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Lecture 7 and 8

The document discusses numerical control (NC) and computer numerical control (CNC) systems. It covers levels of automation, NC coordinate systems, motion control systems, interpolation methods, NC part programming methods including manual, computer-assisted, and CAD/CAM-based approaches. The key components of an NC system and issues in manual and CAD/CAM-based NC part programming are also summarized.

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Philani Xaba
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28 views

Lecture 7 and 8

The document discusses numerical control (NC) and computer numerical control (CNC) systems. It covers levels of automation, NC coordinate systems, motion control systems, interpolation methods, NC part programming methods including manual, computer-assisted, and CAD/CAM-based approaches. The key components of an NC system and issues in manual and CAD/CAM-based NC part programming are also summarized.

Uploaded by

Philani Xaba
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Automation Review

Advanced Automation Functions


1. Safety monitoring
2. Maintenance and repair diagnostics
3. Error detection and recovery

Levels of Automation
1. Device level – actuators, sensors, and other hardware
components to form individual control loops for the next
level
2. Machine level – CNC machine tools and similar production
equipment, industrial robots, material handling equipment
3. Cell or system level – manufacturing cell or system
4. Plant level – factory or production systems level
5. Enterprise level – corporate information system
Numerical Control
Sections:
1. Fundamentals of NC Technology
2. Computer Numerical Control
3. DNC
4. Applications of NC
5. NC Part Programming

Numerical Control Defined


Form of programmable automation in which the mechanical actions of a
machine tool or other equipment are controlled by a program containing
coded alphanumeric data
• The alphanumeric data represent relative positions between a work-head
(e.g., cutting tool) and a work-part
Basic Components of an NC System
1. Program of instructions
 Part program in machining
2. Machine control unit
 Controls the process
3. Processing equipment
 Performs the process

NC Coordinate Systems
For flat and prismatic parts, i.e. Milling operations
• Conventional Cartesian coordinate system
• Rotational axes about each linear axis
• Right hand rule

For rotational parts, i.e. Turning operations


• Conventional Cartesian coordinate
system, but only x- and z-axes
Motion Control Systems

Point-to-Point systems
 Also called position systems
 System moves to a location and
performs an operation at that location
(e.g., drilling)
 Also applicable in robotics

Continuous path systems


 Also called contouring systems in
machining
 System performs an operation during
movement (e.g., milling and turning)
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
(Splines and NURBS – Non-Uniform Rational Basis
Splines)

Absolute and Incremental Positioning


The work-head is presently at point (20, 20)
and is to be moved to point (40, 50)
 In absolute positioning, the move is specified
by x = 40, y = 50
 In incremental positioning, the move is
specified by x = 20, y = 30.
Computer Numerical Control (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
 Acceleration and deceleration computations
 Communications interface
 Diagnostics

Configuration of CNC Machine Control Unit


DNC
 Direct numerical control (DNC) – control of multiple machine tools by a single
(mainframe) computer through direct connection and in real time
 1960s technology
 Two way communication
 Distributed numerical control (DNC) – network consisting of central computer
connected to machine tool MCUs, which are CNC
 Present technology
 Two way communication

General Configuration of a Direct Numerical Control System


Distributed Numerical Control Configurations

Switching network

Local area network (LAN)


Applications of NC

 Machine tool applications:


 Milling, drilling, turning, boring, grinding
 Machining centers, turning centers, mill-turn centers
 Punch presses, thermal cutting machines, etc.
 Other NC applications:
 Component insertion machines in electronics
 Drafting machines (x-y plotters)
 Coordinate measuring machines
 Tape laying machines for polymer composites
 Filament winding machines for polymer composites
CNC Horizontal Milling Machine

 Typical motor and leadscrew arrangement in an NC


positioning system for one linear axis
 For x-y capability, the apparatus would be
piggybacked on top of a second perpendicular axis
Motion Control System
Precision in NC Positioning
Three measures of precision:
1. Control resolution - distance separating two adjacent addressable points in
the axis movement
2. Accuracy - maximum possible error that can occur between the desired
target point and the actual position taken by the system
3. Repeatability - defined as 3 of the mechanical error distribution
associated with the axis
NC Part Programming
1. Manual part programming
2. Computer-assisted part programming
3. Part programming using CAD/CAM
4. Manual data input
Block Format

Organization of words within a block in NC part program


 Also known as tape format because the original formats were designed
for punched tape
 Word address format - used on all modern CNC controllers
 Uses a letter prefix to identify each type of word
 Spaces to separate words within the block
 Allows any order of words in a block
 Words can be omitted if their values do not change from the previous
block
Types of Words
N - sequence number prefix
G - preparatory words
 Example: G00 = PTP rapid traverse move
X, Y, Z - prefixes for x, y, and z-axes
F - feed rate prefix
S - spindle speed
T - tool selection
M - miscellaneous command
 Example: M07 = turn cutting fluid on

N001 G90
N002 M03 S3000 F1400
N003 G00 Z01
N004 X30 Y30
N005 X70
N006 G01 Z-10
Issues in Manual Part Programming

 Adequate for simple jobs, e.g., PTP drilling


 Linear interpolation
G01 G94 X050.0 Y086.5 Z100.0 F40 S800
 Circular interpolation
G02 G17 X088.0 Y040.0 R028.0 F30
 Cutter offset
G42 G01 X100.0 Y040.0 D05
Computer-Assisted Part Programming
 Manual part programming is time-consuming, tedious, and subject to
human errors for complex jobs
 Machining instructions are written in English-like statements that are
translated by the computer into the low-level machine code of the MCU
 APT (Automatically Programmed Tool)
 The various tasks in computer-assisted part programming are divided
between
 The human part programmer
 The computer
Defining Part Geometry

 Underlying assumption: no matter how complex the part geometry, it is


composed of basic geometric elements and mathematically defined
surfaces
 Geometry elements are sometimes defined only for use in specifying tool
path
 Examples of part geometry definitions:
P4 = POINT/35,90,0
L1 = LINE/P1,P2
C1 = CIRCLE/CENTER,P8,RADIUS,30
Specifying Tool Path and Operation Sequence

 Tool path consists of a sequence of points or connected line and arc


segments, using previously defined geometry elements
 Point-to-Point command:
GOTO/P0
 Continuous path command
GOLFT/L2,TANTO,C1
Other Functions in Computer-Assisted Part
Programming

 Specifying cutting speeds and feed rates


 Designating cutter size (for tool offset calculations)
 Specifying tolerances in circular interpolation
 Naming the program
 Identifying the machine tool
NC Part Programming Using CAD/CAM

 Geometry definition
 If the CAD/CAM system was used to define the original part
geometry, no need to recreate that geometry as in APT
 Automatic labeling of geometry elements
 If the CAD part data are not available, geometry must be created,
as in APT, but user gets immediate visual feedback about the
created geometry
Tool Path Generation Using CAD/CAM

 Basic approach: enter the commands one by one (similar to APT)


 CAD/CAM system provides immediate graphical verification of the
command
 Automatic software modules for common machining cycles
 Profile milling
 Pocket milling
 Drilling bolt circles

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