NC, CNC, DNC Machine

UNIT-3
NC, CNC, DNC Machine
Numerical Control (NC) refers to the method of controlling the manufacturing operation by means
of directly inserted coded numerical instructions into the machine tool.
Numerical control (NC) refers to the automation of machine tools that are operated by abstractly
programmed commands encoded on a storage medium, as opposed to manually controlled via
handwheels or levers, or mechanically automated via cams alone.

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The major advantages of NC over conventional methods of machine control are as

follows:
v higher precision: NC machine tool are capable of machining at very close tolerances, in
some operations as small as 0.005 mm;
v machining of complex three-dimensional shapes: this is discussed in Section 6.2 in connectionwith
the problem of milling of complex shapes;
v better quality: NC systems are capable of maintaining constant working conditions forall parts in a
batch thus ensuring less spread of quality characteristics;v higher productivity: NC machine tools
reduce drastically the non machining time.Adjusting the machine tool for a different product is as easy
as changing the computerprogram and tool turret with the new set of cutting tools required for the
particular part.
v multi-operational machining: some NC machine tools, for example machine centers,
are capable of accomplishing a very high number of machining operations thus reducing
significantly the number of machine tools in the workshops.
v low operator qualification: the role of the operation of a NC machine is simply to upload the
workpiece and to download the finished part. In some cases, industrial robots are employed for material
handling, thus eliminating the human operator.

Disadvantages of conventional NC
There are a lot of important setbacks in the conventional NC machines that is worth to be mentioned
because this was the reason that lead to the development of improved numerical control machines. The
most important are:
1. Part programming mistakes. Mistakes in the part programming were quite often and a program
should be rewritten more than two times to function correctly.
2.  Paper tape. The paper tape is by its nature durable and fragile and cannot be used repeatedly without
wear and eventually tear. More durable materials have been used later on, however, these material are
relatively expensive.
3.  Tape reader. This is the least reliable component of the NC system. When a machine breaks down
the first to be checked is the tape reader.

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4.  Controller. The hard-wired NC controller unit means that the control features cannot be easily
altered to incorporate improvements to the unit.
5.  Management information. No timely information on operational performance can be
provided to management.
6.  No optimal speeds and feeds. Since the function of the conventional NC is just to control the
position of the tool relative to the work there is no attempt to optimize speeds and feeds. As a result the
part programmer must plan the cutting conditions conservatively and this reduces productivity.

  
Direct numerical control (DNC)
Direct numerical control is defined as a manufacturing system in which a number of NC machines are
controlled by a computer through direct connection in real time. The tape reader is omitted from the
system. The information or the part program is being transferred directly to the machine tool through
communication lines from the main computer. This is done in real time and the communication is two
way, both the computer and the machine tool can send information to each other. The computer sends
information to the machine tool upon request of the latter and when this occurs the request for
instructions must be satisfied almost instantaneously. The computer stores the information in a bulk
memory and can control more than 100 machine tools.   In addition in cases where the computational
capability of the main computer is not enough to satisfy the needs of the vast number of the machine
tools additional computers are used linked to the main server to satisfy group of machine tools. These
smaller computers are called satellite computers.   
 

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Advantages of DNC
1. Time sharing the control of more than one machine by the computer
2.  There is greater computational capability for operations such as circular interpolation, tapering etc.
3.  There is no need for the computer to be located near the machine because the computer can now
control the machine tools remotely, while situated in a computer type environment.
4.  The tape and tape reader are eliminated and replaced by communication cables
making the machine tool reliable.
5.  The hardwired controller unit is eliminated
6.  Programs stored as cutter location data can be post processed for whatever suitable
machine is assigned to process the job.
   The only disadvantage of the DNC is if the computers break down, but the computer is
so reliable that this is unlikely to occur.
Computer numerical control
omputer numerical control (CNC) is the numerical control system in which a dedicated computer is
built into the control to perform basic and advanced NC functions. CNC controls are also referred to as
soft-wired NC systems because most of their control functions are implemented by the control software
programs. CNC is a computer assisted process to control general purpose machines from instructions
generated by a processor and stored in a memory system. It is a specific form of control system where
position is the principal controlled variable. All numerical control machines manufactured since the

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seventies are of CNC type. The computer allows for the following: storage of additional programs,
program editing, running of program from memory, machine and control diagnostics, special routines,
inch/metric, and incremental/absolute switch ability.
CNC machines can be used as stand alone units or in a network of machines such as flexible machine
centres. The controller uses a permanent resident program called an executive program to process the
codes into the electrical pulses that control the machine. In any CNC machine, executive program
resides in ROM and all the NC codes in RAM. The information in ROM is written into the electronic
chips and cannot be erased and they become active whenever the machine is on. The contents in RAM
are lost when the controller is turned off. Some use special type of RAM called CMOS memory, which
retains its contents even when the power is turned off.

1. The new CNC controllers have enough memory to store large programs, or a lot of small and
medium programs thus reducing the time needed for program loading.

2.  The use of floppy discs has being spread widely the last few years. The new type of NC machines
have the ability to accept information from a diskette or even to store programs that are in the memory
of the CNC computer on the diskette. One floppy disc can store the information that are stored on 8000
ft of punched tape.

3.  Program editing at the machine tool site. The program loaded on a CNC machine can be edited and
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corrected if any errors exist on the machine tool itself. In addition the corrected program can be saved
to a disc or a punched tape for future use.
4.  Fixed cycles and programming subroutines. Due to the large memory of the computer controller
frequently used cycles can be programmed and stored in the computer memory and called when
requested instead or writing the same coding time after time in the different programs.

5.  Interpolation. Special interpolation cycles can only be performed on CNC due to the
high computational capability.

6.  Position features for setup. Setting up the machine tool for a certain job involves installing and
aligning the fixture on the machine tool table. On CNC machines a position set feature is available. The
operator is not required to position the fixture on the machine table with extreme accuracy. Instead, the
machine tool axes are referenced to the location of the fixture by using a target point or set of targets
points on the work or fixture.

7.  Cutter length compensation. A recent innovation on tool length compensation is to use a sensor
which comes in contact with the tool mounted and measures its length. This measured value is then
used to correct the programmed tool path. These method has eliminated the need of supplying tool
length compensations or even fit each part program to the needs of each tool in order to comply with
the tool path desired.
8.  Diagnostics. This is a system found on modern CNC machines and can detect malfunctions or signs
of malfunction on the machine. Depending upon the seriousness of the malfunction the machine can
display the problem on the controller’s CRT monitor, or even stop the operation. This diagnostic
system is very helpful for maintenance purposes because it shows at what part of the machine the
malfunction occurred.

9.  Communications interface. Most CNC machines are equipped with standard communications
interface in order to allow interfacing and networking. With this feature the machine can be interfaced
with computer and other computer driven devices.

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Advantages of CNC
CNC offer greater flexibility and computational capability than normal NC machines. Incorporation of
new system options can be easily done by reprogramming the unit. Other advantages are listed below:

1. The punched tape and the tape reader are used only once to load the program into memory thus
relieving the system from its least reliable components.

2.  Part program edit at the machine site. The program can be edited, corrected,
and stored on the tape or disc.

3.  Greater flexibility. New options can be added to the system easily and with low cost.

4.  Metric conversion. It can use both systems and can convert from the British to
international and vice versa.
 Structure of the CNC Part Program
A CNC part program is essentially a string of characters. A character usually requires 8 bits of memory
to represent its control value. A bit is the basic unit of memory. The control value of a bit is either 1
(high, on) or 0 (low, off). Characters used in CNC part programs can be classified into three categories:
Capitals: A - Z
Digits: 0 - 9
Special Symbols: (, /, %, etc.)

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Structure of the CNC part program.

Characters are often grouped into words (or commands). Each command directs a specific element of
control data (e.g., a machine speed or a tool number). The basic categories of commands are listed as
follows:
1. Sequence or block number (N, H, or P code): Identifies a block.
2. Preparatory function (G): Prepares the MCU to perform specific operations.
      available on a particular machine tool.
3. Dimension words (X, Y, Z, etc.): Specify the coordinate position of the cutting tool.
4. Feed words (F): Specify the feed rate of the cutting tool.
5. Speed words (S): Specify the spindle speed.
6. Tool number (T): Identifies and selects a tool from an automatic tool changer.
7. Miscellaneous functions (M): Specify certain miscellaneous or auxiliary functions
8. End of Block (EOB)

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Classification of CNC/NC system

There are various ways of classification of CNC/NC machine tool system these are

listed below.

(a) According to the type of machine

1) Open loop

2) Close loop

(b) According to the type of machine

1) Point to point positioning

2) Straight line contouring [continuous path type]

(c) According to the principle working such as

1) Analog

2) Digital

(d) According to the programming such as

1) Incremental

2) Absolute etc.

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(A) 1. OPEN LOOP CONTROL SYSTEM:

Pulsating Input

Machine Stepping M/C tool slide

Control Unit Motors Displacement

Open Loop system

The open loop NC/CNC system is always of digital type. In case of open loop system,

there is no feed back from output to input side. This system has good calibration and is free from

external disturbances.

The pulsating input for slide is given to it through stepper motor. Stepper motor decides

the position of slides as per the input.

(A) 2. CLOSE-LOOP CONTROL SYSTEM:

Comparator
Pulsating Error
Input Signal DAC Servo
+ Gear
– Converter Motor

Digital Feedback
Tachometer

Closed Loop System

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Fig. shows the block diagram of close-loop control NC/CNC system. Consisting of comparator, DAC

servomotor, slide and digital tachometer etc.

.In case loop NC/CNC system the output is fed to input. The close loop control measures the actual

position of system and compares it with desired reference position. The difference between the actual &

the desired value error & control system is designed in such a way that to eliminates or to reduced the

error. In this system negative feedback is used.

In this digital control system the input and feedback signal may be sequence of pulses each pulse

representing a unit length. The comparator correlates the two sequences and given to analog to digital

converter a signal representing the position of error which is used to drive the servomotor and position

of slides changes as per the error signal and it will also eliminates the error.

Digital Tachometer :

The feedback device, which is denoted here as a digital tachometer is mounted on the end of lead screw

and supplies a pulsating output to comparator. Here the rate of pulses per minute provided by digital

tachometer is proportional to the rpm of lead screw.

(B) 1. POINT TO POINT POSITIONING NC/CNC CONTROL SYSTEM :

Y

Next Point

Starting Point

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Cutter path between the holes in case of point-to-point system

In point to point positioning control system the job or workpiece is moved to a certain point with

respect to cutting tool.The cutting tool works on the job and moves away. (a hole is drilled).After

completion of process, the work piece moves to the new position or new point. Cutter path between

holes in case of point to point system is shown in fig. above.It is used where accurate p-to-p positional

control is required.

(b) 2. Straight line contouring / continuous path type NC/CNC control system:

Straight line or straight cut CNC system is an extension of point to point control system. In this system

cutting tool is while the axes of motion are moving simultaneously. Consider the example of milling

machine. Here, all axes of motion could move simultaneously and movement speed could keep varying

even between two given points.

(c) 1. Analog type NC/CNC control system:

In analog type of NC/CNC control machine the variable changes continuously with respect to time.

(c) 2. Digital type NC/CNC system :

In this digital type NC/CNC control machine the change can be varied in small descrete steps of order

of 0.01 mm or 0.001 inch.

(d)1. Incremental NC/CNC control system :

An incremental NC/CNC control system the reference point to next instruction could

mean the end-point of the previous operation. Thus each instrument is in the form of an incremental

with respect to the preceding position. Thus the reference point keep changing with every new

instruction.

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(d) 2. Absolute NC/CNC control system:

In this system each dimensional instruction is with reference to a single starting reference point.

Numerical control machine tools

The control machine tools can be classified as

(a) Numerically controlled m/c tool

(b) Computerized numerical control

(c) Direct numerical control

Numerically controlled m/c tool :

The control systems and machine tools in numerically controlled machine tools in numerically

controlled machine tools have varying complexities and capabilities. The instruction to the NC

machines are fed to the external medium i.e. paper tape, magnetic memory, punch card.

CNC machine tool control

DAC Machine Encoder

Tape reader or
Drive
any program Mini
storing device Computer
Counter
Feedback Pulses

Real Time
Clock

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Block Diagram of Computer Numerical Control System

Principle & working of CNC system :

In case of computer numerical control m/c tool a dedicated computer is used to performed the all basic

NC function. Thus purely hardware based NC system has now replaced by software based computer

numerical control system.

This CNC system consists is similar to that of conventional NC system.

Here complete part program to produced a component is input and stored in computer memory and

information for each operation is fed to the machine tools i.e. motor. The part program can be stored in

memory of the computer and used in future.

Here the computer monitors the feedback at periodic intervals of a time it then calculate the error in

position and feeds the same through its output register to DAC. Encoder is used as the feed back

device. Program is executed in step and after each step error is caused then it is measured & corrected.

FEATURES & APPLICATION OF CNC MACHINE TOOL CONTROL

SYSTEM

Features :
1. Program can be input to the controller unit through key-board or paper tape can be read by tape

reader in the control unit.

2. The part program once entered into the computer memory can be used again & again.

3. The part program can be edited and optimized at the machine tool itself. If there is change in the

designed of the component, the part program can be changed according to the requirement.

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4. In CNC, machine have the facility for providing the part program without it, actually running on the

machine tool.

5. CNC control unit allows compensation for any changes in the dimension of the of the cutting tool.

6. The CNC system can provides the information such as number of component produced.

Applications of Computer Numerical System :

1] CNC machines have been widely used in industry.

2] CNC is being used in drilling, turning, boring, milling & grinding machines.

3] CNC is used on machines like pipe bending coil winding, flame cutting, welding etc.

ADVANTAGES & DISADVANTAGES OF CNC MACHINE SYSTEM

1. Reduced lead time :

The time needed for planning, designed and manufacturing a job and machine set up is noted as lead

time. Special jigs and after enter in CNC m/c the whole time needed for layer design.

2. Operator activity :

It is possible for one operator to attend more than one CNC machine at a time to standing position set

and set up one station with the machine take place at other station.

3. Lower labour cost :

One operator can run two or more machine at a time hence reduces the labour cost

4. Longer tool life :

The tool life at the optimum speed and feed. These functions are controlled by the part program itself.

Program speed and feed can be change by the operator and over read if the difficulty or problem may

arrives because of this it can save the tool life.

5. Reduced Inspection :

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It is necessary to inspect first the dimension of machine component. The program is checked and

corrected if immediately required.

6. Accurate costing and scheduling :

In the CNC machine the time taken for producing the component is predictable and consisting and

result in greater accuracy in estimating as well as costing also. It’s consistent if loading and given more

output.

Disadvantages of CNC :

1) Higher investment cost :

The higher investment cost required manufacturing management to use the machine more aggressive

than the general purpose machine. High machine utilization is essential in order to get reasonable return

on the investment.

2) Higher maintenance cost :

The technology used in the CNC machine is to be more complex as compare to the general equipment

so it requires high maintenance cost.

3) Skilled CNC operator is required :

Part programming and CNC operation as well as maintenance requires the skilled operator to overcome

these problems of finding, hearing and trading. These people must be considering the disadvantage to

the CNC shop.

CNC Axis

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Vertical Machine Horizontal Machine

STANDARD LATHE COORDINATE SYSTEM

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(1)Tool changing arrangements

There are two types of tool changing arrangements: manual and automatic. Machining centres

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incorporate automatic tool changer (ATC). It is the automatic tool changing capability that
distinguishes CNC machining centres from CNC milling machines.
(1.1) Manual tool changing arrangement:

Tool changing time belongs to non-productive time. So, it should be kept as minimum as possible.
Also the tool must be located rigidly and accurately in the spindle to assure proper machining and
should maintain the same relation with the work piece each time. This is known as the repeatability of
the tool. CNC milling machines have some type of quick tool changing systems, which generally
comprises of a quick release chuck. The chuck is a different tool holding mechanism that will be inside
the spindle and is operated either hydraulically or pneumatically. The tool holder which fits into the
chuck can be released by pressing a button which releases the hydraulically operated chuck. The
advantage of manual tool changing is that each tool can be checked manually before loading the tools
and there will be no limitation on the number of tools from which selection can be made.
(1.2) Automatic tool changing arrangement
Tooling used with an automatic tool changer should be easy to center in the spindle, each for the tool
changer to grab the tool holder and the tool changer should safely disengage the tool holder after it is
secured properly. Figure 27.1 shows a tool holder used with ATC. The tool changer grips the tool at
point A and places it in a position aligned with the spindle. The tool changer will then insert the tool
holder into the spindle. A split bushing in the spindle will enclose the portion B. Tool changer releases
the tool holder. Tool holder is drawn inside the spindle and is tightened.

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Tool turrets
An advantage of using tool turrets is that the time taken for tool changing will be only the time taken
for indexing the turret. Only limited number of tools can be held in the turret. Tool turrets shown in
figure 27.2 a, b & c are generally used in lathes. The entire turret can be removed from the machine for
setting up of tools.

(3) Tool magazines

Tool magazines are generally found on drilling and milling machines. When compared to tool turrets,
tool magazines can hold more number of tools and also more problems regarding the tool management.
Duplication of the tools is possible and a new tool of same type may be selected when ever a particular
tool has been worn off. Though a larger tool magazine can accommodate more number of tools, but the
power required to move the tool magazine will be more. Hence, a magazine with optimum number of
tool holders must be used. The following types of tool magazines exist: circular, chain and box type.
(3.1)Chain magazine:

These magazines can hold large number of tools and may hold even up to 100 tools. Figures 27.3 a & b
show chain magazines holding 80 and 120 tools respectively. In these chain magazines, tools will be
identified either by their location in the tool holder or by means of some coding on the tool holder. In
the former it is followed for identifying the tool and then the tool must be exactly placed in its location.
The positioning of the magazine for the next tool transfer will take place during the machining
operation.

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Figure 27.3 (a) 80-tool chain magazine Figure 27.3 (b) 120-tool chain magazine

(3.2)Circular magazine:
Circular magazines shown in figure 27.4 will be similar to tool turrets, but in the former the tools will
be transferred from the magazine to the spindle nose. Generally these will be holding about 30 tools.
The identification of the tool will be made either by its location in the tool magazine or by means of
some code on the tool holder. The most common type of circular magazine is known as carousel,
which is similar to a flat disc holding one row of tools around the periphery. Geneva mechanism is
used for changing the tools.

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Figuure 27.4: Circular magazine

(3.3) Box magazine:

In these magazines, the tools are stored in open ended compartments. The tool holder must be removed
from the spindle before loading the new tool holder. Also the spindle should move to the tool storage
location rather than the tool to the spindle. Hence, more time will be consumed in tool changing. Box
magazines are of limited use as compared to circular and chain type of tool magazines.
Machining Center:-

A "horizontal maching center" has a horizontal spindle. With a horizontal spindle, tools stick out the
side of the tool holder and cut across the side of a part (work piece). Horizontal machining centers are
far more expensive than equivalent capacity vertical machines, but have several advantages. Usually
the tool holder of a horizontal machine is more rigid. Also, when machining the side of a part, metal
chips fall out of the area being cut, leaving an uncluttered cutting area.
A "vertical machining center" has a vertical spindle. With a vertical spindle, tools stick straight down
from the tool holder, and often cut across the top of a part. One disadvantage of vertical machining is
that when tools cut across the top of a part, the metal shavings, called "chips," often pile up around the
tool and interfere with the cutting action. However, vertical machining centers are more common,
primarily because they are less expensive than equivalent capacity horizontal machines

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