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`Computer Numerical
`Control: Essentials in
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`Programming and Networking
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`Computer Numerical
`Control: Essentials in
`
`Programming and Networking
`
`Su-Chen Jonathon Lin
`
`Professor of Computer-Aided Manufacturing
`Eastern Michigan University
`
`I®P‘”
`lb
`
`Delmar Publishers Inc.”
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`
`NOTICE TO THE READER
`
`Publisher does not warrant or guarantee any of the products described herein or perform any independent
`analysis in connection with any of the product information contained herein. Publisher does not assume, and
`expressly disclaims, any obligation to obtain and include information other than that provided to it by the
`manufacturer.
`
`The reader is expressly warned to consider and adopt all safety precautions that might be indicated by
`the activities described herein and to avoid all potential hazards. By following the instructions contained
`herein, the reader willingly assumes all risks in connection with such instructions.
`The publisher makes no representations or warranties of any kind, including but not limited to, the
`warranties of fitness for particular purpose or merchantability, nor are any such representations implied
`with respect to the material set forth herein, and the publisher takes no responsibility with respect to such
`material. The publisher shall not be liable for any special, consequential or exemplary damages resulting, in
`whole or in part, from readers’ use of, or reliance upon, this material.
`
`Delmar Staff:
`
`Senior Acquisitions Editor: Vernon R. Anthony
`Editorial Assistant: Alison Foster
`
`Project Editor: Elena M. Mauceri
`Production Coordinator: Karen Smith
`
`Art/Design Coordinator: Cheri Plasse
`
`For information address Delmar Publishers Inc.
`3 Columbia Circle Drive, Box 15-015
`Albany, New York 12203-5015
`
`Copyright © 1994
`By Delmar Publishers Inc.
`
`The trademark ITP is used under license.
`
`All rights reserved. No part of this work covered by the copyright
`hereon may be reproduced or used in any form or by any means-
`graphic, electronic, or mechanical, including photocopying,
`recording, taping, and information storage and retrieval systems-
`without written permission of the publisher.
`
`Printed in the United States of America
`
`Published simultaneously in Canada
`by Nelson Canada,
`a division of The Thomson Corporation
`
`10987654321XX999897969594
`
`Lin, Su—Chen Jonathon.
`
`Computer numerical control : essentials in programming and
`networking / Su—Chen Jonathon Lin.
`p.
`cm.
`Includes index.
`ISBN 0-8273-4715-4
`1. Machine-tools—Numerical control.
`TJl189.L56
`1994
`
`I. Title.
`
`621 .9'023—dc20
`
`93-5254
`CIP
`
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`Additional Titles Available
`
`Learning Computer Numerical Control/ Janke
`ISBN: 0-8273-4536-4
`
`Fundamentals of Computer Numerical Control, 3E/ Luggen
`ISBN: 0-8273-6496-2
`
`Computer Numerical Control: Concepts and Programming, 2E/ Seames
`ISBN: 0-8273-3782-5
`
`To request more information on these publications, Contact your local bookstore, or call
`or write to:
`
`Delmar Publishers Inc.
`
`3 Columbia Circle
`
`PO. Box 15015
`
`Albany, NY 12212-5015
`Phone: 1-800-347-7707 ~ 1-518-464-3500 - Fax: 1-518-464-0301
`
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`
`Contents
`
`Preface
`
`Acknowledgments
`
`PART 1.
`
`Essentials of CNC Technology
`
`Chapter 1.
`
`Introduction to Numerical
`Control
`
`
`
`5-ti-—\>--1-—It—a>—o>-—~
`
`
`
`QCNKII-Feb)f\)*"-‘
`
`1.8
`
`What Is Numerical Control?
`
`Historical Perspective of Numerical
`Control
`
`Basic Elements of a CNC System
`Computer Numerical Control
`Advantages of CNC
`Limitations of CNC
`
`Applications of Computer
`Numerical Control
`
`Future of CNC Technology
`Review Questions
`
`Chapter 2. NC Systems
`
`2.1‘
`2.2
`2.3
`
`Mode of the NC Control Systems
`CNC Interpolation
`Open—Loop and Closed-Control
`Systems
`Review Questions
`
`Chapter 3. NC/CNC Control Hardware
`and Operating Software
`
`3.1
`3.2
`3.3
`3.4
`3.5
`
`3.6
`
`NC versus CNC Systems
`The CNC Machine Control Unit
`CNC Control Selection
`CNC Software
`
`Information Processing of the CNC
`System
`Feed Drives
`
`Review Questions
`
`Xi
`
`Km
`1
`
`2
`
`2
`
`3
`6
`8
`11
`
`12
`
`12
`20
`21
`
`23
`23
`28
`
`33
`36
`
`38
`38
`40
`48
`52
`
`56
`56
`
`73
`
`Chapter 4. Machine Axes and Coordinate
`Systems
`4.1 Machine Axis Identification
`4.2 Coordinate Systems
`4.3
`Positioning Systems
`4.4 Reference Coordinates
`Review Questions
`
`Chapter 5. NC Code Systems
`
`5.1 Number Bases
`5.2 NC Program Storage Media
`5.3 Tape Coding Systems
`5.4 NC Codes
`
`5.5 NC Words
`
`5.6 Tape Formats
`Review Questions
`
`Chapter 6. Planning for NC Operations
`
`6.1 NC Operation
`6.2 Process Planning for NC
`Operations
`6.3 Machining Layout
`6.4 Study of the Part Drawing
`6.5 Considerations for Raw Material
`6.6 Part Features Identification and
`Processes Selection
`
`6.7 Processes Sequencing
`6.8 Tool Path Planning
`6.9 Significant Points of the
`Workpiece
`6.10 Machining Parameters
`6.1 1 Machining Parameters for Turning
`6.12 Machining Parameters for Milling
`6.13 Machining Parameters for Drilling
`6.14 NC Documentation
`
`Review Questions
`
`75
`75
`80
`86
`89
`92
`
`94
`
`94
`97
`99
`102
`
`104
`
`109
`1 11
`
`113
`
`113
`
`1 14
`117
`117
`121
`
`122
`
`130
`132
`
`132
`136
`139
`144
`147
`152
`
`162
`
`vii
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`viii
`
`CONTENTS
`
`Chapter 7. Tooling for NC
`7.1 Tooling System for Milling
`7.2 Tooling System for Turning
`7.3 Tooling Strategies for CNC Turning
`Machines
`7.4
`Identification and Selection of
`7 5
`Selection of
`
`Tgolhglderg
`Review Qugstigns
`
`Chapter 8- Workholding for NC
`8.1 Workholding Principles of NC
`8.2 Types of Workholders
`8.3 Workpiece Locating Principle
`8_4 Locating Devices
`8.5 Clamping Principle
`8.6 Manual Clamping Devices
`8.7 Power Clamping
`8-8 Clamping M6th0dS
`8.9 Modular Workholding
`8.10 Workholding Devices for CNC
`Turning Machines
`Review Questions
`
`_
`PART II. Manual CNC Programming
`
`Chapter 9- Mlllifig P1‘0g1'3mmi“g
`Flmdamemals
`
`9.1 Tool Motion Commands
`9.2 Plane Selection
`9.3
`Positioning Systems (G90 and G91)
`9.4
`Input Unit Selection (G70 and G71)
`9.5 Absolute Zero Setting (G92)
`9.6 Reference Point (Origin) Return
`(G28, G29, and G30)
`9.7 Tool Selection and Change
`9.8 Feed Selection and Input
`9.9 Spindle Speed Selection and
`Control
`Miscellaneous Functions
`Programming Examples
`Review Questions
`
`9.11
`
`Chapter 10. Compensation and Offset in
`Mining
`
`165
`165
`172
`172
`
`174
`
`179
`
`189
`189
`190
`190
`192
`195
`196
`203
`206
`208
`
`214
`219
`
`221
`
`222
`
`223
`240
`242
`244
`244
`
`247
`251
`252
`
`252
`252
`253
`257
`
`260
`
`10.1 Work Coordinate Compensation
`10 2
`(CG54—'G5.9)
`.
`‘
`utter D‘a‘T‘e‘er (Radius)
`10 3
`r%0I?pe?fSatlOn
`'
`00, 0 Set
`.
`Review Questlons
`Chapter 11.
`Fixed Cycles in Milling
`
`Standard Fixed Cycles
`11.1
`Sp€Cl2ll FlX€d CyCl€S
`1 1
`Point Pattern Cycles
`11.3
`11.4 Bridgeport Special Fixed Cycles
`11-5 Usemefined Fixed Cycles
`ReVl€W QUCSUOHS
`.
`_
`.
`Chapter 12. Repetitive Programming:
`LOOPS’ Subpmgrams and
`Macros
`12.1 Loops
`12.2 Subprograms or Subroutines
`123 Macros
`12.4 Macro Programming Examples
`Review Questions
`
`Chapter 13.
`
`"filming Programming
`Fundamentals
`
`13.1 CNC Turning Machines and Their
`Controlled Axes
`
`13.2 Turning Processes
`13.3
`Preparatory Functions for Turning
`13.4 T001 Function
`13.5
`Feed Function
`13.6 Spindle Speed Function
`13.7 Miscellaneous Functions
`13.8 Reference Point and Coordinate
`System
`13.9 Diameter and Radius Programming
`13.10 Positioning Systems (Absolute
`versus Incremental)
`Input Unit System Selection (Inch
`Versus Metric)
`13.12 Tool Motion Commands
`13.13 Thread Cutting
`1314 Reference point Return
`13.15 Programming Examples
`Review Questions
`
`13.11
`
`260
`264
`290
`294
`
`298
`
`298
`3
`317
`323
`326
`329
`
`330
`330
`333
`341
`349
`366
`
`363
`
`368
`
`370
`371
`372
`373
`373
`375
`
`376
`379
`
`380
`
`381
`382
`396
`407
`408
`411
`
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`ix
`CONTENTS
`
`Chapter 14. Compensation and Offset in
`Turning
`
`14.1
`
`14.2
`14.3
`14.4
`
`14.5
`14.6
`
`14.7
`
`14.8
`14.9
`
`Tool Offset
`
`Tool Nose Radius Compensation
`Direction of Imaginary Tool Nose
`Tool Nose Radius Compensation
`Commands (G40, G41, and G42)
`Start-Up of TNR Compensation
`Tool Path during TNR
`Compensation Mode
`TNR Compensation Cancel
`Notes on TNR Compensation
`Programming Examples
`Review Questions
`
`Chapter 15. Fixed Cycles in Turning
`
`Single Fixed Cycles
`15.1
`15.2 Multiple Repetitive Cycles
`15.3 Hole Operating Cycles (G80—G89)
`15.4 Programming Examples
`Review Questions
`
`Chapter 16.
`
`Integration of NC Planning
`and Programming
`
`Turning Project
`16.1
`16.2 Milling Project
`
`PART III. Computer-Assisted
`Programming in APT
`
`Chapter 17. APT: Basic Geometry
`Definition
`
`-
`
`17.1
`17.2
`
`17.3
`17.4
`17.5
`
`17.6
`
`Geometry Definition Statements
`Point Definitions
`Line Definitions
`
`Circle Definitions
`Plane Definitions
`
`Geometry Definition Examples
`Review Questions
`
`415
`
`415
`
`418
`422
`
`423
`425
`
`426
`426
`429
`430
`
`433
`
`434
`
`434
`444
`455
`455
`458
`
`461
`
`461
`477
`
`501
`
`502
`
`502
`504
`5 1 1
`520
`530
`
`540
`545
`
`Chapter 18. APT: Cutter Motion Definition 550
`
`18.1
`
`Point—to—Point Motion
`
`Programming
`
`550
`
`18.2
`18.3
`18.4
`
`18.5
`18.6
`18.7
`
`Controlling Surfaces
`Check Surface Modifiers
`
`Start-Up Statements
`Continuous—Path Programming
`Tolerance Statements
`
`Tool Motion Programming
`Examples
`Review Questions
`
`Chapter 19. Postprocessor Statements
`
`Postprocessor Statements
`19.1
`19.2 Auxiliary Statements
`Review Questions
`
`Chapter 20. Generation and Execution of
`_
`APT Programs
`20.]
`20.2
`
`Structure of an APT Program
`Examples of APT Programs
`The APT Processor
`
`20.3
`20.4
`
`Processing of APT Source
`Programs
`Review Questions
`
`Chapter 21. Advanced Geometry
`Definitions
`
`21.1
`21.2
`21.3
`21.4
`
`21.5
`21.6
`21.7
`
`21.8
`21.9
`21.10
`21.11
`
`General Conic Definitions
`Loft Conics
`
`Tabulated Cylinder Definitions
`Ruled Surface Definitions
`
`Quadric Surface Definitions
`
`Circular Cylinder Definitions
`Cone Definitions
`
`Sphere Definitions
`Vector Definitions
`Pattern Definitions
`
`Programming Examples
`Review Questions
`
`Chapter 22.
`
`Advanced Tool Motion
`Statements
`
`22.1
`22.2
`
`22.3
`22.4
`
`Start-Up Statements
`Part Surface Statements
`
`Cutter—to-Surface Relationships
`Multiple Intersections
`
`553
`555
`555
`
`560
`564
`
`566
`571
`
`574
`
`574
`582
`584
`
`586
`
`586
`587
`595
`
`597
`
`602
`
`603
`
`603
`61 1
`613
`618
`622
`625
`628
`
`629
`632
`
`638
`647
`
`649
`
`652
`
`652
`659
`661
`663
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`CONTENTS
`
`22.5 Multiple Check Surfaces
`22.6 THICK Statement
`227 POCKET Statement
`
`22.8 CYCLE Statements
`22.9 Macro Programming
`22.10 Programming Examples
`Review Questions
`Chapter 23. Computation, Repetitive
`Programming, and Matrix
`.
`.
`Transformation Programming
`. APT
`m
`23.1 Computation
`23.2 Repetitive Programming
`23.3 Looping Programming Using
`LOOPST and LOOPND
`Statements
`23.4 Matrix Transformations
`23.5 Matrix Definitions
`
`23.6 Geometry Transformation
`23.7 TRACUT Statement
`23,8 COPY Statement
`
`23.9 Programming Examples
`Review Questions
`
`666
`668
`671
`
`674
`679
`683
`685
`
`686
`
`686
`692
`
`701
`702
`706
`
`715
`717
`718
`
`724
`730
`
`25.6 Programming Example for Turning
`Review Questions
`
`Chapter 26.
`
`26 1
`26.2
`
`3-D Surface Tool Path
`Fundamentals
`3_D Computer Models
`Profile Elements of Surfaces
`ls):/r:l?:1rSf::::CeS
`‘
`p
`26.5 Sculptured Surfaces
`.
`.
`26.6 Surface Editing Modules
`26.7 NC Parameters for 3-D Surfacing
`Review Questions
`
`PART V. CNC Networking
`Chapter 27. Communications and
`Computer Networking
`Fundamentals for DNC
`
`’
`
`27.1 Data Communications
`27.2 Local Area Networks
`27.3 Network Hardware
`
`27.4 Network Operating Systems
`27.5
`IBM and Digital Network
`Architecture
`
`PART W. CAD/CAM NC Programming
`
`735
`
`276 Computer Network
`
`Chapter 24.
`
`Introduction to Computer-
`
`Aided Design and Its
`Industrial Applications
`24.1 CAD Systems, Peripherals and
`Accessories
`.
`.
`.
`.
`.
`24.2 Basic Geometrical Primitives for
`CAD
`.
`.
`.
`24.3 Three-Dimensional Modeling
`24.4 Drawing Translations
`.
`.
`24.5 Drawing Conversion
`24.6
`Industrial Applications
`.
`.
`Review Questions
`
`2-D Tool Path Eindamentals
`Chapter 25.
`25.1 NC Parameters
`25.2 Boundary Definition
`25.3 NC Modules for Milling
`25.4 Programming Procedure and
`Example for Milling
`25.5 NC Modules for Turning
`
`glgiganlgglszilggls
`
`Chapter 28. DNC Implementation
`.
`28.1 NC Programs Generation and
`Transfer Methods
`282 Direct Numerical Control
`.
`.
`.
`.
`28.3 Distributive Numerical Control
`28 4 DNC Confi urations
`.
`'
`.
`g
`28.5 Connecting NC/CNC Machines to
`DNC S Stems
`y
`28.6 DNC System Hardware
`Components
`28.7 DNC Software
`2&8 DNC Selection Criteria
`Review Questions
`
`References
`
`Index
`
`736
`
`737
`
`744
`
`748
`753
`758
`759
`766
`
`768
`768
`776
`778
`
`787
`792
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`799
`801
`
`805
`
`805
`807
`807
`808
`811
`813
`816
`821
`
`823
`
`824
`
`824
`
`829
`837
`837
`
`838
`
`841
`841
`
`843
`
`843
`844
`
`845
`847
`
`851
`
`853
`853
`855
`856
`
`857
`
`859
`
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`
`Preface
`
`The advent of modern computer technology and a new generation of manufacturing equip-
`ment, particularly the computer numerical control (CNC) machine, have brought enormous
`changes to the manufacturing industry. To compete in the global market, most manufac—
`turers have adopted the approach of computer—aided manufacturing (CAM), computer-
`integrated manufacturing (CIM), or flexible manufacturing systems (FMS) to efficiently
`and economically produce the product. These approaches use all kinds of programmable
`devices and systems, including CNC machines, CAD/CAM systems, robots, computers,
`and programmable logic controllers. CNC machines are the nucleus "of CAM, CIM, and
`FMS. The global evidence shows that the population of CNC machines has been expanding
`at an amazing rate.
`The ever—increasing use of CNC machines in the manufacturing industry has created a
`demand for personnel who are knowledgeable about CNC technology, capable of preparing
`part programs, and competent in managing CNC operations. Responding to this urgent
`need, dedicated CNC courses and related courses on subjects such as CAM and automation
`are being established in colleges, universities, and industrial organizations.
`,
`This book has been prepared as a comprehensive text and reference for the study of
`computer numerical control, with emphasis on the essentials of CNC technology and pro-
`gramming. The book is virtually a one—volume encyclopedia on modern CNC technology.
`It is written for students of industrial technology, engineering technology, and engineering,
`as well as for persons with a technical background, such as manufacturing engineers and
`technicians in industry. The book is written at the undergraduate level and is suitable for
`a two~semester course. It is appropriate for industrial technology, engineering technology,
`and engineering courses in universities and colleges, junior colleges, and trade schools,
`as well as for courses offered by CNC machine tool manufacturers.
`The book is organized into the following five parts:
`
`Part 1: Essentials of CNC Technology (Chapters 1 through 8)
`
`Part II: Manual CNC Programming (Chapters 9 through 16)
`
`Part III: Computer—Assisted Programming in APT (Chapters l7 through 23)
`
`Part IV: CAD/CAM NC Programming (Chapters 24 through 26)
`
`Part V: CNC Networking (Chapters 27 and 28)
`
`A two—semester course is adequate to cover most of the material. The depth and choice
`of topic coverage and projects may vary based on the particular curriculum. The following
`is a list of suggested topics to be covered in two semesters:
`
`First semester
`
`Part I (Chapters 1 through 8)
`
`Part 11 (Chapters 9, 10, ll, 13, 14, and 16)
`
`xi
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`
`xii
`
`PREFACE
`
`Part III (Chapters 17 through 20)
`
`Part IV (Chapters 24 and 25)
`
`Second semester
`
`Part II (Chapters 12 and 15)
`
`Part III (Chapters 21 through 23)
`
`Part IV (Chapter 26)
`
`Part V (Chapters 27 and 28)
`
`The chapters covered in the first semester should be adequate for curricula in which
`the CNC course is offered only in one semester.
`Although Fanuc controller systems are used to develop the chapters on manual pro-
`gramming in Part II, the programming principles can be applied to other systems with
`very little effort.
`Both metric and English units are used in the book.
`Chapter 24 was written by Dr. Fuh—Cwo (Tony) Shiue, a good friend and colleague
`of many years.
`
`Su-Chen Jonathon Lin
`
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`
`Acknowledgments
`
`The author is indebted to many persons and organizations for their help and contributions
`in making this book idea a reality. I wish to express my sincere appreciation to the many
`students, teachers, and industrial personnel who reviewed all or part of the book and made
`many valuable suggestions for its improvement.
`Special thanks are due to Mr. Jia Fei and Mr. Lianggen (Jeff) Zheng, who prepared
`several hundred illustrations in AutoCAD. Without their great skill, care, and amazing
`speed, the book would never have been finished.
`Thanks are also extended to the Delmar staff for their patience and professional help.
`I owe a special debt of gratitude to Michael McDemiott and Vernon Anthony for their
`effort in motivating me to start and complete this project.
`I am greatly indebted to my dear wife, Grace, for her inexhaustible support, patience,
`and encouragement.
`I am also grateful to my son, Andrew, and daughter, Carol, for
`permitting me to spend numerous days and nights in the office preparing the manuscript.
`I also greatly appreciate the assistance of the following firms and their personnel,
`who provided CAD/CAM NC software, technical information, and illustrations for this
`text.
`
`ACMA Computer Inc.
`
`American SIP Corp.
`
`Becker Publishing Company, Inc.
`
`Bridgeport Machines, Inc.
`
`Carboloy, Inc.
`Carr Lane Manufacturing Co.
`Cassell PLC
`
`Cincinnati Milacron
`
`CNC Software, Inc.
`
`Collins Tool Corp.
`
`Forkardt Inc.
`
`Hardinge Brothers, Inc.
`
`Hewlett—Packard Company
`
`Hydraulics and Pneumatics magazine
`
`Industrial Text Company
`
`Ingersoll GmbH, Inc.
`
`Leadwell Manufacturing, Inc.
`
`Macmillan Publishing Company
`
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`xiv
`
`ACKNOWLEDGMENTS
`
`McGraw-Hill Publishing Company
`
`Mid—State Machine Products
`
`Mitsubishi Electric Industrial Control, Inc.
`
`Mori Seiki Co., Ltd.
`
`Numeridex CAM Division, Automation Intelligence, Inc.
`
`Peddinghaus Corp.
`
`‘Pitman Publishing Limited
`
`Point Control, Inc.
`
`Royal Machine and Tool Corp.
`
`3Refix Technology
`
`Valenite Corp.
`
`I also wish to thank the following individuals, who reviewed the book in preparation
`for this new edition. Their insights and criticisms were extremely helpful.
`
`Samuel Owusu—Ofori
`
`James C. Meide
`
`Dept. of Mechanical Engineering
`North Carolina A&T State University
`Greensboro, North Carolina
`
`Brad C. Harriger
`Purdue University
`W. Lafayette, Indiana
`
`Henry R. Putz
`Center for CNC Education
`Wmthington, Ohio
`
`Charles R. Mabbott, Sr.
`Canton, Michigan
`
`Larry T. Williams
`Machine Tool Dept.
`Linn Technical College
`Linn, Missouri
`
`Hennepin Technical College
`Brooklyn Park, Minnesota
`
`Gerald R. Brown
`
`Portsmouth, New Hampshire
`
`Jeff Jackson
`Industrial Engineer
`Howell, Michigan
`
`Dr. Chin—Sheng Chen
`Dept. Of Industrial Engineering
`Florida International University
`Miami, Florida
`
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`PART I
`
`Essentials of CNC
`
`Technology
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`A—
`
`
`
`D Introduction to
`5 Numerical Control
`
`Numerical control (NC) is one of the most important single elements in the transformation
`of the manufacturing industry since the first industrial revolution. Since its inception in the
`early 1950s, NC technology has undergone several major developments in both hardware
`and software. Today over one hundred and sixty thousand NC machine tools are used in
`twenty thousand manufacturing plants in the United States. NC machine tools represent
`about 6 percent of the total U.S. machine tool population, and the percentage has steadily
`increased in recent years. In NC user plants, NC machines account for about 20 percent of
`the machine tools on plant floors. However, they account for approximately 60 percent of
`all machining activities. Today’s computer numerical control (CNC) machine tools have
`become the major driving force for American manufacturers to improve productivity in
`order to survive enormous foreign competition.
`This chapter presents an overview of CNC technology, including definition, historical
`perspective, basic elements, features of CNC, advantages and limitations, CNC applica—
`tidns, and the future of CNC.
`
`1.1 WHAT IS NUMERICAL CONTROL?
`
`Numerical control has been defined by the Electronic Industries Association (EIA) as “a
`system in which actions are controlled by the direct insertion of numerical data at some
`point. The system must automatically interpret at least some portion of this data.” More
`precisely, numerical control can be considered as a versatile form of programmable au-
`tomation in which the machine tool is controlled by a series of coded instructions consisting
`of letters, numbers, punctuation marks, and other symbols. These coded instructions are
`converted into two types of control signals: pulses of electric output signals and on/off
`control signals. Pulses of output signals implement the positioning of the machine spin-
`dle relative to the workpiece and its speed. Functions of the on/off signals include (1)
`control of the speed and direction of the spindle rotation, (2) control of coolant supply,
`(3) selection of the cutting tool, and (4) others, such as stop, optional stop, and automatic
`clamping and unclamping.
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`INTRODUCTION TO NUMERICAL CONTROL
`
`3
`
`1.2 HISTORICAL PERSPECTIVE OF NUMERICAL CONTROL
`
`The idea of using programmed information for controlling a device can be traced back
`to the fourteenth century, when pegged cylinders were used to control the movement of
`ornamental figures on church clocks (Kief and Olling, 1985). Many creative inventions
`have made significant contributions to CNC technology. Here we briefly outline some
`milestones in the course of numerical control development.
`
`1.2.1 Events before the Dawn of the NC Era
`
`The actual concept of numerical control might have originated as early as 1725 in Eng-
`land, where systematized punched cards were used to control the cloth pattern of knitting
`machine operations. In 1808 Joseph M. Jacquard employed punched holes in sheet metal
`cards to automatically control the patterns made by weaving machines. The activation of a
`needle was determined by the presence or absence of its associated hole. Around 1863 M.
`Fourneaux patented the automatic player piano, which used air passing through holes in a
`perforated paper drum approximately 41/2 in. wide to control the keyboard mechanism in
`a preprogrammed sequence. In 1912 Emmanuel Scheyer of New York invented the Kin-
`autograph machine, which used punched paper tape to cut cloth. He proclaimed that his
`device could easily be used to control various types of machinery, including multiple—axis
`machine tools. In 1926 Max Schenker of Switzerland patented the automatic lathe, which
`used punched cards for the storage of information. His device was able to mathematically
`program the lathe to control both direction and speed.
`
`1.2.2 The Birth of the NC Machine
`
`In 1947 John Parsons of the Parsons Corporation, based in Traverse City, Michigan, be-
`gan experimenting with the idea of using three—axis curvature data to control machine tool
`motion for the complex machining of aircraft components. He set up a successful demon-
`stration of the mathematical approach to contour cutting for the Air Force in December
`1948. In June 1949 Parsons was awarded an Air Force research contract of $200,000 for a
`21-month project to develop an automatic contour cutting machine. Shortly after receiving
`the contract, Parsons was joined by the Servomechanisms Laboratory of the Massachusetts
`Institute of Technology (MIT) as a subcontractor. In 1951 MIT was awarded the major
`contract from the Air Force that resulted in the building of the first numerically controlled
`machine tool, a Cincinnati Hydrotel vertical—spindle milling machine, in 1952. The ma-
`chine control unit (MCU), built with electron vacuum tubes,
`took up more floor space
`than the machine. It received machining data from binary—coded punch tapes to generate
`movements of three axes in a linear interpolation manner. The effort over the following
`three years was mainly devoted to hardware refinements and mathematical techniques for
`tape preparation.
`In 1955 the Subcommittee on Numerical Control was organized by the Airframe
`Manufacturing Equipment Committee of the Aerospace Industries Association (AIA) to
`investigate the NC systems under development. The subcommittee made two recommen-
`dations to the Air Force: that forthcoming machines be equipped with numerical control and
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`ESSENTIALS OF CNC TECHNOLOGY
`
`that a standardization of NC systems be established. The Air Force subsequently granted
`$35 million for the manufacture of 100 NC milling machines, which were distributed to
`manufacturers for producing aircraft and missile components. Standardization activities
`centered around hardware and software in three aspects: type and format of control input
`medium, system configuration for interpolation, and part—programming languages.
`
`1.2.3 Programming Languages Development
`
`Following the successful development of the first NC machine, MIT began work on a com-
`puterized NC programming language called Automatically Programmed Tool (APT) in 1954.
`It was a symbol language capable of defining part geometries and cutter paths for simple
`workpieces on a computer. APT II was released from MIT in 1958. This was a more ad-
`vanced version that ran on the IBM 704 computer. In 1961 another, more powerful pro-
`gramming language, APT III, was released. AIA awarded a project to the Illinois Institute
`of Technology Research Institute (IITRI) to further develop and maintaiig the APT III lan-
`guage. Expansion of the APT III system resulted in the release of APT IV, which includes
`more complex surface definitions for machining. APT has become the standard NC pro-
`gramming language for machining complex parts. The majority of today’s computer—aided
`design/computer—aided manufacturing (CAD/CAM) NC systems are APT—based.
`The operation of the APT system required a large computer with a minimum of 256-
`kilobyte storage capability. This requirement seemed costly for parts that did not require
`complex machining. For this reason, several language systems derived from APT were
`developed for smaller computers, including ADAPT (IBM), IFAPT (France), MINIAPT
`(Germany), and FAPT (Japan). Other programming languages that were not APT—related,
`such as COMPACT II, AUTOSPOT, AUTOPROMPT, CAMP I, and SPLIT, were also
`
`developed concurrently with APT.
`
`1.2.4 Direct Numerical Control
`
`In the mid—1960s Cincinnati Milacron and General Electric independently proved the fea-
`sibility of the concept of direct numerical control (DNC),
`in which NC machines are
`operated directly from a remote computer. What may have been the first successful DNC
`demonstration was given in 1966. A computer located about 3000 feet from a hard-wired
`NC milling machine successfully transmitted instructions to the MCU via a telephone
`line. Many DNC systems were soon developed, and a half-dozen exhibitors displayed
`DNC systems at the 1970 National Machine Tool Builders Association (NMTBA) show.
`Figure 1.1 illustrates the concept of direct numerical control, in which a shared computer
`is used to program, service, control, and execute machining processes for a group of NC
`machine tools. The DNC systems were primarily used to download part programs to NC
`‘ machines. Their uses and functions were very limited.
`
`1.2.5 Computer Numerical Control
`
`the idea of computer numerical
`In contrast to the remote~controlled concept of DNC,
`control is to position a computer right at the machine. The emergence of integrated-circuit
`minicomputers and lower—cost CRTs (cathode ray tubes) brought the CNC concept into
`reality. A dedicated computer is built into the MCU to control one machine tool. Nearly all
`
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`INTRODUCTION TO NUMERICAL CONTROL
`
`'
`
`5
`
`
`
`
`MCU '
`
`
`lillllllillli
`
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`
`MCU "
`
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`
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`
`
`
`
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`MCU ‘
`
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`
`l|i|ii|iH|l|'
`
`
`
`
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`
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`
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`
`
`
`FIGURE 1.1
`Direct numerical control.
`
`numerically controlled machine tools are of the CNC type. Today’s computer technology
`provides CNC systems with a higher level of stored intelligence right at the machine, with
`convenient editing capability and memory capacity for part programs storage.
`
`1.2.6 Distributive Numerical Control
`
`Two desirable features of CNC—the ability to run a part program from memory and the
`capability of storing multiple part programs in the memory—make it possible to oper-
`ate a CNC machine independent of the host computer. This frees the host computer’s
`time and capacity for performing other system tasks. With these CNC capabilities and
`other technological advancements in computers, programmable controllers, and data com-
`munication network systems, another form of numerical control—distributive numerical
`control——began to evolve in the early 1980s. In distributive numerical control systems, a
`network of computers is used to coordinate the operation of a number of CNC machines
`(Figure 1.2). In addition to downloading part programs to NC machines, these systems can
`handle several other important functions such as line balancing and scheduling, monitoring
`of machine and control status data, and generation of management information.
`
`1.2.7 CAD/CAM NC Programming
`
`Modern computer technology has had a significant influence on engineering design and
`manufacturing in terms of reducing design and manufacturing cost, inventory, and lead
`time. as well as increasing productivity and product quality. The idea behind CAD/CAM is
`the use of a single technical database by both design and manufacturing personnel during
`the product development and production stages.
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`6
`
`ESSENTIALS OF CNC TECHNOLOGY
`
`CAM NC Programming Section
`CAM
`
`
`
`% —%
`
`CAD SECUOU
`
`CAD
`
`
`
`0223" S‘
`
`"'—'
`
`%
`
`Factory Computer Network
`
`—
`_
`
`CAM
`
`
`
`E33
`
`
`
`Manufacturing cell
`
`-
`
`Manufacturing cell ‘
`
`FIGURE 1.2
`Distributive numerical control.
`
`In numerical control applications, CAD systems are used to define part geometries,
`and CAM systems use these‘ geometrical data to generate the cutter paths that are the
`cutter centerline data. Other features of CAM may include process planning, group tech-
`nology, production planning, production control, and materials requirement planning. The
`implementation of CAD/CAM in NC programming has gained in popularity in recent
`years. Around 60 CAD/CAM NC software systems have been developed. The majority
`of these systems run on microcomputers, and some operate on minicomputers or even on
`mainframes.
`
`11.3 BASIC ELEMENTS OF A CNC SYSTEM
`
`An in~depth discussion of CNC hardware and software is given in Chapter 3, but it would
`be very beneficial at this point to briefly explain the major elements of an NC system and
`their basic functions. A numerically controlled system consists of the following six major
`components (Figure 1.3):
`
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`INTRODUCTION TO NUMERICAL CONTROL 7
`
`Feedback
`transducer
`
`
`
`Servo motor
`
`Machine tool
`
`Lead screw
`
`Feedback
`
`transducer
`
`Servo motor
`
`
`
`
`
`
`
` ROM ~
`lnterpolations
`Control
`l
`
`Computer
`program Control output
`R3_232_C
`Executlon
`signals
`pFOgFCl|'T1
`‘
`
`RAM —
`Amplifier/
`port
`comparator
`
`
`progrorn
`CITCUIIS
`
`Machine Control UN
`
`
`
`
`
`
`
`
`
`Program
`Input
`d€V1Ce
`
`Part
`program
`
`FIGURE 1.3
`
`Basic elements of CNC systems.
`
`0 Part program
`
`- Program input device
`0 Machine control unit
`
`- Drive system
`- Machine tool
`
`- Feedback systenr
`
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`ESSENTIALS OF CNC TECHNOLOGY
`
`A part program consists of the coded instructions required to control the movement
`of a machine tool for producing a part. When loaded to a CNC system, the MCU converts
`these instructions into electric signals that activate machine tool functions and generate
`cutting tool movements.
`The function of the MCU is to read and interpret the coded instructions for machining
`a particular workpiece and then generating electric output signals. These co