Experiment # 09

CNC milling machine

CNC Milling, or Computer Numerically Controlled milling (CNC) is the process of machining
physical objects from 2D or 3D digital information, which is imported from CAD or other design
programs converted to a specific language understood by the machine.
CNC milling, the most common form of computer numerical control (CNC) machining,
performs the functions of both drilling and turning machines. CNC mills are categorized
according to their number of axis and are traditionally programmed using a set of codes that
represent specific functions.

Axis are labeled as x and y for horizontal movement, and z for vertical movement. A standard
manual light-duty mill is typically assumed to have four axis:

1) Table x
2) Table y
3) Table z
4) Milling Head z

CNC Milling Machines

The number of axis of a milling machine is often interpreted in varying ways. A five-axis CNC
milling machine has an extra axis in the form of a horizontal pivot for the milling head. The end
mill is positioned at an angle with respect to the table allowing extra flexibility for machining. A
six-axis CNC milling machine includes an additional horizontal pivot for the milling head,
perpendicular to the fifth axis.
Advanced machines, such as 5-axis milling centers required CAM programming for optimal
performance due to the incredibly complex geometries involved in the machining process. These
devices are extremely useful because they are able to produce shapes that would be nearly
impossible using manual tooling methods. Most CNC milling machines also integrate a device
for pumping cutting fluid to the cutting tool during machining. Cutting fluids are used in metal
machining for variety of reasons such as improving tools life, reducing workpiece thermal
deformation, improving surface finish and flushing away chips from the cutting zone.
Characteristic of CNC Milling Machine Tool Work part machining on CNC machine tools
require controllable and adjustable in feed axes which are runs by servo motors independent of
each other. CNC milling machine on the other hand have at least 3controllable or adjustable feed
axes marked as X, Y and Z.
ABOUT MACHINE HOME POSITION
When a CNC machine is first turned on, it does not know where the axes are positioned in the
work space. Home position is found by the Power On Restart sequence initiated by the operator
by pushing a button on the machine control after turning on the control power.
The Power On Restart sequence simply drives all three axes slowly towards their extreme limits
(-X, +Y, +Z). As each axis reaches its mechanical limit, a microswitch is activated. This signals
to the control that the home position for that axis is reached. Once all three axes have stopped
moving, the machine is said to be “homed”. Machine coordinates are thereafter in relation to this
home position.
WORK COORDINATE SYSTEM
Obviously it would be difficult to write a CNC program in relation to Machine Coordinates. The
home position is far away from the table, so values in the CNC program would be large and have
no easily recognized relation to the part model. To make programming and setting up the CNC
easier, a Work Coordinate System (WCS) is established for each CNC program.
The WCS is a point selected by the CNC programmer on the part, stock or fixture. While the
WCS can be the same as the part origin in CAD, it does not have to be. While it can be located
anywhere in the machine envelope, its selection requires careful consideration.
The WCS location must be able to be found by mechanical means such as an edge finder, coaxial
indicator or part probe.
It must be located with high precision: typically plus or minus .001 inches or less.
It must be repeatable: parts must be placed in exactly the same position every time.
It should take into account how the part will be rotated and moved as different sides of the part
are machined.
Machine Offsets:
Because it is difficult to place a vise in the exact same position on the machine each time, the
distance from Home to the WCS is usually not known until the vise is set and aligned with the
machine. Machine set up is best done after the program is completely written, because it is
expensive to keep a CNC machine idle waiting for the CNC programming to be done. Besides,
the programmer may change their mind during the CAM process, rendering any pre-planned
setup obsolete.
To complicate matters further, different tools extend out from the machine spindle different
lengths, also a value difficult to determine in advance. For example, a long end mill extends
further from the spindle face than a stub length drill. If the tool wears or breaks and must be
replaced, it is almost impossible to set it the exact length out of the tool holder each time.
Therefore, there must be some way to relate the Machine Coordinate system to the part WCS and
take into account varying tool lengths. This is done using machine Tool and Fixture Offsets.
There are many offsets available on CNC machines. Understanding how they work and to
correctly use them together is essential for successful CNC machining.
Part Offset XY:
Fixture offsets provide a way for the CNC control to know the distance from the machine home
position and the part WCS. In conjunction with Tool Offsets, Fixture Offsets allow programs to
be written in relation to the WCS instead of the Machine Coordinates. They make setups easier
because the exact location of the part in the machine envelop does not need to be known before
the CNC program is written.
As long as the part is positioned where the tool can reach all machining operations it can be
located anywhere in the machine envelope. Once the Fixture Offset values are found, entered
into the control, and activated by the CNC program, the CNC control works behind the scene to
translate program coordinates to WCS coordinates.
Part Offset Z
The Part Offset Z value is combined with the Tool Length offset to indicate to the machine how
to shift the Z-datum from part home to the part Z-zero, taking into account the length of the tool.
Fixture Offset Z may or may not be used, depending on how the machine is set up and operated.
Tool Length Offset (TLO)
Every tool loaded into the machine is a different length. In fact, if a tool is replaced due to wear
or breaking, the length of its replacement will likely change because it is almost impossible to set
a new tool in the holder in exactly the same place as the old one. The CNC machine needs some
way of knowing how far each tool extends from the spindle to the tip. This is accomplished using
a Tool Length Offset (TLO)