Chapter 1

NC Technology

1. Introduction:

Conventional machines used for operations like Turning, Drilling, Milling were commonly
used and operated manualy. the worker had to use a detailed working drawing sheet of the
workpart that included dimensions, tolerances, surface roughness,.
He also had to use process sheet, which includes production steps, cutting speed, feed,
feedrate, revolutions,..
This sheet was used to develop the NC coded program.

2. Basic Components of NC Machine System:

NC Machine

Machine
Program Control Unit
Instruction (MCU)
(Computer)
Machine Tool

To produce the program instruction we use the process sheet and convert it to NC coded
program.
The NC coded program is then punched into a tape to be transferred to the machine
control unit.
The machine control unit (MCU) contains a tape reader, it also has register and buffer,
they are used to convert the data from the punched tape into electric signals that are sent
to the machine tool.

1
3. Flow Diagram of the Steps in Processing NC Program:

Engineering Engineering
Design Design

Part Print Process Sheet

Numerical Control
Programming

Production
NC Tape Tool Design
Control

Lot Size &

Fixture Design
Scheduling

Shop
Tool Maker
Management

Fixture
Numerical
Control
Machine

Completed Machining
Operation

2
4. Program of Instructions :
It is the detailed step by step commands that direct the actions of the processing
equipment. In machine tool applications ,the program of instruction is called part
program ,and the person who prepare the program is called a part programmer.
The program is coded on a suitable medium for submission to the machine control unit.
The most common input mediums used are punched tape , punched cards and
magnetic tape .
a. Punched Card:
Punched card is a plastic / paper card which is having holes . It can
accommodate only few sentences of the program so there is restriction on the
size . The advantage of using card is that sequence of operation can be changed
because each operation is on separate card .,program readers and transportation
devices for punched cards are more complicated than for punched tape.
b. Punched Tape :
Different materials have been used for punched tape . These materials are
paper and foil . The following figure shows the shape and dimensions of the
punched tape

3
The following tables shows the standard EIA and ISO (ASCII) codes for
numerical control programming originally designed for punched tape.

4
 c. Magnetic Tape :
Magnetic tape is a plastic tape coated with iron oxide and is similar to the tape
Used in tape recorders (but small size).magnetic tape can store much more
information per unit length as compared to punched cards or magnetic tapes .Also
Information can be easily stored and erased .This is the least preferred in
machining because of the following reasons :
1. electrical and magnetic fields can easily distort program signals
2. any damage of the magnetic tape is not easy detectable because no visual
examination is possible.
3.tape gets damaged in dust in the shop floor.

5.Machine Control Unit :

Information is passed from the NC tape to the machine control unit by means of
the tape reader in the machine control unit (MCU) . After the tape has been read
by the tape reader ,the coded information ,now in the form of signals ,is passed on
to the control. Registers within the control accept the information which consists
of proper coordinates , preparatory functions and miscellaneous functions..This
information is transmitted to the respective register sections where actuation
signals are relayed to the machine tool drives. A fundamental sketch of this process
is illustrated in the following figure .

Tape Reader

Information Read &

Decode Machine Table

Machine X 1 2 3 4 5
Actuating
Registers Y 0 8 5 7 1 X Y

Machine Control
Unit (MCU)

5
 Most modern NC and CNC machine controls are equiped with buffer storage shown
in the following figure ,this feature allows the control to accept information into the
buffer registers while an operation is being performed from the active machine
registers.when the operation is complete the information is transferred from the buffer
storage to the machine actuation registers.

Tape Reader

Information
Read
& Decode

X 1 0 7 6 4 Machine Table
Y 5 8 9 2 4
Information Passed Directly

Machine X 1 2 3 4 5
Actuating X Y
Registers
Y 0 8 5 7 1
Machine Control
Unit (MCU)

Tape reader types:

a.Mechanical Type: as shown in following figure
Consists of pins that read holes in the tape, such that a hole is read as 1 or
signal, tape is red as 0 or no signal.
It is commonly used in point to point motion (like in drilling)
It is slow, reads only about 60 chr/sec
It is reliable, inexpensive, and easy maintainance.

6
b. Photo-electric reader: as shown in the following figure
Consists of a light beam and photo electric cell that gives a signal when light
falls upon it, such that a hole is read as 1 or signal, tape is red as 0 or no signal.
It is commonly used in contouring motion.
It is fast, reads 300-500 chr/sec
It is very expensive
It has high sensitivity to dust

7
C. Pnumatic reader : as shown in the figure
Their principle is similar to that of electromechanical tape reader . Here pressure on
the moving contact is exerted by compressed air . If there is punched hole in front of
nozzle , the compressed air passes and no pressure builds up at the opening of nozzle
.this pressure is utilized to obtain an electric signal . these readers are relatively cheap
.They have the advantage that the dirt particales in the reading zone are automatically
blown off thus providing more reliability .

6. .Axis Relationships:

For Milling/Drilling

+Z

-Y Z
-X +X b
+Y

X
a
8 Y c
-Z
 for Turning:
+X

-Z +Z

-X
Once the NC tape has been read ,decoded and the machine actuation registers loaded ,the
Machine responds with its appropriate coordinate axis movements and other commands
Machines with only X and Y position capability are known as two axis machines. On
Machines of this type distance in Z direction is controlled by the operator or by preset
Stops similar to that of a conventional drill press.
The three basic motions are designed by the electronic industries association (EIA) are the
X,Y,Z , the X motion is parallel to the longest dimension of the machine table,the Ymotion
Is normally parrel to the shortest dimension of the machine table.The Z motion becomes
Complicated by the fact that the NC macines are made with vertical and horizontal spindle
so it can be said that the line through the centre of the machine spindle is actually the Z
axis ,it is only when the actual depth of cut Z axis is controlled by the tape ,the macine is
considered a true three axis NC machine. Machine / axes relationships can be seen in
figures :

9
Vertical Milling Machine Horizontal Milling Machine

Turning Machine

10
7. Types of Motion Control:

1. Point to Point Motion (PTP):

Tool moves to the defined points with only feed back at the specific point.
Used in drilling operations.

2. Contouring Motion:
X,Y,Z motion are always controlled and they have constant feedback.
Used in milling or turning operations.

11
3. Straight Cut:
Only one coordinated is monitored at a time.
Used in simple straight cutting operations.

8.Rectangular Coordinates : Absolute and Incremental

8.1. Cartesian Coordinate System :
The system of cartesian is illustrate in figure , the X axis is the horizontal (left
And right ) and the Y axis is vertical (up and down) and the Z is perpendicular
To the paper with its point at the location where the X and Y lines cross each
Other ,the intersection of the two axes X and Y is called orign or Zero point.
Four quadrant are formed when the X and Y axes cross as shown in the figure

12
8.2 incremental System :
An incremental system works according to the same principle , it positions the
Work or cutter in increments from the immediately preceding point. Calculations
Are made from the location of the tool or table to where it is going. As shown in
figure the use of plus and minus signs involves a new aspect when used in the
incremental mode , a x move directs the tool to the left . Similarly a +Y move
positios the cutter up from the present location and Y is a command to move
down . a + Z directs the cutter away from the workpiece,while a Z is a move
toward or into the workpiece.

8.3 Absolute Systems :

An absolute system operates similar to the absolute dimensioning. All positions
are figured and punched in the tape relative to the same zero or reference point.

One advantage of absolute systems over incremental systems concerns

positioning errors .if a positioning error occurs in an incremental system ,all

13
 subsequent positions are affected and all the remaining moves are incorrect, but
when a positioning error occurs in an absolute system a particular location is in
error but subsequent positions are not affected.

Zero Shift System :

They define the origin of the coordinate axis. They have three types:
1. Fixed Zero:
It is where the machine manufacturers define the origin; normally at the corner of the
table, (X & Y are always positive).

+Z

-X +X
+Y

-Z

2.Floating Zero:
The origin point is left for the operator to define using a special tool, which is lowered
until it touches the desired point with no restrictions.
(X & Y can take positive or negative values)

+Z

-Y
-X +Y +X

-Z
14
9. Engineering Analysis of NC Positioning Systems :

The NC positioning system converts the coordinate axis values in the NC part
program into relative positions of the tool and work part during the processing .
Let us consider the simple positioning system shown in figure .The system consists of
A cutting tool and worktable on which a work part is fixed .The table is designed to
move the part relative to the tool . The worktable moves linearly by means of a
rotating leadscrew ,which is driven by stepping motor or servomotor .For simplicity,
We show only one axis in our sketch .To provide x-y capability ,the leadscrew has a
certain pitch P (in/thread , mm/thread). Thus the table moves a distance equal to the
pitch for one revolution. The velocity of the work table ,which corresponds to the feed
Rate in a machining operation is determined by the rotational speed of the leadscrew.

There are two types of positioning systems used in NC system : shown in figure
a. open loop system operates without verifying that the actual position achieved in
the move is the same as the desired position.
b. Closed loop control system uses feedback measurements to confirm that the
final position of the worktable is the location specified in the program .

Open loop cost less than closed loop systems and are appropriate when the force

15
Resisting the actuating motion is minimal , closed loop systems are normally
specified for machines that perform continuous path operations such as milling or
Turning in which there are significant forces resisting the forward motion of the
cutting tool.

16
 Chapter 2

CNC Machines
1.Introduction:

Punched tape, Punched Card, Computer as input data

Magnetic tape

2.Features of CNC Machines:

1. Storage of more than one part program.

2. Various form of program input
Manual data input
Floppy diskette
Communiction with external computer
Program performs
interpolation
3. Program editing at the machine tool calculations
4. Fixed cycles & programming subroutines
5. Interpolation
6. Cutter length and size compensation
7. Acceleration and deceleration calculation
8. Communication interface
9. Diagnostics

17
3. Machine Control Unit of CNC:

Memory CPU I/O Interface

1.Main Memory: 1.Control Section 1.Operator Panel
.ROM: Operating 2.Arithmetic Logic Unit (Keyboard, CRT,)
Sys. (ALU). 1. 2.Tape Reader
RAM: Part Program 3.Immediate Access
1. 2.Secondary Memory: memory

System Bus

Machine Tool Controls Sequence Controls

Position Control (X,Y,Z) Coolant

Spindle Speed Control Fixture Clamping
Tool Changer

4. CNC Software:
1. Operating system software: is to interpret the NC part program and generate the
corresponding control signals to derive the machine tool axes ,it is installed by the
controller manufacturer and is stored in ROM in the MCU. The operating system
software consists of the following :
Editor: which permits the machine operator to input and edit NC part programs
Control program: which decodes the part program instructions,perform
interpolation and acceleration/deceleration calculations ,and accomplishes
other related functions to produce the coordinate control signals for each axis.
Executive program: which manage the execution of the CNC software as well as
the I / O operations of the MCU.
2. Machine interface software: is used to operate the communication link between the
CPU and the machine tool to accomplish the CNC auxiliary functions (coolant
control ,tool changer ,fixture clamping device ,timers ),as previousely indicated ,the
I / O signals associated with the auxilliary functions are sometimes implemented by
means of a programmable logic controller interfaced to the MCU ,and so the machine
interface software is ofthen written in the form of ladder logic diagram

18
 3. Application software: consists of the NC part programs that are written for
machining.

5. Direct Numerical Control (DNC):

Bulk Memory
Central
NC
Computer
Programming

MCU MCU MCU

DNC can be used for up to 256 machines.

It has two systems:
1. Load:
It's where the machine is directly controlled from the central computer
2. Download:
It is where the MCU attached to the machine downloads the NC code from the central
computer

6. Distributed Numerical Control (DNC):

Data Switching Box

MCU MCU MCU

19
Switching Network
 DNC Computers MCU

Satellite Computer
MCU

LAN Key system

7. Applications of NC & CNC:
1. Machine tool applicatioin:
NC lathe
NC boring mill
NC drill press
NC milling machine
NC cylindrecal grynding
Non-machine tool application:
Welding machining
Thermal cutting machine
8. Part characteristcs to be Suited to Applications of NC & CNC:
1. Batch production of small to medium lot size (1-100 products)
2. Repeated order
3. Complex part geometry
4. Much metal needs to be removed
5. Part is expensive
9. Advantages of using NC,CNC:
1. Greater accuracy
2. Lower scrap rates
3. More complex part geometry
4. Less floor space is required
5. Operator skill level is redued
6. Inspection requirement is reduced
10.Disadvantages of using NC, CNC:
1. Higher investment cost
2. Higher maintainance effort

20
 Chapter 3

NC Coding System

1.Format of NC Coded Program:

Punched tape, Punched Card, Computer as input data

Magnetic tape

Word Adress Format:

1. Sequence Number (N-Word)
2. Preparatory word (G-Word)
3. Coordinates (X,Y,Z Word)
4. Feed Rate (F-Word)
5. Spindle Speed (S-Word)
6. Tool Selection Word (T-Word)
7. Miscellaneous Command (M-Word)
8. End-Of-Block (EOB Symbol)

2. NC coded Program in milling and drilling operations :

The following figure shows the axes convention for the vertical milling machine (VMC)
And Horizontal milling machines(HMC). While the tables indicate a summary of the
G- codes,M- codes used in milling and drilling operations .The remaing part of this
section explains the method of using G codes .

21
22
23
24
25
26
27
28
29
30
31
32
3. NC coded Program in Turning operations :

The following figure shows the axes convention for turning operations . While the
tables indicate a summary of the G- codes,M- codes used in turning operations .The
remaing part of this section explains the method of using G codes .

33
34
35
36
37
38
39
40
41
42
43
44
 Chapter .4

NC Part Program

NC part programming consists of planning and documenting the sequence of processing

Steps to be performed on an NC machines, the part programmer must have a knowledge
Of machining as well as geometry . The documentation portion of the part programming
involves the input medium used to transmit the program of instructions to the NC machine
Control unit (MCU).
The traditional input medium (1950) to the NC machines is 1-inch wide punched tape . more
recently ,the use of magnetic tape and floppy disks have been growing in popularity as
storage technologies for NC .

Part programming can be accomplished using a variety of procedures ranging from highly
Manual to highly automated methods. These methodes are :

1. Manual Part Programming

2. Computer Assisted Part Programming
3. Part Programming Using CAD/CAM
4. Manual Data Input

The following are explanations of the different methods of part programming with some
Examples .

1. Manual part programming:

In manual part programming ,the programmer prepares the NC code using the low level
machine language .the program is either written by hand on a form from which a
punched tape or other storage media is subsequently coded ,or it is entered directly into
A computer equipped with NC part programming software ,which writes the program onto
the storage media .In any case ,the part program is a block by block listing of the
machining instructions for the given job ,formatted for the particular machine tool to be
used.
Manual part programming can be used for both point-to-point and contouring jobs. It is
Most suited for point to-point machining operations such as drilling . It can also be used
for simple contouring jobs, such as milling and turning when two axes are involved.
However ,for complex three dimensional machining operations ,there is an advantage in
using computer assisted part programming.

45
The following are some exercises in drilling ,milling and turning machine operations
using the Boxford CNC machines :

a. Drilling and Milling Exercises :

46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
b. Turning Exercises :

69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
2. Computer Assisted Part Programming :

86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
3.NC Part Programming using CAD/CAM :

102
103
104
4.Manual Data Input :

105
 Chapter .5
Exercises and Previous Examinations
Higher Technological Institute Midterm Examination
Term: JAN./MAY 2007
10 th of Ram adan
Course : Control of
Mechanial Engineering Department m anufacturing
Code : M TE203
S Exam iner :Dr.I brahim Nasr
Tim e :1 Hour

P roblem ONE : [10]

1. W hat are the basic com ponents of NC System ?
2. Ex plain the different zeros of NC m achine tool ?
3.Ex plain the NC P rocedure ?
P roblem TW O: [10]
1.Ex plain briefly the Function controlled by NC ?
2.Ex plain the preparatory functions?
3.W rite a sim ple part program for the follow ing
com ponent:
.. Drilling and taping tw o holes w ith diam eter 10 m m w ith
depth 20 m m ,using m anual Z control.

Higher Technological Institute Midterm Examination

10 th of Ram adan Term: JAN./MAY 2007
Mechanial Engineering Department Course : Control of
m anufacturing
Code : M TE203
106
Exam iner :Dr.I brahim Nasr
Tim e :1 Hour
 S

1.Ex plain briefly the Function controlled by NC ?

2.How to adjust the R- w ork plane ? Give an ex am ple?
3.W rite a sim ple part program for the follow ing

M aterial : P lastic
Tool changed at : X0,Y0,Z25

R equired :
1. M ill the steps [8 m m diam eter slot drill]
2.Drill the holes [ 4 m m diam eter slot drill ]
3.M ill the 30 m m diam eter pocket [ 8 m m diam eter slot drill ]

Higher Technological Institute Midterm Examination

Mechanial Engineering Department Term: MAY/AUG. 2007
Course : Control of m anufacturing
Code : M TE203
Exam iner :Dr.Ow ino George
S Tim e :1 Hour

107
P roblem ONE : [10]
1. W hat are the basic com ponents of NC System ?
2. Ex plain the different zeros of NC m achine tool ?
3.Ex plain the NC Steps?

P roblem TW O: [10]

1.Describe the usage of punched tape as input m edium for NC m achine ?

2. Com pare betw een the punched tape readers operations ?
3.Ex plain the functions of the follow ing : Decoder Buffer storage
interpolator Drive unit
4.Ex plain the basic types of m otion control system ?
5. Draw block diagram of NC system ?

108
Higher Technological Institute Final Examination
Term: JAN./MAY 2007
10 th of Ram adan
Course: Autom atic control in
Mechanial Engineering Department m anufacturing
Code : M TE203
S Exam iner :Dr.I brahim Nasr
Tim e :1 5 Hour

P roblem ONE : [5]

1. Ex plain the basic com ponents of NC system ?

2.W ith draw ing,ex plain m achine registers and buffer storage operations?
3.W hat are the types of NC system ?

P roble m TW O : [10]

1.Using sketches ,ex plain how the Z-ax is control can be done in drilling ?
2.Com pare betw een different zeros used in m illing and drilling?
3.W hat are the functions controlled by NC in m illing and drilling ?

P roblem THR EE : [5]

1.Explain w ith exam ples the different G-codes canned cycle used in
drilling and m illing?
2.Draw sketch and indicate the m achine ax es ?
3.Explain the canned cycles used in turning?

P roblem Four: [20]

P ractical

109
110
111
Higher Technological Institute
10 th of Ram adan Final Examination
Term: Oct./Jan.2008
Mechanial Engineering Department
Course: Autom atic control in
m anufacturing
Code : M TE203
Exam iner :Dr.I brahim Nasr
Tim e :30 m in

W rite the G,M - coded program and sim ulate the production steps on
Com puter

Select the suitable tool , feed rate and cutting speed

112
113
114
Higher Technological Institute
10 th of Ram adan Final Examination
Term: Oct./Jan.2008
Mechanial Engineering Department
Course: Autom atic control in
m anufacturing
Code : M TE203
Exam iner :Dr.I brahim Nasr
Tim e :1 5 Hour
P roblem ONE : [10]
1. W hat are the steps of NC system ?
2. Briefly , com pare betw een NC,CNC, DNC m achines?
3.Explain briefly the com ponents of NC system ?
4.sketch and ex plain the NC coordinate system ?
5.Com pare betw een the types of Zero points ?
P roblem TW O : [10]
1 W hat are the types of m otion control system ?
2.Com pare betw een the different input m edia in NC m achine ?
3.W hat are the types of punched tape readers?
4.Ex plain w ith sketches ,the difference betw een open and closed loop
control system s ?
P roblem Three : [P ractical] [ 20 ]
W rite the G,M - coded program and sim ulate the production steps on
Com puter

Select the suitable tool , feed rate and cutting speed

115
Higher Technological Institute
10 th of Ram adan Final Examination
Term: Jan./May 2008
Mechanial Engineering Department
Course: Autom atic control in
m anufacturing
Code : M TE203
Exam iner :Dr.I brahim Nasr
Tim e :1 5 Hour

P roblem ONE : [5]

1. Com pare betw een the m achine controlunit of NC and CNC m achines?
2.Ex plain the follow ing using sketch:
-NC coordinate system
-Zero point
-The G81 , G82 ,G84 , G85 ,G97.

P roblem TW O : [15]
1.Explain the Tasks in com puter assisted part program m ing ?
2.W rite the APT program to produce the follow ing show n com ponent :

the required :
a. drilling 4 holes w ith feed rate 120 m m / m in. ,cutting tool speed 2000
rpm
b.m illing the outer surface w ith cutting tool diam eter 8 m m ,feed rate
120 m m / m in. and cutting tool speed 2000 rpm

P roblem Three : [P ractical] [ 20 ]

116
Higher Technological Institute
10 th of Ram adan Final Examination
Term: Jan./May 2008
Mechanial Engineering Department
Course: Autom atic control in
m anufacturing
Code : M TE203
Exam iner :Dr.I brahim Nasr
Tim e :1 5 Hour
P roblem ONE : [5]
1. How NC collect inform ations?
2.Ex plain the follow ing using sketch:
--m otion control system
--flow diagram of NC.
--interpolation G-codes.
P roblem TW O : [15]
1. Ex plain the APT language statem ents ?give ex am ples?
2.W rite the APT program to produce the follow ing show n com ponent :

the required :
a. drilling the hole w ith feed rate 120 m m / m in. ,cutting tool speed
2000 rpm
b.m illing the outer surface w ith cutting tool diam eter 8 m m ,feed
rate 120 m m / m in. and cutting tool speed 2000 rpm

P roblem Three : [P ractical] [ 20 ]

117
118
119
120
121
122
123
124
125