Degree In Mechanical Engineering

ECD6323
CAD / CAM
Chapter 3: Numerical Control
(Principles of numerical control. Types of numerical control systems. Types of numerical control machines. NC part programming)
(10 Hours)

By Dr. Umar Nirmal

1
 Overview of Chapter 3

PART 1: INTRODUCTION TO COMPUTER NUMERICAL CONTROL (CNC)

PART 2: TURNING CENTRE PROGRAMMING

PART 3: CNC HARDWARE BASICS

PART 4: CNC TOOLING

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 PART 1: INTRODUCTION TO COMPUTER NUMERICAL CONTROL (CNC)
By Definition:
Computer numerical control (CNC) is a manufacturing method that automates the control, movement and
precision of machine tools through the use of preprogrammed computer software, which is embedded inside the
tools.

Q3.1: In Computer Numerical Control (CNC), what does the part program mainly does?
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PART 1: Historical Development of CNC

4
PART 1: Numerical Control (NC)

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 PART 1: NC (cont’d)

C
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PART 1: Part Program - A

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PART 1: Machine Control Unit (MCU) - B

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PART 1: Machine Tool- C

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PART 1: NC (cont’d)

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PART 1: Elements of NC Machine Tool Operation

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PART 1: Types of NC Systems

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PART 1: Types of NC Systems - Motion Systems

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PART 1: Types of NC Systems - Control Systems

Computer Numerical Control

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 Open Loop vs. Closed Loop

Process A Process B Process C

Input Output

Q3.2: Illustrate by means of a sketch the main difference between an ‘Open Loop’ and a ‘Closed Loop’ system?

Input
Process A Process B Process C Output

Feedback Drive
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PART 1: Types of NC Systems - Positioning Systems

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 PART 1: Types of NC Systems – Power Source

vs.

vs.
Hydraulic Power

Electrical Power Pneumatic Power

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PART 1: Advantages of CNC

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 PART 1: Disadvantages of CNC
Q3.2: State five disadvantages of CNC?

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PART 1: Application of CNC Machines

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PART 1: Types of CNC Machines

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PART 2: TURNING CENTRE PROGRAMMING

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PART 2: Example of a Block Line Address Format in NC

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 PART 2: Axes Systems in CNC

Tool Offset

Q3.4: Illustrate the possible impact of the final work piece after a typical CNC
machining process if the cutting tool is not calibrated to it original tool datum? 24
PART 2: General Programming Functions

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PART 2: General Programming Functions (cont’d)

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 PART 2: General Programming Functions – Tool vs. Turret

B
A

A A D
B C

Turret
Tool

A B C
D
A

Tmmnn
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PART 2: General Programming Functions (cont’d)

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PART 2: General Programming Functions (cont’d)

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PART 2: General Programming Functions (cont’d)

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PART 2: General Programming Functions (cont’d)

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PART 2: General Programming Functions – ‘M’ functions (cont’d)

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 PART 2: Motion Commands

Basic CNC Turning Programming: [Link]

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PART 2: Motion Commands (cont’d)

X = U = -(55-
10)*2 (the
Diameter = 20mm in X-axis shaft
diameter is
taken in this
case)

Z = W = -25
(only the length of
the shaft affected)

Radius = 10mm in X-axis

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PART 2: Motion Commands (cont’d)

Diameter = 20mm in X-axis; point B (10x2)

Diameter = 30mm in X-axis; point C (15x2)

A to A’ in -X direction = ((55-10)*2) = -90
So, U = -90
Diameter = 60mm in X-axis; point D (30x2)
U

A’

A to A’ (diameter mode) A’ to B in -Z direction = 25-0= -25

So, W = -25
A’ to B (diameter mode)

(30-15)*2 in +X axis
25-23 in +Z axis
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PART 2: Motion Commands (cont’d)

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 PART 2: Motion Commands (cont’d)

X = 60 as is the
end of chamfer
starting from
point B

Z = -60-(-20) = -40 ; only the ‘z’ points on C and E

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PART 2: Motion Commands (cont’d)

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 X
; G20 = inch mode / G40 = tool compensation /
G98 = absolute positioning mode
; zero return the tool to its zero position via a
reference point at rapid speed
Standard
Start ; call tool from turret

; set spindle speed

Z

(K = 0)

; zero return the tool to its zero position via a

reference point at rapid speed
Standard
End
; tool return to its turret X
; program end
A (-0.25, 2.75)

A (3.25,1)

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PART 2: Motion Commands (cont’d)

Normally used
for Boring
operations

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PART 2: Cut Planning

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 PART 2: *Setting the Tool Datum wrt the WP

= diameter of the shaft = X Cutting Tool’s Tip

=0=Z

Turning
CNC Turning
CNC
=X

=0=Z
Spindle speed (rpm) = ∏ x d x f;
where; X and Y = ?
∏ = 3.142
d = diameter of the cutting tool in mm
f = feed rate (normally 30 to 40 mm/min)

Q3.5: Illustrate the impact to the workpiece in CNC CNC Milling

machining if the tool datum is not correctly set.

*Setting datum differs with different CNC machines. The one illustrated here is for MMU-FET CNC machines respectively. 42
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44
 G98: return tool to initial cutting point after each cutting cycle
G40: Compensation Off

S200

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46
 G02: is used to machine an arc or radius in a clockwise direction
G03: is used to machine an arc or radius in a anti-clockwise direction
G03
F0.20
(Tapper 3 x 45deg
G02

Can we perform operation N235

Standard End followed by N240 or straight N240?
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PART 2: General Programming Functions – Thread Cutting

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PART 2: General Programming Functions – Thread Cutting (cont’d)

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M08 is the G Code command to turn on the main spindle coolant,
M09 turns off all coolant.

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Q3.6: If the depth of cut for a typical CNC turning machine
is 2mm, can the user perform a turning operation only
once with the given 2mm? Explain your answer.

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PART 2: Canned Cycles

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PART 2: Turning Canned Cycles

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PART 2: Facing Canned Cycles

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PART 2: Thread Cutting Canned Cycles

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PART 2: Thread Cutting Canned Cycles (cont’d)

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57
Conventional CNC Part Programming Canned Cycle CNC Part Programming

vs.

Q3.7: What is the main advantage / advantages of using

canned cycle part program over the conventional
programming method in the CNC Machining industry?

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 Milling Programming

Visit - [Link]

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PART 3: CNC HARDWARE BASICS

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PART 3: CNC HARDWARE BASICS – CNC Machine Layout

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PART 3: CNC HARDWARE BASICS – Spindle Designs

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PART 3: CNC HARDWARE BASICS – Components in a Spindle

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PART 3: CNC HARDWARE BASICS – Types of Spindles

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PART 3: CNC HARDWARE BASICS – Types of Spindles (cont’d)

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PART 3: CNC HARDWARE BASICS – Types of Drive Systems

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PART 3: CNC HARDWARE BASICS – Feedback Devices

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PART 3: CNC HARDWARE BASICS – Feedback Devices: Rotary Encoder

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PART 3: CNC HARDWARE BASICS – Absolute Encoder

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PART 3: CNC HARDWARE BASICS – Axes System

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PART 3: CNC HARDWARE BASICS – Axes System (cont’d)

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 PART 3: CNC HARDWARE BASICS – Axes System (cont’d)

Q3.8: Illustrate the importance to have an

axes system and the possible error that may
develop during a typical CNC machine
operation.

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Q3.9: Provide images (i.e. real or schematic) and briefly explain the working principle for the type of drive systems below:
a) AC drives
b) DC drives
c) DC servo motor
d) Brushed and Brushless motor
e) Stepper motor
f) Linear motor

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PART 4: CNC TOOLING

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PART 4: CNC TOOLING– Cutting Tool Materials

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PART 4: CNC TOOLING– Turning Tool Geometry
Cutting Tool Holder

Cutting Tool

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PART 4: CNC TOOLING– Types of CNC Turning Tools

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PART 4: CNC TOOLING– Types of Turning Operations

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 PART 4: CNC TOOLING – Turning Turrets

Cutting Tool Turret

(Holder + Cutter) Q3.10: Draw a CNC cutting tool and its corresponding tool holder.

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PART 4: CNC TOOLING – Milling Tooling Systems

Drill Bit
Holder

Q3.11. You have a 10mm in diameter slot drill bit

which will be used for CNC milling. What will be
the recommended size of the collet for this slot
drill? Explain your answer briefly.

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PART 4: CNC TOOLING – Type of Milling Operations

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 Q3.12. Name the type of Milling operations as per the schematic drawings shown in Figure a to l respectively.

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Watch Operations on Milling Machines: [Link]
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PART 4: CNC TOOLING – Automatic Tool Changers (ATC)

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PART 4: CNC TOOLING – Types of ATC

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PART 4: CNC TOOLING – ATC: Tool Changing Operation

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PART 4: CNC TOOLING – Types of Work Holding Devices

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Q3.13. A machine grade of Aluminum is to be milled on a CNC machine with a 20mm diameter four tooth end milling
cutter. Cutting speed = 120 m/min and feed = 0.008 mm/tooth. Find the following:
a) Rotational speed
b) Feed rate in the unit of mm/rev and mm/min respectively.

Q3.14. A turning operation is to be performed on a CNC lathe machine. Cutting speed = 2.5m/s, feed rate = 0.2mm/rev
and depth = 4.0mm. Workpiece diameter = 100mm and its length = 400mm. Find the following:
a) Rotational speed of the workpiece
b) Feed rate in the unit of mm/min
c) Time to travel from one end of the part to the other

91
Q3.13. A machine grade of Aluminum is to be milled on a CNC machine with a 20mm diameter four tooth end milling
cutter. Cutting speed = 120 m/min and feed = 0.008 mm/tooth. Find the following:
a) Rotational speed
b) Feed rate in the unit of mm/rev and mm/min respectively.

92
Q3.14. A turning operation is to be performed on a CNC lathe machine. Cutting speed = 2.5m/s, feed rate = 0.2mm/rev
and depth = 4.0mm. Workpiece diameter = 100mm and its length = 400mm. Find the following:
a) Rotational speed of the workpiece
b) Feed rate in the unit of mm/min
c) Time to travel from one end of the part to the other

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~ end ~

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