Numerical Control

Automated Manufacturing!

MEEM4403 Computer-Aided Design Methods

Schematic of an NC machine tool

MCU machine control unit

Controls the motion of the NC machine tool.

DPU data processing unit

Reads and interprets the part program; sends immediate commands to CLU.

CLU control loop unit

Reads positions sensors and sends control signals to motors.
MEEM4403 Computer-Aided Design Methods
Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

History of NC machining
1947 U.S. Air Force has great need for automated machining of freeform surfaces. late 1940s John Parson devises method involving drilling holes at locations specified on punch cards. 1951 Servo-mechanisms Lab at MIT subcontracted to refine system. 1952 Lab demonstrates modified milling machine (First NC machine).
MEEM4403 Computer-Aided Design Methods

History of NC machining
NC Punched Tape (Figure 11.2 from Text):

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

History of NC machining
1970 Computer controller developed (called Computer Numerical Control - CNC). 1970s Direct Numerical Control developed.

One mainframe computer controls many machines.

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

History of NC machining
1980s Distributed Numerical Control (DNC) developed.

Mainframe computer sends program to PC controlling each NC machine.

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

Creating an NC Program
1. Establish coordinate systems tool path
coordinate system must match machine tool coordinate system. z direction: same as tool spindle rotation or workpiece rotation axis. tool moves away from workpiece. +ve x direction: first feed direction (tool movement with respect to workpiece). +ve tool moves away from workpiece. y direction: chosen to give right-hand coordinate system.

MEEM4403 Computer-Aided Design Methods

Establishing Coordinate Systems

Lathe Coordinate System:

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

Establishing Coordinate Systems

Vertical Drill Coordinate System:

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

Establishing Coordinate Systems

Horizontal Milling Machine coordinate system:

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

Establishing Coordinate Systems

Some machine tools have secondary slide motions labeled u, v, and w. Some machine tools have rotational motions about x, y and z axes labeled a, b and c respectively. a 2-axis machine allows controlling two motions simultaneously, a 3-axis machine allows controlling three motions simultaneously, etc. 2-axis, 3-axis, 4-axis and 5-axis machines are most popular; 9-axis is also available.
MEEM4403 Computer-Aided Design Methods

The Hexapod Machine

How many axes is this one?

MEEM4403 Computer-Aided Design Methods

Creating an NC program
2. Specifying Commands
A common format is the Word address format:
N_ G_ X_ Y_ Z_ I_ J_ K_ F_ S_ T_ M_

where:
the letter denotes a type of instruction or instruction parameter, _ is a number that gives the instruction number or parameter value letter and number pairs (words) can be omitted if they have not changed from the last command.
MEEM4403 Computer-Aided Design Methods

Creating an NC program
E.g. N040 G00 X0 Y0 Z300 - means move the tool to the coordinates (0,0,300) N is the sequence number G is the preparatory command (move instruction) X, Y, and Z are relative or absolute coordinates of the cutter
MEEM4403 Computer-Aided Design Methods

Creating an NC program
I, J and K are the center coordinates for tracing arcs F is the feed rate S is the spindle speed T is the tool number M is miscellaneous commands

MEEM4403 Computer-Aided Design Methods

Preparatory Commands

From: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

Miscellaneous Commands

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

Example
Part to be programmed:

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

Example
NC code:
N001 G91 // put in incremental mode N002 G71 // use metric units N003 G00 X0.0 Y0.0 Z40.0 T01 M06 // move to (0,0,40), change to tool 01 N004 G01 X65.0 Y0.0 Z-40.0 F950 S717 M03 // relative, 2-axis move to (65,0,-40), start // spindle rotation
MEEM4403 Computer-Aided Design Methods

Example
N005 G01 X10.0 F350 M08 // relative move to (10,0,0); start coolant N006 G01 X110.0 // straight moves N007 G01 Y70.0 N008 G01 X-40.86

Figure from: K. Lee, Principles of CAD/CAM/CAE Systems, Addison-Wesley, 1999

MEEM4403 Computer-Aided Design Methods

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Example
N009 G02 X-28.28 Y0.0 I14.14 J5.0 // move clockwise to (-28.28,0,0) along arc // centered at (14.14, 5.0, 0) N010 G01 X-40.86 N011 G01 Y-70.0 // last cut N012 G01 X-75.0 Y0.0 Z40.0 F950 M30 // return to start, turn off spindle and coolant

MEEM4403 Computer-Aided Design Methods

Studying for Final Exam

Do Practice Exam Textbook questions:
Ch. 6: 1, 3, 4 (optional: 2) Ch. 7: 4 Ch. 9: questions from optimization lecture Ch. 11: read Ch. 14: 1

MEEM4403 Computer-Aided Design Methods

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