Advantages of NC machine tools:

•Reduced lead time: Time needed for planning, design

and manufacture of jigs, etc
•Elimination of operator errors:
•Operator activity
•Lower labor cost
•Smaller batches
•Longer tool life
•Elimination of special jigs and fixtures
•Flexibility in changes of component design
• Reduced inspection
•Reduced scrap
•Accurate costing and scheduling
 Evolution of CNC:
With the availability of microprocessors in mid 70’s the
controller technology has made a tremendous progress. The new
control systems are termed as computer numerical control
(CNC) which are characterized by the availability of a dedicated
computer and enhanced memory in the controller. These may
also be termed “soft wired numerical control”.
• Part program storage memory.
• Part program editing.
• Part program downloading and uploading
• Part program simulation using tool path
• Tool offset data and tool life management
• Additional part programming facilities.
• Macros and subroutines.
• Background tape preparation, etc.
 Advantages of CNC
1. Increased productivity.
2. High accuracy and repeatability.
3. Reduced production costs.
4. Reduced indirect operating costs.
5. Facilitation of complex machining operations
6. Greater flexibility.
7. Improved production planning and control.
8. Lower operator skill requirement.
9. Facilitation of flexible automation.
 Limitations of CNC
1. High initial investment.
2. High maintenance requirement.
3. Not cost-effective for low production cost.
 Features of CNC
Storage of more than one part program
Various forms of program input
Program editing at the machine tool
Fixed cycles and programming subroutines
Interpolation
Positioning features for setup
Cutter length and size compensation
Acceleration and deceleration calculations
Communications interface
Diagnostics
 Machining centres
• Machining center concept is to bring machine
to the work.
• Machining centres incorporates automatic tool
changer and rotary table. Here, we can do
more operations and in more directions usually
4 or 5.
 Machining centres
Recent machining centre designs have following features:
I. Reduction of non productive time by applying ATC
and more rapid traverse motions.
II. Increased accuracy by using rigid welded construction
for beds and columns.
III. Heavier allowable cutting depths and feeds.
IV. Improved user- oriented machine diagnostics.
V. Using bubble memory to store many part programs.
Machining centres are classified as vertical, horizontal, or
universal. The designation refers to the orientation of the
machine spindle.
 Classification
1. A vertical machining centre has its spindle on a vertical
axis relative to the work table. A vertical machining centre
(VMC) is typically used for flat work that requires tool
access from top. E.g. mould and die cavities, Large
components of aircraft
2. A horizontal machining centre (HMC) is used for cube
shaped parts where tool access can be best achieved on
the sides of the cube. Some times they incorporate double
column. Machine spindle goes to the work.
3. A universal machining centre (UMC) has a work head
that swivels its spindle axis to any angle between
horizontal and vertical making this a very flexible
machine tool. E.g.: Aerofoil shapes, Curvilinear
geometries.
 AUTOMATIC TOOL CHANGER
The CNC machines are designed to perform a number
of operations in a single setting of the job. A number
of tools may be required for making a complex part.
In a manual machine, the tools are changed manually
whenever required. In a CNC machine, tools are
changed through program instructions. The tools are
fitted in a tool magazine or drum. When a tool needs
to be changed, the drum rotates to an empty
position, approaches the old tool and pulls it. Then it
again rotates to position the new tool, fits it and then
retracts. This is a typical tool changing sequence of an
automatic tool changer (ATC).
 The concept of the ATC is that the range of
tools for a specific job shall be made available
for automatic selection and positioning. ATC
cab be
Drum Type
• For holding small number of tools usually not
more than 30, Stored on periphery of drum and
tool search speed is faster.
Chain Type
• For more number of tools (40 or more), tools
search speed is less.
 Automatic Tool Changer Advantages
(a) Lines changed in seconds instead of hours.
(b) Increase operator safety by changing tools
automatically.
(c) Change tools in seconds for maintenance
and repair.
(d) Increase flexibility.
(e) Heavy and large multi-tools that are
automatically exchanged.
• Reference Point: Part programming requires
establishment of some reference points. Three reference
points are either set by manufacturer or user.
• Machine Origin: The machine origin is a fixed point
set by the machine tool builder. Usually it cannot be
changed. Any tool movement is measured from this
point. The controller always remembers tool distance
from the machine origin.
• Program Origin: It is also called home position of the
tool. Program origin is point from where the tool starts
for its motion while executing a program and returns
back at the end of the cycle. This can be any point
within the workspace of the tool which is sufficiently
away from the part. In case of CNC lathe it is a point
where tool change is carried out.
• Part Origin
•

The part origin can be set at any point inside

the machine's electronic grid system.
Establishing the part origin is also known as
zero shift, work shift, floating zero or datum.
Usually part origin needs to be defined for
each new setup. Zero shifting allows the
relocation of the part. Sometimes the part
accuracy is affected by the location of the part
origin. Figures shows the reference points on a
lathe and milling machine.
Machine Control Unit
 Machine Control Unit
The electronic logic was termed an MCU, and it did the
things you would expect of a basic computer control unit. It
took in instructions, and sent out electrical signals to control
motors (servos, usually) which made the slides move.
The controller unit is most vital parts part of the NC and CNC
machines. The controller unit is made of the electronics
components. It reads and interprets the program of instructions
and converts them in the mechanical actions of the machine
tool. Thus the controller unit forms an important link between
the program and the machine tool. The control unit operates
the machines as per the set of instructions given to it.
 Machine Control Unit
The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:
To read the coded instructions.
To decode the coded instructions.
To implement interpolations (linear, circular, and helical)
to generate axis motion commands.
To feed the axis motion commands to the amplifier
circuits for driving the axis mechanisms.
To receive the feedback signals of position and speed for
each drive axis.
To implement auxiliary control functions such as coolant
or spindle on/off and tool change.
 Interpolation Methods
1. Linear interpolation
 Straight line between two points
in space
2. Circular interpolation
 Circular arc defined by starting
point, end point, center or radius,
and direction
3. Helical interpolation
 Circular plus linear motion
4. Parabolic and cubic interpolation
 Free form curves using higher
order equations
 Interpolation
X axis moves ‘p’ units and Y axis ‘q’ units and ‘V’ feed rate . They
are programmed on the tape and fed into the interpolator.
Interpolator provide two velocity signals Vx and Vy in pulsed form.

and