Chapter-8: Advanced Machining

Difficulties (or) Limitation of normal machining methods:-

1) The accuracy of the components produced depends on the efficiency of operator
2) Consistency in manufacturing is not present. Hence 100% inspection of component is
required.
3) The personal needs of the operator are reducing the production rate.
4) Because of large amount of man power is involved. The Labour law problem will be
present.
5) The complex shapes like the parabolic, curvature components, cubical curvature
components, is difficult to manufacture.
6) Frequent design changes in the component cannot be incorporated in the existing layout.
To overcome the above disadvantages, the advanced machining methods like NC, CNC,
DNC, ANC, FMS etc has been developed.

NC MACHINE:-
If each and every axis of a machine tool is controlled by using number. It is called
numerically controlled machine.
Basic Parts:-
1) MCU (or) CPU
2) Drive Unit
3) Feedback Device
4) Tape Reader System
5) Manual Controls
1) MCU (or) CPU [ Machine Control Unit (or) Central Processing Unit]
The MCU is working like brain of human being MCU is taking input information
from the input device available in NC machine, Analyzing the data (or) Information,
taking the decisions and all these decisions will be implemented by using output device
available in the NC machine.
The Input information given by the human being through tape reader system (or)
manual controls is in the form of decimal system. But the machine can understand only
the binary system of information [low level language].
Therefore a device is required in “MCU” to convert the decimal to binary and vice
versa. The device used is Arithematic logic unit [ALU].

Drive Unit:-
The drive unit are electric motor.
Electric Motor are 3 types
1) Induction
2) Stepper
3) Servo
Induction Motor:-
In case of induction motor whenever the power supply is given to motor, if always starts
rotating at only one particular rpm. But in case of NC machine if is required to rotate the motor at
different rpm for performing machining at different cutting velocities. Hence induction motor
cannot be used as drive as drive unit in NC machine.

Stepper Motor:-
In case of stepper motor, when the poised electrical energy will be given as input to motor,
the motor starts rotating. Changing the number of poises of electrical energy. Automatically the
speed of motor at the required destination. Therefore accuracies of component produced is poor.
Servo Motor:-
Servo motor is also working similar to stepper motor. It is taking the poised electrical energy
as input and produces the mechanical energy required for travelling the axis at different rpm. The
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servo motor also consist of quick action braking system. To stop the axis of motor exactly at the
position. Wherever it is required. Therefore high positional accuracies of the machine can be
obtained. Hence accurate (or) close dimensional tolerance component can be produced.
Drive Unit Design:-
150 Pulse = 1 Revolution of motor
= 1 Revolution of lead screw
= 1 Pitch
= 5 mm
150 Pulse = 5 mm
5
1 Pulse =  0.033mm
150
1 Pulse = 1 BLU
BLU- Basic Length Unit
Feedback Device:-
The feedback device is a displacement measuring equipment mounted on the axis of a
machine tool for measurement & actual distance travelled by the axis and sending it as feedback to
the MCU. So that the MCU will compare the actual distance travelled by the axis, determine the
differences in distances. Corresponding to this difference in distance the MCU will again generate
the electrical energy pulses and send it to the motor. So that motor will generate the mechanical
energy required for travelling the remaining distance. Once again the feedback device will measure
the actual distance travelled by the axis and send it as feedback to MCU. This process continues
until the differences in distance travelled is less than (or) equal to 1 BLU.
Tape Reader System:-
Whatever the information is given to NC machine. The first converted into the punched
paper tape and there instruction will be read by the MCU using tape reader system.
The punched tape is divided into 8 tracks

Track 1 to 4 [ALPHABETS]
1-N = Block Number
2-X = X-Axis
3-Y = Y-Axis
4-Z = Z-Axis
5 = Position Check [ For proper Indexing ]
6&7= We used only decimals
8 = End of block
In NC Machine program, one block of information means one complete instruction Is given to the
machine for travelling the axis from present position to next position.
Manual Controls:-
Even though the above device is available in the NC-Machine. Since some manual
intervention are required for
1) Switching ON and OFF
2) Loading and Unloading of work piece.
3) Loading and setting of the tool
4) Loading and Unloading of tape
Classification of NC machines:-
1) Based on the control system
a. Point to point control system
b. Straight line control system
c. Contour control system
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 2) Based on feedback device
a. Open loop system
b. Closed loop system
3) Based on number of simultaneous axis used.
2D, 2 ½ D, 3D, 4D, 5D…………..11D D=Dimensional

1.a) Point to Point control system

If end point of movement of tool is only important and path followed by the tool between end
point is not important. It is called point to point control system.

Point to Point (PTP) is used during, Reaming, Tapping etc

1.b) Straight line control system
In addition to end points of movement of tool. If the path followed by the tool in between end
points is a straight line path, the control system used is called as straight line control system.

A straight line control system. Atleast 2 axis simultaneous movements are required. It is
used in turning, milling, shaping, grinding, planing etc.
1.c) Contour Control System:-
In addition to ends points of movement of the tool. If the path followed by tool In between
end points is a contour path is called as contour control system.

For contour control system atleast 3- axis simultaneous movements are required. It is used
in turning, milling, grinding etc.
2.a) Open Loop System:-
NC machine without the use of feedback device is called open loop system. Because of non
availability of feedback device, the dimensional accuracies is poor.
2.b) Closed Loop System:-
NC machines with use of feedback device is called as closed loop system. It is a fully stable
system and produces accurate components.
3.a) 2-D Axis System:-
If two axis of one tool are moving simultaneously, it is called as 2-D machine tool.
3.b) 3-D Axis System:-
In addition to two axis simultaneous movements of one cutting tool, if the rotation of job is
also considered as a axis, called as 3-D machine tool.
Limitations of NC Machine:-
1) Making the tape is difficult and life of punched tape is limited only.
2) Design modification of the component cant be incorporated In existing tape.
3) Unless one component is manufactured physically. It is not possible to know whether the
program written is correct (or) not.
To overcome above disadvantage scientist introduced the CNC machine.
CNC Machine:-
CNC = Computer Numerical Controlled.
Main parts of CNC Machine:-
1) MCU (or) CPU [Machine Control Unit]
2) DU [Driving Unit]
3) FBD [Feedback Device]
4) Mini Computers
5) Very few manual controls

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Advantage of ‘CNC’ over ‘NC’ :-
1) Use of servomotor, the accuracy of the product is good.
2) Due to usage of mini computers, the program can feed into machine very easily. The
program is stored in the memory. So that many number of time can be copied and used.
3) Design modification can be easily incorporated in the existing program.
4) By using graphic stimulator the cutter point is possible to identify weather it is correct or
not.
5) Automation & mechanization of CNC machine is easier
DNC [ Direct Numerical control system ]
DNC is a system consist of more than one CNC Machine connected to the host computer.

Through tele communication lines in the DNC system. The host computer is downloading
the program corresponding to the component to be manufactured on different machine.
In this one single operator sit at the host computer and control the all CNC machines and
given program by downloading. The speed of the system is increased, large files can be handled and
number of machine tool used is increased.
FMS:-
FMS- Flexible Manufacturing System
FMS consist of a number of manufacturing cells, each containing an industrial robot and an
automated material handling system, all interfaced with a central computer. This system is highly
automated and is capable of optimizing each step of the total manufacturing operation. These steps
may involve one or more processes and operation, as well as handling of raw material, inspection
and assembly.
Basic Elements of Flexible Manufacturing System:-
1) Workstations
2) Automated handling and transport of material and parts.
3) Control system
It is a manufacturing system in which there is some amount of flexibility that allows the system
changes.
Two categories of flexibility:-
1) Machine Flexibility:-
System has ability to changed program and to produce the new product types and ability
to change the order of operation.
2) Routing Flexibility:-
System has ability to use multiple machines to perform the same operation on a part, as
well as system has ability to absorb large scale changes such as in volume, capacity etc.
CAD:-
CAD- Computer Aided Design
Design of components using computer is called Computer aided design.
Basic difference between conventional design and computer aided design:-
In computer design the solid body is divided into number of elements. So it is easier, in
conventional design the body is considered as a single element. So in computer design accuracy is
very high.
In case of CAD the body can be divided into many number of small size. Finite elements and
analysis is continued as a elemental analysis. Because of elemental analysis used CAD the design
of component will be easier and more accurate and because smaller size of elements has been taken
near to change in cross section the stress concentration factor need not be taken. In CAD because of
most of the uncertainities has been considered during the analysis, the maximum factor of safety to
be used is 1.2. whereas in the conventional design to account for the uncertainities present during
the usage of component minimum factor of safety to be used is 2.
Inputs Required:-
1) Loading condition [Tensile, Shear, Compression]

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 2) Approximate shape [ ]
3) Material properties [ Ductile, Brittle etc]
4) Allowable Strains [ Latitude strain, longitudinal strain]
Process steps:-
1) Generation of 2-D drawing
2) Import into the analysis package
3) Convert into solid models
4) Divide into number of finite elements
5) Apply Loading Condition
6) Obtain Max stresses and strain
7) Compare with allowable valves
8) Change the material and dimensions until the stress and strain are nearly equal or less
than allowable stress and strain.
9) Finalize the dimensions
Outputs Obtained:-
1) 2-D Production Drawing
2) BOM [ Bill of Material]
3) Stresses and strains
The output obtained is given to CAM.

CAM:-
CAM means computer aided manufacturing.
CAM = FMS + ASRS + CMM
FMS = Flexible manufacturing system.
ASRS = Automated storage and retrieval system
Automated material handling system used in stores for retrieving the raw material and
storing the finished goods.
CMM = Co-Ordinate measuring machine.
Co-Ordinate measuring machine is used for measuring more than one dimension
simultaneously.
Inputs of CAM:-
1) 2-D Production Drawing
2) BOM [Bill of material]
3) Raw Material
Process:-
1) Generate CNC Part program
2) Retrieving raw material from stores
3) Machining
4) Inspection using CMM
Output :-
Acceptable finished goods
CAD- CAM is an integral approach used for design and manufacturing of components together as a
manless manufacture.
NOTE:- Extension of CAD-CAM is CIM
CIM:- [Computer Integrated Manufacture]
Any industry can be divided into four departments

Integrating different departments present in manufacturing industry by using a computer such

that
manless manufacturing is possible is called as computer integrated manufacturing.

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EX:- DELL company has implemented CIM system.
Part Programming of CNC machine:-
Part programming is a coded programming written based on the standard codes available in
CNC machine.
Each code is indicating the name of the program, written for the specified movement of the
tool. Whenever the code is used in writing the part program. The program corresponding to
specified movement of tool will be automatically executed.
G Codes [Preparatory Codes]
Goo = Rapid Transverse
Whenever the tool is travelling In ideal condition. It is required to travel at maximum
possible speeds. But the machine programmer cannot remember the maximum speeds available in
each and every machine tool of a shop floor. In such cases, if the programmer indicates Goo. The
machine is automatically adapting the maximum possible velocity present in machine tool. So that
ideal motion time is minimum and the machine is also safe.
GOI [Linear interpolation] :-
Whenever the tool is required to travel linearly to produce the linear dimensions on the
components.
G02 = Circular Interpolation clock wise
G03 = Circular Interpolation Anti clock wise
Whenever the contoor shaped components are to be manufacture the circular interpolation
will be used.

Go4 = Dwell:-
Dwell is temporary stoppage of machine for specified duration
Go5 = Hold:-
Temporary stoppage of machine for unlimited duration
Go8 = Acceleration
G09 = Retardation
G17  XY Plane 

G18  YZ Plane  Plane Section
G19  ZX Plane 
G33 = Thread cutting with constant pitch
G34 = Thread cutting with increasing pitch
G35 = Thread cutting with decreasing pitch
G41 = Cutter compensation left
G42 = Cutter compensation right
G40 = Cutter compensation cancel
G70 = English programming [inches]
G71 = Metric Programming [mm]
G81 = Drilling
G82 = Counter boring G-80=Boring
G85 = Reaming
G86 = Boring
G90 = Absolute mode of programming
G91 = Incremental mode
For each and every movement of tool the programming is done with reference to only one
reference point is called absolute mode of programming.
If the present position of tool can be taken as a reference point for programming to the next position
of tool. It is called as incremental mode of programming.
M-CODES [Machine or Mislleneous]
M00 = program stop
Temporary stoppage of machine for unlimited duration
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M01 = planned stop
Temporary stoppage of machine for specified duration
M02 = end of main program without use of sub program
M17 = end of sub program
M30 = end of main program written with use of sub program
M03 = spindle on clockwise
M04 = spindle on counter clockwise
M05 = spindle stop
M06 = tool change
M07 = coolant pump 1 ON
M08 = coolant pump 2 ON
M09 = coolant pump OFF
M10 = clamps ON
M11 = clamps OFF

The End
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