Introduction to mechanical Engineering

Module 4
Computer Numerical Control (CNC) Machine

Computer Numerical Control or CNC is an advanced form of the NC system where the machine
control unit is a dedicated microcomputer instead of a hard-wired controller, as in conventional
NC.
Computer Numerical Control has evolved during the rapid improvements of the computer
technology. The advent of Microprocessors from the 1970s have helped in quick advancements
in the Computer Technology and is in turn adapted in modern CNC Technology. Today's CNC
Controller has latest features like high speeds of operation, large memories, bus architectures,
improved servos, etc.
CNC Technology has powered the Machine Tool industry today. It is used in majority of
machine tools like machining centers, turning centers, grinders, lathes, drilling machines, etc.
Today's CNC Controller has latest features like high speeds of operation, large memories, bus
architectures, improved servos, etc. CNC Technology has powered the Machine Tool industry
today. It is used in majority of machine tools like machining centers, turning centers, grinders,
lathes, drilling machines, etc.
COMPONENT OF A CNC SYSTEM
A CNC System consists of the following elements:
1. Input Device
2. MCU or Machine Control Unit
3. Machine Tool
4. Driving System
5. Feedback devices
6. Display Unit
1. INPUT DEVICE: The part program is entered into the CNC Control or the MCU through
the input device. There are various input devices used on a CNC Machine such as.
a. USB (Universal Serial Bus) Flash drive: Here the USB flash drives transfer data to the
control. USB is very common nowadays and its use is increased in modern computers.
b. Serial Communication: A serial communication port connects a computer system and a
CNC Machine tool through an interface called RS-232. Most machines have RS-232
port and an RS-232 cable connects the computer and the CNC Machine to transfer data
from the computer to the CNC Machine.

Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 1
Introduction to mechanical Engineering

c. Ethernet Communication: The Ethernet communication is a more reliable and efficient

means of transferring part programs from Computer to the CNC Control.
d. Conversational Programming: This is another way to input part programs to the
controller through a keyboard. Built-in intelligent software inside the controller enables
the operator to enter step by step data.

Elements/Components of CNC Machine

2. MCU OR MACHINE CONTROL UNIT: The Machine Control Unit or the MCU is the
heart of the CNC System. It consists of the following components: a. Central Processing Unit:
The CPU is the brain of the MCU and it comprises of:
i. A control section that retrieves data from the memory and generates signals which in turn
activates all MCU components.
ii. An ALU (Arithmetic Logic Unit) that performs integer arithmetic operations like addition,
subtraction, multiplication, counting, etc and logical operations
iii. Immediate Access Store or Immediate Access Memory: This holds the data and programs
temporarily that is required at that instant by the control section.
b. CNC Memory: The memory of the CNC is divided into
i. Main Memory which consists of Read Only Memory (ROM) and Random Access Memory
(RAM). The ROM stores the Operating System Software and machine interface programs.
The RAM stores the Part programs.
ii. Secondary Memory such as Hard disks which is used to store large programs and which
can be used by the main memory when required.

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Introduction to mechanical Engineering

c. Input/output Interface: The Input/output interface or the I/O interface establishes

communication between the machine operator, the components of the CNC system and other
connected computers. The Operator control panel is the interface through which the machine
operator communicates with the CNC system. A keyboard and a display screen are also
included in the panel.
d. Machine tool controls: A Machine Tool consists of various axes such as X, Y, Z, A, B, C
and a spindle which rotates at the designed RPM. The position and velocity control of each
of the axis and the rotational speed control are accomplished by certain hardware
components in the MCU. The MCU generates control signals that are transformed into a
form suitable for the specific position control systems that is required to drive the various
axes of the machine.
e. Sequence controls for auxiliary functions: Apart from the general functions like spindle
speed, feed rate, etc, certain auxiliary functions like cool emergency stop, tool changing
function, etc are carried out under par control program controls.

3. MACHINE TOOL: This can be any type of machine tool such as a Machining center, a
turning center, a lathe, milling machine, etc. The essential parts of the machine tool include
the machine table, machine slide, the driving lead screw, ball screw, rigid and heavy machine
Structure, and automatic tool changing system, spindle and spindle drive system, chip
removal System etc. The machine table is controlled in the X and Y axes, while the spindle
runs along the Z axis. In other machine tools, there are additional axes such as A, B or C that
allows rotary motions around the X, Y and Z axes.

4. DRIVING SYSTEM: A drive system essentially is made up of amplifier circuits, drive

motors, and ball lead-screws. The control signals (position and speed) of each axis are fed by
the Machine Control Unit (MCU) to the amplifier circuits. Then, the control signals are
augmented to actuate drive motors which in turn rotate the ball lead-screws to position the
machine table. The commonly used types of electrical motors include DC Servo Motor, AC
Servo Motor, Stepping Motor and Linear Motor.

5. FEEDBACK DEVICES: For the accurate operation of a CNC Machine, the positional
values and speed of the axes needs to be continuously updated. This is done by the feedback
devices.
Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 3
Introduction to mechanical Engineering

Closed Loop Control System (Feedback Control System): In this control system, the
output variable is compared to an input parameter and the difference between the output
variable (which is the actual condition) and input parameter (which is the input condition) is
sensed and fed back to drive the output according to input requirements. The basic elements
of a feedback control system shown in Fig. above are:
a. Input parameter: This is the set point which defines what must be the output value.
b. Process: Process is the operation that is being controlled.
c. Output variable: The output variable is the actual value of the parameter.
d. Feedback Sensors: Sensors measure the output variable and feeds it back to the control
system. Thus, a feedback loop is created between input and output.
e. Controller: The function of the controller is to compare the actual output with the desired
input, compute the difference and make suitable process adjustments that reduce the
difference between output and input.
f. Actuators: The adjustments made in the process are actuated by hardware devices called

Closed Loop feedback system.

Open Loop Control System: In this control system, there is no comparison of the output
variable to the input parameter since feedback element is missing here. The Open loop control
system is given below in terms of a simple block diagram.

Open Loop feedback system.

Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 4
 Introduction to mechanical Engineering

The open loop control system is chosen when the actions performed by the control system are
simple, the reliability of the actuator is very high and the reaction forces counteracting the
actuator are so negligible that they do not have any effect on the actuator.

6. DISPLAY UNIT: The display unit is the device that ensures interaction between the
machine operator and the machine. Display unit displays the current status of operation such as
the spindle RPM, the running part program, the feed rate, position of the machine slide, etc.

Features of CNC milling

• Flexible and versatile.
• High machining accuracy.
• High production efficiency.
• It can process complex shapes.
• Reduce the labor intensity of the operator.
• Complex shapes of machined parts.

Advantages of CNC machines

1. The accuracy and repeatability obtained is high.
2. Complex shaped contours can be machined.
3. Can be easily programmed to handle variety of product styles.
4. High volume of production compared to conventional machines.
5. Even lesser skilled or trained people can operate CNC Machines unlike the Conventional
ones where highly skilled people are required.
6. CNC Machines can be used uninterruptedly without turning them off provided regular
maintenance is done.
7. Prototypes can be produced faster and thus results in reduced lead times.
8. Avoids errors that were otherwise committed by humans operating conventional machines.
9. Since CNC machines can be programmed, one person may well take care of a number of
CNC Machines. This reduces the employees and hence costs are reduced.
10. Using CNC Machines results in a safer work environment since the operator is not
exposed to the machine area during machining.

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Introduction to mechanical Engineering

11. CNC Machines can be upgraded to newer technologies by replacing the existing CNC
Control with an advanced one.
12. Many CNC Machines can be linked together to a main 'computer. Programs from the
main computer can be downloaded to any connected CNC Machine. This leads us to
another type of NC concept called as the Direct Numerical Control (DNC).

Disadvantages of CNC machines

1. A thorough programming knowledge is required by the operators or programmers. This
again requires skilled programmer and hence the cost of labor can be high.
2. Cost of a CNC Machine is high compared to the Conventional Machine Tools.
3. The spares of CNC Machines are relatively costlier than Conventional Machines.
4. CNC Machines require air conditioned environment and/or a chiller unit. Thus extra costs
are involved.

Dr. Kiran M D, Asst. Professor, Dept. of Mechanical Engg, BMSIT&M, Bangalore Page 6