1.

0 TITLE: CNC Milling (Non Traditional Machining)

2.0 OBJECTIVE:

1. To develop more understanding about development and principle of CNC machine.

2. To learn various type of modern CNC machines and CNC modes of operations.
3. To understand the fundamentals of part programming in terms of the various steps
needed to be taken for completing a successful CNC program.
4. To understand the different preparatory (G codes) and miscellaneous functions (M
codes) as used in CNC part program.
5. To understand the advantages and disadvantages of CNC machines and their applications

3.0 INTRODUCTION

Numerical control (NC) refers to the automation of machine tools that are operated by abstractly

programmed commands encoded on a storage medium, as opposed to manually controlled or mechanically

automated via cams alone. The first NC machines were built in the 1940s and '50s, based on existing tools that

were modified with motors that moved the controls to follow points fed into the system on paper tape. These

early servomechanisms were rapidly augmented with analog and digital computers, creating the modern

computer numerical controlled (CNC) machine tools that have revolutionized the design process. In modern

CNC systems, end-to-end component design is highly automated using CAD/CAM programs. The programs

produce a computer file that is interpreted to extract the commands needed to operate a particular machine, and

then loaded into the CNC machines for production. Since any particular component might require the use of a

number of different tools, modern machines often combine multiple tools into a single "cell".

Diagram 1.1: CNC milling machine

 Modern CNC mills differ little in concept from the original model built at MIT in 1952. Mills typically

consist of a table that moves in the Y axis, and a tool chuck that moves in X and Z (depth). The position of the

tool is driven by motors through a series of step-down gears in order to provide highly accurate movements, or

in modern designs, direct-drive stepper motors. As the controller hardware evolved, the mills themselves also

evolved. One change has been to enclose the entire mechanism in a large box as a safety measure, often with

additional safety interlocks to ensure the operator is far enough from the working piecefor safe operation.

Mechanical manual controls disappeared long ago. CNC-like systems are now used for any process that can be

described as a series of movements and operations. These include laser cutting, welding, friction stir welding,

ultrasonic welding, flame and plasma cutting, bending, spinning, pinning, gluing, fabric cutting, sewing, tape

and fiber placement, routing, picking and placing (PnP), and sawing.

Diagram 1.2: the Data Processing in a CNC Machine Tool

Features of CNC

CNC systems include additional features beyond what is feasible with conventional hard- wired NC. These
features, many of which are standard of most CNC machine control units (MCU) where others are optional,
include the following:

1. Storages of more than one part. With improvements in computer storage technology,
newer CNC controllers have sufficient capacity to store multiple programs.

2. Various forms of program input. Hard-wired MCUs are limited to punched tape as the input medium for

entering part programs, whereas CNC controllers possess multiple data entry capabilities.

3. Program editing at the machine tool. CNC permits a part program to be edited while it resides in the MCU

computer memory. Hence, the process of testing and correcting a program can be done entirely at the machine

site rather than returning to the programming office to edit the tape.

4. Fixed cycles and programming subroutines. The increased memory capacity and the ability to program the

control computer provide the opportunity to store frequently used machining cycles as macros that can be called

by the part program. Instead of writing the full instructions for the particular cycle into every program, a call

statement is included in the part program to indicate that the macro cycle should be executed.

5. Interpolation. Linear and circular interpolation is sometimes hard-wired into the control unit, but helical,

parabolic and cubic interpolations are usually executed in a stored program algorithm.

6. Positioning features for set up. Setting up the machine tool for a given workpart involves installing and

aligning a fixture on the machine tool table. The alignment task can be facilitated using certain features made

possible by software option in CNC system. Position set is one of these features. With position set, the operator

is not required to locate the fixture on the machine table with extreme accuracy.

7. Cutter length and size compensation. In older style controls, cutter dimensions had to be
set very precisely to agree with the tool path defined in the part program.

8. Acceleration and deceleration calculation. This feature is applicable when the cutter moves at high feed rates.

It is designed to avoid tool marks on the work surface that would be generated due to machine tool dynamics

when the cutter path changes abruptly.

9. Communication interface. Most modern CNC controllers are equipped with RS-232 or other communication

interface to allow machine to be linked to other computers and computer driven devices.

10. Diagnostic. Many CNC systems possess an online diagnostics capability that monitors certain aspects of the

machine tool to detect malfunctions or sign of impending malfunctions or to diagnose system breakdowns.

 Advantages of CNC machine

CNC machine has several advantages with emphasis on machine tool applications. When the

production application satisfies the characteristics needed, CNC yields many benefits over manual production

methods. The benefits translate into economic saving for the user company. Some of the advantages are:

i. Nonproductive time is reduced through fewer setup, less setup time, less workpiece
handling time, and automatic tool changes.

ii. Greater accurancy and repeatability

iii. Lower scrap rates.

iv. Inspections requirements are reduced.

v. More complex part geometries are possible

vi. Enginnering changes can be accommodated more gracefully.

vii. Simple fixture are needed.

viii. Shorter manufacturung lead times.

ix. Reduced parts inventory.

x. Less floorspace required

xi. Operator skill level requirements are reduced.

Machine Control Unit (MCU)

CNC machine is fitted with MCU which is performs the various controlling functions under the

program control. The MCU may be generally housed in a seperated cabinet like cabinet body or may be

mounted on the machine itself. Apperance wise it looks like a computer with a display panel generally of small

size and a number of button to control the machine tool along with a keyboard. This control unit control the

motion of cutting tool, spindle speeds, feed rate, tool changes, cutting fluids application and several other

functions of the mahine tool. The MCU consists of the following components and subsystems: (1) central
processing unit, (2) memory, (3) input and output interface, (4) control for machine tool axes and spindle speed,

and (5) sequence control for other machine tools. This subsystem interconneted by means of a system bus.

Numerical Control Mode

The controller have number of modes in which the can operate. There could be four possible modes in which
the controller can function in relation to a machine centre.

1. Termed as point to point mode. In this, the control has the capability to operate all the three axes, but not
necessarily simultaneously. It would be possible to move the tool to any point (in X and Y axes) and carry out
the machining operation in one axis (Z axis) at that point.

2. Improvement over point to point mode. The machine tool has the capability to carry out a
continuous motion in each of the axis direction.
3. A control system, which has simultaneous motion capability in any two axes.
4. The highest form of control that gives the capability of simultaneous three or more axes
motion.

Part Program

Part program is a very important software element in the NC manufacturing system. It is a detailed

plan of manufacturing instructions required for machining the part as per drawing.

ISO Standards for coding

Preparatory functions

This is denoted by ‘G’. It is a pre-set function associated with the movement of machine axes and the

associated geometry. It has two digits as per ISO specifications. Some examples are shown:

CODE FUNCTION

G00 rapid traverse

G01 line interpolation
G02 ciccular interpolation, clockwise
G03 circular interpolation, anti-clockwise
G04 dwell
G05 hold/delay
G06 parabolic interpolation
G33 thread cutting, constant lead
G53 deletion of zero offset
G64 change in feed rate or speed
G80 canned cycle cancelled

Miscellaneous functions

These functions operate some controls on the machine tool and affect the running of the machine. Generally,

only one M-code is supposed to be given in a single block. The ISO standard examples are:

CODE FUNCTION

M00 program stop, spindle and coolant off

M01 optional programmable stop
M02 end of program
M03 spindle on, clockwise
M04 spindle on, anticlockwise
M09 coolant off
M10 clamp
M31 interlock by-pass
M68 unclamp piece art

9.0 REFER EN C ES
i. Mikell P. Groover, Automation, Production Systems and Computer Integrated Manufacturing, 2nd
edition, Prentice Hall, 2001
ii. P. N. Rao, CAD/CAM Principles and Applications, 2nd edition, Mc Graw Hill, 2004,
iii. Serope Kalpakjian, W.R. Schmid, Manufacturing Technology and Fundamental,
5th edition, Prentice Hall, 2004