COMPUTER AIDED
MANUFACTURING
(CAM )
UNIT 1 (NC MACHINES)
Numerical Control (NC) is a form of programmable automation
in which the mechanical actions of a machine tool or other
equipment are controlled by a program containing coded
instructions (alphanumeric data)
The collection of all instructions (or program of instruction)
necessary to machine a part is called an NC program, CNC
program, or a part program.
The person who prepares this program is called a part
programmer.
Basic Components of NC System
An NC system consists of three basic components:
1.A program of instructions,
2.A machine control unit, and
3.Processing equipment.
Basic Components of NC System
1-Program of instruction
The program of instructions is the detailed step-by-step
commands which refer to positions of a cutting tool relative to the
worktable on which the workpart is fixed.
2-Machine Control Unit
It consists of a microcomputer and related control hardware that
stores the program of instructions and executes it by converting
each command into mechanical actions of the processing
equipment, one command at a time.
3-Processing Equipment
It accomplishes the processing steps to transform the starting
workpiece into a completed part. Its operation is directed by the
control unit, which in turn is driven by instructions contained in
the part program.
NC and CNC Technology
•The NC stands for the older and original Numerical Control technology.
•The CNC stands for the newer Computerized Numerical Control
technology.
•Both systems perform the same task, namely manipulation of data for
the purpose of machining a part.
•In both cases, the internal design of the control system contains the
logical instructions that process the data.
NC Technology
•The NC system uses a fixed logical functions, those that are built-in and
permanently wired within the control unit.
•These functions can not be changed by the programmer or the machine
tool operator.
•The system can interpret a part program, but it does not allow any
changes to the program.
•NC system requires the use of punched tapes for input of the program
instructions.
Types of NC systems
Open-loop Control system
Stepper motor is used, having a predefined amount of revolution.
Current pulses are send from MCU to individual motors.
Movement/rotation depends on number of pulses send.
Advantages:
1. Position is maintained just by keeping track of number of
revolutions.
2. Can produce a movement of 1/1000th of an inch, for a single pulse.
3. Cheap and less complex.
4. Easy to maintain.
Drawback:
1. Assumption: Motor movement is precise, i.e. motor is moving the
exact amount depending on the number of pulses.
2. No way to correct errors, because no feedback.
3. This control is not suitable for large machines requiring greater
power
because of limitation of stepper motor to generate high torque.
Closed-loop Control
• Direct current (DC) motors are used.
• Can generate high levels of torque.
• Can be reversed.
• Unlike stepper motors, it cannot achieve very precise movement.
• Separate positions sensors are required.
• Position information is fed back as a signal to the controller.
• Major advantage: because of feed back and servo motors
• Types of NC control systems
• reversible feature, errors can be corrected, by comparing with
• target position.
• Thus formed a closed loop.
• Higher accuracy than open loop systems because of feed back.
• Applications:
1. Larger NC machines because of higher loads.
2. For greater accuracy, any kind of load.
• Expensive and complex.
Advantages and Disadvantages of NC
The advantages generally attributed to NC, with emphasis on
machine tool applications, are the following:
1.Non-productive time is reduced (fewer setups, less setup time,
reduced work piece handling time, and automatic tool changes).
2.Greater accuracy and repeatability.
3.More-complex part geometries are possible.
4.Simplified tooling and work holding.
5.Operator skill-level requirements are reduced.
6.Inspection requirements are reduced.
The disadvantages of NC include the following:
1.Higher investment cost.
2.Higher maintenance effort.
3.Part programming.
APPLICATION OF NC MACHINE
NC lathe, either horizontal or vertical axis. Turning requires two-axis, continuous path
control, either to produce a straight cylindrical geometry [called straight turning) or
to create a profile (contour turning).
• NC boring mill, horizontal and vertical spindle. Boring is similar to turning. except that an
internal cylinder is created instead of an external cylinder. The operation requires
continuous path, two-axis control.
• NC drill press. These machines use point-to-point control of the work head (spindle
containing the drill bit) and two axis (x-y) control of the worktable. Some NC drill
presses have turrets containing six or eight drill bits. The turret position is programmed
under NC control. thus allowing different drill bits to be applied to the same work part
during the machine cycle without requiring the machine operator to manually
change the tool.
• NC milling machine. Milling machines require continuous path control to perform
straight cut or contouring operations. Figure 6.11 illustrates the features of a four axis
milling machine.
METHODS FOR IMPROVING
ACCURACY
For accurate machining or other processing performed by an NC system, the positioning
system must possess a high degree of precision. Three measures of precision can be
defined for an NC positioning system: (I) control resolution. (2) accuracy, and (3)
repeatability. These terms are most readily explained by considering a single axis of the
positioning system. Control resolution refers to the control system's ability to divide the total
range of the axis movement into closely spaced points that can be distinguished by the Men
Control resolution is defined as the distance separating two adjacent addressable points in
the axis movement. Addressable points are locations along the axis to which the worktable
can be specifically directed to go. It is desirable for control resolution to be as small as
possible. This depends on limitations imposed by:
(1) the electromechanical components of the positioning system and/or
(2) the number of bits used by the controller to define the axis coordinate location.
A number of electromechanical factors affect control resolution, including: lead screw
pitch, gear ratio in the drive system, and the step angle in a stepping motor for an open-loop
system or the angle between slots in an encoder disk for a closed-loop system. For an open
loop positioning system driven by a stepper motor, these factors can be combined into an
expression that defines control resolution as follows:
where CRj = control resolution of the electromechanical components (rnrn.in],
p '= lead screw pitch (nun/rev, in/rev), n. = number of steps per revolution, and
'g = gear ratio between the motor shaft and the lead screw as defined in
equation. A similar expression can be developed for a closed-loop positioning
system, except that the gear reduction between the lead screw and the
encoder shaft must be included:
The second factor that limits control resolution is the number of bits used by the
MeV 10 specify the axis coordinate value. For example, this limitation may be
imposed by the bit storage capacity of the controller. If B '" the number of bits in the
storage register for the axis, then the number of control points into which the axis
range can be divided = 2B.Assuming that the control points are separated equally
within the range, then
where CR2 '= control resolution of the computer control system [mm, in), and L =
axis
range (rom, in). The control resolution of the positioning system is the maximum of
the two
values; that is :
A desirable criterion is for CR2 : CR1, meaning that the electromechanical system
is the limiting factor that determines control resolution. The bit storage capacity of a
modem computer controller is sufficient to satisfy this criterion except in unusual
situations. Resolutions of 0.0025 mm (0,0001 in) are within the current state of NC
technology.
