COMPUTER NUMERICAL CONTROL
OF MACHINE TOOLS
Laboratory for Manufacturing Systems and Automation
Department of Mechanical Engineering and Aeronautics
University of Patras, Greece
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Chapter 1:
An Introduction to Numerical Control
Machinery
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Objectives of Chapter 1
Describe the difference between direct and distributive
Numerical Control (NC)
Describe the difference between a numerical control tape
machine and a Computer Numerical Control (CNC) machine
Describe four ways that programs can be entered into a
computer numerical controller
Explain two tape code formats in use with CNC machinery
Give the major objectives of Numerical Control
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Objectives of Chapter 1
Numerical Control (NC) helps solve the problem of making
Manufacturing Systems (MFG) more flexible
“A Numerical Control machine is a machine positioned
automatically along a pre
pre--programmed path by means of
coded instructions”
Programming:: Manual programming of the
Manual Part Programming
machines
Computer Aided Programming (CAP): (CAP): Programming done
by a computer
(MDI): A manual program is entered into
Manual Data Input (MDI):
the machine’s controller via its own keyboard
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Objectives of Chapter 1
Computer is used as the Control Unit (CU) of the modern
Numerical Control machinery
Computer replaced the Tape Reader found on earlier NC
machines
Program is loaded into and executed from the machine’s
computer
Computer Numerical Control (CNC) machines are the NC
machines of today
on:: MDI programming of CNC machinery
FOCUS on
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES
Numerical control (NC) has been used in industry for more
than 40 years
NC is a method of automatically operating a manufacturing
machine based on a code of letters, numbers, and special
characters
A complete set of coded instructions for executing an
operation is called a program
The program is translated into corresponding electrical
signals for input to motors that run the machine
Numerical control machines can be programmed manually
If a computer is used to create a program, the process is
known as computer
computer--aided programming
The approach we take is in the form of Manual Programming
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
The History of NC
1947: J. Parsons (Parsons Corporation) began
experimenting for using 3-axis curvature data to control
machine tool motion for the production of aircraft
components
1949: Parsons awarded a US Air Force contract to build the
first NC machine
1951: MIT was involved in the project
1952: NC achieved when MIT demonstrated that
simultaneous 3-axis movements were possible using a
laboratory-build controller and a Cincinnati HYDROTEL
vertical spindle
1955: after refinements NC become available to industry
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
The History of NC
1959: MIT announces Automatic Programmed Tools (APT)
programming language
1960: Direct Numerical Control (DNC). This eliminates paper
tape punch programs and allows programmers to send files
directly to machine tools
1968: Kearney & Trecker machine tool builders market first
machining center
1970’s: CNC machine tools & DNC
1980’s: Graphics based CAM systems introduced. Unix and
PC based systems available
1990’s: Price drop in CNC technology
1997: PC Windows/NT based “Open Modular Architecture
Control (OMAC)” systems introduced to replace “firmware”
controllers
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
The History of NC
Early NC machines run off punched cards and tape
Due to the time and effort for editing and changing tapes
Computers where introduced for programming
Computers’ Involvement
Computer Aided Programming Direct Numerical Control
Languages
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
The History of NC
Languages:
Computer Aided Programming Languages:
Allow the development of an NC program using a set of
universal “pidgin English” commands
Computer translate commands into machine codes
Machine codes are punched into the tapes
Control::
Direct Numerical Control
A computer is used as a partial or complete controller of one
or more NC machines
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
The History of NC
(DNC):
Direct Numerical Control (DNC):
Expensive mainframe or mini mini--
computers were required in the past
Due to cost the use of DNC was
limited to large companies
Powerful PCs given rise to affordable
PC-
PC-based DNC systems
Most of PC-
PC-based DNC systems
running on MS Windows OS
FIGURE 1-
1-1: Direct numerical control
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
The History of NC
(DNC):
Distributed Numerical Control (DNC):
A network of computers is used to
coordinate the operation of a number
of CNC machines
Ultimately an entire factory can be
coordinated in this manner
Alternative System 1: NC program is
transferred in its entirety from a host
computer directly to machines
controller
Alternative System 2: NC program is
transferred from a mainframe or a
host computer to a PC on the Shop
Floor, stored and used when needed
FIGURE 1-
1-2: Distributed numerical control transferred to machine controller
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES
Numerical control systems’ components:
Tape punch: converts written instructions into a
corresponding hole pattern
The hole pattern is punched into tape, which passes through
this device
Much older units used a typewriter device called a
Flexowriter
Later devices included a microcomputer coupled with a tape
punch unit
Tape reader: reads the hole pattern on the tape and
converts the pattern to a corresponding electrical signal code
Controller: receives the electrical signal code from the tape
reader and subsequently causes the NC machine to respond
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES
machine:: responds to programmed signals from the
NC machine
controller. Accordingly, the machine executes the required
controller.
motions to manufacture a part (spindle rotation on/off, table and
or spindle movement along programmed axis directions, etc etc..).
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
NUMERICAL CONTROL DEFINITION, ITS CONCEPTS AND ADVANTAGES
FIGURE 1-
1-3 Components of traditional NC systems
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
DEFINITION OF CNC AND ITS COMPONENTS
A computer numerical control (CNC) machine is an NC
machine with the added feature of an on-
on-board computer
The on-
on-board computer is often referred to as the machine
control unit or MCU
Control units for NC machines are usu-ally hard wired
wired.. This
means that all machine functions are controlled by the physical
electronic elements that are built into the controller
The on-
on-board computer, on the other hand, is "soft" wired.
wired.
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
DEFINITION OF CNC AND ITS COMPONENTS
Thus, the machine functions are encoded into the computer at
the time of manufacture
They will not be erased when the CNC machine is turned off
off..
Computer memory that holds such infor-mation is known as
ROM or read
read--only memory
The MCU usually has an al-phanumeric keyboard for direct or
manual data input (MDI) of part programs
programs.. Such programs are
stored in RAM or the random
random--access memory portion of the
computer
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
DEFINITION OF CNC AND ITS COMPONENTS
They can be played back, edited, and processed by the
control. All pro-grams residing in RAM, however, are lost when
control.
the CNC machine is turned off
These programs can be saved on auxiliary storage devices
such as punched tape, magnetic tape, or magnetic disk
Newer MCU units have graphics screens that can display not
only the CNC program but the cutter paths generated and any
errors in the program
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
DEFINITION OF CNC AND ITS COMPONENTS
The components found in many CNC systems are shown in Figure
1- 3.
Machine control unit:
unit: generates, stores, and processes
CNC programs
programs.. The machine control unit also contains the
machine motion controller in the form of an executive software
program.. See Figure 1-4.
program
machine:: responds to programmed signals from the
NC machine
machine control unit and manufactures the part
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
DEFINITION OF CNC AND ITS COMPONENTS
machine:: responds to programmed signals from the
NC machine
machine control unit and manufactures the part
FIGURE 1-
1-4 Components of modern CNC systems
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
CNC Machines
A CNC machine has more programmable features than
older NC tape machinery
A CNC machine may be used as stand
stand--alone unit in a
network of machines – Flexible Machining Centers or
Machining Cells
CNC machines are easier to program by more than one
method::
method
On board computer keyboard
Tape reader / electronic connector to transfer a
program to CNC machine
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
CNC Machines
A CNC machine is a softsoft--wired controller
Once the CNC program is loaded into the computer’s
memory no HW is required to transfer the NC codes to the
controller
The controller uses a permanent resident program –
EXECUTIVE PROGRAM – to process the codes into
electrical pulses to control the machine
EXECUTIVE Program is called “executive software” or
“executive firmware”
EXECUTIVE program resides in ROM (Read Only
Memory)
NC code resides in RAM (Random Access Memory)
Firmware:: Routines of SW including low-
Firmware low-level instructions stored in ROM only for
reading
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
CNC Machines
ROM (Read Only Memory)
Is an electronic chip which can be accessed by a computer but not
altered (erased or written) without special equipment
The EXECUTIVE program can not be erased
The EXECUTIVE program is always active when machine is on
RAM (Random Access Memory)
RAM can be altered by the computer
NC code is written into RAM by keyboard or other outside source
The content of RAM is lost when the controller is turned off
Battery backup system is used for saving the program in the event
of power loss
CMOS (Complementary Metal
Metal––Oxide
Oxide––Semiconductor) memory
special type of RAM which retains the information content in the
case of power loos
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
CNC Machines
FIGURE 1-5 A high speed 4-axis vertical machining FIGURE 1-6 A high speed 4-axis horizontal
center machining center
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
CNC Machines
FIGURE 1-7 FIGURE 1-8
31/2 axis horizontal machining center A Tsugami ‘’lightning’’ 3 ½ axis horizontal
machining center
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
CNC Machines
FIGURE 1-
1-9 A precision NC lathe FIGURE 1-
1-10 A NC lathe
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
SPECIAL REQUIREMENTS FOR UTILIZING CNC
Computer numerical control machines can dramatically boost
productivity. The CNC manager, however, can only ensure
such gains by first addressing several critical issues
1. Sufficient capital must be allocated for purchasing quality CNC
equipment
2. CNC equipment must be maintained on a regular basis basis.. This
can be accomplished by obtaining a fullfull--service contract or by
hiring an in-
in-house technician
3. Personnel must be thoroughly trained in the setup and
operation of CNC machines
4. Careful production planning must be studied
studied.. This is because
the hourly cost of operating a CNC machine is usually higher
than that for conventional machines
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
FINANCIAL REWARDS OF CNC INVESTMENT
Investors are encouraged to look to the CNC machine tool as
a production so-lution with the following savings benefits
1. Savings in direct labor
labor..
2. One CNC machine's output is commonly equivalent to several
conventional machines
2. Savings in operator training expenses
3. Savings in shop supervisory costs
4. Savings due to tighter, more predictable production scheduling
5. Savings in real estate since fewer CNC machines are needed
6. Savings in power consumption since CNC machines produce
parts with a minimum of motor idle time
7. Savings from improved cost estimation and pricing
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
FINANCIAL REWARDS OF CNC INVESTMENT
8. Savings due to the elimination of construction of precision jigs,
and the reduced need for special fixtures Maintenance and
storage costs of these items are also reduced
9. Savings in tool engineering/design and documentation
documentation.. The
CNC's machining capability eliminates the need for special
form tools, special boring bars, special thread cutters, etc
etc..
10.
10. Reduced inspection time due to the CNC machine's ability to
produce parts with superior accuracy and repeatability
repeatability.. In many
cases, only spot checking of critical areas is necessary without
loss of machine time
time..
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
FINANCIAL REWARDS OF CNC INVESTMENT
Using Payback Period to Estimate Investment Efficiency
The Payback Period calculation estimates the number of years
required to re-cover the net cost of the CNC machine tool
Using ROI to Estimate Investment Efficiency
The ROI calculation predicts what percent of the net cost of the
CNC will be recovered each year year.. The ROI calculation accounts
for the useful life of the CNC machine tool
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
EXAMPLE 1 -1
Given the investment figures in Table 1-1 for implementing a
new CNC machine tool, determine the payback period and the
annual return on investment
investment.. The CNC is conservatively
estimated to have a useful life of 12 years
years..
This calculation estimates that the investor can expect 57% of
the net cost of the CNC or (.57 x $95,250) = $54,293 to be
recovered each year if the CNC machine's useful life is 12
years
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
CNC Machines
FIGURE 1-11
A CNC centerless grinding machine with an epoxy
granite bed, (Photo courtesy of Cincinnati
Machine)
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Input Media
Input Media for the NC code into the Controller
Are used to electronically or mechanically store the NC programs
An NC program is read from the input medium when it is loaded into the
machine
Old NC machinery could only read programs from punched tape or DNC
CNC machines may process multiple means of program input
Punched Tape
The oldest medium for program storage
Made from paper or Mylar plastic (stronger than paper)
The NC program code is entered into the tape by tape puncher in a form
of a series of holes representing the NC codes
A tape reader by electrical, optical or mechanical means senses the
holes and transfers the coded information into the machine computer
The NC code is entered into CAM or Word Processor program and
punched into tape
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Input Media
Magnetic Tape
Early experiments were not successful due to machine shop environment
High quality tapes of today can be used with reasonable care in handling
The most commonly used format is ¼ - inch computer cassette tape
Standards for tape format and coding have been developed by the
Electronics Industries Association (EIA)
Floppy Diskette
Popularized by the use of PCs in NC programming
The NC program is transferred into the CNC control by means of a
portable diskette drive attached to the communication port of the CNC
machine
The most common used port is RS232
RS232 (serial communication port)
Floppy diskettes are cheaper than other program storage options
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Input Media
FIGURE 1-
1-12 CNC input and storage media
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Binary Numbers
How controller processes information?
It is important in learning to program CNC machinery
Computers and Computer
Computer-- Controlled machinery do not deal in Arabic
symbols or numbers
All of the internal processing is done by calculating or comparing binary
numbers
Binary numbers contain only two digits
digits:: ZERO (0) and ONE (1)
Within CNC controller
controller::
Each binary digit “1” may represent a “positive charge” or
A binary digit “0” may represent a “negative charge” or
A “1” may be the “ON” or
A “0” may be the “OFF”
The CNC program code in binary form must be loaded into the computer
Programming formats and languages allow the NC code to be written
using alphabetic characters / base
base--ten decimal numbers
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Binary Numbers
When the NC program is
punched or recorded on
tape or other storage media
the information is
translated to binary form
FIGURE 1-
1-13 Binary numbers compared to Arabic numbers
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Tape Formats
General
Toady punched tape is not often used for NC program storage
Formats used in NC programming are still referred as Tape Formats
Computer files containing the NC programs are referred as “tape files”,
“punch files” or “tape image files”
Old machinery is still used in machine shops
RS-
RS-274 Format
Follows Electronics Industries Association (EIA) standard
Program information is contained in program lines called “Blocks”
“Blocks” are punched into the tape in one or two tape code standards
RS-
RS-274 is a “variable block coding” format
The information contained in a block may be arranged in any order
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Tape Formats
RS-
RS-244 Binary Coded Decimal (BCD)
The EIA RS-
RS-244 standard is one of the two tape codes used for NC tapes
Became a standard early in the development of NC – limited punctuation
Each hole represents the digit “1” while each blank the digit “0”
The tape code allows alphabetic characters and base
base--ten numbers to be
translated into the binary code the controller requires (Binary Coded
Decimal – BDC)
RS-
RS-358 Format
Government, telephone and Computer industries required tape code
containing upper and lower case letters
The existing tape coding formats were sufficient only for machining
The standard accepted was American Standard Code for Information
Interchange (ASCII)
EIA RS-
RS-358 was adopted
EIA RS-
RS-358 is also as ISO and ASCII is a subset of the ASCII code used
in other applications – Today is dominant over RS-
RS-244
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Tape Formats
FIGURE 1-
1-14, EIA RS-
RS-244 tape code
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Objectives of Numerical Control
Numerical control (NC) was developed with these goals in mind:
mind:
To increase production
To reduce labor costs
To make production more economical
To do jobs that would be impossible or impractical without NC
To increase the accuracy of duplicate parts
Before deciding to utilize an NC or CNC machine for a particular job the
requirements and economics must be weighted against the advantages
and disadvantages of the machinery
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Objectives of Numerical Control
Advantages
Increased productivity
Reduced tool/fixture storage and cost
New functions can be programmed into the MCU as software Less
hardware
Many different CNC programs can be stored in the MCU
Faster setup time
Reduced parts inventory
Flexibility that speeds changes in design
Better accuracy of parts
Reduction in parts handling
Better uniformity of parts
Better quality control
Improvement in manufacturing control
Several DNC can be networked forming a large distributive NC system
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Objectives of Numerical Control
Disadvantages
Increase in electrical maintenance
High initial investment
Higher per
per--hour operating cost than traditional machine tools
Retraining of existing personnel
NC is a general term used for Numerical Control. CNC refers
specifically to COMPUTER NUMERICAL CONTROL. CNC machines are
all NC machines but not all NC machines are CNC machines
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Applications in Industry
Originally developed for use in Aerospace industries
Widespread in manufacturing
manufacturing::
Aerospace
Defence
Automotive
Electronic
Appliance
Tooling industries
Advances in microelectronics have lowered the cost of acquiring CNC
equipment
Bending, Forming, Stamping and Inspection Machines have been
produced as NC systems
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Summary 1/2
An NC machine is a machine positioned automatically along a
preprogrammed path by way of coded instructions
DNC involves a computer that acts as a partial or full controller to
one or more NC machines
Distributive NC is a network of computers and NC machinery
coordinated to perform some task
CNC machines use an on
on--board computer as a controller
Offline programming is the programming of a part away from the
computer keyboard - usually done with a micro-
micro-computer
computer..
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Summary 2/2
There are four ways to input programs into CNC machinery
machinery::
MDI (Manual Data Input)
Punched Tape
Magnetic Tape
DNC (Direct Numerical Control / Distributive Numerical Control)
The CNC program must be loaded into the controller in binary form
RS-
RS-244 and RS-
RS-358 tape codes used to place information on punched
tape information being punched into the tape in binary form
Before deciding on a NC machine for a specific job, the advantages
and disadvantages of NC must be weighed in view of the primary
objectives of numerical control
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
Vocabulary Introduced in this chapter
ASCII
Binary coded decimal (BCD)
Computer Aided Programming (CAP)
Computer Numerical Control (CNC)
Direct Numerical Control (DNC)
Distributive numerical control
Input media
Manual Data Input (MDI)
Manual part programming
Numerical control (NC)
Random Access Memory (RAM)
Read
Read--only Memory (ROM)
Word address format
Laboratory for Manufacturing Systems and Automation Dr. Dimitris Mourtzis
