20 25 30
N10 G00 X1 Z1
X N15 Z0.1
Z0 1
N20 G01 Z-0.125
F5
Z N25 X2 Z2 F10

G02 Circular Interpolation
G02 is also a preparatory function to specify

that the tool should be moved to a specified
l
location
ti alongl a circular
i l path th in
i a clockwise
l k i
direction. In order to specify the path to the
MCU the end point of the arc and the
MCU,
location of the center of the arc should be
specified.
p Within the block in which the G02
code is programmed, the center of the arc is
given by specifying its location relative to the
start off the arc.
(CW)
The G02 command requires an

endpoint
e dpo t and
a d a radius
ad us in o
order
de
to cut the arc.
I,J, and K are relative to the
start
a point.
po
N_ G02 X2 Y1 I0 J-1 F10

or
N_ G02 X2 Y1 R1

Rajeev 142
(CW)
Circular interpolation
p from A to B
about a circle centered at C
N10 G02 X20000 Y10000
25 I5000 J15000 F2500
I=5 A C
20
15
J=15
10 B
C
5
2004 5 10 15 20 25 30
Canned Cycles
The sequence of some machining operations is may
be the same for any part and for any machine. For
example, drilling a hole involves the following steps:
Position the tool above the point where the hole will be
drilled
Set the correct spindle speed
Feed the tool into the workpiece at a controlled feed

rate to a predetermined depth
Retract the tool at a rapid rate to just above the point

where the hole started

Some Commonly Used Canned Cycle
Code Function Down feed At bottom Retracti
on
G81 Drilling Continuous No action Rapid
feed
G82 Spot
p face,, Continuous Dwell Rapid
p
counterbore feed
G83 Deep hole drilling Peck No action Rapid
G84 Tapping Continuous Reverse Feed
feed spindle rate
G85 Through boring(in Continuous No action Feed
& out) feed rate
G86 g boring(in
Through g( Continuous Stopp Rapid
p
only) feed spindle
Rajeev 145
G81 ILLUSTRATION

Three Main parts of a CNC
program
Part 1-
1- Program Petup
N5 G90 G21 (Absolute units, metric)
N10 M06 T2 (Stop for tool change, use tool # 2)

N15 M03 S1200 (Turn
(T th
the spindle
i dl on CW to
t
1200 rpm)

program
Part 2-
2- Chip Removal
N20 G00 X1 Y1 (Rapid to X1,Y1 from origin point)

N25 Z0.125 (Rapid down to Z0.125)
N30 G01 Z-0.125 F100 (Feed down to Z-0.125 at 100
mm/min)
N35 G01 X2 Y2 ((Feed diagonally
g y to X2,Y2)
, )
N40 G00 Z1 (Rapid up to Z1)
N45 X0 Y0 (Rapid to X0,Y0)

program
Part 3-
3- System Shutdown
N50 M05 (Turn the spindle off)
N55 M00 (Program stop)

EXAMPLE OPERATION on CNC
MILLING MACHINE

G-CODE PROGRAM
First pass : conventional mill to
a depth of 0.125 around edge
profile. Tool 1 is a ½ inch dia.
end mill
mill.
%
:1002
N5 G90 G20
N10 M06 T1
N15 M03 S1200
N20 G00 X0.125 Y0.125
N30 Z0.125
N35 G01 Z-0.125 F5
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
Rajeev 151
Second pass:
conventional mill to a
depth of 0.25 around
edge profile.
N35 Z-0.250
N40 X3.875
N45 Y4.125
N50 X0.125
N55 Y0.125
N60 Z0.125

Rajeev 152
Third pass:
conventional mill to a
depth of 0.125
around ppocket profile.
p
N65 G00 X1.25 Y1.0

N70 G01 Z-0.125 F5
N75 X1.75
N80 Y2.5
N85 X1.25
N90 Y1.0
N95 Z0.125

Rajeev 153
Fourth pass: climb
mill to a depth of
0.125 across
remaining
emaining material.
mate ial
N100 Y2
Y2.125
125
N105 X2.625
N110 Z0.125
N115 G00 X-5 Y-5 Z5
N120 M05
N125 M30

Rajeev 154
Advanced features:
Execution of the part of the program in a

rotated or mirrored position.
Abilityy to scale the p
program
g and produce
p
larger or smaller programs.
Three dimensional circular interpolation
p
which produces a helical shape.
Parabolic and cubic interpolation.

Rajeev 155
Program Loading:
Through
g keyboard
y
Through punched tape reader
Through diskette drive
Through RS 232 serial port
Through network interface card

Rajeev 156
Numerical Control through
communication channels
Another variation in the implementation of
numerical control involves sending part
programs over telecommunications lines
from a central computer to individual
machine tools in the factory, thus
eliminating the use of the punched tape
altogether.
Thi form
This f off numerical
i l controll is
i called
ll d
direct numerical control, or DNC.

Di t N
Direct Numerical
i lC Control
t l (DNC)
(DNC):
A system in which a central computer

downloads the NC programs block by block
to many NC machine tools simultaneously is
called Direct Numerical Control (DNC)
system.

Rajeev 158
Direct Numerical Control (DNC):
This system used to work with the early NC

machine tools which can not read more than a
block of information at a time. The central
computer feed the program information one
block at a time. When the machine execute the
information, the next block of information
would be fed.

Rajeev 159
Distributed Numerical Control (DNC):
( )
Distributed NC is known by the same acronym

as Direct Numerical Control (DNC). After the
introduction of CNC, the machine tools have
h d the
had th capability
bilit off storing
t i large
l amountt off
information. Therefore, there have been no
need to have drip p feed information system,
y ,
like, Direct Numerical Control. Instead,
Distributed Numerical Control is introduced. In
such a system,
system a host computer communicate
with many CNC machine tools via networks
and download or uploadp programs.
p g

Rajeev 160
Distributed Numerical Control (DNC):
( )
With Distributed Numerical Control systems, it

is p
possible to monitor the activities in individual
CNC machine tools on host computer.
Therefore, better shop floor control can be
achie ed
achieved.

Rajeev 161
Computer Aided Part Programming:
NC p program
g preparation
p p mayy be tedious and
difficult if the part to be machined has a
complex geometry. The main difficulty is to
find out the cutter locations during the
machining. Computers may be used to assist
the pprogrammers
g in preparing
p p g the NC codes.

Rajeev 162
Advantages of applying computer
computer-aided
aided part
programming include the following:
It reduces the manual calculations involves in

determining the geometric characteristics of
the part
part.
It provides the cutter path simulation.
It provides tool collision checking
checking.
It shortens the program preparation time.
It makes the program preparation easier
easier.
Rajeev 163
The Aerospace Industries Association
sponsored the work that led to the first part
programming language,
language developed in MIT in
1955.
This was called: Automatically Programmed
Tools (APT).
APT is an English like simple programming
language which basically produce the Cutter
Location (CL) data.
Using the cutter location data
data, the program can
generate the actual NC codes by using a
postprocessor
p p .

Rajeev 164
CAD/CAM Based Part Programming:
g g
The output of any CAD package include the

geometric data of the part to be machined.
Therefore, many CAD/CAM package can
produce cutter location (CL) data to be used
for NC code generation.
There is still to be a process planning module
for a workable NC code generation.
Some of the CAD/CAM packages that have the
NC code generation capabilities are
Computervision, CATIA, CADAM, ProEngineer,
MechanicalDesktop (Auto Desk).
Desk)
Rajeev 165
Adaptive Control
Research Began in Early 1950s

A Logical Extension of CNC
Operator Parameter Adjust Themselves
to Fit in New Circumstances
It Is a Feedback System Basically

Basic Functions on AC
Determine Operating Conditions of

Process
Configure the Process Control in
Response
espo se to tthe
e Ope
Operating
at g Co
Conditions
dto s
Continue to Monitor the Process

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Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

PROFIT = INCOME - COST

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

PRODUCTIVITY through AUTOMATION

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 8

transfer of the skill of

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 9

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Cutting motion Feed motion

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

work holding device

tool holding device

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

THOSE USING THOSE USING THOSE USING

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Z axis of spindle, perpendicular to work

MACHINE MACHINE TOOL WITH

X radial and horizontal horizontal parallel to and positive in

Y apply right hand rules

Rajeev Agrawal, Notes on Automation 2004

Rajeev Agrawal, Notes on Automation 2004

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 27

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 28

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 29

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 30

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev Agrawal, Notes on Automation in32

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 33

By sequencing these positions in the

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 34

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 35

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 36

The main components of NC machine tool

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 37

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 39

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 40

Point-To-Point: Desired positions of

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

turning the spindle on and off

are performed by Machine Control Unit

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 43

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 44

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

Rajeev Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3 47

US Air Force commissioned MIT to develop

Rajeev Agrawal, Notes on Automation 2004

In CNC (Computer Numerical Control),

Rajeev Agrawal, Notes on Automation 2004

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3

2004Agrawal, Notes on Automation in Manufacturing ,Module 2 and 3