Introduction To CNC Machining: Department of Materials and Metallurgical Engineering IIT Kanpur
Introduction To CNC Machining: Department of Materials and Metallurgical Engineering IIT Kanpur
Introduction To CNC Machining: Department of Materials and Metallurgical Engineering IIT Kanpur
CNC Machining
Krishanu Biswas
Department of Materials and Metallurgical Engineering
IIT Kanpur
CNC Machines
Overview
A numerical control, or NC, system controls many machine
functions and movements which were traditionally performed
by skilled machinists.
Numerical control developed out of the need to meet the
requirements of high production rates, uniformity and
consistent part quality.
Programmed instructions are converted into output signals
which in turn control machine operations such as spindle
speeds, tool selection, tool movement, and cutting fluid flow.
Overview
By integrating a computer processor, computer
numerical control, or CNC as it is now known,
allows part machining programs to be edited and
stored in the computer memory as well as
permitting diagnostics and quality control functions
during the actual machining.
All CNC machining begins with a part program,
which is a sequential instructions or coded
commands that direct the specific machine
functions.
The part program may be manually generated or,
more commonly, generated by computer aided part
Figure 2:
Figure 3:
Figure 4
Figure 5
Work Positioning
The method of accurate work positioning in relation to the cutting tool is
called the rectangular coordinate system. On the vertical mill, the
horizontal base line is designated the X axis, while the vertical base line
is designated the Y axis. The Z axis is at a right angle, perpendicular to
both the X and Y axes.
Increments for all base lines are specified in linear measurements, for
most machines the smallest increment is one ten-thousandth of an inch
(.0001). If the machine is graduated in metric the smallest increment is
usually one thousandth of a millimeter (.001mm).
The rectangular coordinate system allows the mathematical plotting of
points in space. These points or locations are called coordinates. The
coordinates in turn relate to the tool center and dictate the tool path
through the work.
Figure 6:
CNC MachinesAdvantages/Disadvantages
Advantages:
High Repeatability and Precision e.g. Aircraft parts
Volume of production is very high
Complex contours/surfaces need to be machined. E.g. Turbines
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
Types of Machine
Lathes for metal and plastics
Used to produce 3D product shapes and
moulds for plastic products.
CNC Lathe
Automated version of a manual lathe.
Programmed to change tools
automatically.
Used for turning and boring wood, metal
and plastic.
Tools
Most are made from
high speed steel (HSS),
tungsten carbide or ceramics.
Tools are designed to direct waste away
from the material.
Some tools need coolant such as oil to
protect the tool and work.
Figure 7:
Figure 8:
CNC programming
Important things to know:
Coordinate System
Units, incremental or absolute positioning
Coordinates: X,Y,Z, RX,RY,RZ
Feed rate and spindle speed
Coolant Control: On/Off, Flood, Mist
Tool Control: Tool and tool parameters
CNC programming
Preparatory Codes:
G codes- Initial machining setup and establishing operating
conditions
Feed and Speed Codes: F and S- Specify feed and spindle speed
Explanation of commonly
used G codes
G00 Preparatory code to control final position of the
tool and not concerned with the path that is followed in
arriving at the final destination.
CAD/CAM
Two computer-based systems which impact the use of CNC technology are
computer aided design and 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.
25
Cylindrical Part
Raw Material
Finished Part
20
22.5
17.5
70
Part)
G53
T0303
G57 G00 X26.00 Z0.0 S500 M04
G01 X-0.20 F100
G00 Z2.0
X50.0 Z50.0
T0404
G57 G00 X22.50 Z2.0 S500
G01 Z-30.0 F100
G00 X23.0 Z2.0 S500
G84 X17.5 Z-20.0 D0=200 D2=200 D3=650
G00 Z2.0
X50.0 Z50.0
M30
Thank You