1.

INTRODUCTION TO CNC MACHINING

CNC stands for Computer Numerical Control. It is in practice in
since 1970s. Till that time the controlling system used for Machine tools is Numerical
Control which involved use of programmed tapes for controlling the Machine tools.

CNC machining stands for Computer Numerical Control machining.

In this a computer controller reads code and instructions (in the form of a program) and
drives a machining tool in order to make a product according to specific requirements. It is
a union of the field s of Software and Manufacturing that gives very effective and useful
outputs. Before there was CNC machining, there was NC machining. NC stands for
numerically controlled machining. This kind of machining does not use the aid of
computers and can not be reprogrammed to suit the manufacturer’s or customer’s needs.
Making products was very straight cut and inflexible in Numerical Control Machining.

1.1 Advantages of CNC machining:

 Setup time reduction:

Modular fixturing, standardised tooling, fixed locators, automatic
tool changing, pallets, and other advanced features make setup time in CNC
machining more efficient.

 Lead time reduction:

Once a part program is written and is found to give the correct
output, then it is ready to be used again in future. So though the lead time is
comparatively more for first time, the lead time for second and subsequent
production of the same component is less or virtually nil. Any engineering
modification can be obtained by just modifying the program.

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 Accuracy and repeatability:
The accuracy of the CNC machining is very high. It is of the order
of 0.005. In CNC machining the same product can be obtained any number of
times.

 Contouring of complex shapes:

CNC lathes and machining centres are capable of contouring a large
variety of different shapes without making a prototype or model of that component.

 Consistent cutting time:

Cutting time is known as “cycle time” in CNC machining
terminology. It is always consistent, i.e. a CNC machine takes same amount of time
for producing each unit of same component.

 Easy way of updating:

The CNC machines can be easily updated by just improving the
software used to drive the machine.

 Single user can supervise more than one machine simultaneously:

One person can supervise many CNC machines as once they are
programmed they can usually be left to work by themselves. Sometimes only the
cutting tools need replacing occasionally.

 Excellent surface finish:

The surface finish of the component that is produced by CNC
machining is very high.

 Reduction of Human error:

The use of computer program eliminates the need for an operator to
take trial cuts, make trial measurements, and make positioning movements or
change tools. This reduces the human error in obtaining the desired component.

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 Lower tooling cost:
CNC machines generally use simple holding fixtures, which reduce
the cost of tooling by as much as 70 percent. Standard turning and milling tools
eliminate the need the need for special form tools.

 Greater machine tool safety:

As there is less intervention of the operator the operator error is
eliminated resulting in greater machine tool safety.

 Simplified tooling:
Non-standard and operator machined tooling are used in a
conventional machine, which can be eliminated by using standard tooling, specially
designed for computer numerical control applications. Multi-step tools such as pilot
drills, step drills, combination tools, counter borers and others, are replaced with
several individual standard tools in the case of CNC machines. These tools are
often cheaper and easier to replace than special and non-standard tools.

 Simplified work holding:

Fixtures and work holding devices used for CNC machines have
only one major purpose, to hold the part rigidly and in the same position. Fixtures
designed for CNC work do not normally require special jigs, pilot holes and other
hole-locating aids.

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 1.2 Applications of CNC machining:

 In industries for removing metal:

The metal removing industries remove the metal from the raw
material to give it the desired shape as per the requirements. These can be the
automotive industries for making the shafts, gears, and many other parts. These can
be manufacturing industries for making the various rounded, square, rectangular,
threaded and other jobs. All these metal removal works are performed by different
machine tools like lathe, milling machine, drilling machine, boring machine,
shaping machine, reamer, etc. Traditionally these machines are operated by the
operators, but the CNC versions of all these machines are now used extensively.

 In industries for fabricating metals:

In many industries thin plates like steel plates are required for
various purposes, in fabrications industry the machining operations are performed
on such plates. In these industries the CNC machines are used for various
machining operations like shearing, flame or plasma cutting, punching, laser
cutting, forming, and welding and many other applications. To bring the plates to
their final shape CNC lasers and CNC plasma cutters are used commonly. To punch
the holes in the plates of all sizes CNC turret punch presses are used. And if you
want to bend the plate so as to give it a final shape, you can use CNC press brakes.
In some cases the CNC back gages are coupled with the shearing machines, this
enables controlling the length of the plate to be sheared as for different applications.

 Electrical Discharge Machining (EDM) industry:

The EDM machines remove the metal by creating the sparks that
burn the metal. There are two types of EDM with the CNC automation – Vertical
EDM and Wire EDM. The Vertical EDM needs an electrode of the shape and size
of the cavity that is be made in the job. Wire EDM is used to make the punch and
die combinations for the dies set that are used in the industries where fabrication is
done.

 CNC metal spinning:

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 It involves a lathe set with a blank that rotates at high speeds while a
metal spinning roller shapes the work piece into a desired shape.

 Surface finishing with CNC machines:

Ultra finished surfaces are obtained by using a Computer Numerical
Controlled grinding machine. Normally the surface grinding machine is used for
final machining process to the work piece which has been machined by other
method to get high accuracy in dimension of the work piece.

 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. There are also CNC
machines for the electrical industry such as CNC coil winders, and CNC terminal
location and soldering machines.

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 2. COORDINATE GEOMETRY

2.1 Description:
One of the first and foremost steps towards basic understanding of
CNC principles and geometrical concepts is thorough understanding of a subject known in
mathematics as the system of coordinates. System of coordinates is founded on a number
of mathematical principles dating back over four hundred years. The most important of
these principles are those that can be applied to CNC technology of today. In various
publications on mathematics and geometry, these principles are often listed under the
headings such as the real number system and the rectangular coordinates.

2.2 Rectangular coordinate system:

 Basic system:
Rectangular coordinate system is a concept used to define a planar 2D
point (two dimensions), using the XY coordinates, or a spatial 3D point (three dimensions),
using the XYZ coordinates. It is also called as the Cartesian coordinate system.

Fig. 2.1 Rectangular Coordinates Fig. 2.2 Origin and axes

A given point can be mathematically defined on a plane or in space.

The definition of one point is relative to another point as a distance parallel with one of
three axes that are perpendicular to each other. In a plane, only two axes are required, in
space, all three axes must be specified. In programming, point represents an exact location.
If such a location is on a plane, the point is defined as a 2D point, along two axes. If the

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location is in space, the point is defined as a 3D point, along three axes. The intersection of
two points is called Origin. It refers to the point (0, 0) in 2D coordinate system and (0, 0, 0)
in 3D coordinate system.
 Quadrants:
Viewing the two intersecting axes and the new plane, four distinct
areas can be clearly identified. Each area is bounded by two axes. These areas are called
quadrants. A quadrant is any one of the four parts of the plane formed by the system of
rectangular coordinates.

Fig. 2.3 Quadrants

 Right hand coordinate system:

In the right-hand coordinate system, the positive axis starts at origin
and is directed towards the right for X-axis, upwards for Y-axis and towards the
perpendicular viewpoint for Z-axis. Opposite directions are always negative.

 Machine geometry:
Machine geometry defines the relationship of distances and
dimensions between fixed point of the machine and selectable point of the part. Typical
geometry of CNC machines uses the right hand coordinate system.

 Absolute Coordinate System:

CNC machines are normally programmed using the absolute
coordinate system, which is based on the point of origin being (0,0,0). This absolute
programming method follows very strictly the rules of rectangular coordinate geometry.

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 User Coordinate System:
A CNC machine of any type can be designed with one or more
additional axes, normally designated as the secondary - or parallel - axes using the U, V
and W letters. These axes are normally parallel to the primary X, Y and Z axes
respectively.

 3D Coordinate representation:

Fig. 2.4 3D-Coordinate System

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 3. TYPES OF CNC MACHINE TOOLS

3.1Description:
Different types of CNC machines cover rather large variety. Number of
installations is rapidly increasing, and the technology development advances at a rapid
pace. It is impossible to identify all possible applications, they would make along list. Here
is a brief list of some of the groups CNC machines can be part of:

 Mills and Machining centres

 Lathes and Turning centres
 Drilling machines
 Boring mills and Profilers
 EDM wire machines
 Punch presses and Shears
 Flame cutting machines
 Routers
 Water jet and Laser profilers
 Cylindrical grinders
 Welding machines
 Benders, Winding and Spinning machines, etc.

CNC machining centers and lathes dominate the number of installations in an

industry. These two groups are the most prominent of the types of CNC machine tools.
Some industries may have a higher need for a particular type of machines, depending on
their needs. There are many models of lathes and machining canters available. However,
the programming process for a vertical machine is similar to the one for a horizontal
machine or even a simple CNC mill, for example. Even between different machine groups,
there is a great amount of general applications, while the programming process is generally
unchanged. For example, a contour milled with an end mill has a lot in common with a
contour cut with a wire on an EDM machine.

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3.2 Mills and Machining Centers:

CNC mills, also called CNC milling machines are usually small, simple
machines, without a tool changer or other automatic features. Their power rating is often
low. In industry, they are used for tool room work, maintenance purposes, or small part
production. They are usually designed for simple contouring, unlike CNC drills. Minimum
number of axes on a milling machine is three (X, Y and Z axes). Part set on a milling
machine is always stationary, mounted on a moving machine table. The cutting tool
rotates, it can move up and down but it does not physically follow the tool path.

CNC machining centers are far more efficient than CNC drills and CNC mills
mainly in case of their flexibility. The main benefit users get out of a CNC machining
center is the ability to group several diverse operations into a single setup. For example,
drilling, boring, counter boring, tapping, spot facing and contour milling can be
incorporated into a single CNC program operation. In addition, the flexibility is enhanced
by automatic tool changing, using pallets to minimize idle time, indexing to a different face
of the part, using a rotary movement of additional axes, and number of other time saving
features. CNC machining center scan be equipped with special software that controls
cutting speeds and feeds, life of the cutting tool, automatic in-process gauging, broken tool
detection, offset adjustment and other production enhancing and time saving devices.

There are two basic designs of a typical CNC machining center. They are
vertical and horizontal machining centers .The major difference between the two types is
the nature of work that can be done on them efficiently. For a vertical CNC machining
center, the most suitable type of work are flat parts, either mounted to the table fixture, or
held in a vise or a chuck. The work that requires machining on two or more faces (sides) in
a single setup is more desirable to be done on a CNC horizontal machining center .A good
example is pump housing and other cubic-like shapes, often irregular. Some multi-face
machining of small parts can also be done on a CNC vertical machining center equipped
with a rotary table.

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3.3 Lathes and Turning Centers:

A CNC lathe in its basic form is a machine tool with two axes, vertical X axis
and horizontal Z axis. The main feature of a lathe that distinguishes it from a mill is that
the part is rotating about the machine center line. In addition, the cutting tool is normally
stationary, mounted in a sliding turret. Cutting tool follows the contour of the programmed
tool path.

A CNC lathe can be horizontal or vertical one. Horizontal type is far more
common than vertical type, but both designs have their purpose in manufacturing. Several
different designs exist for either group. For example, a typical CNC lathe of the horizontal
group can be designed with a flat bed or a slant bed, as a bar type, chucker type or a
universal type. Added to these combinations are many accessories that make a CNC lathe
an extremely flexible machine tool. Accessories such as tailstock, steady rests or follow-up
rests, part catchers, pullout fingers and a third axis milling attachment are popular
components of CNC lathes. A CNC lathe can be very versatile - so versatile in fact, that it
is often called a CNC Turning Center.

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 4. CNC TURNING CENTRE

4.1 Introduction:

Conventional engine lathe or a turret lathe is a common machine in

just about every machine shop. A lathe is used for machining cylindrical or conical work,
such as shafts, rings, wheels, bores, threads, etc. A lathe can also be used for internal
operations such as boring, as well as for facing, grooving, threading, etc., if a proper
cutting tool is used. Turret lathes are usually weaker in machining power than engine
lathes, but they do have a special holder that stores several mounted cutting tools. An
engine lathe has often only one or two cutting tools mounted at a time, but it has more
machining power.

The term 'turning centre' is an overall description of a CNC lathe that

can be used for a great number of machining operations during single setup. For example,
in addition to the standard lathe operations such as turning and boring, CNC lathe can be
used for drilling, grooving, threading, knurling and even burnishing. It can also be used in
different modes, such as chuck and collets work, bar feeder, or between centers. Many
other combinations also exist. CNC lathes are designed to hold several tools in special
turrets, they can have a milling attachment (live tooling), chuck with indexing, a sub
spindle, tailstock, steady rest and many other features not always associated with a
convention all a the design. The tools possess changeable special “inserts”.

4.2 Lokesh CNC turning centre – TL 30 ER:

Fig. 4.1 Overview of the LOKESH-TL30ER turning centre

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 Specifications:

Table 4.1 Specifications of TL30ER turning centre

I Capacity:
Bed 30º to Horizontal
Swing over saddle mm Ø500
Max. turning dia.(overall length) mm Ø340
Max. turning length(without chuck) mm 510
Max. turning length(with chuck) mm 460
Distance between centers mm 620
Component loading height mm 1000
Distance from Guard to spindle centre mm 400

II Spindle:
Spindle nose No. A2 -6
Front bearing size mm 100
Bearing accuracy class ISO P4
Bore through spindle mm 56
Spindle ID taper No. MT-6
Spindle power KW 11/15
Spindle speed rpm 50-5000
Full power range rpm 1250-5000
Bar capacity rpm 40

III Tailstock:
Quill dia. mm 90
Quill stroke mm 120
Quill taper No. MT-4
Base travel mm 395

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IV Chuck:
Model No. B- 208 (Kitagawa)
Size mm Ø210
Gripping range mm Ø13-Ø210
Through hole mm Ø52

V Chucking Cylinder:
Model No. S 1552 (Kitagawa)
Max. pulling force Kgf. 5710
Piston stroke mm 22
Through hole mm Ø52

VI Z-axis:
Stroke mm 510+(15 Safety on each side)
Rapid traverse m/min 30
Motor type Alpha 12/3000i
Motor max. speed rpm 3000

VII X-axis:
Stroke mm 260(170+90)+2x15 Safety
Rapid traverse m/min 30
Motor (Built in brake) Alpha 8/3000i
Motor max. speed rpm 3000

VIII Turret:
Model No. SMH 20 (Diplomatic)
No. of stations mm 12
Tool shank size mm 25x25
Max. boring bar dia. sec Ø40
Index time (30º) sec 0.31
Index time (180º) sec 0.82

IX Accuracies:

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 Position accuracy mm 0.01
Repeatability mm ±0.005
Turret indexing accuracy ±4”
Turret repeatability ±1.6”

X Coolant system:
Coolant tank capacity I 140
Coolant pump capacity Ipm 120

XI Machine physical parameters:

Total connected power KVA 43
Overall sizes without chip conveyor (LxBxH) mm 2600x2700x1730
Machine weight Kg 4500

4.3 Constructional features of Lokesh TL 30 ER turning centre:

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 Fig. 4.2 Various parts inside a turning centre’s cabin
 Bed:
The turning centre has a robust rear type slant bed. It is 30 0 to the
horizontal. The entire machine is based on the bed.

 Casing and doors:

This is the outer protective cover that compactly encloses the internal
machinery of the turning centre and the doors give access to the interior of the cabin of
turning centre when opened and prevents the coolant from splashing outside when closed.

 Hydraulic chuck:
The function of the hydraulic chuck is to clamp and unclamp the job.
It has three jaws that hold the job in between them. The jaws vary for different sizes of the
jobs that are to be held. The jaws can be removed and changed according to the
requirement. The clamping and unclamping of job is entirely a hydraulic mechanism.

Fig 4.3 Hydraulic chuck of the turning centre.

 Tailstock:

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 Its purpose is same to that as in conventional lathe. The tailstock is
used to support long jobs at both ends, that is one end in chuck and the other end is
supported by the tailstock. The movement of quill is controlled by hydraulic mechanism.

Fig. 4.4 Tailstock of a turning centre.

 Turret:
The turning centre has a twelve station, bidirectional indexing turret.
The turret is designed to hold twelve different tools simultaneously. During the CNC
machining process the turret automatically rotates to bring the right tool, to right position,
at right time of the process. The motion of the turret is controlled by hydraulic mechanism.

Fig. 4.5 The turret of a turning centre.

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 Lubricating system:
A centralised lubrication system is incorporated in the machine. The
lubricant is pumped to all the required regions in the machine along pipelines. The
lubricant used is servo way32 lubricating oil. The lubrication unit supplies the lubrication
oil to side ways of the X-axis and Z-axis at an interval of 30 minutes. Also the lubricant is
pumped once as and when the CNC ON button is pushed in the control panel. The
lubrication unit is preset with pressure setting relief valve. However it should be reset if the
viscosity of the oil changed.

 Chip evacuation system:

The chip evacuation system employed in this machine is an automatic
chip conveyor. The conveyor takes away the chip in the cabin that falls on it to outside of
the machine and dumps the chip in the chip collection bin. All this process takes place
when the chip conveyor button on the control panel is in on position.

 Stabilizer:
The CNC turning centre is supplied with 3-pahse input power by an
Exelon stabilizer. The rating of the stabilizer is 20 KVA. The input frequency is 5o Hz.
The input voltage to the stabilizer is 295V-465V and the output of the stabilizer is 415V.

 Operation panel:
The entire machining and other operations of the CNC turning centre
are controlled by the various functions that are present on the operation panel. It has
various functions like mode selection, rapid over ride, program edit lock, CNC on-off,
coolant on-off, start and stop operation, spindle speed, automatic feed etc.

Fig. 4.6 The operation panel of a turning centre.

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 Control panel:
The control panel has two main components- keypad and a display
screen. The display screen shows the program that is fed into the control system and other
operational features like feed, speed of spindle, coordinates of tool and work piece etc.

Fig. 4.7 The control panel of a turning centre.

 Cooling system:

A continuous supply of coolant is pumped to the part that is machined.

The coolant used is Servo-S coolant oil (Servo 68 oil). The control panel is cooled by an
air cooler to keep it at desired room temperature.

 Hydraulic system:
The motion of the quill, turret, clamping and unclamping of chuck are
all controlled by the high pressure hydraulic system. Especially the motion of the turret is
controlled by hydraulic mechanism in conjunction with telescopic covers.

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 Fig. 4.8 Telescopic covers
4.4 Coordinate system of a turning centre:
A typical CNC turning centre is designed with two standard axes - one
axis is the X-axis, the other axis is the Z-axis. Both axes are perpendicular to each other
and represent the typical two-axis turning centre’s motions. X-axis also represents cross
travel of the cutting tool, Z-axis represents its longitudinal motion. All varieties of cutting
tools are mounted in a turret. Because of this design, a turret loaded with all cutting tools
moves along both X and Z axes, which means all tools are in the work area at all times.

Fig. 4.9 Coordinates of a turning centre.

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 5. CNC MILLING CENTRE

5.1 Introduction:

CNC milling machines vary in size, features, suitability for certain work, but they all have
one common denominator, that is , their primary axes are X and Y axes and for this
reason, they are called the XY machines. Milling machine is a machine capable of a
simultaneous cutting motion, using an end mill as the primary cutting tool, along at least two axes
at the same time. It even performs more operations than milling.

5.2 General specifications of a vertical milling machine:

Table 5.1 General specifications of CNC vertical milling machine

Sl. No. Description Specification

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 1 Number of axes 3 axes (XYZ)
2 Table dimensions 780 x 400 mm
3 No. of tools 20
4 Max. travel of X-axis 575 mm
5 Max. travel of Y-axis 380 mm
6 Max. travel of Z-axis 470 mm
7 Spindle speed 60-8000 rpm
8 Spindle output AC 7.5/5/5 KW
9 Spindle nose to table distance Z-axis 150-625 mm
10 Spindle centre to column distance Y-axis 430 mm
11 Spindle taper No. 40
12 Tool shank size CAT 50
13 Feed rate range 2-10000 mm/min
14 Rapid traverse range 40000 mm/min (XY)
35000 mm/min (Z)
15 Tool selection Random memory
16 Max. tool diameter 80 mm (150w/ empty pockets)
17 Max. tool length 300 mm
18 Tool change time (chip to chip) 2.5 seconds
5.3 Construction of a CNC vertical milling machine:

Fig. 5.1 Vertical CNC milling machine

 Bed:
The vertical milling machine has a robust rear type slant bed. It is 30 0
to the horizontal. The entire machine is based on the bed.

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 Casing and doors:
This is the outer protective cover that compactly encloses the internal
machinery of the turning centre and the doors give access to the interior of the cabin of
turning centre when opened and prevents the coolant from splashing outside when closed.

 Clamping system:
The job is clamped on the machine table using a solid heel clamp on
the table. The screw is loosened and the job is placed between the table surface and the
clamp. Then the screw is tightened.

Fig. 5.2 Clamping of work piece on table.

 ATC:
ATC stands for automatic tool changer. It has a tool magazine and a
gripper. The tool magazine carries all the tools that are required. The gripper replaces the
current tool with the required tool. The capacity of the tool magazine in the CNC milling
machine’s ATC is 20 tools.

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 Fig. 5.3 ATC

 Telescopic covers: The motion of the table is controlled by hydraulic mechanism

in conjunction with telescopic covers.

Fig. 5.4 Telescopic covers

 Lubricating system:
A centralised lubrication system is incorporated in the machine. The
lubricant is pumped to all the required regions in the machine along pipelines. The
lubricant used is servo way32 lubricating oil. The lubrication unit supplies the lubrication
oil at an interval of 30 minutes. Also the lubricant is pumped once as and when the CNC

24
ON button is pushed in the control panel. The lubrication unit is preset with pressure
setting relief valve. However it should be reset if the viscosity of the oil changed.

 Stabilizer:
The CNC milling machine is supplied with 3-pahse input power by an
Exelon stabilizer. The rating of the stabilizer is 20 KVA. The input frequency is 5o Hz.
The input voltage to the stabilizer is 295V-465V and the output of the stabilizer is 415V.

 Operation panel:
The entire machining and other operations of the CNC turning centre
are controlled by the various functions that are present on the operation panel. It has
various functions like mode selection, rapid over ride, program edit lock, CNC on-off,
coolant on-off, start and stop operation, spindle speed, automatic feed etc.

Fig. 5.5 The operation panel of a CNC milling machine.

 Control panel:
The control panel has two main components- keypad and a display
screen. The display screen shows the program that is fed into the control system and other

25
operational features like feed speed of spindle, coordinates of tool and work piece etc. The
key pad is useful for manipulating the data entry.

Fig. 5.6 The control panel of a CNC milling machine.

 Cooling system:

A continuous supply of coolant is pumped to the part that is machined.

The coolant used is Servo-S coolant oil (Servo 68 oil). The control panel is cooled by an
air cooler to keep it at desired room temperature.

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5.4 Coordinate system of a vertical CNC milling machine:

Fig. 5.7 Coordinate system of a CNC milling machine.

A typical vertical machining centre has three mutually perpendicular
controlled axes, defined as X-axis, Y-axis, and Z-axis. X-axis is parallel to the longest
dimension of machine table, Y-axis is parallel to the shortest dimension of the table and Z-
axis is the spindle movement. So the X and Y directions specify the table movement, while
the Z-direction specifies the tool movement.

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 6. CONTROL SYSTEM OF A CNC MACHINE

6.1 GENERAL DESCRIPTION:

A CNC machine is equipped with a computerized numerical control

system. In an analogy of the machine tool being the body of a CNC machine system, the
control unit is its brain. All machine speeds, feeds, axes motions and hundreds of other
tasks are programmed by a CNC programmer and controlled by a computer that is major
part of the CNC unit.

Any control unit has two basic components - one is the operation
panel, full of rotary switches, toggle switches and push buttons and the other component is
the display screen with a keyboard or a keypad. CNC programmer has to use either the
operation panel or the display screen. The control unit of a CNC system contains features
that work in conjunction with the program. Some features can be used only if the program
supports them. All switches and buttons and keys are used by the machine operator, to
exercise control over program execution and machining process.

Fig. 6.1 Operation panel of a CNC machine.

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 Features of operation panel:

Table 6.1 Features of operation panel

Sl. Feature Description

No.

1 On/Off switch Power and control switch for the main power
and control unit.

2 Cycle start Starts program execution or MDI command.

3 Emergency stop Stops all machine activity and turns off power to
control unit.

4 Free hold Temporarily stops motion of all axes.

5 Single block Allows program to run one block at a time (one

block is executed each time start cycle is
pressed).

6 Optional stop Temporarily stops program execution (M01

required in program).

7 Block skip Ignores blocks preceded with a forward slash

(/) in the program.

8 Dry run Enables program testing at fast feed rates

(without a mounted part).

9 Spindle over ride Overrides programmed spindle speed, usually

within 50-120% range.

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10 Feed rate over ride Overrides programmed feed rate, usually within
0-200% range.

11 Chuck clamp Shows current status of the chuck clamping

(Outside / Inside clamping).

12 Table clamp Table Clamp Shows current status of table

clamping.

13 Coolant switch Coolant control ON / OFF / AUTO.

14 Gear selection Shows current status of working gear range

selection.

15 Spindle rotation Indicates spindle rotation direction (clockwise

or counter clockwise).

16 Spindle orientation Manual orientation of the spindle.

17 Tool change Tool Change Switch allowing a manual tool

change.

18 Reference position Switches and lights relating to setup of machine,

from reference position.

19 Handle (MPG) Manual Pulse Generator (MPG), used for

selection of and handling increment switches.

20 Tailstock switch Tailstock and/or quill switch to manually

position the tailstock.

21 Indexing table switch Manually indexes machine table during setup.

22 MDI mode Mode Manual Data Input mode.

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 23 Auto mode
Allows automatic operations.

24 Memory mode
Allows program execution from memory of the
CNC unit.

25 Tape / Ext or DNC mode

Allows program execution from an external
device, such as a desktop computer (Direct
Numerical Control) or a punched tape.

26 Edit mode
Allows changes to be made to a program stored
in CNC memory.

27 Manual mode
Allows manual operations during setup.

28 Jog mode
Selects jog mode for setup. In this mode the
coordinates can be set using X, Y, Z, buttons
quickly.

29 Rapid mode
Selects rapid motion mode for setup. The
motion is faster than the initial speed for which
program is written.

30 Memory access mode

Key (switch) to allow program editing.

31 Error lights
Red light indicates an error in corresponding
field.

 Control panel:

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 Fig. 6.2 The control panel of a CNC machine.

The control panel has two main components- keypad and a display
screen. The display screen shows the program that is fed into the control system and other
operational features like feed, speed of spindle, coordinates of tool and work piece etc. The
key pad is useful for manipulating, entering and deleting the data on the screen and other
data entry related functions.

7. INSPECTION

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7.1 Definitions:
 Quality:

Quality in manufacturing context can be defined as the degree to

which a product or its components conform to certain standards that have been specified by
the designer.

 Inspection:

The process of checking the quality of a product or a component is

called as inspection. The inspection process enquires into the deviations of a component
from standard specifications. These deviations are known as defects.

 Manual inspection:
The process of manual inspection is done by:
1. Visual inspection.
2. Using instruments.

In visual inspection the parts or components are observed and defects

are identified. It is the basic method of inspection. The operators of machines usually
segregate the defective parts.

Using instruments like micrometer, vernier calipers, depth gauge

various dimensions of the parts or components are checked. Another way of inspection is
using the limit gauges. Using go and no-go gauges the components are checked for any
deviation. Go gauge corresponds to the maximum metal limit and no-go gauge corresponds
to minimum metal limit of the component.

If the go gauge passes through a component and no-go gauge doesn’t

pass then the part is within the standard limits. If both the gauges doesn’t pass it means that

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the hole is of under size or the shaft is of over size. If both gauges pass then it means that
the hole is of over size or the shaft is of under size.

7.2 Tesa microhite plus M 600 (Inspecting machine):

Tessa microhite plus M 600 is a height gauge used to check the
deviation of the dimensions of a part or a component from its standard design dimensions.
It has a robust base, a magnetic V-block that holds the job, a display unit that shows the
mode of the system and the measurement of the deviation. This microhite enables 2D
measurement that is measurement in two directions.

First a standard is placed on the base of the microhite and then the
microhite probe is adjusted to the height of the probe. Then the job that is to be checked is
positioned in required manner in the magnetic V-block. Then the reference point is set.
Then various dimensions (up to the tip of the probe) are obtained with respect to reference
point . The obtained values are verified for allowable deviation.

Fig. 7.1 Tesa microhite 600 plus M.

8. CONCLUSION

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 After studying and analysing the processes of CNC machining and
inspection it was found out that Computer Numerical Control machining is more efficient
and economical than conventional machining process. It saves time, cost of production,
increases productivity and accuracy, and gives the products a very high degree of surface
finish. Considering all these benefits CNC machines make an essential part of a machine
shop of any manufacturing industry.

Inspection is a very important process in any industry. The efficiency

of the process of inspection determines the quality of the products or components
manufactured by an industry.

It is also observed that if the inspection process is integrated with the

CNC machining (instead of a separate inspection process) a lot of time, resources and
material can be saved.

BIBILOGRAPHY

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1) CNC programming hand book by Peter Smid
2) www.google.com
3) www.cnczone.com
4) www.wikipedia.com

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