CNC Machines

Computer Numeric Control

Numerical control (CNC) (also computer numerical control (CNC)) is the automated
control of machining tools (drills, boring tools, lathes) and 3D printers by means of a computer. A
CNC machine processes a piece of material (metal, plastic, wood, ceramic, or composite) to meet
specifications by following a coded programmed instruction and without a manual operator.
A CNC machine is an NC machine with the added feature of an onboard computer. The onboard
computer is often referred to as the machine control unit or MCU. Control units for NC machines
are usually hardwired, which means that all machine functions are controlled by the physical
electronic elements that are built into the controller. The onboard computer, on the other hand, is
“soft” wired, which means the machine functions are encoded into the computer at the time of
manufacture, and they will not be erased when the CNC machine is turned off. Computer
memory that holds such information is known as ROM or read-only memory. The MCU usually
has an alphanumeric keyboard for direct or manual data input (MDI) of part programs. Such
programs are stored in RAM or the random-access memory portion of the computer. They can be
played back, edited, and processed by the control. All programs residing in RAM, however, are
lost when the CNC machine is turned off. These programs can be saved on auxiliary storage
devices such as punched tape, magnetic tape, or magnetic disk. Newer MCU units have graphics
screens that can display not only the CNC program but the cutter paths generated and any errors
in the program.
A CNC machine is a motorized maneuverable tool and often a motorized maneuverable platform,
which are both controlled by a computer, according to specific input instructions. Instructions are
delivered to a CNC machine in the form of a sequential program of machine control instructions such
as G-code and then executed. The program can be written by a person or, far more often this
century, generated by graphical computer-aided design (CAD) software. In the case of 3D Printers,
the part to be printed is "sliced", before the instructions (or the program) is generated. 3D printers
also use G-Code.
CNC is a vast improvement over non-computerized machining that must be manually controlled
(e.g., using devices such as hand wheels or levers) or mechanically controlled by pre-fabricated
pattern guides (cams). In modern CNC systems, the design of a mechanical part and its
manufacturing program is highly automated. The part's mechanical dimensions are defined using
CAD software, and then translated into manufacturing directives by computer-aided
manufacturing (CAM) software. The resulting directives are transformed (by "post processor"
software) into the specific commands necessary for a particular machine to produce the component,
and then are loaded into the CNC machine.
Motion is controlling multiple axes, normally at least two (X and Y),[1] and a tool spindle that moves in
the Z (depth). The position of the tool is driven by direct-drive stepper motorsor servo motors in order
to provide highly accurate movements, or in older designs, motors through a series of step-down
gears. Open-loop control works as long as the forces are kept small enough and speeds are not too
great. On commercial metalworking machines, closed loop controls are standard and required in
order to provide the accuracy, speed, and repeatability demanded
ypes of CNC Machines: CNC machines typically fall into one the two general
categories: conventional machining technologies and novel machining
technology:

Conventional Technologies:

1. Drills: Drills work by spinning a drill bit and moving the bit
about and into contact with a stationary block of stock material.

2. Lathes: Lathes, very much the inverse of drills, spin the block
of material against the drill bit (instead of spinning the drill bit and
putting it into contact with the material). Lathes typically make contact
with the material by laterally moving a cutting tool until it progressively
touches the spinning material.

3. Milling Machines: milling machines are probably the most

common CNC machine in use today. They involve the use of rotary
cutting tools to remove material from the stock unit.

Novel Technologies:

1. Electrical and/or Chemical Machining: There are a number of novel

technologies that use specialized techniques to cut material. Examples
include Electron Beam Machining, Electrochemical machining, Electrical
Discharge Machining (EDM), Photochemical machining, and Ultrasonic
machining. Most of these technologies are highly specialized and are
used in special cases for mass-production involving a particular type of
material.
2. Other Cutting Mediums: There are a number of other novel
technologies that use different mediums to cut material. Examples
include laser cutting machines, oxy-fuel cutting machines, plasma
cutting machines, and water-jet cutting technology.
Positioning control system[edit]
In numerical control systems, the position of the tool is defined by a set of instructions called
the part program.
Positioning control is handled by means of either an open loop or a closed loop system. In an
open loop system, communication takes place in one direction only: from the controller to the
motor. In a closed loop system, feedback is provided to the controller so that it can correct for
errors in position, velocity, and acceleration, which can arise due to variations in load or
temperature. Open loop systems are generally cheaper but less accurate. Stepper motors can be
used in both types of systems, while servo motors can only be used in closed systems.
Cartesian Coordinates
The G & M code positions are all based on a three dimensional Cartesian coordinate system.
This system is a typical plane often seen in mathematics when graphing. This system is required
to map out the machine tool paths and any other kind of actions that need to happen in a specific
coordinate. Absolute coordinates are what is generally used more commonly for machines and
represent the (0,0,0) point on the plane. This point is set on the stock material in order to give a
starting point or "home position" before starting the actual machining.

M-codes[edit]
[Code Miscellaneous Functions (M-Code)][citation needed]. M-codes are miscellaneous machine
commands that do not command axis motion. The format for an M-code is the letter M followed
by two to three digits; for example:
[M02 End of Program]
[M03 Start Spindle - Clockwise]
[M04 Start Spindle - Counter Clockwise]
[M05 Stop Spindle]
[M06 Tool Change]

G-codes[edit]
G-codes are used to command specific movements of the machine, such as machine moves or
drilling functions. The format for a G-code is the letter G followed by two to three digits; for example
G01. G-codes differ slightly between a mill and lathe application, for example:
[G00 Rapid Motion Positioning]
[G01 Linear Interpolation Motion]
[G02 Circular Interpolation Motion-Clockwise]
[G03 Circular Interpolation Motion-Counter Clockwise]
[

G-codes[edit]
G-codes are used to command specific movements of the machine, such as machine moves or
drilling functions. The format for a G-code is the letter G followed by two to three digits; for example
G01. G-codes differ slightly between a mill and lathe application, for example:
[G00 Rapid Motion Positioning]
[G01 Linear Interpolation Motion]
[G02 Circular Interpolation Motion-Clockwise]
[G03 Circular Interpolation Motion-Counter Clockwise]
[

G-codes[edit]
G-codes are used to command specific movements of the machine, such as machine moves or
drilling functions. The format for a G-code is the letter G followed by two to three digits; for example
G01. G-codes differ slightly between a mill and lathe application, for example:
[G00 Rapid Motion Positioning]
[G01 Linear Interpolation Motion]
[G02 Circular Interpolation Motion-Clockwise]
[G03 Circular Interpolation Motion-Counter Clockwise]

Why CNC Machining is Important for Manufacturing?

Friday, February 16, 2018

Computer Numerical Control (CNC) refers to - manipulating traditional machines by the

use of computer systems. CNC machining has become common as the use of computers
has increased in industrial manufacturing processes. Conventional industrial equipment
like centre lathes, routers, drills and millers are now operated through computers to
achieve better control.

On the surface, it may seem like a simple computer is controlling the machine, but the
unique software and control is what really sets the system apart in CNC machining.

Nowadays, CNC machining is found in many industries to aid production as it

streamlines the manufacturing process. Some major benefits of CNC machining in
manufacturing are:

1. Greater Efficiency
One reason for using CNC machining for production is efficiency. Since computers are
used to control machines, it means that all major operations of production can be
automated to increase speed and quality of manufacturing. On the other hand, if CNC
machine is not used, a technician will have to drill which would take more time.

CNC machines do not have to be switched off, unless maintenance is needed, meaning
that the production can go on without any break. Human beings get tired and require
rest which means that production must halt. Machines controlled through computers
don’t fatigue and do not need break, thus the process of production is streamlined.
Such efficiency can never be achieved through a manual process.

2. More Accuracy
Another reason CNC machining is beneficial for manufacturing is its accuracy. CNC
machines are programmable and each and every detail of the production process can
be fed into the machine. By using CNC machines, identical parts can made with the
highest accuracy levels. Programming the specification and designs into the machine
leaves no room for mistake or error.

Reducing errors from the manufacturing process eliminates unnecessary waste. CNC
machines can manufacture ideal parts to meet requirements of clients. High accuracy
level also makes it hard for others to duplicate and steal the design of products. CNC
machines allow producing products which otherwise may be impossible to produce
through manual processes as human beings are limited in their capabilities.

3. Fabrication
For fabrication, CNC machines are very important. Several operations are involved in
fabrication such as welding sheets of metal, shearing, punching holes and flame cutting
which can be done safely by using CNC machines. Large machines can be fabricated
through CNC according to any desired specification. CNC machines are
reprogrammable and flexible which makes them an ideal choice for fabrication.

CNC machining is absolutely essential for manufacturing and it is important that the
machine keeps running otherwise major loss would be suffered. But like any other
machine, CNC machines also wear and tear and if some parts of a CNC machine get
damaged, it can be hard to find a replacement

Literature freview

Linyan Liu et al. (2014) presents a knowledge-centric process management framework for the CNC
machine tool design and development (D&D) with the integration of process and knowledge.
Requirements for the framework are generated based primarily on the nature of the machine tool
design practice. The proposed framework consists of process integration model, process simulation,
process execution and knowledge objects management modules. Each of these modules is elaborated to
support the knowledge-centric machine tool development process management. The prototype
development is also presented by the author. Results of this study facilitate the knowledge integration
in CNC machine tool D&D, and thus increase machine tool development capability, reduce development
cycle time and cost, and ultimately speed up the effectiveness and ensure the excellent machine tool
development. Finally the study has outlined a framework within which designers are encouraged to
participate in the machine tool development efficiently and conveniently, for the benefit of each
individual and the company. Compared with the existing references, the proposed framework of
knowledge-centric CNC machine tool D&D process management includes the following results: Based
primarily on the nature of the machine tool design practice, requirements for the knowledge-centric
frame-work with integration of process and knowledge are analyzed in consideration of the design
objects, the D&D process, the knowledge-centric demand and its implementing and monitoring
demand. Then, the framework of knowledge-centric CNC machine tool D&D process management used
in the CNC machine tool industry is proposed, which includes the modelling, simulation and its execution
and takes the knowledge into consideration. The design process of KVC1050N Vertical machining center
is also studied as an example to demonstrate the feasibility and availability of the proposed framework.
The results of this study significantly contribute to efforts to achieve knowledge and process integration
in CNC machine tool D&D. In a word, ongoing efforts are being taken to make the framework more
practical in the industrial application. Thus, this solution can serve machine tool companies in this
important industry sector by increasing machine tool development capabilities, improving work
efficiency and ultimately reducing development cycle time and costs. [1] Venkata Krishna pabolu et al
(2010) discuss the design and implementation of low cost three dimensional computerised numerical
control system (CNC) for industrial application. In this paper prototyping an Embedded CNC machine
was created Literature Review for Designing of Portable CNC Machine (IJIRST/ Volume 4 / Issue 6 / 005)
All rights reserved by www.ijirst.org 37 .Detail description of different modules such as software
development, Electronic/Electrical development, along with technical details of their implementation
have been given. [2] Dr.J.B. Jayachandraiah et al (2014) provide the idea to develop the low cost Router
system which is capable of 3 axis simultaneous interpolated. The low cost is prototyping is achieved by
incorporating the features of standard PC interface with microcontroller base CNC system in an Arduino
based embedded system. With limited budget the author conclude that small machine tools to fabricate
small parts can provide flexibility and efficiency in manufacturing approach and reduce the capital cost,
which is beneficial for small business owners. [3] Ahmed A.D.Sarhan et al. (2015) in this paper, an initial
CNC gantry milling machine structure with the potential to produce high surface finish has been
designed and analyzed. The target of the author is to achieve lowest natural frequency of 202Hz
corresponding to 12000 rpm at all motion amplitudes with a full range of suitable frequency responses.
Modal analysis of the initial gantry structure design was performed and its natural frequency was
102.36HZ. To improve the dynamic behavior of the gantry structure so it can endure at frequencies
above 200HZ, a modification process was carried out to increase stiffness. The above enhancement,
appropriate behavior was attained. Deformation of less than 10 microns ensued at the tip of the spindle
when the minimum natural frequency of the gantry structure rose slightly above 200Hz. An increase in
the structure’s weight was the significant factor for the identified deformation. However, the variation
did not have a negative impact on the precision of the machine. As a result, the weight increased after
modifications to the gantry structure were made, while the amount of deformation and overall dynamic
behavior improved. In addition, the efficacy of the Z-axis part’s position on the dynamic behavior of the
gantry structure was studied. By displacement of the spindle position, the dynamic behavior of gantry
structures will change. Evaluations on the gantry structure’s behavior demonstrated that the least
natural frequency occurred while the Z-axis part was located below the middle of the beam. This
signifies that the structure was in a critical situation. The results shown by the author, that according to
the critical condition, the minimum frequency of the structure is acceptable. The research results shows
that the designed CNC gantry machine is capable of functioning at a speed of 12,000rpm. [4] Nikita R.
Saharkar et al. (2013) design the CAD Model in Solidworks and Done the FEA analysis in hyper mesh tool
providing the appropriate constrains, loads, and moment values. According to the author he got the
stress value around 14 Mpa which is less than the allowable stress value of M.S. concluding the design is
safe. Author also generate the G & M codes by simulating the CAD file in Power mill software which is
nothing but the CAM software. [5] Sundar Pandian et al. (2014) develop low cost 3 axis CNC machine
using of- the- shelf component, stepper motors with drivers, Arduino open source, microcontroller and
open source motor control software. Author used ready to assemble kit from Zen Tool works, USA. Kit
provided stepper motor, lead screw, guide rod, anti-backlash falans and spring. He made the Body with
high density PVC. The machine has fix gantry and mobile bed so there is restriction in working area.
Author develop Low cost CNC machine only for educational purpose. [6] B.Malleswara Swami et al.
(2012) in this paper author describe the method for static and dynamic analysis. Author used standard
bed for analysis. The investigation is carried to reduce the weight without changing the structural rigidity
and the accuracy by adding the ribs at the suitable location. Static analysis is done for 1g i.e.
gravitational force is consider with external load on structure and 5g i.e. gravitational force 5 times ‘g’
value is applied on structure along with external load .In modal analysis ,the natural frequency of the
body is evaluated to find the dynamic and vibration characteristics. Then the optimize design is
generated using optistruct tool. The results which gets after optimization reduces the weight by 1.55%
with original value and average frequency shifted by appx. 8.8 % with 1st natural frequency. [7] Druv
Patel et al. (2014) studied influences of various parameter like tool speed, tool feed and depth of cut on
CNC router and concluded from ANOVA that percentage contribution of feed rate is maximum and it
means Feed rate is the most dominating factor for modelling surface finish. [8] Monika Nowak et al.
(2012) formulated methods of selection of geometric and physical structure of the mobile machine by
specifying the design requirements and the development of the elimination conditions based on these
requirements. The selection procedure was based on an analysis of the functional description of the
required shaping movements, carefully developing appropriate conditions for the elimination of
alternatives using the information concerning the needs of future portable machine operators. [9]
Grzegorz szwengier et al. (2012) gives the results of research on selection on geometric-kinematic
structure of newly designed milling machine. There was various types of structure combination available
for milling machine, author suggested best procedure and help to select useful combination of machine
parts with desired output provided with constraints of machine

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