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CHAPTER: 1
INTRODUCTION
1.1 MACHINE:
Machine is an apparatus using mechanical power and having several parts, each with a
definite function and together performing a particular task.
Mechanical
Chemical
Thermal
Electrical
In olden days Conventional Machines were used for performing operations .It takes lots of
time to do operations and by the improvement of technology the NC Machines came into existence.
By this NC machines, the conventional machine drawbacks were overcome. But the problem with
the NC machines was that it has no storage facility and functions achieved by this were limited. By
technology development the CNC Machines came into existence. The machine was equipped with
the computer and supportive software's with help of this it was been made too easy to operate with
the complicated operations and has lots of space to store the data.
The concepts of Conventional, NC, and CNC machines are been discussed below.
1.2.1Conventional Machines:-
Machines that are driven or operated with the help of human resource are termed as
Conventional Machines. Example: -Small scale welding. - Small scale moulding. - Lathing.
Conventional machines require direct contact of tool with work piece material for metal
removing in form of chip. Conventional machining process involves tool wearing as there is a
physical contact between the tool and the work piece. Turning, drilling, grinding, broaching, are
example of conventional machining process. Conventional machining process have many
advantages over non-conventional machining process as they are more precise, no wear of tool, no
heat generation etc.
Manufacturing processes can be broadly divided into two groups and they are Primary
manufacturing process and Secondary manufacturing process. The former ones provide basic shape
and size to the material as per designer's requirement. Casting, forming, powder metallurgy are
such processes to name. Few secondary manufacturing processes provide the final shape and size
with tighter control on dimension, surface characteristics etc.; Material removal processes are
mainly secondary manufacturing processes.
Material removal processes are once again divided into mainly two groups on there are
"Conventional machining processes" and "Non Traditional Manufacturing processes".
Conventional machining usually involves changing the shape of work piece using an
implement made of a harder material. Using conventional methods to machine hard metals and
alloys means increased demand of time and energy and therefore increase in cost in some cases
conventional machining may not be feasible.
Conventional machining also cost in terms of tool ware and in loss of quality in the product
owing to induced residual stresses during manufacture with ever increasing demand for
manufactured goods of hard alloys and metals such as inconel718 or Titanium. Bore interest as
gravitated to Non-conventional machining methods.
There may be a physical tool present. For example a cutting tool in a lathe machine.
Cutting tool is harder than work piece at room temperature as well as under machining
conditions.
Material removal takes place due to the application of cutting forces-energy domain can be
classified as mechanical.
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Conventional machining involves the direct contact of tool and work piece.
Lower accuracy and surface finish
Suitable for every type of material economically.
Tool life is less due to high surface contact and wear.
Higher waste of material due to higher wear.
Nice operation mostly causes sound pollution.
Lower capital cost
Easy setup of equipment.
Skilled or unskilled operator may be required.
Generally they manual to operate.
They can't be used to produce proto type parts very efficiently and economically.
Program of instructions.
Controller unit also called as machine tool unit.
Machine tool or other controlled process.
The program of instructions serves as input to the controller unit, which in turn commands the
machine tool or other process to be controlled.
The program of instructions is the detailed step by step set of instructions which tell the
machine what to do. It is coded in numerical or symbolic form on some type of input medium that
can be interpreted by the controller unit. The most common one is the 1-inch-wide punched tape.
Over the years, other forms of input media have been used, including punched cards, magnetic tape,
and even 35mm motion picture film.
There are two other methods of input to the NC system which should be mentioned. The
first is by manual entry of instructional data to the controller unit. This is time consuming and is
rarely used except as an auxiliary means of control or when one or a very limited number of parts to
be made. The second method of input is by means of a direct link with the computer. This is called
Direct Numerical Control, or DNC.
The second basic component of NC system is the controller unit. This consists of
electronics and hardware that read and interpret the program of instructions and convert it to
mechanical actions of the machine tool. The typical elements of the controller unit include the tape
reader, a data buffer, signal output channels to the machine tool, and the sequence controls to
coordinate the overall operation of the foregoing elements.
The tape reader is an electrical-mechanical device for the winding and reading the punched
tape containing the program of instructions. The signal output channels are connected to the
servomotor and other controls in machine tools. Most N.C. tools today are provided with positive
feedback controls for this purpose and are referred as closed loop systems. However there has been
growth in the open loop systems which do not make use of feedback signals to the controller unit.
The advocates of the open loop concept claim that the reliability of the system is great enough that
the feedback controls are not needed.
The third basic component of an NC system is the machine tool or other controlled process.
It is part of the NC system which performs useful work. In the most common example of an NC
system, one designed to perform machining operations, It also includes the cutting tools, work
fixtures and other auxiliary equipments .
CNC is the short form for COMPUTER NUMERICAL CONTROL. As we all know that
NC (NUMERICAL CONTROL) Machine works as per the program of instructions fed into the
controller unit of the machine. The CNC Machine comprises of the mini computer or the
microcomputer that acts as the controller unit of the machine. While in the NC machine the
program is fed into punch cards, in CNC Machines the program of instructions is fed directly into
the computer via a small board similar to the traditional keyboard.
In CNC Machine the program is stored in the memory of the computer. The programmer
can easily write the codes and edit the programs as per the requirements. These programs can be
stored in the memory of the computer. These programs can be used for different parts, and they
dont have to be repeated again and again.
Compare to the NC machine, the CNC machine offers greater additional flexibility and
computer capability. New systems can be incorporated into the CNC controller simply by
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reprogramming the unit. Because of its capacity and the flexibility the CNC machines are called as
soft-wired NC. The numerical data required to produce a part is provided to a CNC machine in
the form of program, called Part Program. The program is translated into the appropriate
electrical signals for input to motors that run the machine. A CNC Machine is a Numerical Control
Machine with the added feature of an on board computer which is referred to as the machine
control unit (MCU).
CNC Machine Operators work in a wide variety of fields. People from all different pursuits,
such as hobbyists and even military group, take advantage of the cost saving accrued by using CNC
machines to turn raw materials into final products. The machines are faster, more efficient and
safer, too.
The CNC machine comprises of the computer in which the program is fed for cutting of the
metal of the job as per the requirements. All the cutting processes that are to be carried out and all
the final dimensions are fed into the computer via the program. The computer thus knows what
exactly is to be done and carries out all the cutting processes. CNC machine works like the Robot,
which has to be fed with the program and it follows all your instructions.
Some of the common machine tools that can run on the CNC are: Lathe, Milling machines,
Drilling Machine etc. The main purpose of these machines is to remove some of the metal so as to
give it proper shape such as round, rectangular, etc. In the traditional methods these machines are
operated by the operators who are experts in the operation of these machines. Most of the jobs need
to be machined accurately, and the operator should be expert enough to make the precision jobs. In
the CNC machines the role of the operators is minimized. The operator has to merely feed the
program of instructions in the computer, load the required tools in the machine, and rest of the work
is done by the computer automatically. The computer directs the machine tool to perform various
machining operations as per the program of instructions fed by the operator.
There are many different types of CNC Machines used industry, such as
Fewer workers are required to operate the CNC machines compared to manual operated
machines. Investment in CNC Machine can leads to unemployment.
Industries For Fabricating Materials: In many industries thin plates like steel plates are
required for various purpose inn fabrication industry the machining operations are
performed on such plates.
Other Industries Where CNC Machines Are Used: CNC Machines are also used extensively
in the wood working industries to perform various operations like routing and drilling. CNC
technology is also used in number of lettering and engraving systems.
Some of the CNC Machines are shown in the figures below:
CHAPTER: 2
CNC PROGRAMMING BASICS
Each letter address relates to a specific machine function. G and M letter addresses are
two of the most common. A G letter specifies certain machine preparations such as inch or metric
modes, or absolutes versus incremental modes.
An M letter specifies miscellaneous machine functions and work like on/off switches for
coolant flow, tool changing, or spindle rotation. Other letter addresses are used to direct a wide
variety of other machine commands.
job precisely. When points are located on a work piece, two straight intersecting lines, one vertical
and one horizontal, are used. These lines must be at right angles to each other, and the point where
they cross is called the origin, or zero point .
Fig.2.1. Intersecting lines from right angles and Fig.2.2. The three dimensional coordinate
planes establish the zero point (Allen-Bradley) (axes) used in CNC. (The Superior
Electric Company)
2.1.2 Machine Coordinate System (MCS):
The machine coordinate system comprises all the physically existing machine axes.
Reference points and tool and pallet changing points (fixed machine points) are defined in the
machine coordinate system.
The Orientation the coordinates system relative to the machine depends on the machine
type. The axis directions follow the so-called "Three Finger Rule" of the right (according to
DIN66217).
When seen from the front of machine, the middle finger of the right hand machines is in the
opposite direction to the in feed of the main spindle. Therefore,
The thumb points in the +X direction
The index finger points in the +Y direction
The middle finger points in the +Z direction
Positions of the coordinate system in milling machine the positions of the coordinate system
resulting from the three figure rule can have a different orientation for different machine type, as
mentioned below
2.1.4 Quadrant System:
The three-dimensional coordinate planes are shown in Fig. 2. The X and Y planes (axes) are
horizontal and represent horizontal machine table motions. The Z plane or axis represents the
vertical tool motion. The plus (+) and minus (-) signs indicate the direction from the zero point
(origin) along the axis of movement. The four quadrants formed when the XY axes cross are
numbered in a counter clockwise direction (Fig. 3). All positions located in quadrant1 would be
positive (X+) and positive (Y+). In the second quadrant, all positions would be negative X (X-) and
positive (Y+).In the third quadrant, all locations would be negative X (X-) and negative (Y-). In the
fourth quadrant, all locations would be positive
X (X+) and negative Y (Y-).
Fig.2.5.Quadrant System
The quadrants formed when the X and Y axes cross are used to accurately locate points
from the XY zero, or origin, point (Allen-Bradley).
In Fig, point A would be 2 units to the right of the Y axis and 2units above the X axis.
Assume that each unit equals 1.000. The location of point A would be X + 2.000 and Y + 2.000. For
point B, the location would be X + 1.000 and Y - 2.000. In CNC programming it is not necessary to
indicate plus (+) values since these are assumed. However, the minus (-) values must be indicated.
For example, the locations of both A and B would be indicated as follows:
A X2.000 Y2.000
B X1.000 Y-2.000
2.2 PROGRAMMING SYSTEM
Two types of programming modes, the incremental system and the absolute system, are
used for CNC. Both systems have applications in CNC programming, and no system is either right
or wrong all the time. Most controls on machine tools today are capable of handling either
incremental or absolute programming.
Incremental programs locations are always given as the distance and direction from the
immediately preceding point (Fig. 6). Command codes which tell the machine to move the table,
spindle, and knee are explained here using a vertical milling machine as an example:
Fig.2.6.Programming System
Work piece being dimensioned in the Incremental system mode (Icon Corporation).
A X plus (X+) command will cause the cutting tool to be located to the right of the last
point.
An X minus (X-) command will cause the cutting tool to be located to the left of the last
point.
A Y plus (Y+) command will cause the cutting tool to be located toward the column.
A Y minus (Y-) will cause the cutting tool to be located away from the column.
A Z plus (Z+) command will cause the cutting tool or spindle to move up or away from
the work piece.
A Z minus (Z-) moves the cutting tool down or into the work piece.
In incremental programming, the G91 command indicates to the computer and MCU (Machine
Control Unit) that programming is in the incremental mode.
Absolute program locations are always given from a single fixed zero or origin point (Fig.
7). The zero or origin point may be a position on the machine table, such as the corner of the
worktable or at any specific point on the work piece. In absolute dimensioning and programming,
each point or location
Note: All dimensions are given from a known point of reference (Icon Corporation) on the work
piece is givens a certain distance from the zero or reference point.
A X plus (X+) command will cause the cutting tool to be located to the right of the zero or
origin point.
A X minus (X-) command will cause the cutting tool to be located to the left of the zero or
origin point.
A Y plus (Y+) command will cause the cutting tool to be located toward the column.
A Y minus (Y-) command will cause the cutting tool to be located away from the column.
In absolute programming, the G90 command indicates to the computer and MCU that the
programming is in the absolute mode.
2.3 Incremental and Absolute systems:
CNC systems are further divided into incremental and absolute systems. In incremental
mode, the distance is measured from one point to the next. For example, if you want to drill five
holes at different locations, the x-position commands are
x + 500, + 200, +600, - 300, -700, -300.
An absolute system is one in which all the moving commands are referred from a reference
point (zero point or origin). For the above case, the x-position commands are,
x 500,700, 1300, 1000, 300, 0.
Both systems are incorporated in most CNC systems. For an inexperienced operator, it is
wise to use incremental mode.
2.3.1 The absolute system has two significant advantages over the incremental system:
Interruptions caused by, for example, tool breakage (or tool change, or checking the parts),
and would not affect the position at the interruption. If a tool is to be replaced at some stage, the
operator manually moves the table, exchanges the tool, and has to return the table to the beginning
of the segment in which the interruption has occurred. In the absolute mode, the tool is
automatically returned to the position. In incremental mode, it is almost impossible to bring it
precisely to that location unless you repeat the part program2. Easy change of dimensional data
The incremental mode has two advantages over the absolute mode.
Inspection of the program is easier because the sum of position commands for each axis
must be zero. A nonzero sum indicates an error. Such an inspection is impossible with the
absolute system.
Mirror image programming (for example, symmetrical geometry of the parts) is simple by
changing the signs of the position commands.
In the above block, X moves a distance of 5 in. in the negative direction while Y moves
distance of 7 in. in the positive direction. Other axes remain stationary. In some systems, actual
distances are used. In others, the dimension words are programmed in BLUs.
Feed rate, F
It is expressed in in/min or mm/min and, is used in contouring or point-to-point or straight-
cut systems. For example, a feed rate of F100 implies 100 in/min or 100 mm/min. Feed rates are
independent of spindle speed.
In linear motions, the federate of the cutting tool is not corrected for the cutter radius. But in
circular motions, the feed rate should be corrected for the tool radius as follows:
F= [(part contour radius tool radius)/part contour radius] (required feed rate)
For cutting around the outside of a circle, the plus sign in the above equation is used, and
the feed rate is increased. For cutting around the inside of a circle, the minus sign is used, and the
feed rate is decreased.
Spindle speed, S
Programmed in rev/min, it is expressed as RPM or by a three-digit code number that is
related to the RPM.
Tool word, T Consisting of a maximum of five digits, each cutting tool has a different code
number. The tool is automatically selected by the automatic tool changer when the code number is
programmed in a block.
Miscellaneous Function, M
Consisting of two digits, this word relates to the movement of the machine in terms of
spindle on/off, coolant on/off etc.
EOB
The EOB character is used at the end of each block to complete a line
CHAPTER: 3
CNC SOFTWARES
3.1 CNC SOFTWARES
There are many software used in CNC Machine, some of them are listed as below.
SIEMENS
FANUC
HANS
MITSUBHUSHI
HADEN HAND
In this machine we have Siemens software, and the Siemens have following softwares. They are:
Siemens 802D
Siemens 802DCL
Siemens 810 D
Siemens 810 DI
Siemens 810DISL
Siemens 840 D
Siemens 840 DI
Siemens 840 DISL
As per consumer requirement they had simplified their software between from Siemen802D
to Siemen840D for their use similar work they had created new software called SIEMENS
828D.
1. Low-maintenance
No battery (non-volatile data buffer thanks to NV-RAM technology)
No hard disk
No fan
2. User-Friendly
Full QWERTY keyboard
Hard keys with protective foil
IP65 degree of protection
3. Clever
3/8th thread for additional components
4. Optimally connected
Rear side parts
USB 2.0
RJ45 Ethernet
DRIVE-CLiQ
PLC I/O Interface
RS 232 C
NC Inputs/Outputs
By devising the SINUMERIK 828D, we have managed to develop a panel-based CNC that
is tailor-made for use in milling and turning machines. The product combines CNC, PLC, operating
and axis control functions for six CNC measuring circuits into one Compact units, which is
designed to fit any operator panel housing. Despite its compact Dimensions, the SINUMERIK
828D is a real powerhouse. Equipped with premium CNC functions such as the ability to execute
kinematic transformations or powerful Tool management, the product leaves nothing to be
desiredand all without being unnecessarily complicated. The SINUMERIK 828D is ideal for the
shop floor thanks to its unique graphical user interface. Users can quickly commission, operate,
program, Service and maintain machines and tasks without the need for extensive training.
3.2.1Heavyduty:
The operator panel front of the SINUMERIK 828D is made from heavy duty die-cast
magnesium. This ensures that the SINUMERIK 828D remains in good condition even if subjected
to harsh operating conditions. The hard keys on the CNC keyboard are covered In embossed foil to
provide perfect protection against moisture.
3.2.4 Low-maintenance:
The SINUMERIK 828D has no hard disk and no fan. Thanks to the removal of these parts,
which are subject to wear, the SINUMERIK 828D is relatively easy to maintain and easy to service.
In addition, no battery is required and the use of NV-RAM does away with the need for backup.
3.2.5 Scalable:
The SINUMERIK 828D is available with both a horizontal and a vertical operator panel
layout. Both operator panel orientations are available in conjunction with two different performance
ratings. As a result, the SINUMERIK 828D can be perfectly matched to the installation locations
well as the power requirements
Standard version
PPU 260 (vertical operator panel layout)
PPU 261 (horizontal operator panel layout)
Performance version
PPU 280 (vertical operator panel layout)
PPU 281 (horizontal operator panel layout)
Milling machines: Setting up and getting started.
The SINUMERIK 828D is perfect for equipping vertical and straight forward horizontal
milling centers featuring up to six CNC measuring circuits. And thanks to the new Advanced
Surface motion control function it can also be used in tool- and mould making applications. Straight
forward operation across the board.
As well as being suitable for use with milling spindles and geometry axes (X-, Y-, and Z-
axes), the CNC can be used to operate other machine units as an alternative. These include:
The SINUMERIK 828D is perfect for equipping vertical and straightforward horizontal
milling centers featuring up to six CNC measuring circuits. And thanks to the new Advanced
Surface motion control function it can also be used in tool- and mould making applications. Straight
forward operation, across the board.
As well as being suitable for use with milling spindles and geometry axes (X-, Y-, and Z-
axes), the CNC can be used to operate other machine units as an alternative.
These include:
CNC rotary table (C-axis) for machining on two stations
CNC reversible clamping device (A-axis) for milling and hole machining on cylindrical work
pieces
CNC gantry axes (gantry operation)
Inclinable heads or swivel tables for milling and hole machining in statically rotated machining
planes
CNC-controlled tool changer
Another application for the SINUMERIK 828D is the control of turning machines. The
functional scope has been tailored for horizontal and vertical turning centers equipped with one
machining channel and up to eight CNC measuring circuits.
3.3.1Flexible Use:
Besides being suitable for use with lathe spindles and geometry axes (X- and Z-axes), as an
alternative the product can be used to operate other machine units:
Power tools, peripheral C-axis mode, and Y-axis (orthogonal or diagonal) for end face and
surface machining
Counter spindle with synchronous spindle function for two-sided work piece machining
Tailstock axis (with travel to fixed stop function)
CNC-controlled turret
3.4 TOOL MANAGEMENT:
Fig.3.6.Tool Management
Tool management made easy. The SINUMERIK 828D features a command center for all
tool and magazine tasks so that the machining process is never interrupted. If the tool is at the end
of its service life, the SINUMERIK 828D will send a text message (SMS) as necessary thanks to
the Easy Message technology.
Fig.3.7.CNC Simulation
Fig.3.8.Optimum view
Perfectly Aligned:
All you need to do is trace the edge, corner or boreholes and the system will determine the
clamping position including the work pieces basic rotation. The SINUMERIK 828D offers a
variety of measurement variants even for sloping Work piece surfaces.
Particularly within the context of job shop manufacturing (small batch production),
machines frequently need to be reset. Tracer processes for work piece setup or process
measurement for the establishment of tool geometries are provided in a format tailored to the users
requirements. Perfectly equipped
The SINUMERIK 828D makes it really easy to quickly determine the tool length. Whether
you are determining the tool geometry by scratching or using a tool measurement system, all you
need to do is press a button and the geometry will be stored in the CNCs tool offset memory.
The SINUMERIK 828D is already equipped with a basic 3 or 5 MB user memory. If this
memory capacity is not sufficient, then memory can be expanded by inserting a Compact Flash
(CF) Card into the front port.
Perfect Diagnostics:
Need quick and easy service? The SINUMERIK 828D is available to you from anywhere.
The remote diagnostics function enables remote operation as well as supporting file transfer. The
contents of the CNC screen are displayed directly on the workstation where the remote diagnostics
are being carried out. Simply connect a modem that supports the required
Data transfer method (analogue, ISDN, etc.)
Text message (SMS), USB and Ethernet the SINUMERIK 828D uses the latest methods
of communication to guarantee data transfer at all times. To the front Ethernet port of the
SINUMERIK 828D and youre online. The CNC also offers a user-friendly PC tool in the form of
the RCS Commander.
CHAPTER: 4
HISTORY AND DEVELOPEMENT OF CNC MACHINES
Numerical control machining began in the aircraft industry. Engineers wanted to make
complex aircraft parts quickly and accurately. In 1947, two aircraft component contractors for the
U.S. Air Force, John Parsons and Frank Stolen, perfected the use of three-axis curvature data to
control machine tool motion. In 1951, the government funded the Servomechanisms Lab of the
Massachusetts Institute of Technology to design and build the first NC Machine. The first prototype
of a three-axis vertical milling machine debuted in 1952. Parsons was able to end mill and face mill
an aluminum plate.
As the benefits to NC machining became more apparent between 1958 and 1960, aerospace
company managers started to place their orders for the new equipment, and some even began to
build their own machines. NC machines soon after began competing with manual machines like the
manual mill in Figure.4.1. In many shops, manual machines have been retrofitted with CNC, like
the mill in Figure.4.2.NC machines quickly displayed their worth. They were more accurate, held
better tolerances, and produced more uniform dimensions than the manual machining methods of
the day. In addition to increasing accuracy, NC machines reduced the amount of non-productive
time in the machining cycle.
NC machines read and executed one line of The machine operator calls and executes
Code at a time from a part program punched a part program from the control panel.
Into paper are Mylar tapes.
Mills or machining centers (Figure 4.7): Generally, the work piece is held on the table while cutting
tools perform their work.
Lathes or turning centers (Figure 4.8): A work piece spins as the cutting tools are brought in
contact with it. Lathes create symmetrical pieces.
In every CNC use, a programmer plans the best way to cut the work piece and then codes
the movement of the tool. These instructions are interpreted by the computer controller. The
controller then ensures that every part is handled in exactly the same manner for both small and
large production runs. This process eliminates guesswork and the downtime involved while a
human operator decides the best method for machining a part in the middle of production
You will also find CNC systems in operations that involve robotics, laser cutting, automatic
testing machines, drafting systems, electronic assembly systems, and more. As you can see,
computers have proven very useful in many aspects of manufacturing.
Fig.4.9. A CNC grinder creates a smoother Fig.4.10. A CNC punch press uses one tool.
Surface on a work piece.
CNC (Computer Numerical Control) is the combination of Numerical Control (NC, the
controlling of machinery using numbers either to manipulate discrete controls, or more directly via
punch cards or tapes or other electrical signals) and computers.
The history starts with early efforts to automate industrial machinery such as looms.
1801-Jacquard Loom
The Jacquard loom is a mechanical loom, invented by Joseph Marie Jacquard, first
demonstrated in 1801, that simplifies the process of manufacturing textiles with complex patterns
using punch cards.
1810-Milling Machine
Machines which make use of rotary filing are developed for metalworking.
1820-Cams
Used in gun-stock copying and turret lathes. Development continued through World War I.
1822-Difference Engine
Charles Babbage conceives of the Difference Engine, an early mechanical computer for
calculating polynomials.
The first electrical power tool, the wood router inaugurated the idea of bringing the tool to
the piece being worked, a concept central to CNC.
Adding power to Cams didn't address the matter of controlling the position accurately under
all possible circumstances. Servomechanisms and seasons allowed the machine to provide
measurement information as it worked, increasing accuracy.
1940-Tracer Control
Adding hydraulics to Cams allowed for the use of a stylus to trace a template controlling a
machine which would cut a part to match.
1946-Numerical Control
John T. Parsons developed Numerical Control (NC) so as to be able to fabricate parts for
helicopter rotors for the Sikorsky Helicopter Company using funding from the United States Air
Force.
M.I.T. instead attempted to develop a machine on their own, but Parsons filed for a patent
on "Motor Controlled Apparatus for Positioning Machine Tool" on 5 May 1952, sparking a filing by
MIT for a "Numerical Control Servo-System" on 14 August 1952. Parsons received US Patent
2,820,187 on 14 January 1958, and the company sold an exclusive license to Bendix. IBM, Fujitsu
and General Electric all took sub-licenses after having already started development of their own
devices.
M.I.T. continued with their development, using roller chains to manipulate the machine
along three axes (X, Y, and Z) and used standard 7-track punch tape for input.
1953-Proliferation of NC
The Air Force Numeric Control and Milling Machine projects formally concluded in 1953,
but development continued at the Giddings and Lewis Machine Tool Co. and other locations.
1955-G-Code/Magnetic Tape
Electronic control was added with the use of magnetic tapes to record and play back
calculated machine paths, which are described using the nascent G-code.
The Automatically Programmed Tool project and the report, then later project, Computer-
Aided Design: A Statement of Objectives 1960 of Douglas T. Ross were the first CAD systems.
On 25 February 1959, Aircraft Industries Association (AIA) and Air Material Command at
Wright-Patterson Air Force Base produce a fully computer-controlled NC system and demonstrate
it to the press, including an ashtray made of machined aluminum in the press kits.
The falling price of computers and the rising costs of labour resulted in a proliferation of
CNC machines using PDP-8s and the Data General Nova.
Chuck Hull of 3D Systems Corp invented a process known as stereo lithography employing
UV lasers to cure photopolymers.
First concept developed for the manufacture of helicopter blades Alongside Frank L. Stulen,
John T. Parsons first utilized computer methods to overcome machining setbacks, especially the
accurate interpolation of the curves found in helicopter blades. In the process of developing
smoother rotors, Parsons and Stuller generated an early version of a Numerical Control (NC)
machine.
While the US Air Force halted its funding in 1953 due to expense, the project was resumed
by Giddings and Lewis Machine Tool Co. who reduced expense but improved quality and
efficiency.
The first CNC machine was developed when John Runyon managed to produce punch tapes
under computer control. By doing this, he managed to reduce the normal production time of 8 hours
down to 15 minutes. By 1956, the US Air Force had accepted the proposal to produce a generalized
programming language for NC.
The invention of CNC machines paved the way for automated tools that enabled efficient
production for manufacturers. Todays CNC machines bear little difference with the original
machines in terms of concept. Both produce outputs in three dimensional directions: X and Y axes
and depth.
The types of CNC machine that exist today include the following:
CNC turning lathes CNC turning lathes produce parts by turning rod materials and feeding a
cutting tool into the turning material.
CNC milling machines Using a rotating cylindrical cutting tool, CNC Milling utilizes a
machining process similar to both drilling and cutting. The cutter in a milling machine has the
ability to move along multiple axes and can create a variety of shapes, slots and holes
CNC routers - CNC routers are similar to handheld routers but the tool paths are instead controlled
via computer numerical control. CNC routers can be used for cutting various hard materials
including wood, composites, aluminum, steel, plastics and foams.
In conventional lathe, all the operations are manual. Changing tool, moving the tool post,
adjusting feed, depth of cut etc. must be done manually.
In CNC lathe, all these operations can be programmed and saved it in the machine. You can
machine as many parts as you want. You need to load the work piece and press CYCLE START.
The machining work is performed based on your program automatically.
CNC lathes - High precision CNC lathes even for the most complicated parts. Various
modern options for perfect efficiency.
Conventional lathes - Efficient machining of work pieces, in both serial and unit production.
Highly accurate finishing and roughing of various types of metals and plastics.
Conventional Lathes are the pioneer of manufacturing. The operations like knurling,
drilling, facing, cut-off, boring etc. are done .In all the above mentioned operations ,gear shifting
for speed(Belt changing in case of Belt lathes which are out of date),tool changing, feeding the
work piece etc. are done by the machine operator manually. Also the high accuracy of microns
cannot be achieved in conventional machines.
CNC standing for computer numerical control is the present market trend. CNC turning
centers are those machines where the operations of tool changing, Speed etc. are controlled
automatically through the programmers. In case of turning centers, only the work piece had to be
fed to the machine and the operations are carried automatically.
CHAPTER: 5
ACTUAL PROJECT WORK
5.1 AIM
Designing of a profile and Manufacturing the desired profile by using CNC Smartrun Lathe
machine.
5.2 DESCRIPTION
The profile is designed by using SINUMERIK 828D software. In this software we gave the
required dimensions of the profile that we want to produce by using CNC Lathe machine. The
design of this profile is given by the manual or cycle program in the software. After giving the
program, the program is been simulated before executing in the CNC machine.
Basic profile design of the profile using AUTOCAD is shown in the figure below:
MSG("PROJECT5")
WORKPIECE(,,,"CYLINDER",0,0,-120,-85,60)
T="FINISHING_T35 A"
M06 D1
G00 X60 Z5
G01 Z0 F0.2
CYCLE62(,2,"GSS1","GSS2")
CYCLE95("",1,0.1,0.1,0,0.1,0.1,0.1,9,0,0,2,1,1002)
T="PLUNGE_CUTTER_3 A"
M06 D1
G00 X60 Z5
G01 Z0 F0.2
CYCLE930(40,-40,6,6,5,,0,0,0,1,1,1,1,0.2,0.5,5,10530,,1,30,0.1,1,0.2,0.2,2,1001010)
T="THREADING_TOOL"
M06 D1
G00 X60 Z5
G01 Z0 F0.2
CYCLE99(0,20,-
18,,1,2,1,0,40.892563,0,10,5,2.5,1310101,4,2,0.1,0.5,0,0,1,0,0.866,1,,"ISO_METRIC","M20",1002
,1001)
M05
M08
M30
GSS1:
G01 X0 Z0 F0.2
X20 CHF=2
Z-20
GSS2:
The SINUMERIC 828D software is shown in the figure below with the profile program:
Fig.5.5. Grooving
SIMULATION
2D SIMULATION
Fig.5.6. 2D simulation
3D SIMULATION
Fig.5.7. 3D simulation
HALF-CUT SIMULATION
After designing the profile using the SINUERIK 828D Software it is simulated in the
different views as shown in the above figures. The program for this profile design is copied and
pasted in the actual CNC Lathe machine for execution.
Before manufacturing the given profile the following points should be followed:
Measure the diameter and length of the given work piece that is to be manufactured.
Clamp the work piece within the chucks tightly.
Start the spindle by giving command in MDI mode to check whether the work piece
clamped properly or not.
Clamp the tools in the tool holder that are used for manufacturing the given profile.
Measure the tool offset manually through JOG mode and fixes the X and Z axis.
Give the command to move the X axis and Z axis to the work piece with less feed rate. If
the tool doesnt make any error and reaches the work piece zero point then the tool offset
given is correct. Now bring the X axis and Z axis to the reference point by using
REFERENCE mode.
Now the machine is ready to design the given profile.
The work piece used is aluminum for profile manufacturing is shown in the below figure:
The work piece dimensions before manufacturing the profile is as follows,
150 X 63.5 diameter
All dimensions are in mm.
CHAPTER: 6
RESULT & CONCLUSION
RESULT
Thus we achieved desired profile, by using CNC machines we can complete the work with
less time and with great accuracy compare to conventional machines. The profile produced by this
Smart run CNC lathe machine has good finishing surface and with accurate dimensions in 1Hour
and 20 minutes cycle time.
The required profile design is obtained and it is shown in the figure below.
CONCLUSION:
The Indian CNC systems though have made a beginning with both imported technologies
and indigenous development, the technologies adopted in this field are comparatively outdated and
do not incorporate recent development and, also, are found to be wanting in terms of meantime
between failures. There is a high degree of obsolescence in this area. It is an acknowledged fact that
latest developments in these fields are not effectively transferred by advanced countries, under the
normal technology transfer. Under these circumstances, a long term strategy for keeping abreast in
this important sphere, by self-reliant efforts, needs to be speedily evolved.
CNC Machines are very accurate. The CNC machines produce high production compare to
conventional machines.
These CNC Machines doesnt require a skilled operator to perform specified operations,
whereas in conventional machining the operator should have good skill and well trained.
In CNC Machines we can produce complicated profiles easily with less time rather than
conventional machine.
Now-a-days large numbers of industries are coming forward to plant CNC Machines in their
respective industries which increase the demand of CNC Machines and their developments.
CNC machines are applicable to perform any type of processing easily within short time
required.
Many industries would like to prefer using CNC machines for productivity as well as
quality of the products.
CNC machine have high storage capacity which store lot of programs and these will be used
for mass production.
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PHOTOGRAPHS