REPORT ON CNC MACHINES

MAYANK JAIN

| ELEX INTERNATIONAL |

CNC Machine

Mayank Jain
130106095

Preface
I have made this report file on the topic CNC Machine. I have tried my best to elucidate all the
relevant detail to the topic to be included in the report. While in the beginning I have tried to give
a general view about this topic.
My efforts and wholehearted co-corporation of each and every one has ended on a successful
note. I express my sincere gratitude to M/s ELEX INTERNATIONAL who assisting me
throughout the preparation of this topic. I thank them for providing me the reinforcement,
confidence and most importantly the track for the topic whenever I needed it.

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CONTENTS
S.No

Name of the Chapter

1.

Introduction

2.

Meaning of CNC

3.

Use of typical CNC machine

4.

Parts of CNC machine

5.

CNC machine Input-Process-Output

6.

Control panel of CNC

7.

CNC Router

8.

CNC Machine & Safety

9.

Advantages & Disadvantages Of CNC

10.

Appendix 1

11.

Program #CNC

12.

Discussion & Safety Precautions

13.

Recommendation

14.

Reference

15.
Introduction
In Industry it is not efficient or profitable to make everyday products by hand. On a CNC
machine it is possible to make hundreds or even thousands of the same items in a day. First a
design is drawn using design software, and then it is processed by the computer and
manufactured using the CNC machine. This is a small CNC machine and can be used to machine
woods, plastics and aluminum. In industry, CNC machines can be extremely large.

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MEANING OF CNC
CNC means Computer Numerical Control. This means a computer converts the design into
numbers which the computer uses to control the cutting and shaping of the material.

USE OF TYPICAL CNC MACHINE

1. The design is loaded into the computer which is attached to the CNC machine. The computer
changes the design into a special code (numerical) that controls the way the CNC cuts and shapes
the material

2. The material to be shaped is taped on to a block with double sided tape. This must be done
carefully so that it does not come off the block during machining.

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3. The block is then placed in the vice, inside the CNC. It must be tightened up carefully. If it is
not secure when the machine starts to cut the material it can come away from the vice. When the
machine starts working, the vice moves up, down, right and left according to the design.

4. The guard is placed in position. It protects the machine operator in case the material is pulled
out of the vice by the power of the cutter. For safety reasons, if the guard is not in position the
motor will not start.

5. The CNC is turned on and the shape is cut from the material. When the cutter has stopped the
shaped material can be removed from the vice.

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PARTS OF CNC MACHINE

VICE: This holds the material to be cut or shaped. Material must be held securely otherwise it
may 'fly' out of the vice when the CNC begins to machine. Normally the vice will be like a
clamp that holds the material in the correct position.
GUARD: The guard protects the person using the CNC. When the CNC is machining the
material small pieces can be 'shoot' off the material at high speed. This could be dangerous if a
piece hit the person operating the machine. The guard completely encloses the dangerous areas
of the CNC.
CHUCK: This holds the material that is to be shaped. The material must be placed in it very
carefully so that when the CNC is working the material is not thrown out at high speed.

MOTOR: The motor is enclosed inside the machine. This is the part that rotates the chuck at
high speed.
LATHE BED: The base of the machine. Usually a CNC is bolted down so that it cannot move
through the vibration of the machine when it is working.
CUTTING TOOL: This is usually made from high quality steel and it is the part that actually
cuts the material to be shaped.

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CNC MACHINE: INPUT - PROCESS - OUTPUT

A CNC production facility needs three pieces of equipment:
A Computer: The computer is used to draw the design. However, the design is only a picture and
the CNC machine cannot use this to manufacture the product. The computer software must also
convert the drawing into numbers (coordinates) that the CNC machine can use when it starts to
cut and shape the material.
An Interface: A computer cannot be directly connected to a CNC machine. The computer is
connected to an interface. This converts the signals from the computer to a form that the CNC
machine understands. The signals are in the form of digital signals when they are sent to the
CNC machine.
CNC (Computer Numerical Control) Machine: The signals from the interface control the motors
on the CNC machine. The signals determine the way the vice moves. The vice moves in three
directions X, Y and Z. (Horizontally, vertically and depth). The signals also control the speed of
the cutting tool.

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CONTROL PANEL OF CNC

A CNC machine is normally controlled by a computer and software. However, most CNC
machines have a range of controls for manual use. It is rare for a CNC machine to be used
manually as simple operations are best carried out on cheap/basic/manual machines. When a
CNC machine is used manually it is been used well below its capability and specification.

RESET BUTTON: The most important control button is usually the reset button. When the CNC
machine is turned on, the reset button is pressed by the machine operator. This zeros the cutter,
moving the cutter to coordinates 0, 0, 0 on the X, And Z axis. In simple terms, the reset button
moves the cutter to the corner of the machine, above the work table.
If the reset button is not pressed, it is possible that the CNC machine will start cutting the
material in the wrong place or even miss cutting the material and plunge into the work table.
MANUAL CONTROL: The cutter can be controlled manually although this is rarely needed.
The X and Y buttons control the movement of the cutter along the horizontal surfaces. The Z
buttons control depth and up / down movement.
STOP BUTTON: Most control panels have stop buttons. When pressed these
stop the machine very quickly.
SPEED AND FEED: On some CNC machines it is possible to manually vary the speed and feed
of the cutter.

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CNC ROUTER - THE IMPORTANT PARTS

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CNC MACHINES AND SAFETY

CNC machines are very safe to use as they are designed to be as safe as possible. One of the
main advantages of CNC machines is that they are much safer than manually operated machines.

1. Most modern CNC machines are designed so that the cutting tool will not start unless the
guard is in position. Also, the best CNC machines automatically lock the guard in position whilst
the cutter is shaping material. The guard can only be opened if the cutter has stopped.
2. It is essential that pupils / students / machine operators receive quality instruction before
attempting to use any CNC equipment.
3. CNC routers, used for shaping materials such as woods and plastics, have built in extraction.
Dust can be very dangerous if inhaled and can also cause eye irritation. The CNC Router shown
above has an outlet for an extraction unit. As the router is fully enclosed, dust cannot escape into
the atmosphere. If an extraction unit is attached the dust is removed automatically. Most
manually operated machine routers have very limited extraction systems which leave some dust
in the air.
4. The CNC router above has a single phase electrical supply. Older machines such as manually
operated milling machines and centre lathes have three phase supplies. A single phase electrical
supply can be plugged into any available socket. The electrical supply for the machine comes
through a residual circuit breaker (RCB). If an electrical fault develops the RCB will cut off
electrical power immediately.
5. Single phase CNC machines can be moved more easily because they are simply unplugged
and relocated. Three phase machines are specially wired by an electrician into the electrical
supply and cannot be unplugged.
6. Most CNC machines work behind a guard or even a closed, transparent safety door. This
means that the operated cannot be hurt by 'flying' pieces of sharp/hot material.
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7. Commonsense applies to the use of all machines including CNC machines. Basic safety
training regarding working in a workshop and with other machines applies to CNC machines as
well.

ADVANTAGES AND DISADVANTAGES OF CNC MACHINES

CNC (Computer Numerical Control machines) are widely used in manufacturing industry.
Traditional machines such as vertical millers, centre lathes, shaping machines, routers etc.
operated by a trained engineer have, in many cases, been replaced by computer control
machines.

ADVANTAGES
1. CNC machines can be used continuously
24 hours a day, 365 days a year and only need
to be switched off for occasional
maintenance.
2. CNC machines are programmed with
design which can then be manufactured
hundreds or even thousands of times. Each
manufactured product will be exactly the
same.
3. Less skilled/trained people can operate
CNCs unlike manual lathes / milling
machines etc... Which need skilled engineers?
4. CNC machines can be updated by
improving the software used to drive the
machines
5. Training in the use of CNCs is available
through the use of virtual software. This is
software that allows the operator to practice
using the CNC machine on the screen of a
computer. The software is similar to a
computer game.
6. CNC machines can be programmed by
advanced design software such as Pro-E.
7. Modern design software allows the
designer to simulate the manufacture of

DISADVANTAGES
1. CNC machines are more expensive than
manually operated machines, although costs
are slowly coming down.
2. The CNC machine operator only needs
basic training and skills, enough to supervise
several machines. In years gone by, engineers
needed years of training to operate centre
lathes, milling machines and other manually
operated machines. This means many of the
old skills are been lost.
3. Less workers are required to operate CNC
machines compared to manually operated
machines. Investment in CNC machines can
lead to unemployment.
4. Many countries no longer teach pupils /
students how to use manually operated
lathes / milling machines etc... Pupils /
students no longer develop the detailed skills
required by engineers of the past. These
include mathematical and engineering skills.

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his/her idea. There is no need to make a

prototype or a model. This saves time and
money.
8. One person can supervise many CNC
machines as once they are programmed they
can usually be left to work by themselves.

Appendix-1
In this appendix we provide a list of G and M-codes for the reader to have an idea of the kind of
functionality that can be realized using these codes. These codes were originally designed to be
read from paper tapes and are designed to direct tool motion with simple commands.
A basic list of G operation codes is given below. These direct motion of the tool.
G00 - Rapid move (not cutting)
G01 - Linear move
G02 - Clockwise circular motion
G03 - Counterclockwise circular motion
G04 - Dwell
G05 - Pause (for operator intervention)
G08 - Acceleration
G09 - Deceleration
G17 - x-y plane for circular interpolation
G18 - z-x plane for circular interpolation
G19 - y-z plane for circular interpolation
G20 - turning cycle or inch data specification
G21 - thread cutting cycle or metric data
specification
G24 - face turning cycle
G25 - wait for input to go low
G26 - wait for input to go high
G28 - return to reference point
G29 - return from reference point
G31 - Stop on input
G33-35 - thread cutting functions
G35 - wait for input to go low
G36 - wait for input to go high
G40 - cutter compensation cancel
G41 - cutter compensation to the left
G42 - cutter compensation to the right
G43 - tool length compensation, positive
G44 - tool length compensation, negative
G50 - Preset position G70 - set inch based units
or finishing cycle
G71 - set metric units or stock removal

G74.1 - disable 360 deg arcs

G75 - pattern repeating
G75.1 - enable 360 degree arcs
G76 - deep hole drilling, cut cycle in z-axis
G77 - cut-in cycle in x-axis
G78 - multiple threading cycle
G80 - fixed cycle cancel
G81-89 - fixed cycles specified by machine tool
manufacturers
G81 - drilling cycle
G82 - straight drilling cycle with dwell
G83 - drilling cycle
G83 - peck drilling cycle
G84 - taping cycle
G85 - reaming cycle
G85 - boring cycle
G86 - boring with spindle off and dwell cycle
G89 - boring cycle with dwell
G90 - absolute dimension program
G91 - incremental dimensions
G92 - Spindle speed limit
G93 - Coordinate system setting
G94 - Feed rate in ipm
G95 - Feed rate in ipr
G96 - Surface cutting speed
G97 - Rotational speed rpm
G98 - withdraw the tool to the starting point or
feed per minute
G99 - withdraw the tool to a safe plane or feed
per revolution
G101 - Spline interpolation
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G72 - indicate finishing cycle

G72 - 3D circular interpolation clockwise

M-Codes control machine functions.

M00 - program stop

M01 - optional stop using stop button
M02 - end of program
M03 - spindle on CW
M04 - spindle on CCW
M05 - spindle off
M06 - tool change
M07 - flood with coolant
M08 - mist with coolant
M08 - turn on accessory (e.g. AC power
outlet)
M09 - coolant off
M09 - turn off accessory
M10 - turn on accessory
M11 - turn off accessory or tool change
M17 - subroutine end
M20 - tailstock back
M20 - Chain to next program

M25 - set output #1 off

M26 - close chuck
M26 - set output #1 on
M30 - end of tape (rewind)
M35 - set output #2 off
M36 - set output #2 on
M38 - put stepper motors on low power
standby
M47 - restart a program continuously, or a
fixed number of times
M71 - puff blowing on
M72 - puff blowing off
M96 - compensate for rounded external
curves
M97 - compensate for sharp external curves
M98 - subprogram call
M99 - return from subprogram, jump
instruction
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M21 - tailstock forward

M22 - Write current position to data file
M25 - open chuck

M101 - move x-axis home

M102 - move y-axis home
M103 - move z-axis home

FANUC Series Oi-MD JYOTI VMC-850

|G54:- G-CODE 54-COORDINATE|G90:- G-CODE 90-ABSOLUTE VALUE|
#PROGRAM

%
00007
G54
G91G28Z0
G90
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N1T1
M6
G43H1D31G0X-265Y38Z50.5750M3

Facing Program Cutter Diameter 80mm

M8
X265Y38Z10
Z2
G1Z-1.6F500
X-12F800
X-12F1500
X-249.369F800
Y-32
X-270
Z-2.1
M3S750
X250F850
Y-38
X-265
G0Z50
M05 ||
G54
G90
N1T2
M6
G90G00G40G54
G43H2D36G0X-169.60Y-6.85Z50.S700M3

11.1mm Drilling

M8
X-169.60Y6.85Z10
G98G83Z-48.0R2.Q15F100
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X-86.250
X-169.605
G80
M05

||

G54G90
N1T3
M06
G90G00G40G54
G43H3D3G0X-169.605Y6.85Z50.S650M3

16mm Drilling

M8
X-169.605Y6.85Z10
G98G81Z-11.8R2F45
X-86.205
X-169.605
G80
M05 ||
G54G90
N1T2
M06
G90G00G40M54
G43H2D36G0X-169.605Y-6.85Z50.S700M3

11.1mm Drilling

M08
X-169.605Y6.85Z10
G98G81Z-20R2.F132
X-86.205
X-169.605
G80
M05 ||
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G54G90
N1T4
M06
G90G00G40G54
G43H4D40G0X-127.905Y-32.5Z50.S700M3

12mm Drilling

M8
X-127.905Y-32.5Z10
G98G81Z-25R2F100
X127.905
G80
Z300
X5
Y155
M30
HS [TPS1] %

#Program 2 Setting :-1

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%
O0900G80G49G40
G54
G91G28Z0
G90
M01
N1T1
M6
G90G00G40G54
G43H1D33G0X-155Y-10Z50.S700M3
M8
X-155Y-10Z50.
Z2.
G1Z0F500
X-90F750
X310.345F1000
Y-58.164
X269.509
Y-93.886
X189.892Y-188.77
X145.86
Y-57.291
X101.5
Y-70.5
X52.5

Facing Program Cutter Diameter 80mm

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Y-99.501
X110Y-190
X7.109
X-79Y-90.535
Y-53.665
X-171.377Y-49.056
G0Z50.
G54
G90
G90G00G40G54
G43H1D33G0X-155Y-10Z50.S700M3
M8
X-155Y-10Z50.
Z2.
G1Z-1F500
X-90F750
X310.345F1000
Y-58.164
X269.509
Y-93.886
X189.892Y-188.77
X145.86
Y-57.291
X101.5
Y-70.5
X52.5
Y-99.501
X110Y-190
X7.109
X-79Y-90.535
Y-53.665
X-171.377Y-49.056
G0Z50.
G54
G90
G90G00G40G54
G43H1D33G0X-155Y-10Z50.S700M3
M8
X-155Y-10Z50.
Z2.
G1Z-2F500
X-90F750
X310.345F1000
Y-58.164
X269.509
Y-93.886
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X189.892Y-188.77
X145.86
Y-57.291
X101.5
Y-70.5
X52.5
Y-99.501
X110Y-190
X7.109
X-79Y-90.535
Y-53.665
X-171.377Y-49.056
G0Z50.
G54
G90
G90G00G40G54
G43H1D33G0X-155Y-10Z50.S700M3
M8
X-155Y-10Z50.
Z2.
G1Z-2.5F500
X-90F750
X310.345F1700
Y-58.164
X269.509
Y-93.886
X189.892Y-188.77
X145.86
Y-57.291
X101.5
Y-70.5
X52.5
Y-99.501
X110Y-190
X7.109
X-79Y-90.535
Y-53.665
X-171.377Y-49.056
G0Z50.
M05
Facing Program End
G54
G90
N1T9
M6
G90G00G40G54
G43H9D31G0X-70.Y-27.Z50.S1600M3
Drilling Program 30mm Diameter
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M8
X-70.Y-27.Z10.
G98G83Z-41R2.Q15.F140
X70.
G80
G0Z50.
M05
G55
G90
G90G00G40G55
G43H9D31G0X-70.Y-27.Z50.S1600M3
M8
X-70.Y-27.Z10.
G98G83Z-41R2.Q20.F140
X70.
G80
G0Z350
Y205
M30
[BP-S1]
%

Power-Flat Machine
Discussion
Problems faced using CNC Machine
There some G-CODE in which should be correctly key in so that the cutting process will
be running smoothly.
Its quit complicating to find over the origin of X and Y axis once placed into machine.
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Must be careful while using the hand wheel.

Cutting tool should be in correct size.

Suitable Solution Based on the Problems Raised

In this, the student can make over their simulation process first before cutting take place
so that they will get a clear view of the project they going to do.
Bring the pointer to the work piece on the coordinate of Z. Take the reading. Adjust the
coordinate of X by bringing the milling cutter towards the work piece then take the
reading. The steps 10 for Y coordinate.
Measure the size using Vernier caliper before plug into the machine. To the given
question if theres was given its cutting tool size. If no then chose a suitable size of
cutting tool size.

Safety Precaution

When the student at the workshop, the safety is mainly advised so that any mistakes
happen. Its make the student to be more safe even independent too.
They should wear workshop uniform and safety boots which given by the polytechnic.
Gloves are advised to be wear before holding and after all work done it should be
removed.
Place the matrix card on the pocket of workshop uniform when handling with machines.

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INDUSTRIAL PRODUCTION FLOWCHART

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RECOMMENDATION
Getting the appropriate feeds and speeds for the work piece material, tooling, and cutting
conditions is the most important first step. Consistent speeds and feeds will make a huge
difference on the surface finish. Getting the right speeds and feeds is just as important to obtain a
good surface finish.
Good chip clearing is essential to both surface finish and tool life. It's impossible to get good
surface finish if chips are being re-cut over and over again. If chip clearance is minimal, clumped
up chips can jam the cutter to the point where it breaks.
Flood coolant or an air blast should be used to clear the chips at all times. Aside from cooling the
tool, the coolant cools the work piece. Sometimes this is helpful to accuracy, as a work piece that
heats up is a work piece that is moving due to thermal expansion. Another advantage of coolant
is that it lubricates the tool/work piece interface.
The primary impact of work holding on surface finish is vibration. In the worst case vibration
will turn into chatter, which is a harmonic effect that will be very visible in your surface finish.
Clearly, the more solid we can make our work holding, the less likelihood of vibration there will
be. Make sure the work piece is supported and clamped over as much area as possible
surrounding the cut while still leaving room for the cutter to get in there and do its job.

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REFERENCE
Kalpak Jain, S., and R.S. Schmidt, Automation of Manufacturing Process, Manufacturing
Engineering and Technology, 4th. Edition, Prentice Hall, 2000.
Youssefi, K, Computer Numerical Control (CNC), Product Design and
Manufacturing Minicurriculum, 6 Oct. 2004.
Mikell P. Groover, Principles of Modern Manufacturing, 4thEdition, Wiley 2011.
V. Ryan CNC WORK 20 Aug 2009.
Module-5 CNC Machine V2 IIT Kharagpur.

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