Introduction

Numerical Control (NC) or control by numbers, is the concept,

which has
revolutionised the manufacturing scene that is partially due to
the rapid
advancement in microelectronics that has taken place since late
1960’s.

Numerical control

Numerical control of machine tools may be defined as a method

of
automation in which various functions of machine tools are
controlled by
letters, numbers and symbols.
In NC machine tools one or more of the following functions may
be
automatic:
a) starting and stopping of machine tool spindle
b) controlling the spindle speed
c) positioning the tool tip at desired locations and guiding it along
desired paths by automatic control of the motion of slides
d) controlling the rate of movement of the tool tip (i.e. feed rate)
e) changing of tools in the spindle.
 Principle of operation of a NC machine tool

Principle of operation of the control of axis motion in a

NC
machine tool
Elements of NC machine tool operation
 The data processing in a CNC machine tool in closed
loop
control

The data processing in a CNC machine tool in closed loop

control
 Typical CNC Machine tool operation

Numerical control modes

Types of control systems possible in CNC operation

NC Machine Tools

For the parts having complex contours, that cannot be

manufactured by conventional machine tools.
For small lot production, often for even single (one off) job
production, such as for prototyping, tool manufacturing, etc.
For jobs requiring very high accuracy and repeatability.
For jobs requiring many set-ups and/or the setups very
expensive.
The parts that are subjected to frequent design changes and
consequently require more expensive manufacturing methods.
The inspection cost is a significant portion of the total
manufacturing cost
 Since metallic nuts usually require a viscous lubricant, the
coefficient of friction is both speed and temperature dependent

Lead screw with Acme nut

. A recirculating ball screw and nut arrangement

(Courtesy THK Co. Ltd., Japan).
 A recirculating ball screw and nut arrangement
with external return tube (Courtesy THK Co. Ltd.,
Japan).

Pre-loading of the recirculating ball screw and nut

arrangement
 The closed loop control system used for the control
in a CNC machine tool

CNC Tooling
Cutting tool materials

High speed steel

Cemented carbides

The following guidelines would be useful for selecting a carbide

grade.
1. Choose a grade with the lowest cobalt content and the finest
grain
size consistent with adequate strength to eliminate chipping.
2. Use straight WC grades if cratering, seizure or galling are not
experienced in case of work materials other than steels.
3. To reduce cratering and abrasive wear when machining steel,
use
grades containing TiC.
 4. For heavy cuts in steel where high temperature and high
pressure
deform the cutting edge plastically, use a multi carbide grade
containing W-Ti-Ta and/or lower binder content.

Coated carbides

Ceramics

Use the highest cutting speed recommended and preferably

select square or round inserts with large nose radius.
Use rigid machine with high spindle speeds and safe clamping
angle.
Machine rigid workpieces.
Ensure adequate and uninterrupted power supply.
Use negative rake angles so that less force is applied directly
to the ceramic tip.
The overhang of the tool holder should be kept to a minimum;
not more than 1.5 times the shank thickness.
Large nose radius and side cutting edge angle on the ceramic
insert to reduce the tendency of chipping.
Always take a deeper cut with a light feed rather than a light
cut with heavy feed; ceramic tips are capable of cuts as deep
as one-half the width of the cutting surface on the insert.
Avoid coolants with aluminium oxide based ceramics.
Review machining sequence while converting to ceramics and
if possible introduce chamfer or reduce feed rate at entry.

Summary of applications for various cutting tool

materials
Milling Tooling Systems
The complete tool assembly (for parallel shank tooling)
as used in a CNC machining centre.
 Retention knob as used in the top of tool assembly for
clamping and releasing purpose as used in a CNC
machining centre.

Tool presetting
 Adopter shapes for a) BT style; b) ANSI CAT-V style for
CNC machining centres.

CNC Programming

Part Programming Fundamentals

Process planning
Axes selection
Tool selection
Cutting process parameters planning
Job and tool setup planning
Machining path planning
Part program writing
Part program proving

Process planning

Machine tool used

Fixture(s) required
Sequence of operations
For each of operation
Cutting tools required
Process parameters
The steps involved in the development of a proven part
program in NC machining
Tool selection

Cutting process parameters planning

Job and tool setup planning

Machining path planning

Part program writing

Part program proving

DRAWING :- 1
%PGM1 G71 *
N10 G30 G17 X-10 Y-60 Z-25 *
N20 G31 G90 X+80 Y+10 Z+0 *
N30 T1 G17 S1000 *
N40 G00 G90 Z+5 M3 *
N50 G00 X+0 Y+0 *
N60 G01 Z-5 F25 *
N70 G01 X+0 Y-50 F250 *
N80 G01 X+40 Y-50 *
N90 G01 X+40 Y-20 *
N100 G01 X+70 Y-20 *
N110 G01 X+70 Y+0 *
N120 G01 X+0 Y+0 *
N130 G00 Z+50 M2 *
N99999 %PGM1 G71 *
%PGM1IXY G71 *
N1 G30 G17 X-80 Y-60 Z-25 *
N2 G31 G90 X+40 Y+40 Z+0 *
N3 T1 G17 S1000 *
N4 G00 G90 Z+5 M3 *
N12 G00 X+20 Y+20 *
N14 G98 L1 *
N13 G01 G91 Z-5 F25 *
N15 G01 G90 X+0 Y+0 *
N5 G01 X-70 Y+0 F150 *
N6 G01 X-70 Y-50 *
N7 G01 X-30 Y-50 *
N8 G01 X-30 Y-20 *
N9 G01 X+0 Y-20 *
N10 G01 X+0 Y+0 *
N16 L1.1 *
N11 G00 Z+50 M2 *
N99999 %PGM1IXY G71 *
%PGM1IZ G71 *
N10 G30 G17 X-40 Y-40 Z-25 *

N20 G31 G90 X+80 Y+60 Z+0 *

N30 T1 G17 S2000 *
N40 G00 G90 Z+50 M3 *
N50 G01 X-20 Y-20 F50 *
N55 G01 Z+0 *
N60 G98 L1 *
N70 G01 G91 Z-1 F50 *
N80 G01 G90 X+0 Y+0 *
N90 G01 X+0 Y+50 *
N100 G01 X+70 Y+50 *
N110 G01 X+70 Y+30 *
N120 G01 X+40 Y+30 *
N130 G01 X+40 Y+0 *
N140 G01 X+0 Y+0 *
N150 G01 X-20 Y-20 *
N155 G98 L0 *
N160 L1.9 *
N170 G00 Z+50 M2 *
N99999 %PGM1IZ G71 *
DRAWING:-2
%PGM2 G71 *
N10 G30 G17 X-78 Y-10 Z-25 *
N20 G31 G90 X+22 Y+82 Z+0 *
N30 T1 G17 S1000 *
N40 G00 G90 Z+5 M3 *
N50 G00 X+0 Y+0 *
N60 G01 Z-5 F25 *
N70 G01 X+12 Y+32 F250 *
N80 G01 X-28 Y+44 *
N90 G01 X-28 Y+72 *
N100 G01 X-68 Y+72 *
N110 X-48 Y+0 *
N120 G01 X+0 Y+0 *
N130 G00 Z+50 M2 *
N99999 %PGM2 G71 *
DRAWING :- 3
%PGM3 G71 *
N10 G30 G17 X-10 Y-10 Z-25 *
N20 G31 G90 X+110 Y+90 Z+0 *
N30 T1 G17 S1000 *
N40 G00 G90 Z+5 M3 *
N50 G00 X+0 Y+0 *
N60 G01 Z-5 F25 *
N70 G01 X+0 Y+40 F250 *
N80 G01 X+30 Y+55 *
N90 G01 X+40 Y+80 *
N100 G01 X+60 Y+80 *
N110 G01 X+100 Y+20 *
N120 G01 X+80 Y+0 *
N130 G01 X+10 Y+10 *
N140 G01 X+0 Y+0 *
N150 G00 Z+50 M2 *
N99999 %PGM3 G71 *
DRAWING :- 4
%PGM4 G71 *
N10 G30 G17 X-10 Y-60 Z-25 *
N20 G31 G90 X+150 Y+81 Z+0 *
N30 T1 G17 S1000 *
N40 G00 G90 Z+5 M3 *
N50 G01 X+0 Y+0 F1000 *
N60 Z-5 F25 *
N70 G01 X+50 Y-10 F250 *
N80 G25 R8 F50 *
N90 G01 X+80 Y-50 F250 *
N100 G01 X+140 Y-9 *
N110 G25 R9 F50 *
N120 G01 X+110 Y-9 *
N130 G02 X+80 Y+21 R+30 *
N140 I+90 J+21 *
N150 G12 H+90 *
N160 I+90 J+51 *
N170 G13 H+90 *
N180 G01 X+17.75 Y+71 *
N190 G25 R41 F50 *
N200 X+0 Y+0 F250 *
N210 G00 Z+50 M2 *
N99999 %PGM4 G71 *
DRAWING :-5
%PGM5 G71 *
N10 G30 G17 X-10 Y-110 Z-25 *
N20 G31 G90 X+150 Y+10 Z+0 *
N30 T1 G17 S1000 *
N40 G00 G90 Z+5 M3 *
N50 G75 P01 -5 P02 -10 P03 -1
P04 50 P05 X+68 P06 Y+40 P07
250 *
N60 G01 X+42 Y-28 F1000 M99 *
N70 G77 P01 -5 P02 -10 P03 -1
P04 50 P05 32 P06 50 *
N80 G01 X+96 Y-52 F1000 M99 *
N90 G00 Z+50 M2 *
N99999 %PGM5 G71 *
DRAWING :- 6
%PGM6 G71 *
N10 G30 G17 X-10 Y-100 Z-25 *
N20 G31 G90 X+100 Y+10 Z+0 *
N30 T1 G17 S1000 *
N40 G00 G90 Z+5 M3 *
N50 G83 P01 -5 P02 -10 P03 -1
P04 0 P05 50 *
N60 G01 X+20 Y-20 F1000 M89 *
N70 G01 X+50 Y-50 *
N80 G01 X+80 Y-30 M99 *
N90 G00 Z+50 M2 *
N99999 %PGM6 G71 *
DRAWING :- 7
%PGM7 G71 *
N10 G30 G17 X-10 Y-10 Z-20 *
N20 G31 G90 X+110 Y+125 Z+0 *
N30 T1 G17 S1000 *
N40 G00 G90 Z+5 M3 *
N50 G01 X+40 Y+20 F500 *
N60 Z-5 F500 *
N70 I+20 J+20 G13 H+135 *
N80 G00 Z+5 *
N90 G01 X+40 Y+60 *
N100 Z-5 F500 *
N110 G90 I+60 J+85 G13 H+180 *
N120 G00 Z+25 M2 *
N99999 %PGM7 G71 *
DRAWING :-8

%PGM8 G71 *
N10 G30 G17 X-10 Y-10 Z-25 *
N20 G31 G90 X+150 Y+150 Z+0 *
N30 T1 G17 S2000 *
N40 G00 G90 Z+50 M3 *
N50 I+80 J+70 *
N60 G11 H+40 R+50 F250 *
N70 G01 Z-5 F25 *
N80 G98 L1 *
N90 G11 G91 H+40 F500 *
N100 G98 L0 *
N110 L1.8 *
N120 G00 Z+50 M2 *
N99999 %PGM8 G71 *
DRAWING :- 9