NUMERICAL CONTROL (NC) NOTES
1. Advantages of NC
• Reduced nonproductive time: fewer setups, less setup time, automatic tool changes.
• Greater accuracy and repeatability: less human error, parts closer to nominal dimensions.
• Lower scrap rates: more parts within tolerance.
• Reduced inspection requirements: verified part programs produce consistent parts.
• Complex part geometries possible: functional features, mathematically defined surfaces.
• Easier engineering changes: modify NC program instead of fixtures.
• Simpler fixtures: accurate tool positioning reduces fixture complexity.
• Shorter manufacturing lead times: fewer setups per part.
• Reduced parts inventory: smaller lot sizes feasible.
• Less floor space: fewer machines required.
• Reduced operator skill requirements: mainly load/unload and tool change.
2. Disadvantages of NC
• Higher investment cost: includes CNC controls, electronics, reliable components, additional
features.
• Higher maintenance effort: requires trained personnel.
• Part programming: extra step compared to conventional machines.
• Higher equipment utilization: may require multiple shifts for economic payoff.
3. NC Applications
Machine Tool Applications: - Machining (turning, drilling, milling, grinding). - NC lathes, boring mills,
drill presses, milling machines, cylindrical grinders. - Increased machine cutting time leads to faster
wear on components. - Reduced operator role; single operator can manage multiple machines. -
Machining centers allow multiple operations in one setup with automatic tool changes.
Application Characteristics: - Suitable for low-to-medium production, medium-to-high variety
products. - Best for batch production, repeat orders, complex geometries, heavy metal removal, many
operations, expensive parts.
Other Metalworking Applications: - Punch presses, sheet metal bending, welding, thermal cutting
(laser, plasma, oxy-fuel), tube/wire bending, wire EDM.
Other NC-Type Applications: - Rapid prototyping/additive manufacturing. - Water jet and abrasive
cutting. - Component placement machines for PCBs. - Coordinate Measuring Machines (CMMs). - Wood
routers, granite cutters. - Tape laying and filament winding for polymer composites.
4. NC Positioning Systems
• Converts program coordinates to tool/workpiece relative positions.
• Linear movement via leadscrew/ball screw driven by stepper/servo motor.
• Open-loop: no feedback; lower cost, suitable for low resistance.
• Closed-loop: feedback from encoder; accurate, used in continuous-path operations.
• Optical encoders: measure rotation by counting light pulses; connected to leadscrew/ball screw.
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5. Adaptive Control (AC) Machining Systems
Purpose: - Dynamically adjusts speeds and feeds in response to variability. - Compensates for: work
material hardness, depth/width of cut, air gaps, tool wear.
When AC is Beneficial: 1. Cutter engaged >40% of machine time. 2. Significant variability in job. 3. High
operational cost. 4. Difficult-to-machine materials (steel, titanium, high-strength alloys).
Sources of Variability: - Variable geometry of cut. - Workpiece hardness/machinability. - Workpiece
rigidity. - Tool wear. - Air gaps.
Types of Adaptive Control: - Adaptive Control Optimization (ACO/AGO): Optimizes performance
index (e.g., MRR/TWR). - Adaptive Control Constraint (ACC): Maintains measured variables below
constraint limits; simpler, production-oriented.
ACC Operation: - Feed controlled; cutter force/power measured. - Hardware: spindle force sensors,
motor current sensors, control/display unit, interface to NC/CNC. - Software: machinability program
(APT MACRO) computes feed, speed, and force limits. - Air-gap override: feed increases when cutter
passes through non-cutting area.
Benefits of AC: 1. Increased production rates (20–60% for milling, 33–38% for drilling). 2. Increased tool
life (uniform cutter use, fewer breakages). 3. Greater part protection (force limits based on tolerances).
4. Less operator intervention. 5. Easier part programming (controller selects feed rates, fewer tryouts).
6. Trends and New Developments
• Computer integration: enhanced NC programming (interactive graphics, voice programming),
CNC, DNC, AC.
• Replacement of punched tape: shift toward magnetic tape cartridges, compatible with
computers.
• In-process inspection probes: measure part dimensions during machining, mounted in spindle
or tool drum, automatic tool changer integration.
End of NC Notes
