Chapter No.

CNC Technology

Intro
Evolution of NC technology is closely related to and dependent on the development of computer technology. Computer has made substantial improvements in the controls of NC. 3 types
CNC DNC Adaptive control Robot control

Computer Numerical Control (CNC)

It is an NC system that utilizes a dedicated computer to perform some or all of the basic numerical control functions. Microcomputer or minicomputer.

Part program can be read, same as that of the NC machine.

 In conventional NC punched tape is cycled through the reader for every batch. In CNC, the program is stored in the computer memory.

Punched tape is used for original loading of the part program and data.
Reprogramming is possible in CNC. Presence of RAM, ROM, I/P and O/P devices has raised the level of automation in NC systems.

CNC machine controller

Open or closed loop controller Beside this controls for selection of spindle, supply of coolant, tool changing, controlling lubrication pumps etc. Two types of controller:
Hybrid CNC controller Straight CNC controller

1. Hybrid CNC controller

2. Straight CNC controller

Features and advantages of CNC

Part Storage Online part programming and editing Flexibility of the system Fixed cycles, subroutines and custom built Macros Interpolations Positioning features for setup Expanded tool compensation Digitizing software Easier maintenance of CNC with diagnostic software Communication interface Metric conversions

Direct Numerical control (DNC)

Can be defined as a system which integrates a number of machines by controlling it through a central computer by direct connection and in real time. No tape reader, part programming is through the computer.

 DNC central computer is designed to provide instructions to each machine tool on demand.
There is a two way information exchange between the central computer and each of the machine tool. For very large networks satellite computers are used.

Types of DNC
Depending upon the type of communication link between the central computer and the machine tool, DNC system can be of two types: 1. Behind the tape Reader (BTR) System.

2. Specialized MCU

Behind the tape Reader (BTR) System.

Specialized MCU

Advantages and Disadvantages of DNC

Eliminates the use of punched tape Greater communication Convenient storage of part programs Same program can be run on different machine tool, so no duplication of work Reporting of shop performance Central computer can be placed at convenient location isolated from the shop floor. Data is stored centrally, so as to avoid duplication of work. Computer failure Expensive

Adaptive Control (AC)

NC, CNC system find major application in areas where there is an immediate need to reduce the non-productive time. Non-productive time goes in work piece handling, job setup, lead times between receipt of an order and production, tool changes and operator delays.
Total production time = Nonproductive time + Machining time

The concept of adaptive control aims at reducing the in-process machining time by responding in a manner so as to make optimal use of the machine capability. AC aims at real time control of the operating parameters such as cutting speeds, feeds of cut, cutting temperature, force, torque etc.

 AC automatically adjust the machining/operating parameters so as to : Use the maximum available spindle power Limit deflection of cutter to its permissible value Limit the cutting temperature to its permissible value Limit the vibration amplitude to its permissible value

Use of AC is not appropriate every machining situation.

Where to use adaptive control?
The in-process time consumes a significant portion of the machining cycle time. There are significant sources of variability in the job.

1. Variable geometry of cut due to changing depth or width of the cut.

2. Variable work piece hardness due to the presence of hardspots and non-homogeneity.

3. Variable work piece rigidity

4. Air gaps during cutting

5. Tool wear: Research shows that as tool starts to wear cutting forces have increased. AC should respond to tool wear by reducing feed rate.

 If the cost of operating the machine tool is high. Steel, titanium and high-strength alloys.

Two types of Adaptive Control (AC)

1. Adaptive control Optimization (ACO) 2. Adaptive control constraints (ACC)

1. Adaptive control Optimization (ACO)

PI = Material Removal Rate (MRR) / Tool Wear Rate (TWR)

1. Adaptive control constraints (ACC)

Advantages of Adaptive control

Increased production rate Increased tool life

Increased accuracy by making tolerance as constraint

Less human interactions Easier part programming