Computer Numerical Control

(CNC) Machine Tools

By Mengistu A.
Numerical control (NC) is a form of programmable
automation in which the mechanical actions of a machine
are controlled by alphanumeric data and other symbols.
 These are coded in an appropriate format to define a
program of instruction
 The data represent relative positions between a work-head
(cutting tool) and a work-part (object being processed).
The program of instructions can be changed to process a
new job.
 This makes NC suitable for low and medium
production.
 CNC lathe machine CNC Milling machine

NC Bending Machine
CNC Pantograph machine
Basic Components of an NC System

I. The program of instructions

 Is step-by-step commands that direct the processing
equipment.
 The commands refer to positions of a machining tool
spindle relative to the worktable (fixture).
 With spindle speed, feed rate, cutting tool selection,
and other functions.
II. The machine control unit (MCU)

 This consists of a electronic and related control hardware

that stores instructions.
 Converting each command into mechanical actions of the
equipment, one command at a time.

 The related hardware includes

 Components to interface with the processing equipment
and Feedback control elements.
 One or more Reading devices for entering part programs
into memory.
III. The Processing Equipment
 This performs the useful work to transform the starting
workpiece into a completed part.
 Its operation is directed by the MCU.
Types of NC machine tools
A. Conventional Numerical Control (NC)
 Data is sent to the machine tool by means of direct
insertion of numerical data at some point.

B. . Computer Numerical Control (CNC):

 Computer positioned right at the machine tool.
 Most/all machine tools that are numericaly controlled are
CNC machine tools.

C. Direct/Distributed Numeric Control (DNC):

 Direct NC- a single computer controls many numerical
control machine tools.
 Distributed NC - Hierarchical computers control the
Machine tools.
A. Numerical control (NC)
 Numerical Control (NC) is a system in which actions
are controlled by the direct insertion of alpha-numeric
data at some point (EIA definition).

 The system must automatically interpret at least some

portion of the data.

 The reader at the machine performs no calculations or

interpolations.

 Machines controlled by electronic systems designed to

accept numerical data and other instructions usually in
a coded form.
NC System

NUMERICAL
DATA
(NC CODE)

NUMERICAL
MANUFACTURING CONTROLLER
OPERATOR
Drive Control

PROCESSED
PART

MACHINE UNIT
CNC can be defined as an NC system whose MCU is based
on a dedicated microcomputer rather than on a hard-wired
controller, hence
 size and cost reduction of digital computers and
 substantial increase in their computational capabilities.
Features of CNC
The additional features of CNC System include:
 Sufficient capacity to store of more than one part
program
 Multiple data entry capabilities for various forms of
program input
 Punched and magnetic tape, diskette, RS-232
communications, manual data input
 Program editing at the machine tool (testing and
correcting a program at the machine site),

 Fixed cycle and programming subroutines: to store

frequently used machining cycles as macros that can be
called by the program

 Interpolation

 Positioning features for setup: facilitated alignment task

can be using certain features

 Cutter length and size compensation:

 Acceleration and deceleration calculations.

Communications: interface with other computers/ computer-
driven devices such as:
• Downloading part programs from a central data file,
• Collecting operational data,
• Interfacing with peripheral equipment,

Diagnostics: monitors and detect certain aspects of the

machine tool malfunctions. Common CNC diagnostics
system are:
 Control start-up diagnostics,
 Malfunction and failure analysis,
 Extended diagnostics for individual components,
 Tool life monitoring,
 Preventive maintenance notices,
 Programming diagnostics
 The MCU for CNC consists of five elements which are
interconnected by means of a system bus.

Memory Input/output interface

Central processing
-ROM -Operating sys - Operator panel
unit (CPU)
-RAM -Part programs - Tape reader

System bus
Machine tool controls Sequence controls
- Position control - Coolant
- Spindle Speed control - Fixture clamping
- Tool changer

Fig. Configuration of CNC machine control unit

DNC involves the control of a number of machine tools by a
single (mainframe/ Central) computer.
 A program is transmitted directly to MCU at a time and on
demand


The system consists of:

 Central computer (CC), Bulk memory at CC site, Set of controlled
machines and Telecommunications lines linking machines with
CC.
In operation, the computer calls the required part program from
bulk memory and sent it (one block at a time) to the designated
machine tool.
The CC also receives feedback from the machines to indicate
operating performance in the shop.
Thus, a central objective of DNC is to achieve two-way
communication between the machines and the CC.
General configuration of a DNC system. Connection to MCU is behind
the tape reader.
 In the new DNC configuration, CC is connected to MCUs, which are
themselves computers.
This permits complete part programs to be sent to the machine tools,
rather than one block at a time.
Redundant computers improve system reliability compared with the
original DNC (Direct NC).
The two way communication include:
Data & Info Down loaded from CC to Data & Info Loaded from M/c & Shop
M/c & Shop Floor Floor to CC
NC part programs Piece counts
Machining cycle time for part program Actual machining cycle times
List of tools needed for job Tool life statistics
Data about when program was last M/c up/down time statistics for m/c
used utilization and reliability assessment
Machine setup instructions Product quality data
 DNC
Computer

Satellite Satellite
Computer Computer

MCU MT MCU MT MCU MT MCU MT

Functions of Satellite computers

 Each satellite control several machines
 Receive groups of part program instructions from the CC and
store in buffer
 Dispense these instructions to each machine when required
 To receive feedback from the machine tools before being
collected at central computer
Principal differences are
 DNC computers control a large number of machines.
 CNC computer control single or small number of machines

 DNC are far from the machines under their control

 CNC computers are located very near to their machine tool

 DNC software are designed both to control machine tools

and to serve as MIS
 CNC software developed to augment the capability of a
particular machine tool.
Application of NC

The applications of NC applications can be divided

into two categories:

 Machine tool applications (those usually associated

with metal work industry). These includes:
Turning, Drilling, Milling, Grinding

 Non-machine tool applications (diverse group of

operations in other industries). These may include:
Assembling, Inspection, sorting
 The common NC machine tools with their
typical features are:

 NC lathe requires two-axis, continuous path control, either to

make straight or contour turning.

 NC boring mill requires continuous path, two-axis control for

creating internal cylinder

 NC drill press use point-to-point control of the spindle/ drill bit

and two axis (x-y) control of the worktable.

 NC milling machine require continuous path control to perform

straight cut or contouring operations.

 Cylindrical grinder has continuous path two-axis control,

similar to an NC lathe.
NC Application Characteristics

Characteristics that are most suited to NC application

are:

 Batch production: NC is appropriate in small/ medium

lot sizes as dedicated automation and Manual
production would be uneconomical for these quantities.

 Repeat orders: Batches of the same parts are produced

at random or periodic intervals.
NC Application Characteristics

 Complex part geometry:

 such as those found on airfoils and turbine blades, circles and
helixes.

 Much metal needs to be removed from the work part:

 complex part geometry to fabricate large structural sections
with low weights.

 Many separate machining operations on the part:

 features requiring different cutting tools, such as drilled
and/or tapped holes, slots, flats, and so on.

 The part is expensive:

 when the part is expensive, and mistakes in processing would
be costly .
NC for Other Metalworking Processes include:

 Punch presses for sheet metal hole punching.

 Presses for sheet metal bending.

 Welding machines- both spot and continuous arc

welding

 Thermal cutting Machines, oxy-fuel, laser, plasma arc

cutting.

 Tube bending machines to control location and angle of

bend such as frames for bicycles.
Part Programming (PP) is concerned with the planning and
documentation of the sequence of processing steps to be
performed on NC machine.

The planning portion of part programming requires knowledge

of
 Machining
 Geometry Trigonometry

Documentation of PP involves the input medium that is used

to transmit the program of instructions to the NC MCU.
 The input medium is the punched tape
Figure: NC punched tape format
A binary digit (called bit) has a value of 0 or 1 for the
absence or presence of holes in a certain raw and
column positions on the tape.
Character: is formed on the raw
 Character is a combination of bits which represents a
letter, number or symbol.
A word is a combination of characters used to form part of
instruction.
 Typical NC words can be x-position, y-position cutting
speed, etc.
The block is formed from combined words.
 A block of words is a complete NC instruction.
Part programming include a variety of procedures ranging
from highly manual to highly automated methods.

The methods are:

1. Manual part programming,

2. Computer-assisted part programming,

3. Part programming using CAD/CAM, and

4. Manual data input.

The process of instructions are documented on a form
called part program manuscript.
 Manuscript is a list of positions of the tool relative to
the workpiece that machine should follow to perform
the processing.
 Manuscript can also include other data such as
preparatory commands, miscellaneous instructions,
feed/speed specifications, etc.

Manual part programming is more applicable in PTP

applications and for simple contouring operations
such as milling and turning jobs.
Fundamental elements of manual part
programming are:

Type of Coordinate System

Absolute or Incremental Coordinate systems

Axis Designation
Continuous path control or PTP path control

NC Words
N-word (sequence number): used to identify the block
G-word (preparatory work): used to prepare the controller
for instructions that are to be followed
X-, Y- and Z- words (coordinates): gives the coordinate
positions of the tool
 In two axis only two word will be used
 In three axis only three words will be used
F-word (feed rate): specify the feed rate of the
machining operation in in./min
TABLE - Common G-words (Preparatory Word)
G-word Function
G00 P-t-p movement (rapid) b/n previous point and end point
G01 Linear interpolation movement.
G02; G03 Circular interpolation, clockwise counterclockwise respectively.
G04 Dwell for a specified time
G10 Input of cutter offset data, followed by a P-code and an R-code.
G17; G18; G19 Selection of x-y, x-z and y-z plane in milling respectively.
G20 Input values specified in inches
G28 Return to reference point.
G32 Thread cutting in turning.
G41, G42 Cutter offset compensation, left and right of part surface respectively.
G50 Specify location of origin relative to starting location of tool.
G90; G91 Programming in absolute & incremental coordinates respectively.
G94, G95 Specify feed/minute and feed/revolution respectively
G98; G99 Specify feed/minute and feed/revolution respectively in turning.
S-word (cutting speed): specify the cutting speed of the
process or rate at which the spindle rotates in rev./min

T-word (tool selection): needed for machines with turret or

automatic tool changer.

M-word (miscellaneous functions): used to specify

miscellaneous or auxiliary functions which may be
available on the machine tool
 This function is the last word in the block
M-Word Function
M00; M01 Program stop; and Optional program stop respectively
M02 End of .program. Machine stops
M03; M04 Start spindle in clockwise and counterclockwise direction respectively
.
M05 Spindle stop
M06 Execute tool change, either manually or automatically.
M07; M08; M09 Turn cutting fluid on flood, on mist and off respectively .
M10; M11 Automatic clamping and unclamping of fixture, machine slides, etc
respectively.
M13; M14 Start spindle in clockwise and counterclockwise direction and turn on
cutting fluid respectively.

M17 Spindle and cutting fluid off.

M19 Turn spindle off at oriented position.
M30 End of program. Machine stop.
Common Format of a Block

Sequence Preparatory Dimension Feed Spindle Tool Misc.

# Function Words Rate Function Function Function

N50 G90 G01 X1.40Y2.25 F10 S1500 T01 M03

Individual Words
Manual Part Programming
This example presents the NC part program for drilling the
three holes in the sample part using word address format.
The x-, y-, and z-axes are defined. The program begins with
the tool positioned at at x = 0, y = -50, and z =10 (target
point).
NC Part Program Code Comment
N001 G21 G90 G92 X0 Y-050.0 Z10.0; Define origin of axes.
N002 G00 X070.0 Y030.0; Rapid move to first hole location.
N003 G01 G95 Z-15.0 F0.05 Sl000 M03; Drill first hole.
N004 G01 Z010.0; Retract drill from hole.
N005 G00 Y060.0; Rapid move to second hole.

Fig. Aluminum Sample part

for NC part programming
It is applicable for complicated operations.
such as complex PTP and contouring operations which
are tedious and time consuming and subject to error in
manual part programming.
The various tasks in computer-assisted part
programming are divided between;
The human part programmer
The computer
 The part programmer is situated for two functions
 Defining the geometry of the workpart and
 Specifying the tool path and/or operation
sequence.
Work part geometry definition:
 Work part is composed of basic geometric elements.
 The geometry can be generated by points, lines, plans,
circles, cylinders and other mathematically defined surfaces.
Examples.
P4 = POINT/35, 90,0
L1 = LINE/P1, P2
C1 = CIRCLE/CENTER, P8, RADIUS, 30.0
Tool path construction:
The tool path is the path that the cutter follows to machine
the define part geometry. The tool path specification
involves a detailed step-by-step sequence of cutter
moves. Can be
Point-to-Point command:
 GOTO/P0
Continuous path command:
 GOLFT/L2, TANTO, C1
.
Other Functions in Computer-Assisted Part
Programming

• Specifying cutting speeds and feed rates

• Designating cutter size (for tool offset calculations)
• Specifying tolerances in circular interpolation
• Naming the program
• Identifying the machine tool.
The computer is also situated for four functions

1. Input translation: convert the part program using

APT languages and then converts to computer usable
form.

2. Arithmetic calculations: consists of a

comprehensive set of subroutines for solving the
mathematics required to the part surface.

3. The cutter offset computation: offsets the tool

path from the desired part surface by the radius of the
cutter.
4. Postprocessor: a unit that take the general
instructions and make them specific to a particular
machine tool system.

Cutter Offset
Automatically programmed tool (APT) is a three
dimensional NC language that can control up to five axis.

It is also a computer program that calculate to generate

cutter position based on APT statements.

There are four types of statements in the APT language.

 Geometry Statements
 Motion statements
 Postprocessor statements
 Auxiliary statements
These define the geometric elements that comprise the workpart.
The general form of an APT geometry statement is :
Symbol = geometry type/descriptive data
Ex. P1 = POINT/5.0,4.0,0.0
The statement is made up of three sections.
Symbol: identify the geometric elements
 It can be any combination of six or fewer alphabetic
and numeric characters (at least one of the six
should be alphabet).
 The symbol should not be APT word vocabulary
Ex. PZL, PADCDE, PABCDEF, 1233789, POINT, P1.2 (W/c is corr.)
APT Vocabulary: identifies the types of the geometry
element.
 The geometry elements in the APT vocabulary include
POINT, LINE, PLANE, and CIRCLE.

Descriptive data: defines the element precisely,

completely and unique.
 These data may include quantitative dimensional and
positional data, previously defined geometry elements and
other APT words.
 The slash separates the surface from the descriptive data,
and the comma separates words and numbers in the
descriptive data.
Defining the geometry elements
1. To specify a point: a point can be defined as intersection of two
lines
P2 = POINT/INTOF, L1, L2 (comment INTOF = intersection of)
2. To specify a line: a line can be defined by two points in w/c the line
passes. L3 = LINE/P3, P4
A programmer can define a line parallel to a line w/c has previously
been defined. L4 = LINE/P5, PARLEL, L3
3. To specify a plane: a plane can be defined by three points through
w/c it passes. PL1 = PLANE/P1, P4, P5
A plane can also be defined by a plane parallel to other previously
defined
PL2 = PLANE/P2, PARLEL, PL1
4. To specify a circle: a circle can be defined by center point and the
radius. C1 = CIRCLE/CENTER, P1, RADIUS, 5.0
Ground Rules:
1. The coordinate data must be specific in the order x, y,
and z.
P1 = POINT/5.0, 4.0, 0.0.

2. Any symbols used as descriptive data must have been

previously defined.
P2 = POINT/INTOF, L1, L2
L1 and L2 must have first been defined.

3. A symbol can be used to define only one geometry

elements
P1 = POINT/1.0, 1.0, 1.0 Not correct (P1, P1)
P1 = POINT/2.0, 3.0, 4.0
4. Only one symbol can be used to define any given
element
P1 = POINT/1.0, 1.0, 1.0
Not correct (1.0, 1.0, 1.0)
P2 = POINT/1.0, 1.0, 1.0

5. Lines defined in APT are considered to be of infinite

length in both directions. Similarly, plane extend
indefinitely and circles defined in APT are complete
circles.
Are used to describe the path taken by the cutting tool.
The general form of APT motion statement is given by
Motion command/descriptive data
Ex. GOTO/P1
The basic motion command (GOTO): tells the tool what
to do.
The descriptive data (P1): tells the tool where to go.
At the beginning of the motion statement, the tool must be
given a starting point.
FROM/TARG

The FROM is APT vocabulary word w/c indicates that this

is the initial point from w/c others will be referenced.
TARG is symbol given to the starting point.
Other form is FROM/-2.0, -2.0, 0.0
The PTP Vs Contouring motion
PTP motions: there are two commands GOTO and
GODLTA
GOTO instructs to a particular point
GOTO/P2
GOTO/2.0, 7.0, 0.0
GODLTA: specifies an incremental move for the tool
GODLTA/2.0, 2.0, 0.0
The tool is directed to a particular hole by GOTO then
the GODLTA will be used for drilling the hole.
Illustration:
Write the APT geometry and motion statements necessary
to perform the drilling portion of this job. The plane is
defined by z = 0 about ¼ in. above the part surface. The
part is assumed to be ½ in. thick.
Contouring commands are somewhat complicated due to
continuous control of tool path.

There are six motion commands

GOLFT GOFWD GOUP GORGT GOBACK GODOWN
The tool is directed along three intersecting surfaces
(drive, part and check surface).

Drive surface: the surface that guides the side of the

cutter

Part surface: the surface on w/c the bottom of the cutter

rides. This may or may not be actual surface of the
workpart.

Check surface: is an additional surface that stops the

movement of the tool in its current direction.
 It checks the forward movement of the tool.
.
APT motion statement commands the cutter to move along
the drive and part surfaces and the movement ends when
the tool is at the check surface
There are several ways in which the check surface can
be used. This is determined by the modifier words

Four modifier words

TO: moves the tool in to initial
contact with the check
surface

ON: moves the tool until tool

center is on check surface
PAST: moves the tool beyond
the check surface

TANTO: moves the tool to a

point of tangency
between two surfaces, at
least one of which is
circular.

(d)TANTO
The FROM is used as an initial, like in PTP. FROM defines the
initial drive surface, part surface, and check surface.
FROM/TARG
GO/TO, PL1, TO, PL2, TO, PL3
TARG is a target point the operator has set up the tool.
GO instructs the tool to the intersection of the drive surface
(PL1), the part surface (PL2), and the check surface (PL3)
The periphery of the cutter is tangent to the PL1 and PL3 due to
the modifier word TO.
The three surfaces are ordered as drive, part surface, check
surface.
After initialized, the tool is directed along its path by one of the
six command words.
GORGT/PL3, PAST, PL4
Illustration with examples
Write an APT geometry and motion statement for the workpart of the
figure shown below.
P0 (0, -1.0, 0)
P1 (6.0, 1.25, 0)
P2 (0, 0, 0)
P3 (6.0, 0, 0)
P4 (1.75, 4.5, 0)
 These complete function which are not addressed by
geometry statement and motion commands.

Postprocessor statement: control the operation of the machine

tool and supporting role in generating the path. Such
commands are the cutter size, specify speed and feed, turn
coolant flow on and off, and others.

Syntax
POSTPROCESSORCOMMAND/descriptive data

Postprocessor command: indicates the type of function or action

Descriptive data: consists of APT words and numerical values.
Ex. SPINDL/1000, CLW
 Auxiliary statement: identifies the part program,
which processor to use, insert remarks into the
program, etc.

These statement has not effect on the generation of

the tool path.

Ex. PARTNO: the first program in an APT program, used

to identify the program.
CLPRT: “cutter location print” used to printout the
cutter location sequence.
Part geometry is to be designed and manufactured from Low carbon steel in an automated
single machine cell which is dedicated for end milling. A 20mm diameter cement carbide
multi-teeth end milling cutter with the clockwise spindle rotation capacity is used. The top
surface of the workpart is 20 mm above the machine table. The cutting speed is 1200 rev/min
and feed rate is 75 mm/min. A fixed positioning, located at the lower left corner of the
workpart, with a absolute coordinate system is adopted for this typical machine cell. Since
the cuter cuts only 5mm of the 20mm thick workpart at a time, it needs four round program
for the full cut. Considering the workpart is laid on the x-y plane and the initial position of
the tool is at (-5, 0,25); develop a part program for the first round to generate the geometry
as shown in the figure-1(below) using Computer assisted part programming using the APT
language (6)