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NC Technology
1. Introduction:
Conventional machines used for operations like Turning, Drilling, Milling were commonly
used and operated manualy. the worker had to use a detailed working drawing sheet of the
workpart that included dimensions, tolerances, surface roughness,.
He also had to use process sheet, which includes production steps, cutting speed, feed,
feedrate, revolutions,..
This sheet was used to develop the NC coded program.
2. Basic Components of NC Machine System:
NC Machine
Program
Instruction
Machine
Control Unit
(MCU)
(Computer)
Machine Tool
To produce the program instruction we use the process sheet and convert it to NC coded
program.
The NC coded program is then punched into a tape to be transferred to the machine
control unit.
The machine control unit (MCU) contains a tape reader, it also has register and buffer,
they are used to convert the data from the punched tape into electric signals that are sent
to the machine tool.
Engineering
Design
Part Print
Process Sheet
Numerical Control
Programming
Production
Control
NC Tape
Tool Design
Fixture Design
Shop
Management
Tool Maker
Fixture
Numerical
Control
Machine
Completed Machining
Operation
4. Program of Instructions :
It is the detailed step by step commands that direct the actions of the processing
equipment. In machine tool applications ,the program of instruction is called part
program ,and the person who prepare the program is called a part programmer.
The program is coded on a suitable medium for submission to the machine control unit.
The most common input mediums used are punched tape , punched cards and
magnetic tape .
a. Punched Card:
Punched card is a plastic / paper card which is having holes . It can
accommodate only few sentences of the program so there is restriction on the
size . The advantage of using card is that sequence of operation can be changed
because each operation is on separate card .,program readers and transportation
devices for punched cards are more complicated than for punched tape.
b. Punched Tape :
Different materials have been used for punched tape . These materials are
paper and foil . The following figure shows the shape and dimensions of the
punched tape
The following tables shows the standard EIA and ISO (ASCII) codes for
numerical control programming originally designed for punched tape.
c. Magnetic Tape :
Magnetic tape is a plastic tape coated with iron oxide and is similar to the tape
Used in tape recorders (but small size).magnetic tape can store much more
information per unit length as compared to punched cards or magnetic tapes .Also
Information can be easily stored and erased .This is the least preferred in
machining because of the following reasons :
1. electrical and magnetic fields can easily distort program signals
2. any damage of the magnetic tape is not easy detectable because no visual
examination is possible.
3.tape gets damaged in dust in the shop floor.
Tape Reader
Machine Table
Machine Control
Unit (MCU)
5
Most modern NC and CNC machine controls are equiped with buffer storage shown
in the following figure ,this feature allows the control to accept information into the
buffer registers while an operation is being performed from the active machine
registers.when the operation is complete the information is transferred from the buffer
storage to the machine actuation registers.
Tape Reader
Information
Read
& Decode
X
Y
1
5
0
8
7
9
6
2
4
4
Machine Table
5
X
Machine Control
Unit (MCU)
6. .Axis Relationships:
For Milling/Drilling
+Z
-X
-Y
+Y
-Z
Z
+X
for Turning:
+X
-Z
+Z
-X
Once the NC tape has been read ,decoded and the machine actuation registers loaded ,the
Machine responds with its appropriate coordinate axis movements and other commands
Machines with only X and Y position capability are known as two axis machines. On
Machines of this type distance in Z direction is controlled by the operator or by preset
Stops similar to that of a conventional drill press.
The three basic motions are designed by the electronic industries association (EIA) are the
X,Y,Z , the X motion is parallel to the longest dimension of the machine table,the Ymotion
Is normally parrel to the shortest dimension of the machine table.The Z motion becomes
Complicated by the fact that the NC macines are made with vertical and horizontal spindle
so it can be said that the line through the centre of the machine spindle is actually the Z
axis ,it is only when the actual depth of cut Z axis is controlled by the tape ,the macine is
considered a true three axis NC machine. Machine / axes relationships can be seen in
figures :
Turning Machine
10
2. Contouring Motion:
X,Y,Z motion are always controlled and they have constant feedback.
Used in milling or turning operations.
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3. Straight Cut:
Only one coordinated is monitored at a time.
Used in simple straight cutting operations.
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subsequent positions are affected and all the remaining moves are incorrect, but
when a positioning error occurs in an absolute system a particular location is in
error but subsequent positions are not affected.
+Z
-X
+X
+Y
-Z
2.Floating Zero:
The origin point is left for the operator to define using a special tool, which is lowered
until it touches the desired point with no restrictions.
(X & Y can take positive or negative values)
+Z
-X
+Y
-Y
+X
-Z
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There are two types of positioning systems used in NC system : shown in figure
a. open loop system operates without verifying that the actual position achieved in
the move is the same as the desired position.
b. Closed loop control system uses feedback measurements to confirm that the
final position of the worktable is the location specified in the program .
Open loop cost less than closed loop systems and are appropriate when the force
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Resisting the actuating motion is minimal , closed loop systems are normally
specified for machines that perform continuous path operations such as milling or
Turning in which there are significant forces resisting the forward motion of the
cutting tool.
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Chapter 2
CNC Machines
1.Introduction:
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Program performs
interpolation
calculations
CPU
1.Control Section
2.Arithmetic Logic Unit
(ALU).
3.Immediate Access
memory
I/O Interface
1.Operator Panel
(Keyboard, CRT,)
1. 2.Tape Reader
System Bus
Machine Tool Controls
Sequence Controls
Coolant
Fixture Clamping
Tool Changer
4. CNC Software:
1. Operating system software: is to interpret the NC part program and generate the
corresponding control signals to derive the machine tool axes ,it is installed by the
controller manufacturer and is stored in ROM in the MCU. The operating system
software consists of the following :
Editor: which permits the machine operator to input and edit NC part programs
Control program: which decodes the part program instructions,perform
interpolation and acceleration/deceleration calculations ,and accomplishes
other related functions to produce the coordinate control signals for each axis.
Executive program: which manage the execution of the CNC software as well as
the I / O operations of the MCU.
2. Machine interface software: is used to operate the communication link between the
CPU and the machine tool to accomplish the CNC auxiliary functions (coolant
control ,tool changer ,fixture clamping device ,timers ),as previousely indicated ,the
I / O signals associated with the auxilliary functions are sometimes implemented by
means of a programmable logic controller interfaced to the MCU ,and so the machine
interface software is ofthen written in the form of ladder logic diagram
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Central
Computer
MCU
MCU
MCU
MCU
MCU
MCU
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Switching Network
MCU
DNC Computers
Satellite Computer
MCU
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Chapter 3
NC Coding System
1.Format of NC Coded Program:
Punched tape, Punched Card,
Magnetic tape
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Chapter .4
NC
Part Program
The following are explanations of the different methods of part programming with some
Examples .
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The following are some exercises in drilling ,milling and turning machine operations
using the Boxford CNC machines :
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b. Turning Exercises :
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Chapter .5
10 th of Ram adan
Mechanial Engineering Department
Course
: Control
m anufacturing
Code
: M TE203
Exam iner :Dr.I brahim Nasr
Tim e
:1 Hour
of
P roblem ONE :
[10]
1. W hat are the basic com ponents of NC System ?
2. Ex plain the different zeros of NC m achine tool ?
3.Ex plain the NC P rocedure ?
P roblem TW O:
[10]
1.Ex plain briefly the Function controlled by NC ?
2.Ex plain the preparatory functions?
3.W rite a sim ple part program for the follow ing
com ponent:
.. Drilling and taping tw o holes w ith diam eter 10 m m w ith
depth 20 m m ,using m anual Z control.
10 th of Ram adan
Mechanial Engineering Department
Midterm Examination
Term: JAN./MAY 2007
Course
: Control
m anufacturing
Code
: M TE203
106
Exam iner :Dr.I brahim Nasr
Tim e
:1 Hour
of
M aterial : P lastic
Tool changed at : X0,Y0,Z25
R equired :
1. M ill the steps [8 m m diam eter slot drill]
2.Drill the holes [ 4 m m diam eter slot drill ]
3.M ill the 30 m m diam eter pocket [ 8 m m diam eter slot drill ]
Midterm Examination
Term: MAY/AUG. 2007
Course
Code
Exam iner
Tim e
107
: Control of m anufacturing
: M TE203
:Dr.Ow ino George
:1 Hour
P roblem ONE :
1. W hat are the basic com ponents of NC System ?
2. Ex plain the different zeros of NC m achine tool ?
3.Ex plain the NC Steps?
P roblem TW O:
[10]
[10]
108
Final Examination
Term: JAN./MAY 2007
10 th of Ram adan
Mechanial Engineering Department
P roblem ONE :
in
[5]
[10]
1.Using sketches ,ex plain how the Z-ax is control can be done in drilling ?
2.Com pare betw een different zeros used in m illing and drilling?
3.W hat are the functions controlled by NC in m illing and drilling ?
P roblem THR EE :
[5]
1.Explain w ith exam ples the different G-codes canned cycle used in
drilling and m illing?
2.Draw sketch and indicate the m achine ax es ?
3.Explain the canned cycles used in turning?
P roblem Four:
[20]
P ractical
109
110
111
10 th of Ram adan
Mechanial Engineering Department
Final Examination
Term: Oct./Jan.2008
in
W rite the G,M - coded program and sim ulate the production steps on
Com puter
112
113
114
10 th of Ram adan
Mechanial Engineering Department
Final Examination
Term: Oct./Jan.2008
in
P roblem ONE :
[10]
1. W hat are the steps of NC system ?
2. Briefly , com pare betw een NC,CNC, DNC m achines?
3.Explain briefly the com ponents of NC system ?
4.sketch and ex plain the NC coordinate system ?
5.Com pare betw een the types of Zero points ?
P roblem TW O :
[10]
1 W hat are the types of m otion control system ?
2.Com pare betw een the different input m edia in NC m achine ?
3.W hat are the types of punched tape readers?
4.Ex plain w ith sketches ,the difference betw een open and closed loop
control system s ?
P roblem Three : [P ractical]
[ 20 ]
W rite the G,M - coded program and sim ulate the production steps on
Com puter
115
10 th of Ram adan
Mechanial Engineering Department
Final Examination
Term: Jan./May 2008
in
P roblem ONE :
[5]
1. Com pare betw een the m achine controlunit of NC and CNC m achines?
2.Ex plain the follow ing using sketch:
-NC coordinate system
-Zero point
-The G81 , G82 ,G84 , G85 ,G97.
P roblem TW O :
[15]
1.Explain the Tasks in com puter assisted part program m ing ?
2.W rite the APT program to produce the follow ing show n com ponent :
the required :
a. drilling 4 holes w ith feed rate 120 m m / m in. ,cutting tool speed 2000
rpm
b.m illing the outer surface w ith cutting tool diam eter 8 m m ,feed rate
120 m m / m in. and cutting tool speed 2000 rpm
P roblem Three : [P ractical]
[ 20 ]
116
10 th of Ram adan
Mechanial Engineering Department
Final Examination
Term: Jan./May 2008
in
P roblem ONE :
[5]
1. How NC collect inform ations?
2.Ex plain the follow ing using sketch:
--m otion control system
--flow diagram of NC.
--interpolation G-codes.
P roblem TW O :
[15]
1. Ex plain the APT language statem ents ?give ex am ples?
2.W rite the APT program to produce the follow ing show n com ponent :
the required :
a. drilling the hole w ith feed rate 120 m m / m in. ,cutting tool speed
2000 rpm
b.m illing the outer surface w ith cutting tool diam eter 8 m m ,feed
rate 120 m m / m in. and cutting tool speed 2000 rpm
P roblem Three : [P ractical]
[ 20 ]
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