CNC

LECTURE-1
amr.ahmed@eng.asu.edu.eg
ABOUT THE TUTOR

•B.Sc in mechanical engineering, design and production engineering

department, faculty of engineering, Ain Shams University (year 2007).
•M.sc in the CAD/CAM/CNC field /design and production engineering
department, Faculty of Engineering, Ain Shams University (Oct2007-
Oct2010).
•PhD in the virtual simulation field/design and production
engineering department, Faculty of Engineering, Ain Shams University
(May2011-May2015).
•Course instructor for many courses at various course centers and
academic institutions.
•Currently, Assistant Professor in ASU.
•Email: amr.ahmed@eng.asu.edu.eg.

2 Dr.Amr Shaaban-Introductory session 10/9/2017

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DESIGN PROCESS

DESIGN PROCESS PROBLEM DEFINITION Specifications

CONCEPTUAL DESIGN Concepts

EMBODIMENT DESIGN Layouts

DETAIL DESIGN Analysis

CAD/CAM/CNC/CAE
MANUFACTURE Product

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DESIGN PROCESS
VIRTUAL PROTOTYPING

From CAD to CAE

Need modifications
Need modifications
Static analysis
Normal mode
Frequency response
Transient response
Solids

SIMULATION
APPROACH
Analysis
results
PRODUCT
Fluids
Thermodynamics

Approved design
Aerodynamics
Fluid mechanics
Heat transfer

CAM/CNC
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1-CAD file
4-CNC

2-CAM or Workshop oriented 3-G-code

5-Product

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5 5 Dr.AmrDr.Amr Shaaban-Introductory
Shaaban-Numerical session
Control Machines 10/9/2017
10/9/2017
 CONTROL UNIT

NC – Punched Tape •The control is hard wired, and therefore any modification
needs many changes in the controller.

•The part program punched into paper tape on a separate

punching machine

•Read and executed one line of code at a time from a part

program

•When the entire program was executed, the tape reader

would rewind back to the beginning of the program. The
machine has no means of storing or editing of loaded
programs.
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 CONTROL UNIT
•Developments in electronics industry has led to use the
Computerized
Numerical Control computer in place of conventional dedicated controller.

•No punched tapes; instead, all information flows from a

computer which interfaced with machine control unit. A typical
system for instance can store programs equivalent to about 700
m of punched tape

•Minimum of electronic hardware is used, as some of the hard

ware modules is replaced by software.

•MCU functions of data decoding, control, buffering, feed rate

control, interpolation and position control.
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 CONTROL UNIT

•Utilize a single large frame computer to control

Direct Numerical Control several machines through a data transmission
DNC lines. A minimum of 5 to 10 machine tools is
considered necessary to make the system
economically justifiable.

•It allows machining processes to be fully

integrated with other automation systems, with
data files, and with management information
system.

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 CONTROL SYSTEM

Open Loop System

•Operates without verifying that the actual position is equal to
the specified position.

•Usually stepper motors are used.

•Stepper motor is an electric motor that rotates a set amount

every time it receives an electronic pulse from the MCU.

•The displacement value is controlled by controlling the

number of pulses sent to the stepping motor while the feed
rate is controlled by controlling the rate of pulse.

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 CONTROL SYSTEM
•Use feedback system to verify that the actual position is
Closed Loop System equal to the specified one.

•Use an error detector that returns a signal which is

proportional to the difference between input and feedback.

•Usually servo motors are used with feedback loops.

•Tachometers are attached to motors and drives for velocity

feedback loop, while encoders are attached to sliding parts for
position feedback loop.

•Sensors used for the feedback system make it more

expensive.
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CNC CONTROL SYSTEMS

SINUMERIK 840D

SINUMERIK 802D
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 INTERPOLATION

•Position type or point to point control.

P-Type
•There is no control on the path followed to reach that position. Only
axial path or 45 degree are provided.

•When point-to-point is used for a certain axis, the cutter or work table
moves in rapid positioning mode (maximum feed rate). Hence, no
machining can occur using P-type controlled axis.

•If the tool is at A (X5, Y5) , and the absolute coordinates (X20, Y30) are
input, the movement will take place simultaneously at an angle of 45
degrees on both the X and Y axes until the tool reaches B (X20, Y20),
and then will continue on the Y axis only until the tool is at C (X20,Y30).
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INTERPOLATION

L-Type •Line type control.

•The main difference between this system and p-system is that

it is possible for the rate of movement to be programmed to suit
the machining conditions. This permits machining to be carried
out during the movements.

•A line motion control system can be used to produce a wide

range of work by milling shapes that are composed of lines at 90
degrees and 45 degrees, and can also be used on turning
centers for the production of stepped shafts

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INTERPOLATION

C-Type •Contour type control.

•Different rate of movement can occur at the same time on

different axes.

•There may be from two to eight controllable axes;

movement can take place on a number of axes
simultaneously, all at different feed rates if necessary.

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 CNC TYPES

Commonly, machines have different modes of control on different axes. Frequently

the control system provides circular interpolation on any two axes and linear
interpolation on the remaining third axis. This type of control system is referred to
as 2CL. Similarly, 2PL indicates point-to-point control on two axes and line motion
control on a third axis; 5C is a machine which has contouring on five axes.

2.5-axis
3-axis
Punching CNC machines
Drilling CNC machines VMC
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CNC TYPES
5-Axis Milling Machine

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CNC TYPES CNC LASER MACHINES

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CNC TYPES CNC ROUTER MACHINES

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 MACHINE AXES

RIGHT HAND ROLE

•Z is always the axis of rotation.

•Negative Z is the direction in which the cutter approaches the work piece.

•X axis is the axis of the long path.

•Using RHR, the 3 axes and their signs can be determined.

•A, B, and C are the axes of rotation about X, Y, and Z respectively.

•U, V, and W are three auxiliary axes corresponding to X, Y, and Z respectively.

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MACHINE AXES

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MACHINE AXES
Y X

A C

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COORDINATE SYSTEM

Machine Zero Programming Zero Floating Zero

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ABSOLUTE & INCREMENTAL

G90

Example

G91

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 PART PROGRAM

•Part program is a series of coded instructions required to produce a part.

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 PART PROGRAM

TURNED PARTS
N5 G90 G20
N10 T0101
N15 M03
N20 G00 X2 Z0.1 M08
N35 G71 P40 Q55 U0.05 W0.05
D625 F0.012
N40 G01 X0 Z0
N45 G03 X0.5 Z-0.25 I0 K-0.25
N50 G01 X1.75 Z-1.0
N55 X2.1
N50 T0100 G00 X4 Z3
N65 T0202
N70 G00 X2 Z0.1
N75 G70 P40 Q55 F0.006
N80 G00 X4 Z3 M09
N85 T0200 M05
N90 M30

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 PART PROGRAM

MILLING PARTS
N5 G90 G80 G20 G99
N10 M06 T6
N15 M03 S1300
N20 G00 X1 Y1
N25 Z0.5
N30 G81 Z-0.25 R0.125 F5
N35 X2
N40 X3
N45 Y2
N50 X2
N55 X1
N60 G80 G00 Z1
N65 X0 Y0
N70 M05
N75 M30

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G-CODE GENERATION

SHOP FLOOR/WORKSHOP ORIENTED

CAM SOFTWARE

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 Design Online Academy

CNC-MDP471-Fall2017
Design Online Group
79TZ-7K53
amr.ahmed@eng.asu.edu.eg
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