Outline

1. Introduction to CNC machine

2. Component and Function of CNC
3. Coordinate System
4. Tools
Beginners Guide to Manual & CNC Machining!

• https://www.youtube.com/watch?v=TecC9_nwpUw
1.Introduction to CNC machine

CNC = Computerized Numerical Control

 Conventional vs. CNC machine

• Machine Structure
The CNC machine tools are basically built in the same way as conventional
machine tools. The difference lies in the fact that the machine components
relevant for turning and milling processes are controlled by computers.
 Conventional vs. CNC machine

• Function
Conventional vs. CNC machine
 Conventional vs. CNC machine
• Conventional machine
→ eyes, hands, brain, skill

• CNC machine
Program→ Control unit→ Motor→ Motion

Measuring & Reflection Unit

No skill is required for operating CNC m/c .

 Conventional machine

CNC machine
Difference between Conventional M/C & CNC M/C
Item Conventional CNC
machine machine
1. Movement Acme screw Ball screw

2. Feed manual motor

3.measurement manual Linear scale

 Advantages of CNC
• Flexible, high accuracy
• Short production time
• Complex shapes
• Short setting time
• No skill requirement
• Short inspection time/ high quality product
• Low cost
 Disadvantages of CNC

• High machine cost

• Complicated maintenance
• Skill & training are required for programming and maintenance.
• High tooling cost
• Temperature, humidity & dust must be controlled.
 Basic CNC Principles
• Using a vertical mill
machining center as an
example, there are typically
three linear axes of motion.
Each is given an alphabetic
designation or address. The
machine table motion side
to side is called the “X” axis.
Table movement in and out
is the “Y” axis, while head
movement up and down the
column is the “Z” axis.
 Basic CNC Principles
Coordinates System

Incremental Coordinate System

Absolute Coordinate System
 Basic CNC Principles
All computer controlled machines are able to accurately and
repeatedly control motion in various directions. Each of these
directions of motion is called an axis. Depending on the machine type
there are commonly two to five axes.
Additionally, a CNC axis may be either a linear axis in which movement
is in a straight line, or a rotary axis with motion following a circular
path.
 Basic CNC Principles
If a rotary table is added to the machine table, then
the fourth axis is designated the “b” axis.
 How CNC Works

• Controlled by G and M codes.

• These are number values and co-ordinates.
• Each number or code is assigned to a particular operation.
• Typed in manually to CAD by machine operators.
• G&M codes are automatically generated by the computer software.
 Features of CNC Machinery

• The tool or material moves.

• Tools can operate in 1-5 axes.
• Larger machines have a machine control unit (MCU) which manages operations.
• Movement is controlled by a motors (actuators).
• Feedback is provided by sensors (transducers)
• Tool magazines are used to change tools automatically.
 Tools

• Most are made from

high speed steel (HSS),
tungsten carbide or ceramics.
• Tools are designed to direct waste away from the material.
• Some tools need coolant such as oil to protect the tool and work.
 Drilling

• Creates a round hole in a workpart

• Contrasts with boring which can
only enlarge an existing hole
• Cutting tool is called a drill or drill bit
• Customarily performed on a drill
press, but can be done on a vertical
mill and on a lathe
Reaming

Used to slightly enlarge a hole,

provide better tolerance on
diameter, and improve surface
finish
Tapping

Used to provide internal screw

threads on an existing hole

The tool is called a tap

Counterboring

Provides a stepped hole, in which

a larger diameter follows a smaller
diameter partially into the hole
 Milling Parameters Illustrated

Two forms of milling: (a) peripheral milling, and (b) face milling
 Slab Milling

The basic form of peripheral

milling in which the cutter
width extends beyond the
workpiece on both sides
 Slotting

Width of cutter is less than

workpiece width, creating a
slot in the work
Conventional Face Milling

Cutter overhangs work on both sides

End Milling

Cutter diameter is less than work

width, so a slot is cut into part
Profile Milling

A form of end milling in which

the outside periphery of a flat
part is cut
Pocket Milling

Another form of end milling

used to mill shallow pockets
into flat parts
Surface Contouring

Ball-nose cutter is fed back and

forth across the work along a
curvilinear path at close intervals to
create a three dimensional surface
form
 Tools

A wide range of tool types and configurations are available for CNC milling
machines
• End mills (Flat, Ball, Bull and Chamfer) Face mill
• Corner Rounding tools
• Slot Tools
• Spot-Center Drill
• Twist Drill
• Tap
• Reamer
• Counterbore
 End Mills

Milling tools include flat, ball, bull nose and chamfer.

• Flat nose mills are used for milling 2D contours and
pockets.
• Ball nose mills are used for 3D milling
• Bull nose end mills have a radius corner. They are used
to create a fillet on the bottom of a wall. Because they
are sturdier than an endmill they are also sometimes
used for roughing operations.
• Chamfer mills have an angled nose used to create a
chamfer or to de-burr parts.
 Milling Tools

• Milling tools usually have either two or four cutting flutes.

• Two flute cutters provide more chip clearance when milling in close areas.
• Four flute mills are more rigid, can be fed faster, and are preferred when greater chip
clearance is not required, such as when milling an outside contour.
 Center-Cutting
End Mills

• Milling tools are either center cutting or non-center

cutting.
• Center cutting mills can plunge straight down
into material, while non-center cutting tools
cannot.
• The cutting edges of the center cutting end mill
continues to the center of the tool
• The center of the other has a small hole at the
center.
• Non-center cutting end mills require a pilot hole,
ramping or helical motion to plunge into
material.
 Face Mill

• A face mill has cutting inserts that are

replaced when worn
• They are rigid, may have up to eight or
more cutting edges, and can remove
material quickly.
• They are often used for the first
machining operation to quickly create a
flat finished face on the part.
Corner Radius Tool

• Corner radius (also called

Corner Round) tools are used
to place a fillet on the outside
corner of a part.
 Slot Mill/Slotting Saw

• Slot mills include side milling cutters,

slitting saws, and Woodruff keyset cutters.
• Slitting saws and side milling cutters are
installed on a special arbor.
• Woodruff cutters are single piece tools used
for creating slots and undercuts that can be
held in a standard toolholder.
Hole-Making Tools

• Center-Spot Drills
• Center (spotting)drills are short and very rigid drills used
to create a conic on the face of the part.
• Because they come to a sharp point and resist
bending, they locate the hole precisely.
• The conic helps prevent the subsequent drill from
wobbling and ensure the drill is located precisely
and drills straight down.
• Countersink drills are used to create the conical face for a
machine screw.
• Combined spotting-countersinks are used to create a
screw clearance hole and countersink in one operation.
 Hole-Making Tools

• Twist Drill
• Twist drills are available in many diameters
and lengths.
• Usually made of high speed steel, carbide, or
cobalt, they may also be coated with titanium
nitride (TiN) for longer life.
• The tip angle of most twist drills is 118
degrees.
 Hole-Making Tools

• Taps
• Cutting taps form threads by shearing material away.
• Form taps (roll taps) form the thread by forming the metal to
shape. Form taps produce no chips and are used for soft
materials including aluminum, copper, brass and plastics.
• Bottoming taps are used to tap blind holes.
• Spiral point taps push the chip ahead and out the bottom of a
through hole.
 Hole-Making Tools

• Reamer
• Used to create holes of precise shape and
excellent surface finish.
• Reamed holes are usually accurate within
.0002 inches diameter.
• Reamers require a specific size hole be
drilled before use.
 Cutting Tool
Fundamentals

• Rotation Direction
• All tools (except left-handed taps) rotate
clockwise (M3) when viewed from the
machine spindle looking down at the part.
 Cutting Tool
Fundamentals

• Chip Formation
• Cutting tools remove metal by shearing action
• As the tool advances into the material it
causes a small amount of the material to shear
away, forming a chip.
 Cutting Tool
Fundamentals

• Chip Load
• The thickness of material sheared away by
each cutting tooth is called the feed per tooth,
or chip load.
• As the chip is ejected from the work area it
carries with it some of the heat generated by
the shearing process.
 Cutting Tool Fundamentals

• Climb vs. Conventional Milling

• Climb Milling
• Milling tools can advance through the material so that the cutting flutes
engage the material at maximum thickness and then decreases to zero
• Less friction involved between the cutter and the workpiece as both. This
machine poses a longer tool life and produces a good surface finish.

• Conventional Milling.
• Cutting in the opposite direction causes the tool to scoop up the material,
starting at zero thickness and increasing to maximum
• There is massive friction between the cutter and workpiece which results
in generating a large amount of heat however it is a safe operation
because It has no tendency to drag the workpiece into the cutter.
 Cutting Speeds and Feeds Formulas

• The tool moves through the material at:

• a specified rotational speed, defined in revolutions per minute (RPM), and
• A feed rate, defined in inches per minute (IPM).
• Probably the most vexing problem for the beginning CNC machinist is selecting
proper cutting speeds and feeds.
• This selection is actually more difficult on a NC than a manual mill because, with a
manual mill, the operator can feel the cutting pressure and alter the feed based
in part on the cutting force.
 Cutting Speeds and Feeds Formulas

• CNC mills require calculating speeds and feeds in advance.

• These speeds and feeds can, and often are, adjusted at the machine based on:
• chip shape and color,
• cutting sound, and
• machine horsepower meter readings.
• The best source of data about cutting speeds and feeds for a specific tool, application, and
material is the tool supplier.
• Another source of speeds and feeds data is CAD/CAM software. These have become
increasingly sophisticated and often provide good cutting data.
 Cutting Speeds and Feeds Formulas

• Yet even the best speed and feed data is just a starting point.
• Speeds and feeds require adjustment due to many factors including:
• the maximum spindle speed or horse power of the machine,
• rigidity of work holding, and
• the quality and condition of the machine tool itself.
 Tool Paths, Cutting
and Plotting Motions
• Tool paths describes the route the cutting tool takes.
• Motion can be described as point to point, straight cutting or
contouring.
• Speeds are the rate at which the tool operates e.g. rpm.
• Feeds are the rate at which the cutting tool and work piece
move in relation to each other.
• Feeds and speeds are determined by cutting depth, material
and quality of finish needed. e.g. harder materials need
slower feeds and speeds.
• Rouging cuts remove larger amounts of material than
finishing cuts.
• Rapid traversing allows the tool or work piece to move rapidly
when no machining is taking place.