TITLE : COMPUTER NUMERICAL CONTROL (CNC) MACHINING

OBJECTIVE :

1) To identify and understand the CNC Machine System compared to

conventional machine system.

2) To learn how to develop a CNC machine programming of a selected sample of

product for machining processes.

3) To learn how to do ‘zero set-up’ for machine and work piece before machining
process can be started.

4) To cut a selected sample of product using CNC machine ( CNC Turning/ CNC
Milling).

APPARATUS : HITACHI SEIKI HITEC-TURN20SII

Figure 1: HITACHI SEIKI HITEC-TURN20SII

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 Figure 2: Cutting Operation

THEORY :

CNC is the most advanced NC system that has a computer to control the machine
tool. To produce a component, numerical control program that can run on the CNC
machine computer has to be prepared.

Initially the part programs (numerical control programs) are fed into the system.
Generally, the punched tape readers can be used to feed the part programs into the
system. In NC machines, the tape is passed through the reader for each and every
workpiece and the program is executed block by block only. In CNC machines, the
program is fed only once and stored in the memory of the computer and can be used for
producing any number of parts. The flexibility and computational capability is improved
by the use of CNC. New features or functions can be added into the CNC controller by
reprogramming the unit.

NC is hardware based while CNC is software based. Generally, the CNC are
referred by the term “soft wired” NC because of the reprogramming capability. In a
machining centre with the complete automation of tool and work handling within the cell,
many operations can be carried out at one work station, making batch production highly
economically. The various machining operations that can be performed by a machining
centre are turning, drilling, milling, boring, etc.

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 Using CNC the tool is made to follow any path for machining operation. The
changeover from one machining operation to another is fully automatic with the use of
auto-tool changer.

PROCEDURE :

1. The components of the CNC machine system was observed, identified and studied :
i. Type of tools, tool magazine
ii. Cooling system
iii. Possible way to program the machine
iv. Number of axis of rotation or movement of the machine
v. Jig and fixture of the system to hold the tool and workpiece
vi. Chip removal system
vii. Maintenance required
viii. The accuracy and quality produce
ix. Heart of the control system
x. Power control system: Hydraulic, Pneumatic, electro-pneumatic, electro-
hydraulic
2. The zero set-ups for workpiece and machine was check and observe to determined
why it is very important and how it can be done before the machining process is
actually started.
3. The program that has been developed for the sample to be cut was been studied.
4. The developed program was test-run using available screen graphics simulation of
CNC machine.
5. The machining process was started and the movement of the related component of the
CNC machine (working table, tool, tool spindle, etc) was observed.

6. After the machining process, the dimension, shape and quality of the product produce
was check.

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RESULT AND DISCUSSION :

1. The main components in CNC machine are;

o Computer Part Program

The program is a detailed set of commands to be followed by the machine
tool. It serve and input to Machine Control Unit (MCU) and it is coded in
numerical or symbolic form on some type of input medium that can be
interpreted by the controller unit. Each command specifies a position in the
Cartesian coordinate system (x, y, z) or motion (workpiece travel or cutting
tool travel), machining parameter and on/off motion.

o Machine Control Unit

The MCU is the nucleus of CNC operation. It is responsible for
coordinating all function implemented by the CNC machine, including data
input, data processing, data input, and machine I/O interface. The MCU is a
microcomputer that storage the programs, read and interpret and than execute
the command in to mechanical action by the machine tool.

o Machine Tool
The machine tool consists of the worktable and spindle as well as the
motors and the controls necessary to drive items. It also includes the cutting
tool, work fixtures and auxiliary equipment needed in the machining
operation. The machine tool could be one of the following; lathe, milling
machine, laser, plasma coordinate measuring machine. A right hand
coordinate system is used to describe the motion of a machine tool. There are
three linear axes (x, y, z) and three rotational axes (U, V, W) and other axes
such as tilt (θ) are possible.

2. The codes program used in CNC machine.

o N-word: Sequence number, block identification. Consisting typically of three

digits (could be one or two digits), its purpose is to identify the specific

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 machining operation through the block number particularly when testing a
part program.
o G-word: preparatory word. It prepares the MCU circuit to perform a specific
operation. Used to prepare the controller for instructions that are to follow.
o XYZ-word: co-ordinates/position. Distance dimension words X, Y, Z. circular
dimension words I, J, K for distances to the arc centre. Angular dimension, A,
B, C.
o F-word: feed rate word. It is expressed in in/min or mm/min and is used in
contouring point-to-point or straight-cut system.
o S-word: Spindle cutting speed. Programmed in rev/min, its is expressed as
RPM by a three digit code number that is related to the RPM.
o T-word: tool word, tool number selection. Consisting of a maximum of five
digits, each cutting tool has a different code number. The automatic tool
changer (ATC) automatically selects the tool when the code number is
programmed in the block, such as T18. This causes the tool magazine position
18 or tool number 18 to be brought to spindle, replacing the already present
tool in the spindle. The tool replace from the spindle is brought back to the
empty position created when the tool 18 is loaded.
o M-word: Miscellaneous functions. Consisting of two digits, the controlled
function that are of an on-off auxiliary nature such as coolant on-off, spindle
on clockwise or CCW.

3. The important key parameters in developing CNC program are the percentage of tool,
the dimensions of workpiece, the types of material and the types of cutting tools.
Beside that, there are other parameters needs to be consider such as rakes angles,
relief angles cutting-edges angles nose radius and material removal rate.

4. The basic procedures practiced in developing CNC Turning Machine Programming

are;
o Write and verify CNC program

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 o Used complete knowledge of codes programming example the G-codes and
M-codes
o Used the correct use of cutter compensation
o Adjust speeds and feeds as needed

5. The materials of the product are prospect. The qualities of the product are good, with
high degree of accuracy in dimension because it has very small tolerance in cutting a
material and this result in good surface finish.

Figure 3: The final product of CNC machine.

6. The movement of the main component of the CNC during machining process are;
o The workpiece was setup on machine tables by clamping with the work
holding device.
o The workpieces is fixed with the table and not moving during the machining
process.
o The cutting tools start turning in clockwise or counter-clockwise directions. It
depends on the programmed setup before.
o Beside that cutting tools also moving towards or backwards and upward or
downward. It depends on the programmed setup before.
o The cutting tools will changes automatically based on machining process that
was programmed before.

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7. Zero set-ups for workpiece are carried out by positioning the tools based on
workpiece origin point.

8. Zero set-ups for workpiece and machine tool are important because it establishes the
point of reference for motion commands in a CNC program. This allows the
programmer to specify movements from a common location and the coordinates
needed for the program can be taken directly from the print. This will made easier to
determine the current position for any command.

9. In the run-test graphic screen, we can see simulation of multiple operation process
that occurs for the design program. It is done by the first process take place in the
direction that has been program and the simulation continues by other process after it.
The last simulation shows a finishing process been done to the material. This run-test
graphic screen shows the movement of the process that we have program.

10. The difference between CNC machine and conventional machine is CNC machine
have better automation production because it can run unattended during their entire
machining cycle. Less skill level required for CNC operator because the machine runs
under program control. CNC machine also has flexibility in running a different
workpiece by only loading from the different program and more complex machining
operations and unique shapes machine. CNC turning have more turrets which
equipped with variety of tool that perform several operations on different surface of
the workpiece. CNC turning also equipped with automatic tool changers (ATC).

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Example of HITACHI SEIKI HITEC-TURN20SII machining coding program.

Program 2000(Program Name)

N05 T0100 M40

N15 N10 G00 X70.0 Z0.0;

N20 G01 X1.0 F ;

N30 G00 Z2.0;

N40 X22.0;

N50 GO1 X30.0 Z-2.0;

N60 Z-30.0;

N70 X36.0 Z-50.0;

N80 X40.0;

N90 G03 X50.0 Z-55.0 R5.0 F ;

N100 GO1 Z-70.0;

N110 X70.0;

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 Figure 4: Examples of CNC machining end product.

CONCLUSION :

It can be concluded that;

1. CNC machine is a method of controlling the functions and motion of a machine tool
by means of a prepared program containing instructions in the form of numerical
data.
2. CNC machine offers greater flexibility, greater in quality of product, greater in safety
of workers and the machine tool, and greater in minimize the cost and time of
machining in manufacturing industry than the conventional machine type.
3. CNC machine are widely applied in the manufacturing industry like in aerospace
industry and industrial robots because of it

REFERENCE :

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1. http://www.mfgquote.com/subProcess_machining_turning_machining.cfm

2. Serope Kalpakjian & Steven R. Schmid, Manufacturing Engineering and

Technology, Prentice Hall International, Fourth Edition.

3. Prof. Madya Haji Mohd Yusuff Bin Haji Mohd al-Rangi, Plant Alpha –
Manufacturing Technology Course Manual

4. http://www.emachineshop.com/machines-chip/turning-lathe.htm

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