Me 20me42p Week1 S1 Sy

CNC Programming and Machining -20ME42P 2021-22
WEEK -1 INTRODUCTION TO CNC MACHINES

Session -1
1.1 Introduction:
It is believed that at this time, we are witnessing the digital industrial revolution.
The first revolution attempts to augment the human muscular power. The second
revolution emphasis on human brain power. The challenge is to continue to push
towards new technology and automation without losing sight on designing the system
based on the proper selection of task to be performed by humans and those to be
performed by machines. A number of new manufacturing technologies and machines
have been designed and developed, which can prove useful in increasing the
productivity. In these aspects, a technology leads to focus on development of new
machines like Numerical Control (NC) and Computer Numerical Control (CNC).
1.2 Numerical Control (NC) Machines:
 A Numerical control (NC) is a method employed for controlling the motions
of a machine tool slide and its auxiliary functions with an input in the form of
numerical data.
 A Numerical Control can be defined as a form of programmable automation in
which process is controlled by numbers, letters and symbols.
In Numerical Control (NC), the numbers form a program of instructions designed
for a particular work part or job. The NC program consists of a set of instruction or
statement for controlling the motion of the drives of the machine tools as well as the
motion of the cutting tool. In NC When the job/work changes, the program of
instructions can be changed. This capability to change a program for each new job
gives NC its flexibility.
1.2.1 Basic Components of NC System:
An NC system consists of the following three components:
1. Program of Instructions.
2. Machine control unit.
3. Machine Tool.
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Fig.1: Three basic components of Numerical control system.
1.3 Computer Numerical Control (CNC):

 A Computer numerical control (CNC) is defined as an NC system whose
machine control unit (MCU) is based on a dedicated microcomputer rather
than on a hard-wired controller.
 A Computer numerical control (CNC) is a microprocessor bases system to
store and process the data for the control of slide motions and auxiliary
functions of the machine tool
CNC consists of a computer, which is joined to NC machine to make the machine
more versatile. The programme is read from a storage medium such as the punched
tape and retrieved to the memory of CNC computer. Some CNC machines have
magnetic medium or disks for storing programs. This gives more flexibility for
editing or saving CNC programs.

Fig.2: General configuration of a Computer numerical control (CNC) system
1.3.1 The components of CNC:

a) The Machine Control Unit for CNC
Fig.3: The Machine control unit of a CNC system.

The MCU is the hardware that distinguishes CNC from conventional NC. The
general configuration of the MCU in a CNC system is illustrated in Figure. The MCU
consists of the following components and subsystems: (1) central processing unit, (2)
memory, (3) I/O interface. (4) Controls for machine tool axes and spindle speed, and
(5) sequence controls for other machine tool functions.
b) Central Processing Unit:
The central processing unit (CPU) is the brain of the MCU. It manages the other
components in the MCU based on software contained in main memory. The CPU can
be divided into three sections: (1) control section, (2) arithmetic-logic unit, and (3)
immediate access memory. The control section retrieves commands and data from
memory and generates signals to activate other components in the MCU. The
arithmetic and logical unit (ALU) consists of the circuitry to perform various
calculations (addition, subtraction, multiplication), counting and logical functions

required by software residing in memory. The immediate access memory provides a

temporary storage for data being processed by the CPU.. It is connected to main
memory by means of the system data bus.
c) Memory:
The immediate access memory in the CPU is not intended for storing CNC
software. A much greater storage capacity is required for the various programs and
data needed to operate the CNC system. CNC memory can be divided into two
categories: (I) main memory and (2) secondary memory. Main memory (also known
as primary storage) consists of ROM (read-only memory) and RAMS (random access
memory) devices. Operating system software and machine interface programs are
generally stored in ROM. These programs are usually installed by the manufacturer of
the MCU. Numerical control part programs are stored in RAM devices. High-capacity
secondary memory (also called auxiliary storage or secondary storage) devices are
used to store large programs and data files, which are transferred to main memory as
needed. Common among the secondary memory devices are floppy diskettes and hard
disks.
d) Input/output Interface:
The I/O interface provides communication between the various components of the
CNC system, other computer systems and the machine operator. As its name
suggests, the I/O interface transmits and receives data and signals to and from
external devices. The operator control panel is the basic interface by which the
machine operator communicates to the CNC system. This is used to enter commands
relating to part program editing, MCU operating mode, speeds and feeds, cutting
fluid pump on/off and similar functions. Either an alphanumeric keyboard is included
in the operator control panel. The I/O interface also includes a display (CRT or LED)
for communication of data and information from the MCU to the machine operator.
e) Controls for machine tool axes and spindle speed:
These are hardware components that control the position and velocity (feed rate) of
each machine axis as well as rotational speed of the machine tool spindle. The control
signs generated by MCU must be converted to a form and power level suited to drive
the machine axes. Positioning systems can be classified as open loop and closed loop.
f) Sequence Controls for Other Machine Tool Functions:
In addition to control of table position, feed rate and spindle speed, several
additional functions are accomplished under part program control. These auxiliary

functions are generally on/off (binary] actuations, interlocks and discrete numerical
data.
g) CNC Software:
The computer in CNC operates by means of software. There are three types of
software programs used in CNC systems: (1) operating system software, (2) machine
interface software, and (3) application software. The principal function of the
operating system software is to interpret the NC part programs and generate the
corresponding control signals to drive 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: (1) an editor, which permits the machine operator
to input and edit NC part programs and perform other file management functions: (2)
a control program, which decodes the part program instructions, performs
interpolation and acceleration/deceleration calculations, and to produce the coordinate
control signals for each axis (3) an executive program, which manages the execution
of the CNC software as well as the I/O operations of the MCU. The machine interface
software is used to operate the communication link between the CPU and the machine
tool to accomplish the CNC auxiliary functions. As previously indicated, the I/O
signals associated with the auxiliary functions arc sometimes implemented by means
of a programmable logic controller interfaced to the MCU and so the machine
interface software is often written in the form of ladder logic diagrams. Finally, the
application software consists of the NC part programs that are written for machining
(or other) applications in the user's plant.
Fig.4: CNC Machine (Turning center T65M-750).

1.4 Features of CNC Machines :

The CNC systems have the following advanced features over NC systems.
1. Sufficient capacity to store multiple programs.
2. Multiple data entry capability ex: punched tape, magnetic tape, floppy disk,
RS232 interface etc.
3. Program editing at machine tool.
4. Fixed cycles and program subroutines.
5. Interpolation permits linear, circular, helical, parabolic, and cubic
interpolations.
6. Positioning features for setup.
7. Cutter length and size compensation.
8. Acceleration and deliration calculations.
9. Communication interface – links machine to other computers.
10. Diagnostics – to detect malfunctioning.
1. Storage of more than one part program: CNC have sufficient capacity to store
multiple programmes.
2. Various forms of program input: NC systems are limited to punched type as

input medium. CNC possess multiple data entry capabilities such as punched tape,
floppy diskettes, RS-232 communication port etc.
3. Program editing at the m/c tool:-CNC permits part program to be edited, when it
resides in the MCU computer memory.
4. Fixed cycle and programming subroutines:- Frequently used machining cycles

are stand as macros and can be called by a part program, instead of writing the full
instructions in every program.
5. Interpolation: - Linear and circular interpolation is hard wind in to the control

unit. But helical parabolic and cubic interpolation is stored /executed by part program.
6. Positioning features for set up: - Alignment task is possible by software options
in CNC system.
7. Cutter length & size compensation:- Tool length sensor are built in to m/c. Cutter
is mounted on the spindle and the sensor measures its length and this is used to correct
the programmed tool path.

8. Acceleration and deceleration calculations:- When cutter path changes abruptly,

feed rate is decelerated and accelerated back after the direction of change.
9. Communication Interfaces:-CNC controllers are equipped with standard RS 232

communication interface to link the m/c to other computers and computer driven
devices.
1.5 Advantage and Dis-advantages of CNC machines over

conventional machines:
Advantages of CNC:
1. Increased productivity.
2. High accuracy and repeatability.
3. Reduced production cost.
4. Reduced indirect operating cost.
5. Facilitation of complex machining operations.
6. Greater flexibility.
7. Improved production planning and control.
8. Lower operator skill requirement.
9. Facilitation of flexible automation.
10.Machining of advanced materials.
Disadvantages of CNC machines:

1. They are costly.
2. Trained operator is required to operate the machine.
3. In case of breakdown a highly skilled professional is required to solve the
problem.

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CNC Programming and Machining -20ME42P 2021-22

WEEK -1 INTRODUCTION TO CNC MACHINES

1.2.1 Basic Components of NC System:

An NC system consists of the following three components:

2. Machine control unit.

Department of Collegiate & Technical Education, Bengaluru, Karnataka-560001 1

Fig.1: Three basic components of Numerical control system.

1.3 Computer Numerical Control (CNC):

Department of Collegiate & Technical Education, Bengaluru, Karnataka-560001 2

Fig.2: General configuration of a Computer numerical control (CNC) system

1.3.1 The components of CNC:

Fig.3: The Machine control unit of a CNC system.

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required by software residing in memory. The immediate access memory provides a

Department of Collegiate & Technical Education, Bengaluru, Karnataka-560001 4

Fig.4: CNC Machine (Turning center T65M-750).

Department of Collegiate & Technical Education, Bengaluru, Karnataka-560001 5

1.4 Features of CNC Machines :

2. Various forms of program input: NC systems are limited to punched type as

4. Fixed cycle and programming subroutines:- Frequently used machining cycles

5. Interpolation: - Linear and circular interpolation is hard wind in to the control

Department of Collegiate & Technical Education, Bengaluru, Karnataka-560001 6

8. Acceleration and deceleration calculations:- When cutter path changes abruptly,

9. Communication Interfaces:-CNC controllers are equipped with standard RS 232

1.5 Advantage and Dis-advantages of CNC machines over

Disadvantages of CNC machines:

Department of Collegiate & Technical Education, Bengaluru, Karnataka-560001 7

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