Numeric Control (NC) :

In manufacturing, the designs developed using CAD (Computer-Aided Design) operation need to be converted
to a format that machines can understand. Here's where Numerical Control (NC) comes in. NC is the bridge that
connects CAD and manufacturing.

In NC, the geometrical data from the design is extracted and converted to an alphanumerical code (it also uses
symbols). Generally, a CAM (Computer-Aided Manufacturing) software is used to analyze the design and
generate such alphanumerical codes.

“Numeric Control is a traditional way of establishing an automated control on machining tools.

This process is controlled by numbers, letters, symbols. The processes here are controlled by set of
instructions which is called as a program. As it is a traditional or naive method, so it has less
computational capability. It is less costly and requires less maintenance.”
Example-3D printers, boring tools

Numerical control allows machines to produce parts with high accuracy, and good surface finishes, with less
human intervention, and lower processing time.

But operating and maintaining a numerical control system requires skilled operators who have experience
programming the NC machine tools.

Properties of NC :

1. It is a traditional method of having control over machinery.

2. It provides less flexibility.
3. Instructions are given with the help of punch cards.
4. For changing the functioning, the information on the punch card is modified.
5. It has less computational capability.
6. It cannot run continuously for much time.
7. It is not programmable and considered as hardwired.
8. It is less expensive and has low maintenance.
9. It has high accuracy and more capability.
10. The punch card contains set of instructions.
 ❖ Advantages of NC Machine:

These are the following advantages of NC Machine:

▪ Reduced Non-Productive Time: NC machine helps in increasing the productive working time of the
machine. And helps in reducing the non-productive time by reducing non-productive movements of the
machine like changing the tool, workpiece handling time, etc.

▪ Reduced Time For Completion Of Work: NC machine helps in automating all the manual work like
cutting, drilling, etc. So this results in reducing the time required for the completion of work.

▪ Greater Flexibility: With NC machines it becomes easy to make changes in design, changes in the
production schedule, and change over jobs for rush orders.

▪ Improved Quality: NC machine is used for producing complicated parts where chances for human
mistakes are high. It helps in manufacturing parts with higher accuracy, decreased scarp, and lower examination
requirements.

▪ Reduced space requirements: NC machines require less space compared to conventional machines as
tools are automated in NC machine so it requires less floor space.

▪ Can be operated easily: NC machines can be easily operated by less skilled labor. Because all the
process in NC machines is automated the labor is required only to monitor the work.

▪ Avoids Human Errors: NC machines help in avoiding human errors as all the operations are automated
and involve the least human interference so, the chances of human errors are the least.

▪ Results in a reduction of labor cost: The use of this technology results in the reduction of labor cost as
it requires the least human interference compared to the conventional machine. So the management can save its
cost on labor.

▪ High dimensional accuracy: Using this technology helps in getting higher dimensional accuracy as
compared to the conventional machine.
 ❖ Disadvantages of NC Machine:

These are the following disadvantages of NC Machine:

▪ High Investment Required: This system requires higher investment as it has intricate and complex
technology. And as it requires more investment so, it requires more aggressive use of the machine by the
management to cover its cost by higher production. So that management can bring a greater return on
investment.

▪ Higher maintenance cost: The NC machines use intricate & complex technology and as these are used
heavily to recover the investment so, there is considerable wear and tear due to the extensive use so, this
machine requires higher maintenance than the conventional machine.

▪ Involves trained NC personnel: The NC machine needs highly trained personnel as it involves intricate
technology that cannot be handled by the normal employee. The problem of finding, hiring, training these
employees involves higher costing and time so this is the disadvantage.

▪ Programming Training required: To make changes in the machine and for troubleshooting the NC
machine requires an individual with a deep understanding of NC programming. So, there is a need for
programming training for personnel which involves higher costing.

❖ APPLICATIONS OF NUMERICAL CONTROL:

Numerical control systems are widely used in industry today, especially in the metalworking industry. By far
the most common application of NC is for metal cutting machine tools. Within this category, numerically
controlled equipment has been built to perform virtually the entire range of material removal processes,
including:
Milling
Drilling and related processes
Boring
Turning
Grinding
 ❖ NC Machine Working Principle:
The steps to employ the NC machine in the manufacturing process are as follow:

▪ Planning Process: This process involves the interpretation of engineering drawings of the work-piece
according to manufacturing processes. And this planning process is concerned with the preparation of
the route sheet. A route sheet is a document showing the series of operations that the work-piece has to
go through.
▪ Programming Process: Under this process, the programmer writes the program according to the
sequence of operations the work-piece has to go through or the machining process. The instructions
programmed get converted into the output signal that controls actions such as spindle speed, tool
selection, tool movement, and cutting fluid flow.

▪ Tape Preparation: This step involves the punching of the program in the tape. In manual part
programming, the program punching is done through the typewriter type device with tape punching
ability.

▪ Tape Inspection: After preparing the tape, the next step comes inspection for checking the accuracy.
Sometimes it is performed through the computer program that performs different actions of the tool on
the paper. This method can discover the major blunders in tape. And the other way is the “acid test,”
which includes performing all the action by the tool on the sample work-piece. This sample work-piece
can be made of plastic or foam.

▪ Production: This is the final step of using the NC tape for production. It includes managing the raw
work-piece, specifying and preparing the tooling & any special fixtures, and any other tool required in
setting the NC machine for the operation. The NC machine tool loads the raw workpiece and operates on
it according to the instruction on the tape. After completing the action raw workpiece, it is unloaded and,
another raw material is loaded into the machine.

❖ Parts Involved In Construction of Numeric Control Machine:

The following seven parts involved in the construction of NC Machine:
Set of instructions or Program:
A program is the detailed set of instructions that guides the machine tool on what and how to do. The
programmer is responsible for writing the program in alphanumeric form. Each step of the program indicates
the movement & position of the machine tool. This instruction act as input to the machine control unit (MCU).

To store this set of instructions, we generally use an input medium like L-in wide tape or wide punched tape.
Earlier punched cards, 35mm motion picture film & magnetic tapes were used.

Note: There are two other methods of input. The first one is by manual entry of instructions and, the other is by
the direct link of the computer, also called DNC (Direct Numeric Control).

Machine Control Unit (MCU):

This part is the brain of a machine. Like, CPU is to the computer. It consists of hardware and electronics which
reads and understands the information stored in the input medium and transforms them into action by the
machine tool.
Essential components of the control unit consist of a tape reader, a data buffer, a signal output channel, and a
feedback channel. Let us understand each one in deep.

Signal Output Channel:

These are responsible for sending instructions to the machine tool(servomotor) about what function to perform
and how to perform.

Tape Reader:
It is an electromechanical device that reads the instruction embedded in the punched tape.

Data Buffer:
It reads the data stored in a tape reader.

Feedback Channel:
These are responsible for sending the data back to the machine control unit.

Machine Tools:
It is the part of the machine that performs the function/operation. For example, suppose an NC machine
designed to perform machine drilling operations. This NC machine consists of tools like spindles, motors that
control movement, cutting tools, work tables, work fixtures, and other supporting equipment.
All these elements work according to the set of instructions from the controller unit. These tools are responsible
for performing multiple functions like drilling, cutting, rotation, changing the instruments, etc
 ❖ Types of NC Systems
There are three types of NC machines:

1.Traditional Numerical Control (NC Machine)

NC machines are an evolution of conventional machines and can operate using a tape reader system.
Instructions for desired operations are punched onto a tape, enabling the NC machine to perform the specified
tasks.

2.Computer Numerical Control (CNC Machine)

CNC machines emerged after NC machines to overcome their limitations. Instead of using a tape reader, CNC
machines utilise a computer-generated file containing G-Codes and M-Codes to store the program. This allows
for instant changes to parameters like speed, feed, and depth of cut, making CNC machines highly accurate and
efficient.

Computer numerical control is an NC system that utilizes a dedicated, stored program computer to perform
some or all of the basic numerical control function. Because of the trend toward downsizing in computers, most
of the CNC system sold today use a micro computer based controller unit.

The external appearance of a CNC machine is very similar to that of a conventional NC machine. Part programs
are initially entered in a similar manner. Punched tape readers are still the common device to input the part
program into the system. However, with conventional numerical control, the punched tape is cycled through the
reader for every workpiece in the batch. With CNC, the program is entered once and then stored in the
computer memory.

Thus the tape reader used only for the original loading of the part program and data. Compared to regular NC,
CNC offers additional flexibility and computational capability. New system options can be incorporated into the
CNC controller simply by reprogramming the unit. Because of this reprogramming capacity, both in terms of
partprograms and system control options, CNC is often referred to by the term "soft-wire”NC.
 ❖ Functions of CNC
The principal functions of CNC are:

1.MACHINE TOOL CONROL- The primary function of the CNC system is control of the machine tool. This
involves conversion of the part program instructions into machine tool motions through the computer interface
and servosystem. Some of the control functions, such as circular interpolation, can be accomplished more
efficiently with hard wired circuits than with the computer. This fact has lead to the development of two
alternative controller designs in CNC:

1. Hybrid CNC
2. Straight CNC

In the hybrid CNC system, the controller consists of the soft-wired computer plus hard-wired logic circuits.
The hard-wired components perform those functions which they do best, such as feed rate generation and
circular interpolation. The computer performs the remaining control functions plus other duties not normally
associated with a conventional hard-wired controller. There are several reasons for the popularity of the hybrid
CNC configuration. As mentioned previously, certain NC functions can be performed more efficiently with the
hard-wired circuits.

The straight CNC system uses a computer to perform all the NC functions. The only hard-wired elements are
those required to interface the computer with the machine tool and the operator's console. Interpolation, tool
position feedback, and all other functions are performed by computer software.

2.IN-PROCES COMPENSATION- A function closely related to machine tool control is in-process

compensation. This involves the dynamic correction of the machine tool motions for changes or errors which
occur during processing.

3.IMPROVED PROGRAMING and OPERATING FEATURE - The flexibility of soft-wired control has
permitted the introduction of many convenient programming and operating features.

4.DIAGNOSTICS- NC machine tools are complex and expensive systems. The complexity increases the risk
of component failures which lead to system down time. It also requires that the maintenance personnel be
trained to a higher level of proficiency in order to make repairs. The higher cost of NC provides a motivation to
avoid downtime as much as possible. CNC machines are often equipped with a diagnostics capability to assist
in maintaining and repairing the system.

❖ Advantages of CNC

1. The part program tape and tape reader are used only once to enter the program into computer memory.
2. Tape editing at the machine site. The NC tape can be corrected and even optimized (e.g., tool path, speeds,
and feeds) during tape tryout at the site of the machine tool.
3. Metric conversion- CNC can accommodate conversion of tape prepared in Units of inches into the
International System of units.
4. Greater flexibility- One of the more significant advantages of CNC over conventional NC is its flexibility.
5. User-written programs - One of the possibilities not originally anticipated for CNC was the generation of
specialized programs by the user.
6. Total manufacturing system- CNC is more compatible with the use of a computerized factory-wide
manufacturing system.
Difference between Numerical Control (NC) and Computer Numerical Control (CNC):

S.NO NC CNC

1. NC stands for Numerical Control And CNC stands for Computer Numerical Control.

2. Punch tapes and punch cards are used for input. Keyboards are used for input.

Here, Alteration in operation parameters are not While here, Alteration in operation parameters can be
3.
possible. possible.

Here, Memory does not exist for

4. Here, Memory exists to store instructions.
storing instructions.

5. CN is less expensive. CNC is highly expensive.

6. Maintenance cost is less. Maintenance cost is high.

7. Highly skilled operators are required. Less skilled operators are required.

8. CN is less flexible. CNC is more flexible than CN.

9. The accuracy is less as compared with the CNC. It has high accuracy.

10. It takes more time in the execution of the job. It takes less time in the execution of the job.

It may be run unceasingly for twenty-four hours of

11. It is uphill to run it unceasingly.
each day.

3.Distributed Numerical Control (DNC Machine)

Similar to CNC machines, DNC machines employ a remote computer to control multiple machines performing
various operations simultaneously. The central or remote computer communicates with local CNC computers to
execute the operations.
 ❖ NC machine classification
NC machines can be classified based on the following conditions:

According to Motion Control

o Point to Point Mechanism: The work-piece or spindle moves from one specified position to another for
performing operations like numeric control drilling. It is the simplest and most cost-effective method.

o Straight Cut Mechanism: The cutting tool moves parallel to one of the axes (X, Y, or Z) at a controlled
rate, is suitable for milling rectangular work-pieces, and can also perform point-to-point movements.

o Contouring Mechanism: This complex and expensive mechanism controls two or more axes
simultaneously to achieve desired shapes. The work-piece moves along a continuous path, allowing the
tool to work while axes are in motion, producing angular surfaces and 2D or 3D curves .

According to Control Loops

o Open Loop: Instructions are given to the motor by the controller without precise movement and
direction, but it can still achieve the desired shape. It is a more affordable option.

o Closed Loop: Utilises sensors, transducers, and counters to accurately estimate the table's position. It
uses a feedback unit to compare the workpiece position with signals from the controller unit, making it a
more expensive and intricate system.

Based on Power Supply

o Electric: Utilises AC and DC motors with complicated wiring and control systems using circuits.

o Hydraulic: Utilises hydraulic pumps and rams to provide power, offering high torque and rapid
response, suitable for specific operations.

o Pneumatic System: Rarely used in NC machining due to its large size and low torque.

According to Positioning System

o Incremental Positioning: The change in the previous position serves as the reference point for
determining the next position.
o Absolute Positioning: The point of origin is taken as the reference point, requiring the control unit to
calculate the position independently.
 ❖ PART PROGRAMMING –

Part programme is an important component of the NC/CNC system. The shape of the manufactured components
will depend on how correctly the programme has been prepared.
Part programme is a set of instructions which instructs the machine tool about the processing steps to be
performed for the manufacture of a component. Part programming is the procedure by which the sequence of
processing steps and other related data, to be performed on the NC/CNC machine is planned and documented.
The part programme is then transferred to one of the input media, which is used to instruct the NC/CNC
machine.

➢ To utilize numerical control in manufacturing, the following steps must be accomplished.

1.Preparing of NC Coordinate drawing- The first step in making a NC program is to convert the existing
blue print or shop drawing into an NC coordinate drawing.

2. Process Planning- The engineering drawing of the work part must be interpreted in terms of the
manufacturing processes to be used. this step is referred to as process planning and it is concerned with the
preparation of a route sheet. The route sheet is a listing of the sequence of operations which must be performed
on the work part. It is called a route sheet because it also lists the machines through which the part must be
routed in order to accomplish the sequence of operations.

3. Part programming- A part programmer plans the process for the portions of the job to be accomplished by
NC. Part programmers are knowledgeable about the machining process and they have been trained to program
for numerical control. They are responsible for planning the sequence of machining steps to be performed by
NC and to document these in a special format.

4. Tape preparation- A punched tape is prepared from the part programmers NC process plan. In manual part
programming, the punched tape is prepared directly from the part program manuscript on a typewriter like
device equipped with tape punching capability.

5. Tape verification- After the punched tape has been prepared, a method is usually provided for checking the
accuracy of the tape. Some times the tape is checked by running it through a computer program which plots the
various tool movements (or table movements) on paper. In this way, major errors in the tape can be discovered.
The "acid test" of the tape involves trying it out on the machine tool to make the part. A foam or plastic material
is sometimes used for this tryout. Programming errors are not uncommon, and it may require about three
attempts before the tape is correct and ready to use.

6. Production- The final step in the NC procedure to use the NC tape in production. This involves ordering the
raw work parts specifying and preparing the tooling and any special fixturing that may be required, and setting
up The NC machine tool for the job. The machine tool operator's function during production is to load the raw
work part in the machine and establish the starting position of the cutting tool relative to the workpiece. The NC
system then takes over and machines the part according to the instructions on tape. When the part is completed,
the operator removes it from the machine and loads the next part.
 ❖ Advantages of CAD/CAM in NC Programming:

Savings in geometry definition- Since the part geometry data have already been created during design using
the CAD/CAM graphics system, the part programmer is not required to redefine the geometry of the part. This
can be a time-consuming procedure in conventional APT programming.

2. Immediate visual verification- The graphics terminal provides a display of the tool path for immediate
verification by the part programmer. Most programming errors can be detected by the user and corrected at the
time the error is made. With conventional APT or other NC language, there is a delay between writing the
program and the verification/correction process.

3. Use of automatic programming routines- For common part programming situations such as profiling and
pocketing, the use of automatic MACRO-type routines yields a significant reduction in part programming time.

4. One-of-a-kind jobs- Because the part programming time is significantly reduced when using a CAD/CAM
system, numerical control becomes an economically attractive method for producing one-of-a-kind jobs.
Without CAD/CAM, the time required to prepare the part program represents a significant obstacle which often
precludes the use of NC for one/off production.

5. Integration with other related functions- There is the obvious opportunity to integrate the product design
function with part programming. Other opportunities for functional integration within manufacturing also exist.
These include tool design, process planning, preparation of operator and setup instructions, grouping of parts
into families for programming convenience, and so on.
 ❖ Steps on how to write a part program:
1. 1. Study the given component carefully.
This includes understanding the shape, size, and features of the component, as well as the materials
that it is made of.
2. 2. Assume suitable data if it is not mentioned in the question.
This may include things like the cutting speed, feed rate, and tool type.
3. 3. Decide the path to be followed by the cutter.
This involves planning the order in which the different features of the component will be cut, as well
as the exact path that the cutter will take.
4. 4. Write the coordinates of all the points in a separate table.
This table will be used by the machine controller to move the cutter to the correct positions.
5. 5. Start writing the program.
The first four blocks of the program are usually the same for all parts, so you can copy and paste these
blocks from a previous program. The remaining blocks will be specific to the current component, so
you will need to write them yourself.
Here is an example of a part program:

N100 G00 X0 Y0 Z0

N101 G01 X10 Y10 Z0

N102 G01 X20 Y20 Z0

N103 G01 X30 Y30 Z0

N104 G00 X0 Y0 Z0
6.In the next block bring the tool to Position number 1 but above the workpiece Surface. use G00

7.Then move the tool inside the workpleae use 01

8.Then move the tool to earlier Position.

9.The move the tool to next position by referring the table.

10.After the last tool Position bring Again the tool above the w/p Again the least blocks can be common for all
the programs.
 ❖ component of Part programming:-
1.words - It is a set of character composed of letter as well as Numeric digit. it gives command to the machine
what to perform and in what extent.

2.Address:- it is the single letter character in the begining of each word. it is used to define what the m/c should
do with.

3.Block: It is a series of word defined in a single instruction at the end of each block; we use symbol(;) which
means and of bleak.

4.syntax: - It is basically sequence of programming. It is the systematic arrangement of block of program in

sequential manner.

❖ Codes Used for CNC Programming

Task-specific CNC programming codes, identified by different letters of the alphabet, tell the machine tool
when, where, and how to remove material from the raw stock. These codes are collectively known as "G-
codes," even though, technically, the "g" refers only to the "geometry" of the part. The general term "G-code" is
used to encompass all the different types of coded instructions required to successfully machine a part. Some of
the most common CNC code types are listed below:

1. D-Codes: These refer to the CNC machine's tool offset which can either be the distance from the center
line of a tool to its cutting edge or how far the tool sticks out from the tool holder.
2. F-Codes: These are feed rate codes. They represent the varying speeds at which the tool is required to
move while cutting.
3. G-Codes: The “G in G-codes'' refers to “geometry.” G-codes are used to instruct the machine where to
start moving from, where to stop, and how to move between these two points.
4. M-Codes: These refer to miscellaneous functions such as coolant and spindle control. Basically, M-
codes refer to non-geometric actions.
5. N-Codes: N-codes are identify lines or blocks of machine code. The line labels help the CNC
programmer organize and follow manually written CNC code. Line numbers are often not required for
CAM-generated code.
6. S-Codes: These are speed codes, and represent the desired tool spindle speeds at different times during
the machining process.
7. T-Codes: These identify the tool to be used when machining a specific feature on the work-piece.

8.X – code :X-coordinate -These give the coordinate positions of the tool in x direction.
9.Y – code :Y-coordinate -These give the coordinate positions of the tool in y direction.
10.Z- code: Z-coordinate- These give the coordinate positions of the tool in z direction.
11.EOB - End of block -To identify the end of the instruction
Standard G and M Codes
The most common codes used when programming NC machines tools are G-codes (preparatory functions), and
M codes (miscellaneous functions). The total numbers of these codes are 100, out of which some of important
codes are given as under with their functions :
G-Codes (Preparatory Functions)
Code Function
G00 Rapid positioning
G01 Linear interpolation
G02 Circular interpolation clockwise (CW)
G03 Circular interpolation counterclockwise (CCW)
G20 Inch input (in.)
G21 Metric input (mm)
G24 Radius programming
G28 Return to reference point
G29 Return from reference point
G32 Thread cutting
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation positive (+) direction
G44 Tool length compensation minus (-) direction
G49 Tool length compensation cancels
G 53 Zero offset or M/c reference
G54 Settable zero offset
G84 canned turn cycle
G90 Absolute programming
G91 Incremental programming

M-Codes (Miscellaneous Functions)

M or miscellaneous codes are used to either turn ON or OFF different functions, which control certain machine
tool operations. M-codes are not grouped into categories, although several codes may control the same type of
operations such as M03, M04, and M05, which control the machine tool spindle. Some of important codes are
given as under with their function is:
Code Function
M00 Program stop
M02 End of program
M03 Spindle start (forward CW)
M04 Spindle start (reverse CCW)
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
 ❖ Method of part programming

1.Manual part programming-

To prepare a part program using the manual method, the programmer writes the machining instructions on a
special form called a part programming manuscript. The instructions must be prepared in a very precise manner
because the typist prepares the NC tape directly from the manuscript. Manuscripts come in various forms,
depending on the machine tool and tape format to be used. Manual programming jobs can be divided into two
categories: point-to point
jobs and contouring jobs. Except for complex workparts with many holes to be drilled, manual programming is
ideally suited for point-to-point applications. On the other hand, except for the simplest milling and turning
jobs, manual programming can. Become quite time consuming for applications requiring continuous-path
control of the tool.

2. COMPUTER-ASSISTED PART PROGRAMMING –

Many part programming language systems have been developed to perform automatically most of the
calculations which the programmer would otherwise be forced to do. This saves time and result in a more
accurate and more efficient part program.

Part programmer's job

The computer's job in computer-assisted part programming consists of the following steps:
Input translation- The part programmer enters the program written in the APT or other language. The input
translation component converts the coded instructions contained in the program into computer-usable form,
preparatory to further processing.

2. Arithmetic Calculations- The arithmetic calculations unit of the system consists of a comprehensive set of
subroutines for solving the mathematics required to generate thepart surface. These subroutines are called by the
various part programming language statements. The arithmetic unit is really the fundamental element in the part
programming package. This unit frees the programmer from the time-consuming geometry and trigonometry
calculations, to concentrate on the workpart processing.

3. Cutter offset - The purpose of the cutter offset computations is to offset the tool path from the desired part
surface by the radius of the cutter. This means that the part programmer can define the exact part outline in the
geometry statements. Thanks to the cutter offset calculation provided by the programming system, the
programmer need not be concerned with this task.

4. Post processor- The postprocessor is a separate computer program that has been written to prepare the
punched tape for a specific machine tool. The input to the post-processor is the output from the other three
components: a series of cutter locations and other instructions. The output of the postprocessor is the NC tape
written in the correct format for the machine on which it is to be used.
 ❖ PROBLEMS WITH CONVENTIONAL NC

1.Part programming mistakes - In preparing the punched tape, part programming mistakes are common. The
mistakes can be either syntax or numerical errors, and it is not uncommon for three or more passes to be
required before the NC tape is correct. Another related problem in part programming is to achieve the best
sequence of processing steps. This is mainly a problem in manual part programming.

2. Nonoptimal speeds and feeds - n conventional numerical control, the control system does not provide the
opportunity to make changes in speeds and feeds during the cutting process.

3. Punched tape - Paper tape is especially fragile, and its susceptibility to wear and tear causes it to be
unreliable NC component for repeated use in the shop.

4. Tape Reader – The tape reader tht interprets the punched tape is generally acknowledge among NC users to
be the least reliable hardware component of the machine.

5.Controller – The conventional NC controller unit is hard-wired. This means that its control features cannot be
easily altered to incorporate improvements into the unit.

6. Management Information – the conventional NC system is not equipped to provide timely information
on operational performance to management.

❖ Post Processor
A post processor is software that can translate your CAM data into specific commands for your machine.

Your CAM software analyzes your original CAD model, determining what tooling and tool-paths will be used
to machine the desired features. The post processor will take the NX language of the tool-paths, tools, etc., into
usable G-code to be used for your specific CNC machine and controller.

Essentially, it’s a translator, telling the CNC machine what to do. Each instance of translation is often referred
to as a “post.”

The processor of a computer is what allows it to perform calculations and to carry out other computer
operations.
The processor of a computer, or CPU, acts as its brain and allows it to perform calculations and other functions
associated with any programming on the computer. The processor turns the information entered into a binary
code consisting of zeros and ones. Once converted, this information goes to the CPU, which uses its
Arithmetical Logical Unit, or ALU, to perform any mathematical or logical operations.
The processor completes four basic steps when decoding data, including the following:

• Fetch: When an instruction from a program is uploaded to the computer’s memory, it’s given its own

address number. The processor uses this address to fetch the instruction from the program counter,

which tells the CPU the order it should execute the instructions associated with a particular program.

• Decode: The processor also decodes the instructions from programming into binary code so that it can

understand them. The CPU uses the ALU to complete this process.

• Execute: When executing the instructions from a program, the processor does one of three things. It

performs calculations using the ALU, moves data from one location in the computer’s memory to

another or moves to a different address within the computer’s memory.

• Store: Once the processor has executed an instruction from a program, it must give feedback in the form

of output data. This output data is then written to the computer’s memory for later reference.

Why Do I Need a Post Processor?

Post-processing is a critical part of manufacturing. Without a post processor, or with poor software, you can end
up with longer cycle times, damaged parts, ruined equipment, or worse. Having a specific post minimizes the
time and errors that can be cause by manual G-code editing.
 ❖ Computer-aided process planning:
Computer Aided Process Planning is a process, that is done by using the computer. It is the use of computer
technology to aid in the process planning of a part or product in manufacturing. CAPP is the link between
computer-aided design (CAD) and computer-aided manufacturing (CAM). It focuses on industrial processes
Computer-aided process planning (CAPP) is nothing but to produce a design that needed for manufacturing like
instruction, specifications etc
This is widely used due to the quick response and more flexibility in manufacturing firms. This used to set
standard timings in operation and helps in improving process planning.

This used to give a complete information to manufacture a product. To perform this operation it should be well
coordinate with CAD/CAM. this is an important technique used in the manufacturing industry

CAPP helps in:

• Selecting sequences of operations and machining conditions

• Selecting materials
• Selecting processes
• Selecting machines and tools
• Determining intermediate surfaces
• Selecting fixtures
• Selecting machining parameters
• Estimating cost and time
• Preparing plans
• Generating MC tape images
The general steps involved in CAPP are:

• Design input
• Material selection
• Process selection
• Process sequencing
• Machine and tool selection
• Intermediate surface determination
• Fixture selection
• Machining parameter selection
• Cost/time estimation
• Plan preparation
• Mc tape image generation
Benefits of computer-aided process planning
1.CAPP can give more complete and detailed process plans.
2.Process planning and production lead time is reduced
3.CAPP can give faster response to engineering changes.
4.Greater process plan consistency is ensured.
5.Easy access to up-to-date information in a central database can be made available.
6.CAPP can result in improved cost-estimating procedures and fewer calculation errors.
7.Production scheduling and capacity utilization are facilitated.
8.Improved ability is provided to introduce new manufacturing technology and rapidly update process plans to
utilize the improved technology.

Advantages
The following cost savings list is from a study of several companies:

• 58% effort reduction planning process.

• 10% savings in direct labor.
• 4% savings in material.
• 10% reduction in scrap metal.
• 12% savings on supplies.
• 6% reduction in work in process.

Disadvantages
• If the planner makes a mistake in the classification and coding (TG), there will be no quality process
plan.
• It gives efficient elaboration and control through the reduction of resources.
• It creates standardized procedures, which helps better knowledge.
• Lower cost of software creation and also
• Generative Approach
Types of CAPP
There are two types of systems:

1. Retrieval type:

• In Retrieval type, manufactured parts are used to divided into part families, this is done by
manufacturing characteristics. after this, we used to store the plane about to establish a standard
process plan for each part family. This plan can be retrieved at any time to use for the same
family. after this, we need to give a code number to it by this CAPP program used to find the
required family matrix and compress it. in this modification is done when there is a same code
number in the file is founders and make it to the new design by retrieving from operation
sequence and standard machining routing. By using a process plan format, the paper document is
prepared.

2. Generative type:

• This used to create the plan for process depend on logical procedure and geometric data. this
does not use retrieving or any other type that stored in the database.
• In this type for making a sequence planning it does not require human assistance. This is used for
solving complex problems and it has the high number of programmers in it to operate this it
required high skilled persons.
• In this there are different types of stages, the first stage is this used to store technical knowledge
and logic in process planning.
• The second stage it required developments in the description like computer compatibility, CAD,
group technology etc..
• The third stage is used to solve complex problems by using logic etc.