INTRODUCTION TO CNC

First Nc milling machine in 1952 at in US market. In 1955 - First generation N\c systems in US market . In 1965 - Breakthrough when N\c m\ces were fitted with mini computers. Today - N\c machines are fitted with mini computers and microprocessors.

What is NC?
Numerical control is a technique by which a machine or process can be automated through a series of coded instructions consisting of numbers and other symbols. NC machine have no memory of their own, and hence capable of only single block of information.

Manual NC
Manually one links the hand wheel,by which the motors get actuated & Machining can be done on X,Y,Z axis Cycles are built in menu driven bus Eg: Threading-- Ext or Int
Parameters to be entered like Pitch,Minor dia,Major dia More useful for converting manual machine to semiautomatic machine

What is CNC?
Computerized Numeric control (CNC) the term used when the control system of an NC includes a computer. The availability of dedicated computer permits control features to be made available on CNC systems .

CNC M\CES ARE DESIGNED TO MEET THE REQUIREMENTS OF *

HIGH PRODUCTIVITY.

* FLEXIBILITY

* HIGH RELIABILITY

Functions of CNC system

Data input
Computation Sequence control

Data input
The control of peripheral devices such as control panels,CRT displays,keyboards,etc. Preprocessing the part program data in to from suitable for onward transmission to the computational areas of the system. Distribution of data to all other function areas in the system.

Computation
Axis feed rate from the programme vector rate Interpolated data along a path defined by the programmed co-ordinate data. Positional servo error to establish the correct error input to the axis servo Cutter radius compensation vectors to enable the operator to make fine adjustments to the cutter path

Sequence control
The overall or executive control of the system
The control of machine dependent functions,such as spindles,tool changes,etc..

Control features
Stored programs Editing facilities Stored patterns Canned cycles Compensation possibilities Tool path graphics Control of feed rate
machines go up to 24 m/min

Control features
Control of spindle rotational speeds In latest machine spindle speed go up to 18,000RPM (But optional ) High frequency spindles Control of coolant Control of Accuracy Up to 1 micron Control of tool change Control of other functions eg., tool wear/breakage monitoring,pallet changing,robot loading function.

Configuration of a CNC system

CRT display/ Key Board Computer NC Hardware Micro program and computer storage servo system

There are three basic components they are 1. Programme of instructions 2. Controller unit also called as machine control unit.It is the brain of the CNC system 3. Machine tool or other controlled equipment.
Program of instruction CNC controller Actuating Device (Spindle motor )

Feed back (Transducer ,Resolver Encoder) Machine tool

CNC HARD WARE

Hardware

Main drive Main spindle motor controller ACor DC

Feed Drive Servo motor AC or DC

Feed back Encoder,Resolver, Tacho generator

CNC HARD WARE

Microprocessors that effect control system functions
Peripheral devices for data communications machine tool interfacing

machine

tool status monitoring

CNC SOFTWARE

CONTROL SOFTWARE

APPLICATION SOFTWARE

CNC SOFTWARE ELEMNTS

Operating system System control I/O control Programming languages Graphics CAD/CAM interface

Servo control

Diagnostics

Computation

Special functions

CNC SOFTWARE
Includes programs executed by system microprocessors Process I\O instructions
Make all necessary computations for machine functions

 THREE AXIS OF MOVEMENT ARE IDENTIFIED AS X,YAND Z AXIS.

Z- Axis The Z Axis of motion is always the axis of the main spindle of the machine.It doses not matters whether the spindle carreies the work piece or the cutting tool . X-Axis The axis is always horizontal and is always parallel to the work holding surface.
Y- Axis The axis is always at right angle to both XAxis and Z-Axis Rotary axis.The rotary motion about the X,Y and ZAxis are identified by A,B,C respectively

BENEFITS OF CNC
Improved automation. The operator intervention related to producing workpieces can be reduced or eliminated. Consistent and accurate workpieces. Flexibility. Since these machines are run from programs, running a different workpiece is almost as easy as loading a different program.

BENEFITS OF CNC
Tool inventory low and hence tool storage cost reduced. Costly marking operation and human errors eliminated. Editing the program easy. Metric to inch or viceversa conversion. Applicable from one off to mass production.

LIMITATIONS OF CNC
Initial cost is very high. Maintenance of CNC machines requires skilled personnel. Higher maintenance cost & support cost result in to higherly hourly rate for CNC machines.

Applications of CNC
CNC lathe CNC turning centers CNC milling machines Machining Center

Turn-mill Centers
CNC Drilling machines Gear hobbing machines

Gear shaping
Grinding machine Tool and cutter grinder

Applications of CNC
PCB drilling machines Wire Cut EDM

Electron beam welding

Laser /arc/plasma cutting CNC Transfer lines,SPMs

Co-ordinate measuring machine

Tube Bending Press brakes CNC turret punch presses Multiple Spindle Center

Configuration of a DNC system

Central computer Bulk memory NC programs
Telecommunication lines

Advantages of DNC
Reduction in set-up time, ie only program loading( data transfer task) Status reporting systems Security for part program Downloading the same program in different machine tools Integration with other layers of CIM

 Distribute instruction data and collect data from a large number of machines Computer location is remote from the machines under their control Also serves as Management information system

Comparison DNC Vs CNC

Can control only one machine

Computers are located very near or on the machine tools Augment capabilities of a particular machine tool

Trends and Changes

The changes & trends that have taken place in just the last 20 years: Maximum feed rates were 100 ipm; now 600 ipm is common, and 1200 ipm is better. Data density of 0.04-inch point departures was close and accurate; now closer than 0.004 inch is common and may even be closer than 0.001 inch. Files of 64 kilobytes were very large; now files regularly exceed 10 megabytes (MB) and may exceed even 100 MB. Sculptured surfaces were used occasionally for aesthetics; now sculptured surfaces are widely used for both function and appearance.

Trends and Changes

Digital signal processing uses special dedicated processors to convert and interpret digital signals at very high speeds.

The latest motion control card allows 7000 blocks per second transfer rates, using "dual-ported" (shared) memory technology.

OS like windows & dos are getting replaced with real time operating systems like Qnx,Win-CE,Vxworks,etc.. Tool wear, for example, will be anticipated and operators will be alerted before parts go out of tolerance. Another possibility is changing tool offsets in the tooling databases automatically, thereby compensating for tool wear on the fly.

Dynamic Times For CNC

Today, CNC technology offers shops and plants more options and choices than ever before. It is clear that many companies will be changing their direction, based on the new possibilities and opportunities presented by the widening spectrum of this technology. It is impossible to predict where these trends will lead, except to a future in which the control and monitoring of machine tools will be very unlike what we are accustomed to today.