UNIT V

CNC MACHINE TOOLS AND PART

PROGRAMMING
CNC MACHINE TOOLS AND PART PROGRAMMING

Numerical control (NC) machine tools CNC: types,

constructional details, special features. Part programming
fundamentals manual programming computer assisted part
programming apt language.
COMPUTER NUMERICAL CONTROL (CNC) AND ADVANCED STEPS TO THE
AUTOMATED INDUSTRIES
v The ultimate goal of Computer Aided Manufacturing (CAM) is the automated
industry. The concept of Computer Numerical Control (CNC) the first major step
in this direction was the Numerical Control (NC) of machine tools.
v NC is programmable automation in which certain functions of the machine tools
are controlled by numbers or letters.
v The program of instruction defines how a particular part is to be made.
v If the part design or the manufacturing method change, it is necessary to change
the program instructions.
v Writing software programs for instruction and control of the machines is fairly
common.
The following diagram shows the major streams of automated factory.

ADVANTAGES OF NUMERICAL CONTROL MACHINE TOOLS

• Greater process capability: Greater accuracy and precision is built into the
machines, resulting in better quality and a high order of repeatability.
• Higher production rates: Optimum feeds and speeds can be determined for each
operation, with less time spent in non-cutting functions.
• Less lead time: Programs can be prepared in less time than conventional jigs arid
templates, less setup time is required.
 • Flexibility: It is easy to change from one part to another or to change part design.
Lower tooling corn Expensive jigs and templates may not be needed; more
general purpose work holders can be used.
• Fewer setups per work piece: More operations can be done at each setup of the
work piece.
• Reduced inventory: The overall inventory level may be reduced if parts can be
run economically in smaller quantities.
• Less scrap.’ Operator errors are reduced substantially. The first part of the
machine can be a good part. Follow-on runs of parts previously manufactured can
readily be duplicated.
• Less skill required for the operator: Program planning in preparing tapes reduces
the necessity for operator decisions,
LIMITATIONS OF NUMERICAL CONTROL (NC)
There are some problems inherent in conventional NC which has motivated tool builders
to seek improvements in the basic NC system. The difficulties occurred by using
conventional NC machines are following
• NC manufacturing requires training of personnel both for software as well as
hardware. Part programmers are trained to write instructions in desired languages for
the machines on the shop floor.
• The cost of NC manufacturing setups could be several times more than for their
conventional counter parts. As NC is a complex and sophisticated technology it
also requires higher investments for maintenance in terms of wages of highly
skilled personnel and expensive spares.
• In preparing a punched tape part programming mistakes are common. The
mistakes can be either syntax or numerical errors, and it is not uncommon for
three or more passes to be required before the NC tape is correct.
• Paper tape is especially fragile and susceptibility to wear and tear causes it to be
un-reliable NC component for repeated use on the shop floor, more durable tape
materials. Such a ‘ Mylar’ and ‘ Aluminum Foil’ are used to overcome this
difficulty. How over these materials are relatively expensive.
CNC TECHNOLOGY INTRODUCTION
Ø CNC stands for Computer Numerical Control and has been around since the
1970’ s prior to this, it was called NC, for Numerical Control.
Ø While people in most walks of life have never heard of this term, CNC has
touched almost every form of manufacturing process in one way or another..
In the NC. Systems used machine tools can be broadly classified as
• Hard Wired (or) Conventional Numerical Control.
• Soft Wired (or) Computer Numerical Control (CNC).
• In the hard wired system the entire data input and data handling process including
control functions are determined only by the constant or fixed circuit inter-
connections of decision elements and storage devices.
• The second is computer numerical control system a dedicated stored programme.
• Computer is used to perform all the basic NC functions as pervade control
programme stored in the memory of the computer called Executive programme
that machine control data
A CNC SYSTEM LAYOUT.
 TYPES OF THE CNC SYSTEM
The following are the main classification of the CNC machine tool system.
CNC machine Tool

ACCORDING TO THE TYPE OF MOTION CONTROL SYSTEMS

o .Point-to-point / positioning system.
o Contouring (or) continuous-path.
o Straight cut.

ACCORDING TO THE STRUCTURE OF CONTROL SYSTEMS.

o Analog system
Digital system.

ACCORDING TO THE PROGRAMMING MODE

v Incremental programming mode

v Absolute programming mode

ACCORDING TO THE TYPE OF CONTROL LOOPS.

v Open loop system

v Closed loop system.

POINT-TO-POINT SYSTEM:

v In a Point-to-point system, the path of the cutting tool and its feed while traveling
from one point to the next one are without any significance.
v Therefore, this system would require only position-loops for controlling the final
position of the tool when reaching the place to be drilled.
v The data for desired position is given by co-ordinate values and the resolution
depends on the system.
v The simplest example of a point-to-point NC system is a drilling machine.
v In a drilling machine the work piece is moved along the axis of motion until the
centre of the hole to be drilled is exactly beneath the drill.

STRAIGHT-CUT CNC SYSTEM:

o This system is called a straight-cut system since the cutting tool can move only
along straight lines which are parallel to the main axis of motion of the machine
tool,
o The simplest example in a shaping machine
o Cutting of the work piece is done while the cutting tool is moving, but the latter
can move along the X, Y or Z axis.
 o In this system, velocity control loops, for feed control of the axis of motion, are
used but they are relatively simple as they only have to establish the finished
surface quality and not the dimensions of the part an interpolator is not required
for the straight-cut system as no simultaneous operation of the axis is necessary.

THE CONTINUOUS-PATH MACHINE SYSTEM (OR) CONTOURING SYSTEM

Ø Contouring is the most flexible, complex and the most expensive type of machine
tool control method.
Ø This has the feature of capacity for simultaneous control of more than one axis
movement of the machine tool.
Ø The path of the cutter is continuously controlled to generate the desired geometry
of the work piece.
Ø For this valid reason, this system is also called continuous-path CNC system.
Ø The process of maxing curved path on the work piece surface is performed in a
CNC contouring system the direction of the feed rate must continuously be
changed so as to follow the path.

INTERPOLATION:

The method by which contouring systems move from one programmed point to another is
called interpolation.

LINEAR INTERPOLATION:

• Linear interpolation, programmed points connected by straight lines, is used for

straight line moves, whether the length between the Z points is short or long.
• In the early days of NC, it was used to produce curves that had to be broken into a
very large number of short, straight-line programmed points to produce the
required shape. Most modem CNC controls have circular interpolation that can
produce contour and curved shapes with very few programmed steps.
• Most CNC machine tools can also mill straight lines along either the X or Y axis
figure. In positioning, the tool is moving from one position to the next at a rapid
traverse rate, which could be hundreds of inches per minute.
• A milling cut must be programmed at a feed rate to suit the material being cut and
the type and diameter of the cutter.

CIRCULAR INTERPOIATION

v The programming of circles and arcs has been greatly simplified by the
development of circular interpolation.
v Arcs up to 90° degree may be generated and these may be joined together to form
half, three-quarter or full circle as desired circular interpolation is limited to one
plane at a time.
v Circle requires the start and end point of the used to come close to producing a
curve arc, the center location, the radius, and the on surfaces that are not true arcs.
 v Many other curves and free-form shapes can be closely approximated with a
series of arcs, using circular interpolation

VARIOUS TYPES OF CONTROL AND POSITIONING SYSTEMS.

CIRCULAR INTERPOLATION
PARABOLIC INTERPOLATION:

Parabolic interpolations are used to provide approximations of free-form curves using

higher-order equations.
They require considerable computational power and are not as common as linear and
circular interpolation.

HELICAL INTERPOLATION:

Helical interpolation

v Helical interpolation shown in figure combines the use of 2-axis circular

interpolation with a linear movement of the third axis.
v All 3-axis moves simultaneously to produce a helical spiral cutter path.
 v This method is most commonly used in milling large internal diameter threads,
and requires minimal input data.

Sample program showing 3 types of Motion:

“Step turning linear and circular interpolation:”
Write part program for the following component with depth of cut 1.5 mm and finish
allowance 0.3 mm.
ANALOG AND DIGITAL CONTROL:
• In analog control system the quantities may be varied continuously, while in
digital systems the quantities are varied discreetly
• Such as the presence or absence of a quantity.
• The shortest cycle of presence - absence is the resolution of the digital system and
displays its accuracy.
• In digital system of machine tools, every cycle of in formations provide a voltage-
pulse format.
• The each pulse are represents a basic length unit.
• These pulses are also determines the system resolution.
• Therefore, the digital system is of a finite accuracy.
• While analogue information can accept any value. Both digital and analog
controls are used in CN systems.

INCREMENTAL/ABSOLUTE SYSTEM:

INCREMENTAL SYSTEM:

An incremental system is one in which the reference point to the next instruction
is the end point of the preceding operation.
Each dimensional data is applied to the system as a distance increment, measured
from the preceding point at which the axis of motion was present.
Incremental dimensions are distance between adjacent points.
These distances are converted into incremental co-ordinates by accepting the last
dimension point as the co-ordinate origin for the new point.
ABSOLUTE SYSTEM:

CONTROL SYSTEMS

OPEN —LOOP CONTROL SYSTEMS:

v The term open-loop control system means that since the loop is open there is no
feed back and the action of the controller has no reference to the result it
produces.
v When a command signal is given to the drive system by means of the program.
Instructions though the computer, then the slide of the machine tool moves with
respect to the program, this does not care whether the moving member arrived at
the desired position.
 v This is an open loop CNC system where there is no check on the actual position
arrived with reference to the position desired.

CLOSED LOOP CONTROL SYSTEM:

v In this system, measures the actual position and velocity of the axis and compares
them with the desired reference.
v The difference between the actual and the desired values is the “error” The actual
value is measured by means of feed back system of the machine tool control.
v The most extreme care must be taken during the design of closed-loop systems.
v By increasing the amount of feed back signals which are produced from the feed
back devices (like limit switches and touch sensor etc.) this loop is made more
sensitive.
v That is known as increasing the open-loop gain.
v By excessively increasing the open-loop gain the closed loop system may become
unstable, which should be avoided.
v If actual value.> desired value, then it indicates the “negative feed-back” one.

Error =Desired Value-Actual Value

ADVANTAGESOF CNC

Less Scrap
Reduced Production Lead Time
Less Human Error
High Part Accuracy
Complex Machining Operations
Lower Tooling Costs:
Increased Productivity:
Reduced Inventory:
Less Machine Tool Damage:
Less Inspection:
Greater Machine Uptime:
Reduced Space Requirement:
 DISADVANTAGES OF’ CNC
v CNC machines are more expensive than manually operated machines,
although costs are slowly coming down.
v The CNC machine operator only needs basic training and skills, enough to
supervise several machines.
v Fewer workers are required to operate CNC machines compared to
manually operated machines. Investment in CNC machines can lead to
unemployment.
v Many countries no longer teach pupils, students how to use manually
operated lathes / milling machines etc. Pupils / students no longer develop
the detailed skills required by engineers of the past.
v These include mathematical and engineering skills.

CONSTRUCTIONAL FEATURES:

Various mounting arrangements of Linear Motion Guides.

Antifriction guide ways used in CNC Machine Tools.

 Ball Bush used for Linear Movement in CNC Machine Tools

BALL SCREWS
• Low co-efficient of friction: It is of the order of 0.004 as compared to 0.1 to
0.5 which is typical of sliding friction power screws. Wear is therefore less
and there is very little need for frequent adjustment.
• In a ball screw, the load between the threads of the screw and the nut is not
transmitted by direct method contact but through intermediate rolling
members (spherical balls).
• The ball rotates between the helical grooves of the screw and nut in a manner
akin to their function in ball bearings. An essential feature of almost all ball
screws is the provision of recirculation of balls.
• By preloading the assembly, clearance and consequent backlash can be
eliminated and the axial stiffness of the ball screw can be increased. It should
be noted that the axial stiffness of an ordinary power screw and accuracy of
ball screws also high.
• Friction force is virtually independent of the travel velocity and the friction at
rest is very small consequently. The stick slip phenomenon is absent ensuring
uniformity of motion.
• High transmission efficiency (2-9 times) which is particularly marked at low
values of helix angle of screw (2° —5°) that are typical for power screws.
This high efficiency allows larger thrust loads to be carried with less torque.

Preloading of a Recirculating Ball Screw

 v A high preload makes it possible to obtain better positioning accuracy and higher
system stiffness,
v It will require a higher torque to drive the screw.
v If the preload is too high.
v The increase of the driving torque will exceed that of system stiffness, resulting in
a decrease of life.
v Too high a preload may result in less positioning accuracy.
v It depends on the characteristic of the servo loop.
v The low preload gives low drag torque but also low system stiffness and reduced
positioning accuracy.
DRIVES
In a CNC machine tool there are three major groups of elements
a) Control and electronics.
b) Electric device (Electro mechanical drives).
c) Mechanical elements (table, slide, tool holder, etc.).

Electronics control.
 Electric drives on a CNC lathe.

Spindle Drives:

Function:
Centering the work piece.
Clamping the work piece or cutting tool as the case may be such that the work
piece or cutting tool is reliably held in position during the machining operation.
Imparting rotary motion

Speed power requirement of spindle drive.

INTRODUCTION TO PART PROGRMMING

The part program of a CNC machining centre consists of the following features
v Geometry of a given work piece.
v Motion of the tool with respect to the axis
v Machine auxiliary components controlling features that are (spindle ON, OFF,
coolant ON. OFF)
v Mode of the programming (absolute or incremental).
v Setting the spindle speed, also the direction of the spindle.
v Using tool number and which type of the tool is used to machining also clear idea
about the tool feed.
v In describes the every machining operation by means of the CNC codes. .
v The special feature of the CNC part program is the sub-routine calling and return.
.
FUNDAMENTALS OF PART PROGRAMMING
Ø The basic concept of preparing the part program for the particular machining
operation of a CNC technology consists of its own terminology and special terms
and its jargon.
Ø It has own abbreviations and expressions in the form of codes, that only the
people who having the idea and more knowledge about the CNC programming
instructions. This I programming is a term that refers to the methods for
generating the instructions that controls the CNC machine tool.
Ø This manual preparation of the part program is only for machining the 2-D
components, for machining the complex shapes we go to more sophisticated
techniques.
Ø These techniques are also having the same basic of the manual programming.

TECHNIQUES OF THE CNC PART PROGRAMS

v The basic important step in the concepts of the CNC procedure is the part
programming preparation.
v These part programming generation process basically depending upon the
machining type, (2D or 3D), process type (turning (or) milling, etc) and also the
availability of the system, of automation techniques which are present in the
current industry
v Part programming of CNC production machines comprises the collection of all
data required to produce the part

CNC PART PROGRAMMING METHODS;

Ø Programming in the planning department ofthe particular company.
Ø Programming in the workshop.
Ø Manual programming
Ø Computer- assisted part programming (CAPP)
Ø Higher level program languages (programming using CAM soft wares, like CAPS
MILL, MASTER CAM. EDGE CAM, etc.,)
MANUAL PROGRAMMING:
v In this method the necessary program information is taken directly from the
work piece drawing and set down in the form of program blocks, which are then
input to the control
v Manual programming is suitable only; to develop part programs for 2D and
21/2’ D surface machining.
v Manual programming tends to be some what tedious.
v The words and the commands involved with manual programming can be some
what cryptic.
COMPUTER ASSISTED PART PROGRAMMING (CAPP):

Ø Preparing CNC programs for complicated parts with a programming language

following established standards can involve considerable effort and expenditure.
Ø Thus the number of program blocks may be very high which makes the program
less, clear, fault- prone, and difficult to modify
Ø In addition, difficult mathematical calculations may be required which can only
be carried out with further aids such as books, tables, calculators etc.,
Ø This is the reason why higher NC programming languages are created, for
computer assisted part programming (CAPP).

The following are the some example for NC programming languages-

EXAPT
TC-APT
ELAN
RWT/TRAUB/T2000
PHILIP —il
MITTURN
COMPACT —I
MINIAPT
PROGRAMAT
DIA-PROG etc.
The main important NC programming language is APT (Automatically
programmed tool).

COMPUTER NUMERICAL CONTROL CODES

The CNC programming is the instructions which are used to control the machine
tool movements by means of the codes.
This concept is already we saw the previous pages of programming procedures.
The main important thing is the selecting the correct codes to the correct operations this
purpose, the CNC programming consists of many types of codes.
 List of CNC Codes and its functions

ADDRESS CHARACTERS
The address characters are the meaning and the function of the alphabet (only upper case)
which are used in the CNC part programming. Some of the meaningful alphabets are
listed in the table

Address characters of CNC Programming

LIST OF G-CODES FOR TURNING PROGRAMS
The G-codes are also called as preparatory functions which are used to control the
movement of the machine tool.
FANIJC lathe control various types of G-codes are used.
They are given below in the table
LIST OF M-.CODES USED IN THE CNC TURNING PROGRAMS
o The address M in a CNC program identifies a miscellaneous function,
o Sometimes called a machine functions.
o Not all miscellaneous functions are related to the operation, of a CNC Lathe -
quite few are related to the processing the program itself
o The mainly used M-codes are given below in the table

Applications for Turning

SAMPLE PROGRAMMES FOR CNC LATHE OPERATION

Write a manual part program for simple facing operation for the given component.

Facing operation
For simple turning operation for the given component. Write a manual part program
(using 001 command).
 PART A (2marks)

1. What are the general requirements of CNC machine tool design?

2. What are the classifications of slide wayes?
3. What is automatic tool changer (ATC)?
4. What are the different types of CNC machine tools?
5. What is CNC machining centre?
6. How the CNC milling centers are classified?
7. What is turning centre?
8. What is difference between CNC and NC machines?
9. What is the use of MCU?
10. What is point to point control?
11. What are the various types CNC tooling?
12. What Is CNC controller?
13. How the CNC lathes are classified?

PART B (16 marks)

1. What are the advantages and limitations of CNC machine?
2. Explain various types of CNC system?
3. Explain with neat sketch the open loop and close loop control systems
4. Explain the construction features of CNC machine
5. Explain various derives used in CNC machines
6. Explain part programming
7. Explain CNC codes and its functions