NC machining is a manufacturing process in which pre-programmed

computer software dictates the movement of factory tools and machinery.

The process can be used to control a range of complex machinery, from
grinders and lathes to mills and routers. With CNC machining, three-
dimensional cutting tasks can be accomplished in a single set of prompts.

Short for “computer numerical control,” the CNC process runs in contrast to
— and thereby supersedes — the limitations of manual control, where live
operators are needed to prompt and guide the commands of machining tools
via levers, buttons and wheels. To the onlooker, a CNC system might
resemble a regular set of computer components, but the software programs
and consoles employed in CNC machining distinguish it from all other
forms of computation.

Things to Learn About CNC Machining

When a CNC system is activated, the desired cuts are programmed into the
software and dictated to corresponding tools and machinery, which carry out
the dimensional tasks as specified, much like a robot.

In CNC programming, the code generator within the numerical system will
often assume mechanisms are flawless, despite the possibility of errors,
which is greater whenever a CNC machine is directed to cut in more than
one direction simultaneously. The placement of a tool in a numerical control
system is outlined by a series of inputs known as the part program.
With a numerical control machine, programs are inputted via punch cards.
By contrast, the programs for CNC machines are fed to computers though
small keyboards. CNC programming is retained in a computer’s memory.
The code itself is written and edited by programmers. Therefore, CNC
systems offer far more expansive computational capacity. Best of all, CNC
systems are by no means static, since newer prompts can be added to pre-
existing programs through revised code.

CNC MACHINE
PROGRAMMING
In CNC, machines are operated via numerical control, wherein a software
program is designated to control an object. The language behind CNC
machining is alternately referred to as G-code, and it’s written to control the
various behaviors of a corresponding machine, such as the speed, feed rate
and coordination.

Basically, CNC machining makes it possible to pre-program the speed and

position of machine tool functions and run them via software in repetitive,
predictable cycles, all with little involvement from human operators. Due to
these capabilities, the process has been adopted across all corners of the
manufacturing sector and is especially vital in the areas of metal and plastic
production.

For starters, a 2D or 3D CAD drawing is conceived, which is then translated

to computer code for the CNC system to execute. After the program is
inputted, the operator gives it a trial run to ensure no mistakes are present in
the coding.

Open/Closed-Loop Machining Systems

Position control is determined through an open-loop or closed-loop system.
With the former, the signaling runs in a single direction between the
controller and motor. With a closed-loop system, the controller is capable of
receiving feedback, which makes error correction possible. Thus, a closed-
loop system can rectify irregularities in velocity and position.

In CNC machining, movement is usually directed across X and Y axes. The

tool, in turn, is positioned and guided via stepper or servo motors, which
replicate exact movements as determined by the G-code. If the force and
speed are minimal, the process can be run via open-loop control. For
everything else, closed-loop control is necessary to ensure the speed,
consistency and accuracy required for industrial applications, such as
metalwork.

CNC Machining is Fully Automated

In today’s CNC protocols, the production of parts via pre-programmed

software is mostly automated. The dimensions for a given part are set into
place with computer-aided design (CAD) software and then converted into
an actual finished product with computer-aided manufacturing (CAM)
software.

Any given work piece could necessitate a variety of machine tools, such as
drills and cutters. In order to accommodate these needs, many of today’s
machines combine several different functions into one cell. Alternately, an
installation might consist of several machines and a set of robotic hands that
transfer parts from one application to another, but with everything controlled
by the same program. Regardless of the setup, the CNC process allows for
consistency in parts production that would be difficult, if not impossible, to
replicate manually.
TYPES OF CNC
MACHINES
The earliest numerical control machines date to the 1940s when motors were
first employed to control the movement of pre-existing tools. As
technologies advanced, the mechanisms were enhanced with analog
computers, and ultimately with digital computers, which led to the rise of
CNC machining.

The vast majority of today’s CNC arsenals are completely electronic. Some
of the more common CNC-operated processes include ultrasonic welding,
hole-punching and laser cutting. The most frequently used machines in CNC
systems include the following:

CNC Mills

CNC mills are capable of running on programs comprised of number- and

letter-based prompts, which guide pieces across various distances. The
programming employed for a mill machine could be based on either G-code
or some unique language developed by a manufacturing team. Basic mills
consist of a three-axis system (X, Y and Z), though most newer mills can
accommodate three additional axes.

Lathes

In lathe machines, pieces are cut in a circular direction with indexable tools.
With CNC technology, the cuts employed by lathes are carried out with
precision and high velocity. CNC lathes are used to produce complex
designs that wouldn’t be possible on manually run versions of the machine.
Overall, the control functions of CNC-run mills and lathes are similar. As
with the former, lathes can be directed by G-code or unique proprietary
code. However, most CNC lathes consist of two axes — X and Z.
Plasma Cutters

In a plasma cutter, material is cut with a plasma torch. The process is

foremost applied to metal materials but can also be employed on other
surfaces. In order to produce the speed and heat necessary to cut metal,
plasma is generated through a combination of compressed-air gas and
electrical arcs.

Electric Discharge Machines

Electric-discharge machining (EDM) — alternately referred to as die

sinking and spark machining — is a process that molds work pieces into
particular shapes with electrical sparks. With EDM, current discharges occur
between two electrodes, and this removes sections of a given work piece.

When the space between the electrodes becomes smaller, the electric field
becomes more intense and thus stronger than the dielectric. This makes it
possible for a current to pass between the two electrodes. Consequently,
portions of a work piece are removed by each electrode. Subtypes of EDM
include:

 Wire EDM, whereby spark erosion is used to remove portions from

an electronically conductive material.
 Sinker EDM, where an electrode and work piece are soaked in
dielectric fluid for the purpose of piece formation.

In a process known as flushing, debris from each finished work piece is

carried away by a liquid dielectric, which appears once the current between
the two electrodes has stopped and is meant to eliminate any further electric
charges.

Water Jet Cutters

In CNC machining, water jets are tools that cut hard materials, such as
granite and metal, with high-pressure applications of water. In some cases,
the water is mixed with sand or some other strong substance. Factory
machine parts are often shaped through this process.
Water jets are employed as a cooler alternative for materials that are unable
to bear the heat-intensive processes of other CNC machines. As such, water
jets are used in a range of sectors, such as the aerospace and mining
industries, where the process is powerful for the purposes of carving and
cutting, among other functions.

FURTHER USES OF
CNC MACHINES
As plenty of CNC machine video demonstrations have shown, the system is
used to make highly detailed cuts out of metal pieces for industrial hardware
products. In additional to the aforementioned machines, further tools and
components used within CNC systems include:

 Embroidery machines
 Wood routers
 Turret punchers
 Wire-bending machines
 Foam cutters
 Laser cutters
 Cylindrical grinders
 3D printers
 Glass cutters

When complicated cuts need to be made at various levels and angles on a

work piece, it can all be performed within minutes on a CNC machine. As
long as the machine is programmed with the right code, the machine
functions will carry out the steps as dictated by the software. Providing
everything is coded according to design, a product of detail and
technological value should emerge once the process has finished.
FAULTY CNC
MACHINE
PROGRAMMING
CNC machining is not exactly a foolproof process. In some instances, either
a work piece or the machine itself could be directed in a harmful way. When
this happens, a crash might occur, whereby tools or machine parts end up
broken. The tools that could get damaged by a crash may include the vices
or clamps that hold the work piece in place. When damage occurs within the
machine, it could range from minor screw breakage to serious structural
deformity.

The fact is, CNC equipment lacks the sentience to know exactly which
distances are too far. Therefore, the tools must be exactly programmed in
order to work without fault. If a program code is miscalculated, a CNC
machine could be driven outside its physical bounds and cause an internal
collision. Even though most of today’s CNC machines are manufactured
with parameter boundaries, these inputs can be manipulated by operators.

Likewise, CNC tools are oblivious to a given environment. While certain

CNC machines are equipped with spindle load sensing, others lack this
feature. In the latter case, the software must be coded properly to ensure
nothing goes off parameter, otherwise a crash would be the likely outcome.
Even if a CNC machine is equipped with load sensors, a crash could still
occur. When a tool function goes astray, it’s up to the operator to rectify the
situation.

Crash Prevention on Different Types of CNC Machines

With the installation of encoder-disk position sensors, the possibility of a

crash can be detected in advance and thwarted. Alternately, torque sensors
can help determine whether a CNC machine is moving as intended and also
detect unwanted cutting.
In garage CNC systems, tools are reliant on the rotational precision of
stepper motors for the correct number of degrees. To monitor the tool
position, the pulses that go to the stepper must be counted, because in most
cases, there’s no form of alternate monitoring.

On industrial CNC machines, closed-loop controls are employed, whereby

the control always knows the axis position. If properly controlled, the
potential for crashes is significantly lowered, though it’s still the
responsibility of programmers to see that codes are inputted accurately for
utmost safety.

Over the last two decades, CNC software has advanced to where a vast
range of machine tools — axes, clamps, fixtures, spindles, turrets — can be
based precisely on 3D solid models. With those specs programmed into the
code, it’s easier to determine whether a crash will occur with a particular
cycle.

ASTRO MACHINE
WORKS, INC. —
CUSTOM
MACHINERY AND
PRECISION PARTS
SPECIALISTS
CNC machining is one of the most critical functions of the manufacturing
sector, from the production of computer parts and fasteners to auto parts and
aerospace components. Without the high-tech capabilities unique to CNC
machines, various components seen on everyday household items would be
nearly impossible to produce. As the engineers who’ve undergone CNC
machine training will attest, the coding that makes it possible for a CNC
machine to mold metal parts into shape is complex.

At Astro Machine Works, Inc. we’ve specialized in the making of custom

machines and fabrication for more than a quarter of a century. Our CNC
machines are programmed to the exact specifications of each customer by
our team of in-house experts. Additionally, we’ve expanded into several
related areas of expertise, including machine design, panel wiring, reverse
engineering and metal fabrication.

Having satisfied a vast range of clients across the industrial sector over the
past 25+ years, we understand the importance of delivering things on time
and exactly to the customer’s specifications. By the same token, we
understand customers often have questions about the various aspects of
CNC machining. At Astro Machine Works, Inc., we make it a point to
answer all questions about the pieces and parts we prepare for customers.