History and Working Principle of CNC Machines

HISTORY AND WORKING
PRINCIPLE OF CNC MACHINES

PRESENTATION BY:
SREELAKSHMI S
CHANDRAKALA THAKUR
THEJUS MATHEW
MANU NARAYANAN
WHAT IS CNC MACHINING?
• CNC: COMPUTER NUMERICAL

CONTROL
• CNC machining is a
manufacturing process in which
a computer directs machines
using programming codes to
make a product.
HISTORY OF AUTOMATED MACHINES
• 1771
Richard Arkwright invented the first fully automated spinning mill driven by water power, known
at the time as the water frame.
• 1785
An automatic flour mill was developed by Oliver Evans, making it the first completely automated
industrial process.
• 1794
Eli Whitney patented the cotton gin, a machine that revolutionized the production of cotton by
greatly speeding up the process of removing seeds from cotton fiber.
HISTORY OF CNC MACHINES
• In 1949, John T. Parsons, an early
computing pioneer, developed it as part of
an Air Force research project carried out at
the Massachusetts Institute of Technology
(MIT).
• An experimental milling machine was built
at the institute’s Servomechanisms
Laboratory, with the goal of using
motorized axes to produce helicopter
blades and stiffer skins for aircraft.
DEVELOPMENTS DURING 1952-1958
• In 1952, Richard Kegg, together with MIT, made the first NC milling machine
known as Cincinnati Milacron Hydrotel.
• In 1958, its commercial introduction came with a patent for a “Motor
Controlled Apparatus with Positioning Machine Tool”.
• The initial prototype was operated using an eight-column punched card, a
card reader, and a vacuum-tube electronic control system
THE CINCINNATI MILACRON HYDROTEL
PUNCHED CARDS
• Early CNC machines, in the 1940s and
1950s used punched cards, which was
then commonly used in
telecommunications and data storage.
• A punched card is a piece of stiff paper
that holds digital data represented by
the presence or absence of holes in
predefined positions.
• CNC machining was becoming more recognized across the world during this period.
• In 1960, Direct Numerical Control(DNC) was invented, in which programs are directly
fed into the machine, instead of punched cards.
• This was the time when Computer-Aided Design (CAD) and Computer-Aided
Machining (CAM) was developed in 1972.
• CAD and CAM inclusion in CNC machining led to massive developments in CNC
machining.
• However, the two were not regarded as a standard part of the manufacturing
process.
• In 1976, 3D Computer-Aided
Design and Computer-Aided
Machining were included into CNC
machining.
• In 1989, CAD and CAM software-
controlled machines became the
industrial standard for CNC
machines.
LATEST DEVELOPMENTS IN CNC TECHNOLOGY
• MULTI-AXIS MACHINES
• ADVANCES IN CAD/CAM
• USAGE OF ROBOTS/COBOTS
• DIGITAL TWINNING
WORKING PRINCIPLE
PARTS OF A CNC MACHINE
• PART PROGRAM
• PROGRAM INPUT DEVICE
• MACHINE CONTROL UNIT
• DRIVE SYSTEM
• MACHINE TOOL
• FEEDBACK SYSTEM
DO YOU KNOW WHICH PART IS KNOWN AS THE
HEART OF A CNC MACHINE?
WORKING OF CNC MACHINES
• The program is input into the MCU, and the data is converted into motion
commands at the MCU.
• The MCU sends these motion commands to the driving system.
• The drive system follows the commands given, and manages the motion and
velocity of the machine tool.
• Some CNC machines operates with the aid of feedback devices. Others do
not.
WORKING OF CNC MACHINES CONTINUED
• Without feedback, the tools may overshoot or may not reach the desired position
because of inertia, wear and tear, and friction.
• To achieve higher accuracy and repeatability, sensors measure the position and
velocity, and feed these data back to the MCU.
• These feedback signals are compared with the reference signals in the MCU. And if
there are errors, new commands are sent to the machine tool to compensate for these
errors.
• The operator can see see all the commands, programs and other important data at
the display unit.
CNC PROGRAMMING CODES
M CODES AND THEIR FUNCTIONS
G CODES AND THEIR FUNCTIONS
CODE G00
CODE G02
CODE G03
REFERENCES
• The History of CNC Machinery, https://laszeray.com/blog/the-history-of-cnc-machinery/.
• Trends in CNC Machining, https://www.computer.org/publications/tech-news/trends/6-
computer-numerical-control-cnc-machining-trends-for-2021.
• G Code for CNC Programming, https://www.autodesk.com/products/fusion-360/blog/cnc-
programming-fundamentals-g-code/.
• G Code Explained, https://laptrinhx.com/g-code-explained-list-of-most-important-g-code-
commands-3646170116/amp/.
• Parts of CNC Machines, https://www.smlease.com/entries/mechanical-design-basics/what-is-
cnc-machining-working-principal-and-applications/.
• Working of CNC Machines, https://www.theengineerspost.com/cnc-machine-working/.
THANK YOU
Types of CNC
Machines
TEAM MEMBERS (GROUP 8):
1. Goutham Vinod
2. Irshad Ibrahim
3. Chaithanya Suresh
4. Guguloth Ram Naik
5. Neya Rose Sebastian
Introduction
WHY CNC ?
➔ Rapid
➔ High Precision
➔ Higher Capacity
➔ Better Precision Tolerance
➔ Highly scalable
NC vs CNC
Punched tape Fed directly from

Computer
Operations cannot Operations can be

be changed changed on fly
Has to run off the Runs off the

tape everytime computer memory
Less Flexible Highly Flexible
Less accurate Higher accuracy
High skill operator is High skill not

needed required
Less cost High cost

BASED ON CONTROL LOOPS
OPEN LOOP CLOSED LOOP
Open loop systems have no access to the real In a closed loop system, feedback devices
time data about the performance of the system closely monitor the output and any disturbance
and therefore no immediate corrective action will be corrected in the first instance. Therefore
can be taken in case of system disturbance. high system accuracy is achievable.
OPEN LOOP
CLOSED LOOP
BASED ON POWER SUPPLY
● The input power may be of electrical, hydraulic or pneumatic.

● This input energy is converted to mechanical power, used for driving slides, saddles
forming a part of machine tool.
ELECTRICAL SYSTEMS:
● Electric motors may be used for controlling both positioning and contouring machines.
● They may be either AC or DC motor and the torque and direction of rotation need to be
controlled.
HYDRAULIC SYSTEMS
● Hydraulic systems may be used with positioning

and contouring machine tools of all sizes.
● These systems may be either in the form of
rams or motors.
● Hydraulic motors are smaller than electric
motors of equivalent power.
● The advantage of using hydraulic motors is that
they can be very small and have considerable
torque.
PNEUMATIC SYSTEM
● In contrast to Hydraulic
drives, the Pneumatic
drives does not pose
any fire hazard or any
major corrosion
problem and their
operation are cheaper
as the working
medium is air which is
freely available.
BASED ON NUMBER OF AXES
2 & 3 AXIS CNC MACHINES:
● In 2 axis machines there will be two axes along which motion takes
place.
● The saddle will be moving longitudinally on the bed (Z-axis) and the
cross slide moves transversely on the saddle (along X-axis).
● CNC lathes will be coming under 2 axes machines.

● In 3-axes machines, there will be
one more axis, perpendicular to
the above two axes.
● By the simultaneous control of all

the 3 axes, complex surfaces can
be machined.
4 & 5 AXES CNC MACHINES
● 4 and 5 axes CNC machines provide multi-axis

machining capabilities beyond the standard 3-axis
CNC tool path movements.
● A 5-axis milling centre includes the three X, Y,Z

axes, the A axis which is rotary tilting of the spindle
and the B-axis, which can be a rotary index table.
BASED ON POSITIONING SYSTEM
Absolute Positioning System
● Position of the tool is unique , the tool moves to a coordinate based on the
zero-point.
● It generates a position.
● G 90
Incremental Positioning System
● Last point travelled to becomes the new reference point.

● Relative positioning.
● G 91
ABSOLUTE POSITIONING SYSTEM, G90
P1 - X0 Y0
P2 - X100 Y0
P3 - X100 Y50
P4 - X0 Y50
P1 - X0 Y0
INCREMENTAL POSITIONING SYSTEM, G91
P1 - X0 Y0
P2 - X100 Y0
P3 - X0 Y50
P4 - X-100 Y0
P1 - X0 Y-50
BASED ON MOTION TYPES
POINT TO POINT SYSTEM
● Point-to-point control systems cause the tool to

move to a point on the part and execute an operation
at that point only.
● The tool is not in continuous contact with the part

while it is moving.
● Examples: drilling, reaming, punching, boring and

tapping
SWANSOFT SIMULATION
CONTINUOUS PATH SYSTEM
● Also known as contouring system
● This type of machine tools works in a continuous path by

cutting the material and following a contour of the part.
● The positions of the workpiece and the tool are

simultaneously controlled by a control system.
● These operations include milling along any lines at any

angle, milling arcs and lathe turning.
SWANSOFT SIMULATION
SUMMARY
TYPES OF CNC MACHINES
BASED ON BASED ON BASED ON BASED ON BASED ON

CONTROL NUMBER OF POWER POSITIONING MOTION
LOOPS AXES SUPPLY SYSTEM TYPES
OPEN LOOP 2 & 3 AXES CNC ELECTRICAL POINT TO POINT

INCREMENTAL
MACHINES
CLOSED PNEUMATIC
ABSOLUTE
4 & 5 AXES CNC CONTINUOUS
LOOP
MACHINES HYDRAULIC
THANK YOU
Construction,Working
& Control of CNC
Machines
Created By:
1.Akhila sabbavarapu
(B190577PE)
2.Vinjamuru Srivatsa
(B190469PE)
3.Prasad Ingale (B191118PE)
4.Pavan Kalyan (B180340PE)
What is a CNC Machine?
● Computer numerical control (CNC) is
a method for automating control of
machine tools through the use of
software embedded in a
microcomputer attached to the tool.
● It is commonly used in manufacturing
for machining metal and plastic.
● Mills, lathes, routers, grinders and
lasers are common machine tools
whose operations can be automated
with CNC.
1 Input Device
2 Machine Control Unit

3 Machine Tool
Construction of
CNC Machine 4 Driving System
5 Feedback Devices
6 Display Unit
Input Device
These are the devices which are used to input the Part Program in the CNC
machine
• Floppy disk is a small magnetic storage device for CNC data input. It has been the most
common storage media up to the 1970s
• A USB flash drive is a removable and rewritable portable hard drive with compact size
and bigger storage size than a floppy disk
• Serial communication:The data transfer between a computer and a CNC machine tool is
often accomplished through a serial communication port. Most of the personal computers
and CNC machine tools have built in RS232 port and a standard RS-232 cable is used to
connect a CNC machine to a computer which enables the data transfer in reliable way.
• Ethernet communication:Most companies now built a Local Area Network (LAN)
as their infrastructure. More and more CNC machine tools provide an option of the
Ethernet Card for direct communication within the LAN.
• Due to the advancement of the computer technology and the drastic reduction of
the cost of the computer, it is becoming more practical and economic to transfer
part programs between computers and CNC machines via an Ethernet
communication cable.
Machine Control unit
• The machine control unit is the heart of the CNC system. There are two sub -units
in the machine control unit
Data Processing Control Loop

Unit Unit
• On receiving a part program, the DPU firstly • The data from the DPU are converted into
interprets and encodes the part program into electrical signals in the CLU to control the
internal machine codes. driving system to perform the required
• The interpolator of the DPU then calculate motions.
the intermediate positions of the motion in • Other functions such as machine spindle
terms of BLU (basic length unit) which is the ON/OFF, coolant ON/OFF, tool clamp
smallest unit length that can be handled by ON/OFF are also controlled by this unit
the controller according to the internal machine codes
• The calculated data are passed to CLU for
further action.
Machine Tool
• A CNC machine tool always has a slide table and a spindle to control of the position and
speed. The machine table is controlled in X and Y axis direction and the spindle is
controlled in the Z axis direction.
• This can be any type of machine tool or equipment. In order to obtain high
accuracy and repeatability, the design and make of the machine slide and the
driving leadscrew of a CNC machine is of vital importance.
• The slides are usually machined to high accuracy and coated with anti-friction material
such as PTFE and Turcite in order to reduce the stick and slip phenomenon.
• Large diameter recirculating ball screws are employed to eliminate the backlash and
lost motion.
• Other design features such as rigid and heavy machine structure; short machine table
overhang, quick change tooling system, etc. also contribute to the high accuracy and
high repeatability of CNC machines.
Driving Devices
• The driving system of a CNC machine consists of amplifier circuits, drive motors and
ball lead screw. The MCU feeds the signals (i.e. of position and speed) of each axis to
the amplifier circuits.
• The control signals are than augmented (increased) to actuate the drive motors. And
the actuated drive motors rotate the ball lead screw to position the machine table.
• This system usually uses electric motors although hydraulic motors are sometimes
used for large machine tools. The motor is coupled either directly or through a gear
box to the machine leadscrew to moves the machine slide or the spindle.
• DC servo motor is the most common type of feed motors used in CNC machines. The
The principle of operation is based on the rotation of an armature winding in a
permanently energized magnetic field.
• A stepping motor in CNC machines is a device that converts the electrical pulses into
discrete mechanical rotational motions of the motor shaft.
Feedback Devices
• CNC Feedback consists of transducers that act as sensors. It is also called a
measuring system. It contains position and speed transducers that continuously
monitor the position and speed of the cutting tool located at any instant. The
MCU receives the signals from these transducers and it uses the difference
between the reference signals and feedback signals to generate the control signals
for correcting the position and speed errors.
Velocity/Speed
Positional Feedback
Feedback
Linear Rotary DC
Transducers Encoders Tachometer
Display Unit
• The Display Unit serves as an interactive device between the machine and the
operator. When the machine is running, the Display Unit displays the presents
status such as the position of the machine slide, the spindle RPM, the feed rate,
the part programmes, etc.
• In an advanced CNC machine, the Display Unit can show the graphics simulation
of the tool path so that part programs can be verified before the actually
machining. Much other important information about the CNC system can also
displayed for maintenance and installation work such as machine parameters, logic
diagram of the programmer controller, error massages and diagnostic data.
Control in CNC machines
Open Loop Systems • Open loop systems have no access to the

real time data about the performance of
the system and therefore no immediate
corrective action can be taken in case of
system disturbance.
• This system is normally applied only to
the case where the output is almost
constant and predictable.
• Therefore, an open loop system is unlikely
to be used to control machine tools since
the cutting force and loading of a machine
tool is never a constant.
Control in CNC machines
Close Loop Systems
• In a close loop system, feed back

devices closely monitor the output and
any disturbance will be corrected in
the first instance.
• Therefore high system accuracy is
achievable. This system is more
powerful than the open loop system
and can be applied to the case where
the output is subjected to frequent
change.
• Nowadays, almost all CNC machines
use this control system
How CNC machines work?
Machine
Data
Inputs, Program
display Processed
Driving
Display Unit MCU Mechanism
Miscellaneous
functions
Position/Speed
control
Comparison
with Reference
Feedback Machine Tool

Working of CNC Machine
• A Working of CNC machine Is based on mainly two
software’s-
• CAD(Computer-Aided Design)
• CAM (Computer Aided Manufacturing)
• The basic concept of CNC machine working
• The input is given in the form of G codes and M codes
• Commands are read by reader and stores into the memory
• This memory is in turn converted into binary codes which
gives electric pulses to the servo drives which actuates the
motors and spindle
CNC machines can further categorized into
1. DTC’s - Drill tap centre’s
2. Machining centre’s - 1) Vertical machining centre’s 2) Horizontal machining
centre’s
3. Turning centre’s
4. CNC grinding machines
5. CNC special machines
6. Turn mill centre
Why CNC?
Modernization is the central part of the
Fourth Industrial Revolution and one of
the most significant shifts was CNC
machining implementation.
CNC Machining is enhances
manufacturing because it is:
• Convenient
• Accurate
• Standardized
• Sustainable
• Prototype machining
• Labour Friendly
Therefore CNC machines need continuous
review in terms of construction & control
to meet modern automation needs
efficiently.
Thank
You
SPECIFICATIONS
OF CNC MACHINES
By:
1 . P A R U C H U R I VA R U N
2 . D E E P I L L I S U J AY
3 . A N V E S H R E D DY
4 . G A L A N K I VA M S I
INTRODUCTION
• CNC stands for Computerized Numerical Control. It is a computerized

manufacturing process in which pre-programmed software and code controls the
movement of production equipment. CNC machining controls a range of complex
machinery, such as grinders, lathes, and turning mills, all of which are used to cut,
shape, and create different parts and prototypes.
SPECIFICATIONS
1. Number of controlled axes
2. Interpolation
1. Linear
2. Circular
3. Resolution
4. Feed rate
5. Rapid traverse rate
6. Operating modes
1. Manual
2. Automatic
3. Incremental
7. Type of feedback
SPECIFICATIONS [CONT]
8. Part program handler
9. Part programming
10. Compensations
11. Programmable logic controller
12. Spindle control
13. Custom macros
14. Safety function
15. Mirror imaging
16. Range of Spindle speeds
17. Maximum Diameter
SPECIFICATIONS
• Automatic Tool Changers

• Automatic Pallet Changers
• Ball Screw
• Leading Manufactures
• Cost of Machines
CNC MACHINING CENTRE’S
1 . G E N E R A L C L A S S I F I C AT I O N :
1. CNC Turning machines
2. CNC Milling machines
2 . B A S E D O N O R I E N TAT I O N :
1. Vertical Machining centres
2. Horizontal Machining centres
A U T O M AT I C T O O L
CHANGERS
1 . TO O L
2. TURRET
3 . TO O L M A G A Z I N E
4. SOME OF THE TYPES
1. Drum type tool changer
2. Chain type tool changer
5. MECHANISM
1. Double gripper tool changer
DRUM TYPE
TOOL CHANGERS
Drum type changers are used when the number of
tools is lower than 30.
The tools are stored on the peripher y of the drum .
CHAIN TYPE
TOOL CHANGER
1. Chain type changers are used when the
number of tools is higher than 30
2. Series:
1. SK Series
2. HP Series
3. Rotating Series etc…
DOUBLE GRIPPER
TOOL CHANGERS
• Gripper on each of the
two sides.
• Each gripper can rotate
90°
• One will pick up the old
tool from turret and the
other will pick up the new
tool from the magazine.
• It then rotates to 180° and
places the tools into their
due position.
A U T O M AT I C P A L L E T
CHANGERS
1 . PA L L E T
2. TYPES:
1. Manual pallet systems
2. Automatic pallet systems
3. Robotic pallet systems
3. BENEFITS
1. Minimise manual intervention and hence human errors.
2. Vastly improve speed of changeover to a new part
A U T O M AT I C
PALLET SYSTEMS
1. SH UT T LE T YPE PA LLET CH A NG ERS
2. SWING T YPE PA LLET CH A NG ERS
PALLET CHANGER
IN HORIZONTAL MACHINING
CENTRE
Shuttle pallet changer
combined with a 6 pallet
carousal.
1.
2.
Introduction
Specifications
BALL
1. Bearing Ball Circuit SCREW
2. Load Carrying Balls
3. Land Diameter
4. Ball circle Diameter
5. Root diameter
6. Pitch
7. Lead
3. Purpose
4. Advantages
ST EPS OF
1. Rotational Speed SEL EC T IN G
B AL L
2. Critical Speed SC REW
3. Buckling Load
4. Average speed
5. Average Load
6. Service Life
7. Torque Calculation
CNC MILLING
MACHINES
• 5 control axis are used to create long, slender and
heavy parts
• Resolution:1micron
• Power-22.4KW
• Spindle speed range:minimum 8000rpm
• Closed loop feedback controls
• Tool shank -40/50/63
• Ball screw diameter-25mm
• 2 Axis are present (X,Z)
• Resolution: C N C L AT H E
MACHINES
– 0.5micron(X-axis)
– 1micron(z-axis)
• Continuous power-15KW
• Spindle speed range-50-5000rpm
• AC digital type feedback drive with closed
loop
• Tool shank size-20*20mm
• Tool holinging fixers-VDI 30
• Ball screw diameter-25mm
LEADING MANUFACTURES
OF CNC MACHINES
1. MAZAK
1. Founded in 1919
2. Mainly produces CNC Lathe
2. TRUMPF
1. Founded in 1923
2. Mainly produces various types of lasers
3. DMG MORI
1. Mainly Produces Vertical,Horizontal3,4,5-axis
4. MAG
5. OKUMA
1. Worlds leading company
2. History of more than 100 years
3. Japanese Company MAG SPECHT 600
CNC MACHINE COST
1. Hobby CNC Machine
2. Professional CNC Machine
3. Entry level 3-axis Mill(VMC)
FACTORS AFFECTING
THE PRICE:
1. Size of Machine
– Larger the range of motion, the larger the price
2. Speed
– Speed of 1000inches/min
3. Accuracy and tolerance
4. No of Axis
– As no of axis increases, cost increases
5. Power
MANUFACTURES
IN INDIA
1. Gemsons
– Established in 1982
– Located in Mumbai
2. Chizel
– Specialised in CNC manufacturing
– 3D printing
3. Raghu Vamsi
– Established in 1992
– Mainly provide CNC Turning and CNC Milling
CNC Turning machine
Raghu Vamsi machine tool Pvt ltd
https://tsubakimoto.com/products
https://chains.ustsubaki.com/category/automatic-tool-changers-chains/
https://hwacheonasia.com/how-automatic-pallet-changers-enhance-cnc-
machine-production/
https://www.machinetools.com/en/models/mag-specht-600 REFERENCES
https://tsubakimoto.com/products/application-products-datail/machine-
tool/atc-toolpot/
THANK YOU
Click to edit Master title style
CNC MACHINES
Features, Advantages
and Disadvantages
By:
V Vi gne s h (B181089PE)
S Ud a y B h a s k a r ( B 1 9 0 5 11 P E )
T Ka rthi ke y a (B180937PE)
E Ha r i S ha nka r ( B 1 8 111 9 P E )
1
Click to edit
History andMaster title style
Evolution
➢ NC machines were first created in the late 1940s.
➢ Later in 1967, the idea of CNC machining started to circulate.
➢ The implementation took place from 1972.
➢ In 1976, CNC machines were available.
2 2
Features
➢ Machine Tool Control
➢ In-process compensation
➢ Improved programming and operating features
➢ Diagnostics
➢ Strength and stiffness
3 3
Advantages
➢ CNC machine can produce jobs with highest accuracy and
also good precision.
➢ It also has the capability to produce a complex design with

high accuracy in minimum possible time with minimum
wastage.
➢ Safe to operate.
➢ CNC machines require less number of workers as compared

to manual machines. Hence, less possibility of human error
and also less labour cost.
4 4
Advantages
➢These machines are programmed with a design. So they can
manufacture hundreds or even thousands of items which are similar to
each other.
➢This design software allows the designer to simulate the manufacture of

their own idea without actually making a model, which saves time and
money.
➢These machines can run throughout the day unless there is a

replacement of cutting tools.
➢High output and efficiency – Earlier machines used to be very heavy and
consume lots of power. But CNC machines consume low power and give
high output in terms of number of products manufactured. 5 5
Disadvantages
➢ CNC machines are more expensive than manually operated
machines, although the costs are slowly coming down.
➢ Even the spare parts of CNC machines are relatively costlier

than conventional machine tools.
➢ Less workers are required to operate CNC’s. Hence, investment

in CNC machines lead to reduced unemployment.
➢ Maintenance costs are higher.
➢ Not suitable for small scale production.
➢ A good programming language is required by the operator. This

requires a skilled programmer. Hence the cost of labour can be
high.
6 6
Disadvantages
➢ CNC machines require air conditioned environment. Thus extra
costs are involved.
➢ CNC machine operators only needs basic training and skills

enough to supervise several machines. In the years gone by,
engineers needed years of training for operating lathes , milling
machines etc.
➢ This means many of the old skills are been lost.
7 7
Applications
➢ Metal removing industries – ➢ Fabricating metal industries –
• These industries remove metal from the • In fabrications industry the machining
raw material to give it the desired shape as operations are performed on steel plates.
per the requirements and make shafts, • Here CNC machines are used for shearing,
gears, valves and other parts. plasma cutting, punching etc.
• To bring the plates to their final form, CNC
lasers and CNC plasma cutters are used
commonly.
8 8
Applications
➢ Electrical Discharge Machining – Here, EDM machines use CNC automation to remove the
metal by creating sparks that burn the metal.
➢ CNC technology is used in number of lettering and engraving system.
➢ CNC machines are also used extensively in the wood working industries to perform various
operations to manufacture furniture, wooden frames and musical instruments.
➢ Also used in electrical industry such as CNC coil winders, CNC terminal location and
soldering machines.
9 9
Thank You All
10
Machining Centers
Ayush Tiwari
Bharath S
Gopisetti Poojitha
Maloth Sindhu
What is CNC Machining Center?
• CNC machine centre is a advance
manufacturing machine tool
which performs wide range of
machining operations with
accuracy and good quality surface
finish.
• A CNC machine tool center can
perform drilling, milling and
lathe operations.
Why is CNC Machining Centers Used?
• Accuracy
• Versatile
• Speed of production
• Productivity
• Labor
Advanced Mechanisms used in CNC Machining Centers
• ATC (automatic tool changer)

• APC (automatic pallet changer)
• CNC servo system
• Feedback system
• Re-circulating ball screw and nut
Classification of CNC Machining Centers
• Horizontal Machine Center
• Vertical Machine Centers
• Universal Machining Centers
Horizontal machining center
• As the name says this machining
center has horizontal spindle on
which tool is mounted.
• This are generally single spindle
machines with automatic tool
changer.
• ATC consist of a indexable tool
magazine, which can store
several tools.
Horizontal machining center
• To reduce loading and unloading time automatic pallet changer (APC) in

installed.
• The work piece may be different and may require different programs.
• Because of large material removal rate, the cutting tool are normally big.
• So that tool magazine have large place for each tool and its becomes
heavier.
Advantages of horizontal machining center
Increased productivity through shorter cycle times
Multi-side machining
Complex part machining
More flexibility= more concurrent jobs
Deburring and other specialized tools included

Vertical machining center
• Vertical machining center
(VMC), which employs a spindle
with a vertical orientation.
• It is mainly used for processing
complex parts such as plates,
discs, molds and small shells.
Vertical machining centers can
perform milling, boring, drilling,
tapping and cutting threads.
Vertical machining center
MOTION OF VMC :
• Most vertical machining centers have three
axes, and some have the function of a spindle
head that can be rotated on one or two axes.
• In CNC vertical machining center, the
workpiece is held on the table base and the
spindle which contains the cutting tool is fixed
on vertical spindle Z axis. The table moves in
X and Y axis and spindle with cutting tool
moves in Z axis.
Types of VMCs
1. Travelling column 2. Gantry type 3. Multiple spindle

Advantages of vertical machining centers
• Effectively reducing the clamping time of the workpiece.
• The cutting tool movement track is easy to observe.
• The debugging program is easy to check and measure.
• the chips are easily removed and dropped to avoid scratching the
processed surface.
• Compared with the corresponding horizontal machining center, the
structure is simple, the floor space is small, and the price is low.
Difference between HMC and VMC
HORIZONTAL MACHINING CENTER VERTICAL MACHINING CENTER
• The HMC is comparatively more rigid in • The VMC is comparatively more versatile
construction and hence it is used for heavy in construction and hence it can generate more
workpiece. complex shapes.
• It provides heavy metal

• It has comparatively low material removal capacity.
removal rate so big cutting tool is used.
• Tool magazine have higher capacity to • Tool magazine can accommodate less number of
accommodate the tools. cutting tools.
• Heavier construction increases the cost. • Comparatively less expensive.

Universal Machine Center
• Machining centers can be broadly
classified into three types based
on their structure: horizontal,
vertical, and gantry types. The
horizontal type the first to be
developed can be defined simply
as a machine where the spindle to
which the cutting tool is attached
is mounted horizontally (or
parallel to the floor).
Universal Machine Center
• The universal machine center is similar to a horizontal machining center,
but the spindle shaft can be continuously tilted from a horizontal position
to a vertical position under computer control.
• The universal machine center consists of five or more axes.
• Such machines facilities access to the top surface of the workpiece to be
mounted on a horizontal machining center so that different sides of the
workpiece can be machined in one unit.
Specifications of Universal Machining Center
THANK YOU
Design of CNC
machine Tools
Presented by:-
Hardik Khare
Azim Salam NP
Sharon V
Lingareddy Bharadwaj
What is Design?
• It is the way in which something is planned and made or arranged
• Generally, it is best to design parts so that tools of the
largest diameters possible can machine them.
•It’s also best not to design cavities that are more than four
Basic Rules times deeper than their width.
• When trying to machine text or letters, it is best to use
engraved text rather than embossed.
Machine Types
• Lathe Machine
• Milling Machine
• Router Machine
Lathe
•Lathes are commonly used for complex cylindrical
shapes. Due its capabilities, the lathe is often the most
prominently used for these circular cuts as it offers tight
tolerances and a cost-effective level of operation.
•With lathes, the material turns while the cutting tool

remains stationary, so geometries rely on the movement
and feed rates of the stationary tools along with the
rotational speed control of the material.
Milling Machine
Verical Milling Machine Horizontal Milling Machine
•Vertical milling machines have a spindle • Horizontal milling machine cutters are
axis and cutting tool that is aligned vertical mounted on a horizontal spindle across the
to the machines’ bed. table
Router Machine
•Routers are similar to the vertical milling machine in
that cutting tools are aligned vertically to the
machine’s bed.
• The main difference is the work-area-to-machine

ratio, which is almost 1:1 for a router but closer to 1:3
for a mill.
Tool Restrictions
Tool geometry Tool access Workpiece

stiffness
Tool stiffness Workholding
Machine Setup & Part Orienation
• Tool access is one of the main design limitations in
CNC machining. To reach all surfaces of the model, the
workpiece has to be rotated multiple times.
• It is important to think about machine setups while

designing for two reasons:
i. The total number of machine setups affects the
cost
ii. Achieve the maximum relative positional
accuracy
Design Guidelines
• Inner Edges
• Thin Walls
• Holes:-
i. Extended Holes
ii. Edge Drilling
Inner Edges
•In designing inner edges, the most commonly
recommended vertical corner radius is one-third
of the cavity depth or more.
•In using the recommended corner radii, one

should use a diameter tool that follows the
suggested cavity depth guidelines.
Thin Walls
•Thin walls can be tricky as decreasing the wall
thickness reduces the stiffness of the material, thus
increasing vibrations during machining and lowers
the achievable accuracy.
• Recommended minimums vary based on materials

and tools, but a common guideline machinists work
with is 0.8 mm for metals, 1.5 mm for plastics
Holes
•With holes, it is best to keep the drilling depth low and not to engage in flat-bottomed
holes unless completely necessary, as these can be quite tricky or require specialized
tooling.
•Holes are machined using either a drill bit or an end mill tool and ones with tighter
tolerances require finishing using reamers and boring tools. For high accuracy holes with
a smaller than 20 mm, using a standard diameter is highly recommended.
Extended Holes
•For extended holes, the part can be drilled
from both sides but it’s quite important to
recognize that there will be a mismatch
where the two holes meet.
•To counter such a mismatch users can apply

jigging.
Edge Drilling
•For edge drilling, one must ensure that the entire diameter
of drill is contained within the part.
•If this is not the case, the drill may break, surface finish
could turn out poor and the sharp edge created at the
corner is likely to fold.
• If completely necessary, drill the part first and then mill

material away to leave a partial hole.
Tapping
• Internal threads are usually cut with taps and external threads with dies
• CNC threading tools are common and machinists prefer them because they can limit the
risk of tap breakage
• There are many different types of taps and each have their own qualities.
◦Cut taps
◦Form taps
Thread mills
• These are inserted along the axis of the spindle using helical interpolation to create the thread
• In terms of speed, a high-speed tapping center set up with a rigid tap can thread holes in a
fraction of the time it would take to thread mill the same holes.
• Typically taps and thread-mills are for the internal threads and threading dies and thread-mills for
the external threads.
• Major limitation of tapping centers is that a different size tap is required for each different size
hole.
Smaller features
•Tough after a certain minimum scale
and size.
•Machining cavities and holes below 2.5
mm (0.1”) in diameter is considered
micro-machining.
• Require specialty tools and expertise
Undercuts
•There are different design practices for different kinds of undercuts. The two most common ones are:
•Dove-tail undercuts:
• Dovetail cutting tools vary based on their angle.
• The standard angles used are 45 and 60 degrees.
• If you are designing a part with an undercut on an internal wall, be sure you leave enough clearance
room for the tool.
• T-slot undercuts
• Tools for T-slot cutting feature a horizontal cutting blade on a vertical shaft
• The undercut’s width can be anywhere from three millimeters to 40 millimeters.
• It is recommended that you use whole increments or commonly used fractions when defining your
undercut width.
Chamfer
•A chamfer is a slope cut where two surfaces meet at a
sharp edge.
• This helps ease up assembly for inserting bolts into holes
and reduces risk of injury when handling sharp objects.
•Deburring achieves a similar goal but by breaking the
edges of the part.
•This decreases the size in many instances so chamfering
the material is better for specific sizes.
•Additionally, the edge on a chamfer should be kept at 45°
unless it is vital to use another angle.
Fillets
•Fillets require the rounding of an interior or exterior corner
of the part.
•It’s better to keep any radius on the part greater than the
cutter radius leading to a more straightforward machining
process.
•Internal fillets, on the other hand, should be as large as
possible to allow a large-diameter tool to be used,
decreasing machining time.
•In general, the radius of the internal fillet should be greater
than 1/3 of the depth of the cavity to avoid tool-breakage.
Thank You
Mechatronics Elements
in CNC machines
Alwin Thomas George

Athul Karimbil
Kalidas Manu M
Vimal Joshy
Mechatronics
● Mechatronics is a branch of engineering that

focuses on designing, manufacturing and
maintaining products that have both mechanical
and electronic components.
● Mechatronics can also be termed as replacement
of mechanics with electronics or enhance
mechanics with electronics.
● It involves application of electrical,

mechanical, control and computer engineering to
develop the products, processes and systems
with greater flexibility, ease in redesign
and ability of reprogramming
Key Elements Of Mechatronics
● Mechanical
● Electro mechanical
● Electrical/
Electronics
● Control interface/
Computing hardware
Mechanical System
● Mechanical system includes:

-Mechanical elements
-Machines
-Precision mechanics
● Mechanical elements refer to mechanical
structure, mechanism, thermo-fluid, and
hydraulic aspects of a mechatronics system.
● The mechanical elements of mechatronics systems
require physical power to produce motion,
force, heat, etc.
Electro- Mechanical System
● Electro- mechanical elements refers to

○ Sensors
○ Actuators
Actuators
An actuator is a device that produces a motion

by converting energy and signals going into
the system. Actuators such as:
–light emitting diode
–DC servomotor
–stepper motor
–Relay
–Solenoid
–shape memory alloy
–Electromagnet
Sensors
Used to measure a variety of physical
variables like:
–light using photoresistor
– level and displacement using potentiometer
– direction/tilt using magnetic sensor
– sound using microphone
–stress and pressure using strain gauge
– touch using micro-switch
– temperature using thermistor
–humidity using conductivity sensor
Electrical & Electronics
➔ The electrical/electronic elements are used to
interface electro-mechanical sensors and
actuators to the control interface hardware
elements.
➔ Electronic elements refer to:
–analog/digital electronics
–Transistors
–Thyristors
–opto-isolators
–operational amplifiers
–power electronics
– signal conditioning
➔ •Electrical elements refers to :
–Electrical components
–Circuits
–Analog signal
Control Interface / Computer hardware software
● The control interface hardware allows analog/digital interfacing, i.e.,

communication of sensor signal to the control computer and communication of
control signal from the control computer to the actuator.
● Computer elements refer to hardware/software utilized to perform computer-

aided dynamic system analysis, optimization and PC-based data acquisition and
control.
● Control interface/computing hardware elements refer to:

○ analog-to-digital (A2D) converter
○ digital-to-analog (D2A) converter
○ digital input/output (I/O)
○ data acquisition and control (DAC) board
○ digital signal processing (DSP) board.
Let’s take an example ...
CNC Milling Machine

MECHANICAL COMPONENT ELECTRICAL COMPONENT :
:
1. MICROCONTROLLER BOARD
1. BALL SCREWS
2. STEPPER MOTOR
2. BALL BEARINGS
3. STEPPER MOTOR DRIVER BOARD
3. LINEAR RODS
4. LIMIT SWITCHES
4. SHAFT END SUPPORTS
Ball Screws
1. A ball screw is a mechanical linear actuator that
translates rotational motion to linear motion with little
friction.
2. A threaded shaft provides a helical raceway for ball
bearings which act as a precision screw.
3. As well as being able to apply or withstand high thrust
loads, they can do so with minimum internal friction.
Ball Bearings
1. A ball bearing is a type of rolling-element
bearing that uses balls to maintain the separation
between the bearing races.
2. The purpose of a ball bearing is to reduce
rotational friction and support radial and axial
loads.
Linear Rods
1. Linear rods are rigid strong Mild Steel shafts which are
used to carry the load without affecting the motion and
supports linear movement.
2. Linear rods with linear bearing assembly are used to
carry the loads and supports the structures in linear
motions.
Shaft End Support

1. Shaft supports are used to support linear rods /shafts
rigidly without slip.
2. Shaft support blocks are used for end or intermittent
support where loads are light and slight shaft deflection
is not a concern.
Stepper Motor
1. A stepper motor is a brushless, synchronous

electric motor that converts digital pulses
into mechanical shaft rotation in a number
of equal steps.
2. The motor's position can then be commanded
to move and hold at one of these steps
without any feedback sensor (an open-loop
controller).
Servo Motor
A servo motor is a closed-loop motor that is

linked to an encoder that provides position and
speed feedback. The mechanism uses this feedback
to determine its motion. The controller sends an
error signal to the motor if it is not in the
right position, signaling it to continue its
motion until it reaches the desired position.
MCU & Motor Driver Board
➔ used as the motion control board.

➔ The microcontroller is flashed with the
GCODE interpreter firmware
➔ Motion control is carried away through
output pins connected to the stepper motor
drives according to the firmware code in
microcontroller
➔ Driving a stepper motor is a bit more
complicated than driving a regular brushed
DC motor. Stepper motors require a stepper
controller to energize the phases in a
timely sequence to make the motor turn.
Limit Switches
1. A Limit Switch is the simplest type of

end stop a simple mechanical switch
positioned to trigger when a axis
reaches the end of its motion.
2. Limit switches are used to protect the
stepper motor and circuit by shutting
the motors by triggering the switch
when the axis reaches its end .
3. The signal pin from limit switches are
connected to the microcontroller board
to sense the axes ends
Thank You
SENSORS AND
TRANSDUCERS
MACHINE TOOLS & CNC SYSTEMS JAYAKRISHAN PS PARVATHI MOHAN

GROUP 14 DEEPA MENON NYMA NAZREEN
Presentation Outline
Introduction to Sensors & Transducers

Definition of Sensors & Transducers
Specifications of Sensors & Transducers
Classifications of Sensors & Transducers
Incorporation into CNC Machines
General Applications
COVID 19 Aspect
MACHINE TOOLS & CNC SYSTEMS SEMINAR GROUP 14

What is a sensor ? A sensor is a device that detects and responds to some type of input
from the physical environment. The specific input could be light,
heat, motion, moisture, pressure, or any one of a great number of
other environmental phenomena. The output is generally a signal
that is converted to human-readable display at the sensor location
or transmitted electronically over a network for reading or further
processing.

What is a A transducer is any device that converts one form of energy into a
readable signal. Many transducers have an input that is then
transducer? converted to a proportional electrical signal. Common inputs include
energy, torque, force, light, position, acceleration, and other physical
properties. The output obtained from transducers is always in the
electrical form, which is proportional to the measured quantity
applied to the device.

Sensor specifications inform the user about deviations from the
ideal behaviour of the sensors. Following are the various
Sensor Specifications
specifications :
Range
The range of a sensor indicates the limits between which the input can vary.
For example, a thermocouple for the measurement of temperature might
have a range of 25-225 °C.
Span
The span is difference between the maximum and minimum values of the
input. Thus, the above-mentioned thermocouple will have a span of 200 °C.
Error
Error is the difference between the result of the measurement and the true
value of the quantity being measured. A sensor might give a displacement
reading of 29.8 mm, when the actual displacement had been 30 mm, then the
error is –0.2 mm

Accuracy
The accuracy defines the closeness of the agreement between the actual
measurement result and a true value of the measurand. It is often
expressed as a percentage of the full range output or full–scale deflection.
Sensitivity
Sensitivity of a sensor is defined as the ratio of change in output value of
a sensor to the per unit change in input value that causes the output
change.
Nonlinearity
The nonlinearity indicates the maximum deviation of the actual measured
curve of a sensor from the ideal curve.
Resolution
Resolution is the smallest detectable incremental change of input parameter
that can be detected in the output signal. Resolution can be expressed either
as a proportion of the full-scale reading or in absolute terms.

Response time
Response time describes the speed of change in the output on a stepwise change of the measurand. It is
always specified with an indication of input step and the output range for which the response time is
defined.
Repeatability
It specifies the ability of a sensor to give the same output for repeated applications of the same input value. It is
usually expressed as a percentage of the full range output:
Repeatability = (maximum – minimum values given) X 100 ⁄ full range

Classification of Sensors

Based on the power requirements:
1. Active Sensors :
They don’t need any external energy source but directly generates an electric signal in response to
the external.
Example: Thermocouple, Piezoelectric sensor.
2. Passive Sensors :
They require external power called excitation signal. Sensors modify the excitation signal to provide output.
Example : Strain gauge
Based on Contact and Non-Contact type :
1. Contact type: This requires physical contact to measure the parameter.

Example: Strain gauges, temperature sensors.
2. Non-contact type: It requires no physical contact.

Example: Optical sensors, Magnetic sensors, Infrared thermometer.

Based on physical parameters:
1. Flow
Orifice plate, Turbine plate
2. Pressure
Piezo-electric sensors
3. Level
Floats, radar sensors
4. Temperature
Thermistors, Thermocouples
5. Proximity and displacement
Optical encoders, pneumatic sensors
6. Velocity and motion
Tachogenerator, Incremental encoder
7. Force
Strain gauge load cell

Classification of Transducers

Active and Passive Transducers:
1. Active Transducer/ Self-generating Type Transducer:

No need for any external source of power for their operation. self-generating type transducer.
Examples: Piezo-electric, Electromagnetic.
2. Passive Transducer:
Needs an external source of power for their operation.
Examples : Resistive, Inductive,Capacitive transducers.
Analog and Digital Transducers:

Based on the output which may be a continuous function of time, or in discrete steps.
1. Analog Transducers:
This type of transducer converts the input quantity into an analog signal output.
Example: LVDT, Thermocouples, or thermistors
2. Digital Transducers:
They generate an electrical output in the form of pulses which form a unique code which is generated for each
discrete value sensed.

Primary and Secondary Transducers:
Some transducers consist of a mechanical device along with an electrical device. In such types of transducers, the
mechanical device acts as a primary transducer and converts physical quantity into the mechanical signal. The
mechanical signal produced by the primary transducer converts into an electrical signal by the electrical device and it
is called a secondary transducer. Therefore, an electrical device acts as a secondary transducer.

Feedback System in
CNC Machines
The closed-loop system has a feedback

subsystem to monitor the actual output
and correct any discrepancy from the
programmed input.

Variable factors
Lead screw non linearity
affecting feedback
system Static deflection
Tool wear
Resolution

Sensors Application of displacement detection
incorporated into
CNC Machines Application of speed detection

Application of pressure detection

Temperature detection and application

Tool wear monitoring


Application of The sensors in CNC machine tools for displacement
detection mainly include
displacement
detection Encoders
Linear Scales

Optical • A device to measure the angular displacement.
• It cannot measure linear displacement directly so error may occur
Encoder due to backlash of screw and motor etc.
• The encoders generally come in two forms:
- Absolute encoder
- Incremental encoder.

Incremental Absolute
Encoder Encoder
• The encoder disk of an • An absolute encoder the

incremental encoder encoder disc is etched
consists of one track and with distinct positions, so
two sensors. that the associated sensor
• It can only measure the can know the exact
relative position position of the shaft.
• Can be binary or grey
code.

Linear Scale • It measures the absolute and exact position of the slide directly
• It is a graded scale made up of glass or stainless scale along with
measuring surface and sacnning unit

Application of speed detection
• Can detect both linear speed and angular speed

• Commonly used are pulse encoders and tachogenerators
• Mainly used in the speed detection of the cnc motor unit
Application of pressure detection
• A pressure sensor is a collective term for detecting a kind of

interaction energy between solids and gases
• According to the working principle of the pressure sensor, it can be
divided into capacitive, piezoelectric, and piezoresistive sensors.
• The pressure sensor can detect the clamping of the workpiece in the
CNC machine

Temperature detection and application
• The temperature sensor detects the temperature in the CNC machine tool
and then performs corresponding overheat protection and temperature
compensation
• Commonly a thermistor sensor or thermal resistance sensor is used
• Temperature sensors are installed on some parts of the CNC machine tool
that are susceptible to temperature

General
Application
A sensor and a transducer are used to

sense a change within the environment
they are surrounded by or an object
they are attached to, but, a sensor will
give an output in the same format and a
transducer will convert the
measurement into an electrical signal.

Why do we use
them?
Operating the system efficiently.

Monitoring the operations for any
abnormalities.
Controlling the operations.
Utilizing the resources effectively.
Making design changes to improve
performance further.
Enhancing Future product portfolio.

Types Properties Technology
Temperature Sensor Distance Acoustic

Proximity Sensor Temperature Capacitive
Infrared Sensor Sound Intensity Electro Magnetic
Light Sensor Pressure Electro-Mechanical
Accelerometer sensor Proximity Thermistor
Pressure Sensor Speed Hall effect
Ultrasonic Sensor Velocity Inductance
Touch Sensor Torque Infrared
Smoke, Gas, Alcohol Tilt Laser
Humidity Sensor Oxygen Microwave
Flow and level sensor Acceleration Radiofrequency
Tilt Sensor Altitude
Motion

Automotive
Braking and Traction Control:

Antilock Braking System (ABS) Sensors connected to the wheel,
measures the speed of the wheel and braking pressure and keeps
sending them to ABS controlling When the driver applies the sudden
brake, ABS system, with breaking pressure and speed data received
from the sensors, releases the braking pressure to avoid
skidding/locking of wheels. It is one of the critical safety aspects of
vehicles.
Air Bags:
Anti Cushion Restraint System (ACRS): Crush sensors and
accelerometers placed in the vehicle measures the force and sends it to
During accidents on sensing the force exceeds the limit, ACRS will
activate the Airbag and save the life of passengers.

Avoiding Collisions:
Proximity sensors in the front, back, and sides of the vehicle
forewarn the driver of a possible Infrared, Video assistance,
Ultrasonic technologies assist drivers while parking their vehicles.
Comfort and Convenience:

Many sensors provide inputs and warnings to drivers on Vehicle
Speed, Engine Speed, Fuel level, Tire pressure, Door/deck, light
bulbs for driving comfort and convenience.
Engine Data:
Sensors provide so much data on Engine performance, such as
Ignition, Combustion, Exhaust gas oxygen, Fuel mix, Exhaust gas
recycling, Transmission control etc.,

Manufacturing
Predictive maintenance of the machinery, Assembly equipment using the data collected from sensors in
the machines.
Optimal utilization of Machines by continuously monitoring the performances and effectively rejigging
the operations with the data collected from sensors.
Fine-tuning the Quality systems and enhance the quality standards using the data collected from
sensors. Design notifications and alerts in case of a deterioration of quality and process standards.
Agility in reacting to market demands.

Aviation
Sensors deployed in the aviation industry measures the data during navigation
of aircraft, monitoring various systems, and controlling instruments. These
data are utilized inefficient flight operations, improve aircraft performance and
design improvements.
Some of the instrumentation sensors are tachometers, gauges to measure
engine pressure and oil& fuel quantity, Altimeters, airspeed meters, etc.
Sensors help measure the testing of the ground conditions, vibration and
environment factors and provide useful inputs to the pilot to manage the
general operation and emergency conditions.
Marine
Sensors in ship measures fuel tank levels, liquid cargo levels, tank pressure/temperature.
Pitch, roll, speed and other vessel moments are also measured and monitored with
sensors’ help.
There are a lot of sensors in Engines measuring typical attributes of internal combustion
parameters.

Temperature Transducer
A temperature transducer is used to measure the temperature of the air such that to control the
temperature of several control systems like air-conditioning, heating, ventilation, and so on.

Piezoelectric Transducer
This transducer is mainly used to detect the stick drummer’s impact on electronic drum pads. And
also used to detect the movement of the muscle, which can be named acceleromyography.
The load of the engine can be determined by calculating diverse absolute pressure, which can be
done by using these transducers in fuel injection systems.
This sensor can be used as a knock sensor in automotive engine management systems for noticing
the knock of the engine.

Pressure Transducer
The applications of pressure transducers mainly involve altitude sensing, pressure sensing, level or
depth sensing, flow sensing, and leak testing.
These transducers can be used for generating electrical power under the speed breakers on the
highways or roads where the force of the vehicles can be converted into electrical energy.

COVID 19 Aspect
With the onset of COVID 19, the usage of sensors & transducers have been in used various groundbreaking
methods in order to tackle the pandemic
Blood pressure monitoring (self).

Continuous glucose monitoring by Individuals.
Automatic measurement of vitals of the patient and
sending it to the patient’s doctor.
More home care facilities and ambulatory treatments.
Automatic detection of visitors spreading the disease to
patients in hospitals.
Decentralized laboratories.
Robotics in Operation Theater.

MACHINE TOOL TESTING
AMAN SINGH B191211PE

TEDY FRANCY VALAMPARAMBIL B191115PE
VISHAL KUMAR B191196PE

PANCHAGIRI NAVEEN B181085PE
INTRODUCTION
Machine tools for the workshop must be able to produce work piece of given accuracy
within prescribed limits consistently and without require in artistic skill on the part of the
operator and that quality of work pieces depends upon:
1. Stiffness and Rigidity of the machine tool and its component parts.
2. The alignment of various machine parts in relation to one another.
3. The quality and accuracy of the control devices and the driving mechanism.
INTRODUCTION
Machine tools are tested at various stages, during assembly, after assembly, installation,
repairs or overhauls as per accuracy test chart in order to determine whether it meets
requirement of specification or not.
Acceptance test for a machine tool:
1. Alignment Test or Geometrical Test
2. Performance Test or Practical Test
DIFFERENTIATE BETWEEN ALIGNMENT AND PERFORMANCE TEST
ALIGNMENT TEST PERFORMANCE TEST
• Various geometric checks are carried out • Actual Performance of job on machine tool is
known as alignment test. performance test.
• These tests are carried out at static conditions. • These tests are carried out at working
conditions.
• These tests are checking positions of
component and displacement to one another. • It is checking of job manufacturing on
machine and tolerance limit as per design.
• Alignment of axis of lathe spindle to saddle
movement. • Manufacturing of lathe.
FACTORS AFFECTING WORKING
ACCURACY
In addition to the manufacturing accuracy the working accuracy of the
machine is influenced by the following factors.
1. Geometry of the cutting tool (rake angle, clearance angle)
2. Material of the cutting tool, shape and rigidity.
3. Material of the work piece, its size, shape and rigidity.
4. Cutting speed, feed and depth of cut.
5. Work holding and clamping equipment.
6. Skill of operator.
7. Working conditions.
VARIOUS GEOMETRICAL TESTS
a. Straightness
i. Straightness of a line in two planes
ii. Straightness of sideways of machine tools
iii. Straight line motion
b. Flatness
c. Parallelism, equidistance and coincidence.
Parallelism includes
i. Parallelism of lines and planes
ii. Parallel motion
iii. d. Rectangular movements or squareness of straight lines and planes. Quality of the guiding
and bearing surface of beads, upright and base plates are also tested.
e. Rotation
f. Movement of all the working components
PARALLELISM BETWEEN TWO PLANES
1. The dial gauge is to be arranged on the base with a stand.
2. The Reading of a dial gauge is at the initial position move the
base on a plane.
Here we can see the variation of dial gauge.
The variation within the given range then the plane (1)&(2) are
parallel to each other.

PARALLELISM OF TWO AXES
1. The instrument used for testing is dial gauge indicator it is supported on base of such shape that
base slides along one of the cylinders.
2. Dial indicator is so adjusted that is plunger slides along one of the cylinders.
3. The Maximum deviation between the axes of cylinders at any point may be determined by rocking
dial.
PARALLELISM BETWEEN AXIS AND PLANE
1. Arrange the dial gauge indicator on the table with stand which is considered as the plane for a
Reference.
2. Touch the pointer of a dial gauge plunger to the mandrel.
3. If the variation is with the given range the axis is parallel to the plane.
PARALLELISM TESTING OF LATHE AXIS WITH LATHE BED
In testing of lathe axis With lathe bed we have to check in vertical and. Horizontal plane.
Measuring instruments: Test Mandrel with taper shank (or) 300 mm long
Cylindrical measuring part and dial gauge.
Procedure: The Dial gauge is mounted on the saddle the dial gauge spindle is
Made to touch the mandrel and the saddle is moved to and fro
it is checked in vertical as well as in Horizontal plane.

Permissible error:
1. 0.2/300 mm mandrel rising towards free each only.
2. 0.2/300 mm mandrel inclined at free end towards tool pressure is on

PARALLELISM OF TAILSTOCK SLEEVE TO SADDLE MOVEMENT
• Measuring instrument : Dial indicator.

• Procedure. Tailstock sleeve is fed outwards.
The dial gauge is mounted on the saddle. Its spindle
is touched to the sleeve at one end and then saddle
is moved to and fro, it is checked in H.P. and V.P. also.
• Permissible error
(a) 0.01/100 mm (Tailstock Sleeve inclined towards tool pressure only).
(b) 0.01/100 mm(Tailstock Sleeve rising towards free end only).
TRUE RUNNING OF HEAD STOCK CENTRE
• Measuring instrument : Dial gauge.
• Procedure. The live center is held in the tail
Stock spindle and it is rotated. Its trueness is

checked by means of a dial gauge.
• Permissible error - 0.01 mm
FLATNESS OF WORK TABLE
(a) In longitudinal direction. (6) In transverse direction
• Measuring instruments : Spirit level.
• Procedure. A spirit level is placed directly on the

table at points about 25 to 30 cm apart, at A,B, C
for longitudinal tests and D, E and F forth transverse
test.
The readings are noted.
• Permissible error : Direction A-B-C , + 0.04 mm
Direction D-E-F,+ 0.04 mm
SQUARENESS OF CLAMPING SURFACE OF TABLE TO ITS AXIS
• Instruments : Dial gauge.

• Procedure : The dial indicator is mounted in the tapered
hole of the spindle and its feeler is made to touches the

surface of table. The table is then moved slowly and the
readings of dial gauge noted down.
• Permissible error : The permissible error should

not exceed 0.05/300 am diameter.
TRUE RUNNING OF SPINDLE TAPER
• Instruments : Test mandrel, dial gauge.
• Procedure : The test mandrel is placed in the tapered hole of
spindle and a dial indicator is fixed on the table and its feeler
made to scan the mandrel. The spindle is rotated slowly and
readings of indicator noted down.
• Permissible error : The error should not exceed 0.03/100 mm

for machines with taper up to Morse No. 2 and 0.04/300mm
for machines with taper larger than Morse No. 2.
SQUARENESS CHECKING BETWEEN TWO PLANES
• Squareness of two planes 1and 2, is checked by placing the square on one plane and then checking
the parallelism of 2nd plane with the free arm of square by sliding the dial indicator along 2nd plane
and its feeler moving away the free arm of the square variation in dial indicator within limits.
Squareness is ok.
SQUARENESS OF AN AXIS OF ROTATION WITH A GIVEN PLANE
• a dial indicator is mounted on the arm attached to the spindle

• adjust the position of plunger
• will be parallel to axis of rotation

• plunger made to touch the plane
• revolve the spindle slowly.
• note down the readings

ALIGNMENT TEST ON PILLAR TYPE DRILLING MACHINE
• Test - flatness of clamping surface of base

• Clamping surface over base as shown in figure
• Two gauge blocks separated by a distance on the base

• Straight edge just over the gauge blocks
• Error should not exceed 0.1/1000 mm clamping surface
• Error within limit then surface is flat

FLATNESS OF A WORK TABLE ON A MILING MACHINE CAN BE
MEASURED USING STRAIGHT EDGE
• Part above milling machine is straight edge.
• Feeler gauge to be placed in gap.
• To put the plate of different thickness in plate .

• Perfectly fitted feeler gauge of defined thickness is the gap.
• If thickness is within limit, surface is flat .
DIFFERENTIATE BETWEEN ROUNDNESS AND
CIRCULARITY
ROUNDNESS CIRCULARITY
• Defined as a condition of a surface of • Defined as a two-dimensional geometric tolerance
revolution (like cylinder, cone or that control how much a feature can deviate form
sphere)where all points of the surface a perfect circle.
intersected by anyplace perpendicular to the
common axis in case of cylinder and cone or
passing through common center in case of
sphere • Circularity is the Characteristic form of the entire
• Roundness expresses a particular geometric periphery of a plane figure i.e. two dimensions.
form of a body of revolution in all the three
THANK YOU
DDA INTERPolATION
By
➢ Yash Ingle (B191239PE)
➢ Muhammed Shafeel K (B191102PE)
➢ Rajayogeshwar G (B190597PE)
➢ Fazil KT (B190451PE)
INTRODUCTION
❑ Calculation of the coordinated movement of several axes

using the programmed parameters, in order to obtain a
resulting trajectory
❑ The operation of producing the required shape based on

information is termed as Interpolation and the corresponding
electronic unit is the Interpolator.
❑ Interpolation Module > Servo Module > Motors

TYPES OF INTERPOLATORS
❑DDA Hardware Interpolator.

a) Linear Interpolator.
b) Circular Interpolator.
c) Complete Interpolator.
❑CNC Software Interpolator.
❑Software DDA Interpolator.
❑Reference word CNC Interpolator.
DDA Algorithm
❑Algorithm for digital integration
❑Generates a pulse train varying in frequency.
❑Digital integration is performed by successive additions
using an Euler approximation method.
Where,
2D Linear Interpolation
❑ The ability to control the

movement along a straight line
between given initial and final
coordinates.
❑ It supplies velocity commands, in
pulses per second, simultaneously
to two machine axes and adjusts the
ratio between the pulse frequencies
depending on the slope of the
trajectory.
x
DDA-based Linear Reference
Pulse Interpolator
Servo Control
Linear Interpolator
Advantages Disadvantages
❑Simplicity ❑Not accurate

❑Less computation ❑Not smooth
❑ Not fast
CNC software interpolator
❑In CNC system ,the interpolation is performed
by means of a special routine which generates
command signals for each segment of the
produced part based on the initial and final
points and type of curvature of the segment.
Two main types of CNC systems
• Reference Pulse System

• Sampled Data System
Reference pulse system
❑The computer produces a sequence of reference
pulses for each axis of motion.
❑Each pulse generating a motion of one BLU.(Basic
Length Unit)
❑The pulse frequency is proportional to the axis
velocity.
❑These pulses can either actuate a stepping motor in
an open loop system or be fed as a reference to a
closed loop system.
Open loop and Closed loop controls
Sampled data system
❑The control loop of each axis is closed through the
computer itself, which generates reference binary
words.
❑Maximum velocity is not limited by the computer but
the interpolator routine is more complex.
❑Control loop gain is lower, which results in larger axial
positions errors.
Software DDA Interpolator
❑It is based on the operation of hardware DDA

interpolator.
❑The DDA interpolator requires successive addition
operations in order to create new interpolated points.
❑It is suited for assembly language simulation.
❑The rate of iterations in the hardware interpolator is
controlled by a high frequency clock.
❑Clock frequency will be in the range of 100 KHz.
Reference word CNC Interpolator
❑ In reference pulse systems a pulse train of varying frequency is
output to the servo control module.
❑ The servo system for an axis causes an incremental displacement
along the axis, for each pulse. As mentioned before, this can cause
a speed limitation for the CNC, depending on the execution speed
of the interpolation loop.
❑ In contrast, in reference word interpolation systems the maximum
velocity is not limited by the execution speed of the processor.
❑ The interpolation subroutines continuously provide velocity set
points to the servo system, which realizes it through the drive.
❑ we discuss a circular interpolation using the reference word
method. This require the use of a “controlled speed drive” rather
then a “position servo”.
❑ In circular interpolation, at a constant tangential velocity, V and
radius R, the axial velocities satisfy the following equations:
❑The velocity components Vx and Vy are computed by the

circular interpolator and are supplied as reference inputs to
the computer closed loops.
❑The more the number of sides of the polygon, the better is
the accuracy of the generated circle. The optimal number of
sides is the smallest one for which the path error is within
one BLU.
❑Actually what is generated is a polygon inscribed on a circle.
At the beginning of each side the interpolator provides new
velocity references to the axes.
Position and velocities at two successive points on a
circle
❑From Fig. one can derive the following recursive update
eqns. for the two coordinate axes
❑where, cosα =A and sinα =B . The velocity set points for the
axis drives are computed as follows.
❑where K = V/Rα. These velocity set points are provided to

the servo control systems
Current Methods For Machining Of
Curves
Thank You
CNC PROGRAMMING
By : Mrityunjai
Dharma teja
Naresh
Elisha
OUTLINE
➢INTRODUCTION
➢STRUCTURE OF A PROGRAM
➢G-CODE
➢M-CODE
➢EXAMPLE
CNC PROGRAM STRUCTURE
• Four basic terms used in CNC programming:
Character -> Word -> Block -> Program
• Character is the smallest unit of CNC program.
• Word is a combination of alpha-numeric character.
• Each word begins with a capital letter, followed by numeral.
• Words are used to represent axes positions, federate, speed, preparatory
commands and miscellaneous functions.
• A program block may contain multiple words, sequenced in a logical order of
processing.
• The program comprises of multiple lines of instructions, ‘blocks’ which will be
executed by the machine control unit (MCU).
SAMPLE CNC PROGRAM
• Basically three sections viz. initial commands section; main
section and end commands section.
• In the initial commands section, the program number, its ID,
initial safety preparatory codes such as ‘cancel all the activated
cycles by previous program’ are to be specified.
• In the main section, commands/instructions related the machine
tool axes movements, tool change. Are to be mentioned.
• At the end, the commands instructing cancellation of cycles,
homing the tool and program end are to be provided.
SAMPLE CNC PROGRAM
TYPES OF POSITIONING SYSTEMS IN CNC
PROGRAMMING
• There are two types of positioning
systems in CNC programming, viz.,
incremental system and absolute
system.
• In the incremental positioning, the
locations are provided relative to
the immediately preceding point.
(shown in figure)
• In absolute positioning , location are
defined relative to the single fixed
point or origin.
• The origin may be a position on the
machine table , such as corner of
worktable or any specific point on the
workpiece.
INTERPOLATION
The method by which countering machine tool move from one
programmed point to next is called interpolation.
• In general mathematics , interpolation is the estimation of an value of
an intermediate point between two points with known value in
a range various points.
• There are five method of interpolation , viz.,
i. Linear interpolation
ii. Circular interpolation
iii. Helical interpolation
iv. Parabolic interpolation and
v. Cubic interpolation
LINEAR INTERPOLATION
• Linear interpolation consist of a number of
programmed point linked together by straight line
as shown in figure .
• Curve can be linearly interpolated by
breaking them into short, straight line segments .
• This method has limitation for
a smooth path with frequently changing
curvature because a very large number of
points would have to be programmed to describe
the required contour.
• A contour defined using linear
interpolation requires the coordinate positions for
the start and finish of each line segments.
therefore end point of one line or segment
become the start point foe next segment, and so
on , throughout the program.
CIRCULAR INTERPOLATION
• To interpolate an arc the machine

requires only the coordinate
position of circle , the start and end
point of arc being cut , and the
direction in which the arc is to be
cut (clockwise or counterclockwise.
CHARACTER ADDRESS
A- Rotation about X-axis. B- Rotation about Y-axis.

C- Rotation about Z-axis. D- Cutter diameter compensation (CDC) offset address
E- Rotation about special axis F- Feed function
G- preparatory function H- Tool length offset (TLO).
I- Arc center X-vector, also used in drill cycles J- Arc center Y-vector, also used in drill cycles.
K- Arc center Z-vector, also used in drill cycles L- Do not use
M-Code (miscellaneous code). N- Block Number.Program Number
O- Reference rewind stop P- Dwell time.
Q- Used in drill cycles R- Arc radius, also used in drill cycles
S- Spindle speed in RPM T- Tool function
U-Secondary motion dimension parallel to X* V- Secondary motion dimension parallel to Y*
W-Secondary motion dimension parallel to Z* X- Primary X motion dimension
Y- Primary Y motion dimension Z - Primary Z motion dimension
Main Programs are written using I.S.O. address codes listed below.
➢ N refers to the block number.

➢ G refers to the G code (preparatory function).
➢ X refers to the absolute /incremental distance travelled by the slide tool in the X
axis direction.
➢ Y refers to the absolute /incremental distance travelled by the slide tool in the Y
axis direction.
➢ Z refers to the absolute /incremental distance travelled by the slide tool in the Z
axis direction.
➢ F refers to the feed rate.
➢ M refers to the M code (miscellaneous function).
➢ S refers to the spindle speed.
➢ T refers to the tooling management.
G - CODES
• Preparatory functions, called G codes , describe the tool
movement such as linear cutting movement , drilling
directions and unit of measurement.
• They are normally programmed at the start of a block . A
G code defined using the G address letter and a two
digit number as follow
G ØØ
Address Two digit number

Some commonly used G - codes are as follows:
G00 - Fast traverse
G01 - Linear interpolation
G02 - Circular interpolation (Clockwise)
G03 - Circular interpolation (Counterclockwise)
G04 - DwellG20 - Input in inches
G21 - Input in mm
G28 - Go to reference
G40 - Cutter compensation cancel
G41 - Cutter compensation left
G42 - Cutter compensation right
G90 - Absolute coordinate system
G91 - Incremental coordinate system
G98 - Feed per minute G99 - Feed per revolution
M CODES
• Miscellaneous functions, called M codes , M codes are the instructions

describing the various miscellaneous functions like calling the tool , spindle
rotation, coolant on etc .
• * An M code is defined using the M address letter and a two digit number as
follows: Diagram
M ØØ
Address Two digit number

• Commonly used M codes are as follows:
• M03 - Spindle on clockwise
• M04 - Spindle on counterclockwise
• M05 - Spindle stop
• M06 - Tool change
• M08 - Coolant on
• M09 - Coolant off
• M30 - Program end
CNC PROGRAMMING : DRILLING OPERATIONS
➢ Write an efficient CNC part program

to drill 35 holes of diameter of 0.5
inch each in a machine component
as shown in the figure.
➢ The raw material to be employed is
mild steel plate of 0.4 inch
thickness.
APPLICATIONS OF
CNC MACHINES
Presented by:
JOEL SEBASTIAN, B190409PE
EDWIN ROY, B190121PE
FATHIMA NISHATH C.V, B190897PE
MEGHNA MARY SAJAN, B190595PE
MEDICAL INDUSTRY
• Consists of hospitals, clinics, manufacturing of medical
devices and equipment etc.
• CNC Machining plays a vital role in the manufacturing

of various medical devices ranging from the
sophisticated MRI Scanners, ultra sound equipment to
biomedical implants like hip implants, spine implants
etc. to even micromachining of extra small medical
devices like exploratory surgical tools, drug delivering
technologies.
WHY CNC MACHINING?
Machining in medical Wide range of

Medical device
industry is complicated materials used ranging Complex shapes and
compared to other machining requires from metal to plastic
great expertise. geometries required.
industries. as raw materials.
Comprehensive surface
Economical
finish required.
MACHINING OF STENTS
• Due to its ability to machine with the highest speed, precision, and quality, laser cutting
CNC Machines have been used in stent fabrication.
• Laser cutting is able to produce the thin walled stents from high quality metal alloys like
stainless steel, cobalt chromium alloys etc.
• The fine grid structures which are pre requisite for the impressive diameter expansion
ratios of stents can also only be machined by the precise laser cutting machines.
• Fiber lasers and ultrashort pulse lasers are the mainly used type of lasers.
• Here metal removal takes place chiefly by material vaporization.
• Little or no residue or molten material left behind with a clean backwall obtained finally.
DEFENCE INDUSTRY
Defense industry comprises of the government’s military capabilities across the naval, land,
aerospace, and electronic systems for defence and military requirements.
Applications of CNC in Defence

• Weapons Development
• Aircraft Parts
• Radar Technology
• Land and Combat Vehicles
• Naval Ship Components
WHY CNC MACHINING
• Weapon machining requires strict adherence to safety
practices and also require high precision and versatility.
• CNC machining helps to ensure that the Military aircraft

have very low observability (VLO). CNC made it possible
for the skins of the aircraft to be fabricated to such close
tolerances that adjacent parts match fluidly and precisely.
• Construction of radome.
MACHINING USING 6
AXIS CNC MACHINE
• Missiles are generally made using multi axis
cnc machines. The leading Raytheon company
uses a six-axis cnc milling machine. This allows
a single department to manufacture the entire
20-foot cruise missile on its own.
• The primary benefit 6-axis CNC milling offers
over the closely-related 5-axis configuration is
faster cutting times. With an additional axis of
freedom, certain tool movements and transitions
can be executed with greater speed and
efficiency.
MARINE INDUSTRIES
• Includes designing, constructing,

manufacturing, supplying, maintaining vessels
or parts, operating and managing shipping
lines, or crewing ships.
• CNC Machining is used for the machining of

polyurethane products like impellers, bears,
blocks etc and solid carbon fibre yacht keels.
Components of marine industries want
high-precision.
Turning and Milling (4 and 5 Axis)

machining is needed to make complex
WHY CNC components .
MACHINING? Faster, stronger and economical way of

sourcing low-volume components than
the pattern making and casting process.
Its highly necessary to maintain the
standard tolerance and critical
dimensions.
CAD file created
Two roughing and finishing procedure is decided.
In the first roughing, higher depth of cuts made(to reduce

MACHINING machining time)
OF
In the second roughing, finer cutting conditions are used for
IMPELLERS. the finishing.
The tool trajectories selected for these processes can be

cyclic spiral or straight lines.
Machining conditions ,i.e. Cutting speed ,feed rate and

depth of cut are chosen wisely so as to have smooth and
clear final surface.
Continued…
■ For the 2 roughing procedures, 2 flat end mills with different diameters are used.
■ For the finishing procedure, ball end mill is used
(a)CNC milling machine used for impeller manufacturing

(b)flat end cutting tool
(c) ball end cutting tool
(d) workpiece
(e)inside the cabin during the process
AEROSPACE
•Aerospace is the assemblage of manufacturing concerns that deal
with vehicular flight within and beyond Earths atmosphere
•Applications of CNC in Aerospace
• 3D Printing and production :Industry can save on the high cost
of wasted materials , error correction ,and missed working hours
by ensuring accurate and faster manufacturing
• 5 Axis machining is used to manufacture complex aircraft
components .This allows for parts to be milled ,drilled and
manipulated along X,Y,Z And linear axis.
• CNC Machining plays a vital part in aerospace research and This Photo by Unknown author is licensed under CC BY-SA.
development .
APPLICATION ALONG SECTORS:
1. AVIATION
From outer shells and wings to engines and cockpit components are manufactured.
2.SPACEFLIGHT
Spacecraft must be built and assembled with accuracy and precision.
WHY CNC MACHINING

⚫ CNC Creates strong , light weight , and complex plastic parts for the aerospace industry.
⚫ Accuracy is important in aircraft construction.
⚫ Aerospace machining offers high precision.
⚫ Reduces potential for human error by automating manufacturing process.
⚫ Offers compatibility with an extensive variety of materials and providing seamless fabrication
of these metals.
MACHINING OF LANDING GEAR
It should be manufactured to a minimum volume or size in order to
reduce the space requirements.
Involves high strength steels, titanium and aluminum alloys.
Precise tolerances are required for all components such as

actuators, axles, shock absorbers and wheels.
Heat treatment is performed after the initial rough machining.
Final machining, plating and painting are completed

THANK YOU
CNC MACHINES –
THE LATEST
TECHNOLOGIES
SL. 3 ASADI SRI SAI HARSHITHA B190592PE
SL. 5 AYUSH KUMAR B190883PE
SL. 7 BANOTH AKHILA B190914PE
SL.28 MODEPALLI VENKATA CHANDU B190459PE
CNC MACHINING
CNC machining can be defined as a process in which
pre-programmed computer software dictates the
movement of factory machinery and tools.
Having the following as advantages,

● Reduced Manufacturing time
● Cost efficient
● Highly flexible
● High accuracy
● Increased Productivity
● Can perform Complex machining operations
● Versatile
WHY SHOULD WE LEARN
NEW TECHNOLOGIES?
▪ CNC milling is the most common type of computer
numerical control (CNC) machining, even more
widely used than 3D printing.
▪ Combined, the CNC machines market is constantly

growing and is predicted to have a global value of
$93.45 billion by 2024. Much of that market growth
will be driven by innovations and trends in CNC
milling techniques.
▪ Developments in CNC machine technology made it

more cost efficient, Versatile, made complex
manufacturing easier.
NOW, WE WILL SEE THE NEW
TECHNOLOGIES/TRENDS IN CNC
MACHINING
1.HIGHER - SPEED & ACCURACY
• The current CNC systems use a higher-frequency processor
with a bit-digit.
• Ultra-large-scale integrated circuits and multi-processor

structures are used to to improve the data processing
capability of system, that is to improve the speed and
accuracy of the interpolation operations.
• Upgrading to a five or six axis machines
• The use of feed-forward control technology greatly

improves the machining accuracy.
Fastest CNC in The world:- INTEGREX i- 400 S
2. BoXZY
BoXZY = 3D printer+CNC mill + Laser Engraver
MULTI- AXES CNC MACHINES
▪ Modern-day multi-axis CNC Milling Machines come with a wide
range of features, which adds value and functionality. However,
these are only useful when the machine can move seamlessly
along its axes.
▪ Furthermore, these axes are primarily responsible for maintaining
accuracy in shaping the feed..
3-Axis CNC Machining
▪ 3-axis CNC machining evolved from rotary filing. Here, the work
piece occupies a stationary position while the cutting tool moves
across the X-, Y-, and Z-axes. The X-axis is along with the lathe table,
the Y-axis is towards the front/back of the table, and the spindle that
drops from the top marks the Z-axis.
▪ It is ideal for simple tasks that do not require intricate detailing or

depth. As such, it is one of the most preferred techniques for
creating mechanical parts for automation. Additionally, you can
also use it for cutting sharp edges, boring, milling slots, tapping, and
drilling holes.
Limitations
3-axis machining possesses the following limitations:
▪ It functions in a complex programming environment.

▪ The initial capital investment and the installation costs are high.
▪ It requires highly skilled professionals for operating and maintaining
the machine.
▪ 4-axis machining involves an additional axis apart from the usual X,
Y, and Z planes. This extra movement is present in the form of
rotation along the X-axis, which forms the fourth plane – the A-axis
(horizontally). However, the cutting may also take place along the
B-axis (vertically). But since Horizontal Machining is considered
more productive than Vertical Machining, the former is more
common.
▪ This milling technique is useful for cutting holes, cutting along an
arc, or carving cutouts, especially on the sides or around a
cylinder. It is also useful for high-quality precision engravings,
millings, and drillings.
Limitations
▪ The greatest limitation of the 4-axis milling machine is its Geneva
Mechanism. While the Geneva Mechanism is quite common for its
simplicity, reliability, and precision, it allows the 4th axis only in
principle. However, it does not support continuous machining in
practicality as it possesses a fixed set of stops. Hence, the operators
can only use the machine as a pure indexer. Other drawbacks
include:
▪ Quick wear and tear of the worm gear mechanism, especially
during high-intensity use.
▪ The issue of backlash can affect your accuracy or the durability of
the machine.
▪ In this setup, the X, Y, and Z-axes are similar to a 3-axis
machine layout. The table then rotates along the A-axis, as it
does with the 4-axis. However, the 5-axis machine involves
the pivoting action at the joint of the table, followed by
rotation along the C-axis, which defines the fifth movement.
▪ 5-axis machining allows the operator to simultaneously hit

five different sides or more of a part depending on the
design complexities. Resultantly, the tool is highly capable of
creating highly precise products and parts. Hence, it should
come as no surprise that it finds wide usage in medical
technology, research and development, architecture,
military, automotive industry, and even creative arts. It also
finds use in hole drilling at compound angles.
Limitations
▪ While the 5-axis CNC machine is excellent in terms of speed and

accuracy, it ails with the following issues:
▪ The CAD/CAM programming for 5-axis machines can be extremely
complicated.
▪ Since 5-axis milling machines are not that common yet, purchasing
and maintaining one is quite a hefty investment. Similarly, the
tooling solutions are equally expensive.
▪ You would require a highly skilled CNC machine operator that you
can trust with your 5-axis beauty.
▪ The 7-axis CNC milling machine can create long, slender, and
heavily detailed parts. The 7-axes involved are the usual right-left,
top-down, back-front, followed by the axes defined by the spinning
of the tool, rotation of the part, rotation of the tool head, and
movement for clamping, reclamping, or removing the part. This
high degree of movement imparts greater accuracy to the finished
product without the need for post-fabrication processes.
▪ The 9-axis CNC blends lathe and 5-axis machining. As a result, the
part can be turned and milled along various planes in a single
setup, thereby offering sharp accuracy. One of the greatest
advantages of a 9-axis CNC is the elimination of secondary fixtures
and manual loading. The 9-axis CNC is highly capable to the point
where it can complete an entire fully-finished product in a single
operation!
▪ If 9-axis CNC machining is the whole package, then its 12-axis
counterpart is an absolute beast. The 12-axis CNC machines
typically contain two heads that allow movement along the X, Y, Z,
A, B, and C-axes. This configuration doubles the productivity and
accuracy while cutting down manufacturing time by half!
4.ROBOTS & COBOTS
▪ Robots and cobots (collaborative robots) have been used in CNC
machining in the past.
▪ Collaborative robots are effective and versatile and specifically
designed to work with humans.
▪ As machine learning accelerates and continues to be
incorporated into the programming, cobots will be able to
accomplish more.
▪ Humans, however, will still need to assist with running and
maintaining the cobots.
MACHINE TENDING
COBOTS FOR TENDING
OMRON COBOT UR5e FUSION OEM

IT WAS ABLE TO PRECISELY INSERT IT IS FOCUSED ON AUTOMATING
INBUILT VISION FEATURE
THE MULTI-THREADED PART INTO THE MACHINE TENDING SOLUTIONS
FIXTURING. THE CNC OPERATION FOR CNC TURNING & MILLING
INCLUDES 3 OPERATIONS IN A MACHINES TO INCREASE
VERTICAL MACHINING CENTER, 2 IN
PRODUCTIVITY.
VISE FIXTURES & 1 IN FOURTH-AXIS
ROTATORY UNIT
ROBOTS IN ASSEMBLY
▪ ASSEMBLY ROBOTS ARE USED FOR LEAN INDUSTRIAL
PROCESSES AND HAVE EXPANDED PRODUCTION
CAPABILITIES IN THE MANUFACTURING WORLD .
▪ AN ASSEMBLY LINE ROBOT CAN DRAMATICALLY INCREASE
PRODUCTION SPEED AND CONSISTENCY
▪ THEY ALSO SAVE WORKERS FROM TEDIOUS AND DULL
ASSEMBLY LINE JOBS
▪ END OF ARM TOOLING CAN BE CUSTOMIZED FOR EACH
ASSEMBLY ROBOT TO CATER TO THE MANUFACTURING
REQUIREMENTS.
▪ ADDITIONAL OPTIONS, LIKE ROBOTIC VISION CAN ALSO BE
INCORPORATED TO IMPROVE EFFICIENCY AND ACCURACY
OF PART ORIENTATION OR SORTING INDENTIFIERS
WELDING
5.CAD-CAM SOFTWARE
▪ CAD-CAM software facilitates the process
of transforming raw materials into finished
products
▪ It is used to program toolpaths & to
generate the G-Code that controls CNC
machines like mills, routers, lathes & wire
EDM’s.
▪ Used in manufacturing for increased
automation.
▪ Eliminates errors that can occur when
manually programming a CNC machine.
▪ Fusion360, SolidWorks 3D CAD, Solid Edge
CAM Pro are few top CAD-CAM tools.
▪ More affordable, accessible,
user-friendly and powerful.
▪ Upgraded CAD-CAM software
enables increased efficiency &
accuracy as well as even more
innovative workflows.
▪ It offers countless integrations with
machine platforms, model based
definition software , 3D viewing
systems and more.
▪ Emerging specially shaped cutters
to enable surface finishing.
MACHINE ALERTS ON
SMARTPHONES
▪ The latest innovation in CNC machining now includes alerts on your
mobile devices.
▪ The newly developed automation process has allowed users to

connect as many machines as possible in one system that will notify
the users through email or phone about the status of the machine.
MACHINING OF ICE
CNC MACHINES CAN CREATE
INTRICATE ICE SCULPTURES BY
CONVERTING VECTOR INFORMATION
INTO G-CODE TO MILL THE ICE.
IT PROVIDES A NEW WAY TO EXPRESS
CREATIVITY.
3D ON ROCKS
CONCLUSION
▪ CNC machining continues to stay relevant and effective, serving

various manufacturing-intensive sectors and maintains product
quality, precision, and standardization.
▪ CNC machines are versatile and efficient machines that continue

to evolve as demand continues.
THANK YOU
QUESTIONS
HISTORY AND WORKING PRINCIPLE OF CNC MACHINES
1. LIST AND EXPLAIN THE WORKING PRINCIPLE OF A CNC MACHINE?

2. WHAT ARE THE MAIN DIFFERENCES BETWEEN G CODES AND M CODES?
3. BRIEFLY EXPLAIN THE DIFFERENT PARTS OF A CNC MACHINE.
4. WHAT ARE PUNCHED CARDS? EXPLAIN ABOUT THE MACHINES IN WHICH
PUNCHED CARDS ARE USED.
5. GIVE A BRIEF ACCOUNT OF THE LATEST DEVELOPMENTS IN CNC
TECHNOLOGY.
TYPES OF CNC MACHINES
1. What are the additional components required in a closed loop system, compared to an
open-loop system ? Explain their functions briefly.
2. What is meant by the HMC axis convention of CNC machines? Explain.
3. Which positioning system is better and why? Absolute or incremental?
4. How does a point-to-point system help in reducing machining time? Explain.
5. What are the advantages of pneumatic drives over hydraulic drives? Explain
Construction, working and control of CNC machines
1.Explain various types of input devices used in construction of CNC machines.

2.differentiate between open loop and close loop feedback system
3.What is the working principle of CNC machine?
4.draw and explain briefly block diagram of CNC machine.
5.what is the function of machine control unit?
SPECIFICATIONS OF CNC MACHINES

1.What are the types of PLC’s. What is the most commonly used PLC and why.
2. Explain automatic tool Changer mechanism and its types.
3. Why ball screw is better than lead screw in applications?
4. Explain briefly about the central processing unit in PLC.
5.what are the safety functions installed in a CNC machine.
Features, Advantages, Disadvantages.
1. What are the main features of a CNC machine?

2. Name some profitable advantages of using CNC machines.
3. Write some applications of CNC machines.
4. Differences between CNC and NC machines.
5. What are some disadvantages of using CNC?
MACHINING CENTERS
1. Name any two advanced mechanisms used in CNC machining centers and explain any one
of them.
2.Why are CNC machining centers used?
3.What are the disadvantages of horizontal machining centers which are industrially an
advantage?
4.Write 4 differences between Horizontal and vertical machining centers.
5.An operator has to choose a machining centre for his requirements to manufacture 250 new
dies with a total of around 1,000 cavities where the shape and structure are complex with low
cost consideration. Suggest a suitable machining centre for the given operation and explain
why?
DESIGN OF CNC MACHINE TOOLS
1. What are the basic rules of design in CNC machine parts?

2. What are the different machine types used in designing?
3. Why thin walls are challenging when decreasing wall thickness?
4. What are the tool restrictions associated with design? Explain each one of them
5. What are the different kinds of undercut and the different design practices used for
them?
MECHATRONIC ELEMENTS IN CNC

1. What is Mechatronics? Explain various key elements of the mechatronics system.
2. What is the advantage of a ball screw over other types of screws?
3. What are the main electro-mechanical elements? Explain with example.
4. What is the role of the control interface in a mechatronics system?
5. What is limit switches?
SENSORS & TRANSDUCERS
1. Explain the working of linear scale for displacement detection in a CNC machine?
2. What are the variable factors affecting feedback signals in a CNC machine?
3. Explain the applications of sensors & transducers in the automotive industry with the
help of 2 detailed examples.
4. Which transducer is used to notice the knock of the engine? Explain it’s functioning &
application in noticing the knock of the engine.
5. Explain the following sensor specifications.
1. Span
2. Range
3. Error
4. Accuracy
6. How can sensors be classified based on the power requirements? Give suitable
examples for each.
Machine Tool Testing
1. Differentiate Between Alignment and Performance test.

2. Why working condition affect the working accuracy?
3. What is the procedure of parallelism of testing of lathe axis with lathe bed?
4. How do we check the flatness of a worktable?
5. What would be the proper way to check whether there is any gap between milling machine
and straight edge how to measure that gap?
Interpolation Questions
1. Define interpolator and interpolation.

2. What does the the servo drive do?
The servo drive coordinates the communication between the control board and the servo motor.
A command signal is sent from the control board.
The servo drive receives the signal and amplifies the low power signal up to move the servo
motor.
A sensor on the servo motor reports the status of the motor to the servo drive through a
feedback signal.
The servo drive regulates the voltage frequency to match the initial signal from the control
panel.
3. Describe the functions of an interpolator in a CNC machine tool.

4. Differentiate between CNC and NC systems on the basis on interpolator implementation.
5. Differentiate between Linear and circular interpolators.
CNC PROGRAMMING
1. What is the use of cutter compensation. Explain with an example?

2. Briefly explain about G and M codes along with its importance.
3. Write a small program on explaining the circular interpolation.
4. Write a part program for step turning operation using absolute coordinate system for the
component shown in figure below
Consider spindle speed=1200rpm; feed=30mm/min ; tool number=5

5. Write a part program of drilling operation for the figure shown Consider spindle
speed=1200rpm; feed=10mm/min; tool number=1
APPLICATIONS OF CNC MACHINES IN DIFFERENT INDUSTRIES
1. What makes CNC machines ideal for industrial use?

2. Briefly describe laser cutting procedure and why are they used in the medical
industry?
3. How does 6-axis milling machines work? Give an application.
4. Why CNC machining is important in manufacturing of aerospace vehicles?
5. How is CNC helpful in machining low volume materials?
CNC MACHINES- THE LATEST TECHNOLOGIES

1) Briefly explain few ways to improve the speed and accuracy of a CNC machine.
2) In between Robots and Cobots, What do you think are more helpful for CNC
machining
operations? Explain.
3) Explain the 3-axis, 4-axis, 5-axis CNC machines briefly along with their Limitations.
4) How is CAD-CAM software useful in CNC machining? Explain in detail.
5) What is Feed- Forward Control Technology and how is it useful in CNC machining
operations?

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HISTORY AND WORKING

PRINCIPLE OF CNC MACHINES

• CNC: COMPUTER NUMERICAL

TEAM MEMBERS (GROUP 8):

➔ Better Precision Tolerance

Punched tape Fed directly from

Operations cannot Operations can be

Has to run off the Runs off the

Less Flexible Highly Flexible

Less accurate Higher accuracy

High skill operator is High skill not

Less cost High cost

● The input power may be of electrical, hydraulic or pneumatic.

● Hydraulic systems may be used with positioning

2 & 3 AXIS CNC MACHINES:

● CNC lathes will be coming under 2 axes machines.

● By the simultaneous control of all

● 4 and 5 axes CNC machines provide multi-axis

● A 5-axis milling centre includes the three X, Y,Z

Absolute Positioning System

Incremental Positioning System

● Last point travelled to becomes the new reference point.

POINT TO POINT SYSTEM

● Point-to-point control systems cause the tool to

● The tool is not in continuous contact with the part

● Examples: drilling, reaming, punching, boring and

● Also known as contouring system

● This type of machine tools works in a continuous path by

● The positions of the workpiece and the tool are

● These operations include milling along any lines at any

BASED ON BASED ON BASED ON BASED ON BASED ON

OPEN LOOP 2 & 3 AXES CNC ELECTRICAL POINT TO POINT

2 Machine Control Unit

Data Processing Control Loop

Open Loop Systems • Open loop systems have no access to the

• In a close loop system, feed back

Feedback Machine Tool

• CNC stands for Computerized Numerical Control. It is a computerized

• Automatic Tool Changers

➢ Later in 1967, the idea of CNC machining started to circulate.

➢ The implementation took place from 1972.

➢ In 1976, CNC machines were available.

➢ Improved programming and operating features

➢ Strength and stiffness

➢ It also has the capability to produce a complex design with

➢ CNC machines require less number of workers as compared

➢This design software allows the designer to simulate the manufacture of

➢These machines can run throughout the day unless there is a

➢ Even the spare parts of CNC machines are relatively costlier

➢ Less workers are required to operate CNC’s. Hence, investment

➢ Maintenance costs are higher.

➢ Not suitable for small scale production.

➢ A good programming language is required by the operator. This

➢ CNC machine operators only needs basic training and skills

➢ This means many of the old skills are been lost.

➢ CNC technology is used in number of lettering and engraving system.

Thank You All

• ATC (automatic tool changer)

• To reduce loading and unloading time automatic pallet changer (APC) in

1. Contact type: This requires physical contact to measure the parameter.

2. Non-contact type: It requires no physical contact.