UNIT 2: COMPUTER NUMERICAL CONTROL AND PROGRAMMING SYSTEMS
1. GEOMETRIC TRANSFORMATIONS
Definition:
Geometric transformations change the position, orientation, or size of an object in CAD/CAM
systems.
Types:
1. Translation: Moves object position. (x' = x + tx, y' = y + ty)
2. Rotation: Rotates around a point or axis. (x' = x cos(angle) - y sin(angle), y' = x sin(angle) + y
cos(angle))
3. Scaling: Enlarges or reduces object. (x' = Sx * x, y' = Sy * y)
4. Reflection: Creates mirror image across axis/plane.
5. Projection: Converts 3D object to 2D. (Orthographic, Perspective)
Hidden Surface Removal: Determines visible parts of 3D models (Z-buffer, scan-line).
Shading: Improves realism (Flat, Gouraud, Phong).
------------------------------------------------------------
2. FUNDAMENTALS OF COMPUTER NUMERICAL CONTROL (CNC)
Principle:
CNC uses numeric data to control machines automatically.
Classification of NC:
- Point-to-Point (Drilling)
- Straight Line (Slot cutting)
- Contouring (Milling, Lathe)
Motion Control:
- Open-loop: No feedback.
- Closed-loop: Feedback sensors ensure precision.
Control Loops: Position, Velocity, and Current loops.
Positioning Systems:
- Absolute: From origin.
- Incremental: From last position.
Types: NC, CNC, DNC, Combined CNC/DNC.
CNC Components:
- MCU: Brain of CNC, interprets program.
- Drives: Convert control signals to motion.
- Transducers: Feedback sensors.
- Lead screw, guideways: Precision movement.
- Interpolation: Linear, circular, helical.
- Tooling: Automatic Tool Changer, multiple pallets.
------------------------------------------------------------
3. NUMERICAL CONTROL PROGRAMMING
Manual Part Programming:
Written using G and M codes.
Example: N10 G01 X50 Y25 F200 S1200 M03
Tool Compensation:
- Length (G43/G44)
- Radius (G41/G42)
Tool Path Simulation:
Simulates lathe/milling tool movement to detect errors.
Computer Assisted Programming:
CAD/CAM generates NC code automatically.
APT Language Example:
PARTNO/1001
CUTTER/10
FROM/0,0,0
GO/TO,20,0,0
Post Processor: Converts generic APT data to machine-specific G/M codes.
Auxiliary Codes:
M03: Spindle CW, M05: Stop, M06: Tool change, M08: Coolant on.
------------------------------------------------------------
4. ADAPTIVE CONTROL SYSTEMS
Definition:
Automatically modifies machining parameters during operation.
Types:
- ACC: Works under constraints (e.g., torque limit).
- ACO: Optimizes cutting speed/feed for best performance.
Working:
Sensors measure force/temp -> Controller compares -> Adjusts feed/speed -> Continuous
monitoring.
Advantages:
- Higher productivity
- Longer tool life
- Better surface finish
- Reduced tool breakage
Adaptive Control in Turning:
Controller adjusts feed rate based on cutting load.
------------------------------------------------------------
Summary:
Geometric transformations (translation, rotation, scaling) are used in CAD.
CNC fundamentals include NC types, components, and interpolation.
NC programming uses G/M codes, APT language, and post processors.
Adaptive control enhances machining efficiency through feedback control.