Table of Contents

1.

CNC Machining ....................................................................................................................... 2

1.1.

What is CNC Machining .................................................................................................. 2

1.2.

The Evolution of NC ........................................................................................................ 2

1.3.

CNC Machining Process .................................................................................................. 2

1.4.

Types of CNC Machine.................................................................................................... 2

1.5.

Program Input ................................................................................................................... 3

1.6.

Operational Features of CNC Machines .......................................................................... 4

1.7.

CAD/CAM in CNC Machining ....................................................................................... 4

1.8.

CNC Machines- Advantages/Disadvantages ................................................................... 5

Manufacturing Processes Assignment

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1. CNC Machining
1.1.

What is CNC Machining

CNC Machining is a process used in the manufacturing sector that involves the use of computers
to control machine tools. Tools that can be controlled in this manner include lathes, mills, routers
and grinders. The CNC in CNC Machining stands for Computer Numerical Control.

1.2.

The Evolution of NC

It was in 1947 when numerical control was born. It began when John C. Parsons of the Parsons
Corporation, Traverse City, Michigan, a manufacturer of helicopter rotor blades, could not make
his templates fast enough. So, he invented a way of coupling computer equipment with a jig
borer. Mr. Parsons used punched cards to operate his digit Ron system. 1949 was the year of
another Urgent need. The U.S. Air Material command realized that parts for its planes and
missiles were becoming more complex. Also, as the designs were constantly being improved,
changes in the drawing were frequently made. Thus, in their search for methods of faster
production, an Air Force study contract was awarded to the Parsons Corporation. The servo
mechanisms laboratory of the Massachusetts Institute of Technology (MIT) was the
subcontractor. In 1951, MIT took over the complete job, and in 1952, the prototype of todays
NC machine, a modified Cincinnati Hydrotel Milling Machine, was successfully demonstrated.
The term numerical control was originated at MIT.

1.3.

CNC Machining Process

Under CNC Machining, machine tools function through numerical control. A computer program
is customized for an object and the machines are programmed with CNC machining language
(called G-code) that essentially controls all features like feed rate, coordination, location and
speeds. With CNC machining, the computer can control exact positioning and velocity. CNC
machining is used in manufacturing both metal and plastic parts.
First a CAD drawing is created (either 2D or 3D), and then a code is created that the CNC
machine will understand. The program is loaded and finally an operator runs a test of the
program to ensure there are no problems. This trial run is referred to as "cutting air" and it is an
important step because any mistake with speed and tool position could result in a scraped part or
a damaged machine.
There are many advantages to using CNC Machining. The process is more precise than manual
machining, and can be repeated in exactly the same manner over and over again. Because of the
precision possible with CNC Machining, this process can produce complex shapes that would be
almost impossible to achieve with manual machining. CNC Machining is used in the production
of many complex three-dimensional shapes. It is because of these qualities that CNC Machining
is used in jobs that need a high level of precision or very repetitive tasks.

1.4.

Types of CNC Machine

There are many different types of CNC Machines used in industry, Such as:

Mills and Machining Centers

Lathes and Turning Centers
Drilling Machines
EDM Sinker and wire cut Machines

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 Flame and Laser-Cutting Machines

Water Jet Profilers
1.4.1. CNC Machine Lathes
Some view Lathes as the only universal machine tool because a lathe can make all of the parts
needed for another lathe. A lathe spins the work piece in a spindle while a fixed cutting tool
approaches the work piece to slice chips off of it. Because of this geometry, lathes are ideal for
parts that have symmetry around some axis that could be chucked up in the spindle. CNC Lathes
have at the very least the ability to drive the cutting tool under g-code control over 2 axes,
referred to as X and Z. They may have a considerable amount of other functionality as well, and
there are many variations on lathes such as Swiss Lathes. The act of cutting a work piece on a
lathe is called "Turning".
1.4.2. CNC Milling Machines
In a mill, the cutter is placed in the spindle where it rotates. The work piece then moves past the
cutter so that chips may be sliced off. The act of cutting a work piece on a mill is called
"Milling". CNC Mills have at the very least the ability to drive cut in 3 dimensions (some older
machines may be limited to 2 or 2 1/2 if there are limitations on when that 3rd dimension may be
used) which are referred to as the X, Y, and Z axes.
1.4.3. CNC Routers
A CNC Router is actually a type of CNC Mill, typically one that uses what's called a "gantry"
configuration. Typically they're called CNC Routers instead of CNC Gantry Mills when they're
used to cut wood, but this need not exclusively be the case. Many think of CNC machines as
being focused on cutting metal, but there is a huge market for CNC woodworking machines of
which the CNC Router is the principle example.
There are many more types of CNC machine than just these three most common types including
CNC presses of various kinds and so on.

1.5.

Program Input

Different ways of data input are:

MDI : Manual Data Input

PROGRAM PREPARATION WITH CAD CAM
PROGRAM DATA TRANSFER FROM PC TO CNC M/C
PROGRAM DATA TRANSFER FROM PC TO DNC
OPERATIONS

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1.6.

Operational Features of CNC Machines

Figure 1 CNC Control System

For a CNC machine control unit (MCU) decides cutting speed, feed, depth of cut, tool selection,
coolant on off and tool paths. The MCU issues commands in form of numeric data to motors
that position slides and tool accordingly.

1.7.

CAD/CAM in CNC Machining

Two computer-based systems which impact the use of CNC technology are CAD(computer
aided design )and CAM (computer aided manufacturing). A computer aided design, or CAD,
system uses computers to graphically create product designs and models. These designs can be
reviewed, revised, and refined for optimum end use and application. Once finalized, the CAD
design is then exported to a computer aided manufacturing, or CAM, system. CAM systems
assist in all phases of manufacturing a product, including process planning, production planning,
machining, scheduling, management and quality control.
1.7.1.

Programming Key Letters

O - Program number (Used for program identification)
N - Sequence number (Used for line identification)
G - Preparatory function
X - X axis designation
Y - Y axis designation
Z - Z axis designation
R - Radius designation

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1.7.2.

F Feed rate designation

S - Spindle speed designation
H - Tool length offset designation
D - Tool radius offset designation
T - Tool Designation
M - Miscellaneous function
Programming Example Cylindrical Part

1.7.3. Program for Part

O0077
N0005 G28 U0.0 W0.0;
N0010 T0202;
N0020 G97 S1500 M03;
N0030 G00 X50.0 Z1.0 ;
N0040 G71 U1.0 R2.0;
N0050 G71 P0060 Q00 U0.5 W0.2 F0.2;
N0060 G01 X13.0;
N0070 X15.0 Z-1.0;
N0080 Z-30.0
N0090 X23.0
N0100 X25.0 Z-50.0;
N0110 X50.0;
N0120 G70 P0060 Q0110 S2500 F0.1;
N0130 G28 U0.0 W0.0,
N0140 M30

1.8.

CNC Machines- Advantages/Disadvantages

Manufacturing Processes Assignment

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1.8.1.

1.8.2.

Advantages:
High Repeatability and Precision e.g. Aircraft parts
Volume of production is very high
Complex contours/surfaces need to be machined. etc
Flexibility in job change, automatic tool settings, less scrap
More safe, higher productivity, better quality
Less paper work, faster prototype production, reduction in lead times
Disadvantages:
Costly setup, skilled operators
Computers, programming knowledge required
Maintenance is difficult

Manufacturing Processes Assignment

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