CNC

NC,CNC machines and Control Programming
History of CNC
1949 US Air Force asks MIT to develop a "numerically controlled" machine. 1952 Prototype NC machine demonstrated (punched tape input)
1980CNC machines (computer used to link directly to controller)

1990DNC: external computer drip feeds control programmer to machine tool controller
Motivation and uses
To manufacture complex curved geometries in 2D or 3D was extremely expensive by mechanical means (which usually would require complex jigs to control the cutter motions)
Machining components with repeatable accuracy
Unmanned machining operations
Advantages of CNC
- Easier to program; - Easy storage of existing programs; - Easy to change a program - Avoids human errors - NC machines are safer to operate
- Complex geometry is produced as cheaply as simple ones

- Usually generates closer tolerances than manual machines
Conventional milling machines
Vertical milling machine

Vertical Milling machine architecture

Horizontal Milling machine architecture
How does the table move along X- Y- and Z- axes ?
NC machines
Motion control is done by: servo-controlled motors
Table Leadscrew Encoder A/C Motor ~
Servo Controller Counter Comparator
Input (converted from analog to digital value)
CNC terminology
BLU: basic length unit smallest programmable move of each axis.
Controller: (Machine Control Unit, MCU) Electronic and computerized interface between operator and m/c Controller components: 1. Data Processing Unit (DPU) 2. Control-Loops Unit (CLU)
Controller components
Data Processing Unit: Input device [RS-232 port/ Tape Reader/ Punched Tape Reader] Data Reading Circuits and Parity Checking Circuits
Decoders to distribute data to the axes controllers.
Control Loops Unit: Interpolator to supply machine-motion commands between data points
Position control loop hardware for each axis of motion
Types of CNC machines

Based on Motion Type: Point-to-Point
or
Continuous path
Based on Control Loops: Open loop or Closed loop
Based on Power Supply: Electric or Hydraulic or Pneumatic
Based on Positioning System Incremental or Absolute
Open Loop vs. Closed Loop controls
Open loop control of a Point-to-Point NC drilling machine

NOTE: this machine uses stepper motor control
Components of Servo-motor controlled CNC

Motor lead screw rotation table moves
Motor speed control
feedback
position sensed by encoder
Two types of encoder configurations
Motion Control and feedback
Encoder outputs: electrical pulses (e.g. 500 pulses per revolution) Rotation of the motor linear motion of the table: by the leadscrew The pitch of the leadscrew: horizontal distance between successive threads One thread in a screw single start screw: Dist moved in 1 rev = pitch Two threads in screw double start screw: Dist moved in 1 rev = 2* pitch
Example 1
A Stepping motor of 20 steps per revolution moves a machine table through a leadscrew of 0.2 mm pitch.
(a) What is the BLU of the system ?
(b) If the motor receives 2000 pulses per minute, what is the linear velocity in inch/min ?
Example 2
A DC servo-motor is coupled to a leadscrew (pitch 5mm) of a machine table. A digital encoder, which emits 500 pulses per revolution, is mounted on the leadscrew. If the motor rotates at 600 rpm, find (a) The linear velocity of the table
(b) The BLU of the machine
(c) The frequency of pulses emitted by the encoder.
Manual NC programming
Part program: A computer program to specify
- Which tool should be loaded on the machine spindle; - What are the cutting conditions (speed, feed, coolant ON/OFF etc) - The start point and end point of a motion segment - how to move the tool with respect to the machine.
Standard Part programming language: RS 274-D (Gerber, GN-code)
History of CNC
The RS274-D is a word address format
Each line of program == 1 block
Each block is composed of several instructions, or (words) Sequence and format of words:
N3
sequence no
G2 X+1.4 Y+1.4 Z+1.4 I1.4 J1.4 K1.4 F3.2 S4 T4 M2

destination coordinates dist to center of circle tool spindle speed
preparatory function
feed rate
miscellaneous function
Manual Part Programming Example

5 2.5 p2 1 p3 p4 p5
45 (4, 4) p1 p0 (2, 2)
Tool size = 0.25 inch, Feed rate = 6 inch per minute, Cutting speed = 300 rpm, Tool start position: 2.0, 2.0 Programming in inches
Motion of tool: p0 p1 p2 p3 p4 p5 p1 p0
1. Set up the programming parameters

5 2.5 p2 1 p3 p4 p5
Programming in inches
5
Use absolute coordinates Feed in ipm

45
N010 G70 G90 G94 G97 M04

(4, 4) p1 p0 (2, 2)
Spindle speed in rpm Spindle CCW
2. Set up the machining conditions

5 2.5 p2 1 p3 p4 p5
Machine moves in XY-plane Use full-circle interpolation

5
Feed rate Spindle speed

45
N020 G17 G75 F6.0 S300 T1001 M08

(4, 4) p1 p0 (2, 2)
Tool no. Flood coolant ON
3. Move tool from p0 to p1 in straight line

5 2.5 p2 1 p3 p4 p5
Linear interpolation target coordinates
N030 G01 X3.875 Y3.698
45 (4, 4) p1 p0 (2, 2)
4. Cut profile from p1 to p2

5 2.5 p2 1 p3 p4 p5
Linear interpolation
5
target coordinates
N040 G01 X3.875 Y9.125

45
or
(4, 4) p1 p0 (2, 2)
N040 G01 Y9.125
X-coordinate does not change no need to program it
5. Cut profile from p2 to p3

5 2.5 p2 1 p3 p4 p5
Linear interpolation target coordinates
N050 G01 X5.634 Y9.125

5
y = 9 + 0.125 = 9.125 (6.5 - x)2 + 0.1252 = (1 - 0.125)2 x = 5.634 p3 (x, y)
45 (4, 4) p1 p0 (2, 2)
1
(6.5, 9) .125
6. Cut along circle from p3 to p4

5 2.5 p2 1 p3 p4 p5
circular interpolation, CCW motion

5
target coordinates
45 (4, 4) p1 p0 (2, 2)
N060 G03 X7.366 Y9.125 I6.5 J9.0

coordinates of center of circle
7. Cut from p4 to p5
5 2.5 p2 1 p3 p4 p5
45 (4, 4) p1 p0 (2, 2)
target coordinates (Y is unchanged)
N070 G01 X9.302
8. Cut from p5 to p1
5 2.5 p2 1 p3 p4 p5
Linear interpolation target coordinates (see step 3)

45
N080 G01 X3.875 Y3.698

(4, 4) p1 p0 (2, 2)
9. Return to home position, stop program

5 2.5 p2 1 p3 p4 p5
5
target coordinates (see step 3)
N090 G01 X2.0 Y2.0 M30

45 (4, 4) p1 p0 (2, 2)
end of data
N100 M00
program stop
Automatic Part Programming

Software programs can automatic generation of CNC data
Define Tool
CNC data
Make 3D model Simulate cutting
Automatic part programming and DNC

Very complex part shapes very large NC program NC controller memory may not handle HUGE part program
computer feeds few blocks of NC program to controller
When almost all blocks executed, controller requests more blocks

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NC,CNC machines and Control Programming

1980CNC machines (computer used to link directly to controller)

Motivation and uses

Machining components with repeatable accuracy

Unmanned machining operations

- Complex geometry is produced as cheaply as simple ones

Conventional milling machines

Vertical milling machine

Conventional milling machines

Conventional milling machines

How does the table move along X- Y- and Z- axes ?

Table Leadscrew Encoder A/C Motor ~

Servo Controller Counter Comparator

Input (converted from analog to digital value)

BLU: basic length unit smallest programmable move of each axis.

Decoders to distribute data to the axes controllers.

Position control loop hardware for each axis of motion

Types of CNC machines

Based on Control Loops: Open loop or Closed loop

Based on Power Supply: Electric or Hydraulic or Pneumatic

Based on Positioning System Incremental or Absolute

Open Loop vs. Closed Loop controls

Open loop control of a Point-to-Point NC drilling machine

Components of Servo-motor controlled CNC

Motor speed control

position sensed by encoder

Two types of encoder configurations

Motion Control and feedback

(a) What is the BLU of the system ?

(b) The BLU of the machine

(c) The frequency of pulses emitted by the encoder.

Standard Part programming language: RS 274-D (Gerber, GN-code)

Each line of program == 1 block

G2 X+1.4 Y+1.4 Z+1.4 I1.4 J1.4 K1.4 F3.2 S4 T4 M2

Manual Part Programming Example

1. Set up the programming parameters

Use absolute coordinates Feed in ipm

N010 G70 G90 G94 G97 M04

Spindle speed in rpm Spindle CCW

2. Set up the machining conditions

Machine moves in XY-plane Use full-circle interpolation

Feed rate Spindle speed

N020 G17 G75 F6.0 S300 T1001 M08

Tool no. Flood coolant ON

3. Move tool from p0 to p1 in straight line

Linear interpolation target coordinates

N030 G01 X3.875 Y3.698

4. Cut profile from p1 to p2

N040 G01 X3.875 Y9.125

N040 G01 Y9.125

X-coordinate does not change no need to program it

5. Cut profile from p2 to p3

Linear interpolation target coordinates

N050 G01 X5.634 Y9.125

6. Cut along circle from p3 to p4

circular interpolation, CCW motion

N060 G03 X7.366 Y9.125 I6.5 J9.0

target coordinates (Y is unchanged)