TABLE OF CONTENTS

CHAPTER1: INTRODUCTION:
1.1 History of CNC
1.1.1 Background
1.1.2 What is CNC?
1.2 Type of CNC machine
1.2.1 Milling CNC machine
1.2.2 Lathe CNC machine
1.2.3 Drilling CNC machine
1.2.4 Grinding CNC machine
1.2.5 Laser cutting CNC machine
1.2.6 Plasma cutting CNC machine
1.2.7 Water jet cutting CNC machine
1.2.8 Electric discharge machine
1.2.9 Router CNC machine
1.3 Advantage and disadvantage
1.3.1 Advantage of CNC Machines
1.3.2 Disadvantage of CNC Machines
1.4 Different of NC, DNC, CNC
1.4.1 Numerical Control (NC)
1.4.2 Computer Numerical Control (CNC)
1.4.3 Distributed numerical control (DNC)
1.5 controller
1.5.1 CNC Controller Board Manufacturers in World
1.6 codes M-G general
1.6.1 What are G Codes?
1.6.2 What is M code?
1.7 Different Softwares
1.7.1 Computer Aided Design (CAD)
1.7.2 Computer Aided engineering (CAM)
1.7.3 Computer Aided manufacturing (CAE)

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 List of tables
No. Subject Page
Table 1-1 Difference between CNC milling machine and 7
manual milling machine.
Table 1-2 CNC and Conventional Lathe Machines 11
Table 1-3 CNC and Conventional Drilling Machines 14
Table 1-4 Advantage and disadvantage of Grinders CNC 19
Machining
Table 1-5 Advantage and Disadvantage of EDM 35
Table 1-6 difference between NC, CNC, DNC 50

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 List of figures
No. Subject Page

Fig. 1.1 The Vital Parts of a CNC Milling Machine. 7

Fig. 1.2 manual milling machine. 8
Fig. 1.3 CNC milling machine 8
Fig. 1.4 vertical CNC milling machine 9
Fig. 1.5 Horizontal CNC machine 10
Fig. 1.6 lathe CNC machine 11
Fig. 1.7 External Cylindrical Grinding Machine 15
Fig. 1.8 internal Cylindrical Grinding 16
Fig. 1.9 Axis of Grinding Machine 17
Fig. 1.10 axis of laser cut machine 23
Fig. 1.11 2D CNC plasma 26
Fig. 1.12 3D CNC plasma 27
Fig. 1.13 water jet CNC machine 27
Fig. 1.14 water jet process 28
Fig. 1.15 abrasive flow machining 29
Fig. 1.16 abrasive jet machining 30
Fig. 1.17 Electro Discharge Machine 32
Fig. 1.18 EDM working principle 33
Fig. 1.19 sinker EDM 34
Fig. 1.20 wire EDM machine 34
Fig. 1.21 CNC Router Machine 37
Fig. 1.22 CNC Router component 38

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 NOMENCLATURE
Symbol Definition
CNC Computer numerical control
NC Numerical control
DNC Distributed numerical control
CAM Computer aided manufacturing
CAD Computer aided design
CAE Computer aided engineering

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 Chapter one
Introduction

1.1 History of CNC

1.1.1 Background

Computer numerical control (CNC) machine is the advanced version of the

conventional/old manual machine. The first manual metal working lathe was
invented in the year 1800 by Henry Maudslay, a British machine tool innovator and
inventor. In the beginning, the lathe machine was a simple machine which held the
work piece between two rigid and strong supports [1].

After the time period of the first metal cutting machine, manual machines became
little advanced but still needed the operator for its operation. Apart from this, these
machines have some problems such as inability to make complex shapes, causes
variation in dimensions, high scrap rate, fitting problem, wastage of raw material,
high production cost and machine run time. Despite this, we are not saying that
conventional/manual machine was not good. During that time, these machines were
the best ones [1].

Due to the above-mentioned drawbacks, during World War I and II the American Air
force faced some problems in equipment like the helicopter rotor blade and other
machine parts because the manually operated machine was unable to perform three-
dimensional complex operations as intended. In 1952, the Massachusetts Institute of
Technology (MIT) introduced the first semiautomatic NC machine with the support
of Mr. John T Parson and IBM. It was an American government funded project for
the American Air force. This initial machine solved the initial requirements of the
American Air force and gave revolutionary results to the manufacturing industry.
Numerical control (NC) machine was the design of the mechanical and electronics
technology. This NC machine performed its work perfectly and resolved maximum
machine related problems. These machines technology was the best machine
technology of that time. We can say these machines were the back bone of that time

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industry like aviation industry etc. But after development in machine technologies,
in the 1970s, Mr. John T Parson and the MIT together developed the first CNC
machine tools with the help of IBM. This CNC machine was fully automatic and
owns a computation system [1].

1.1.2 What is CNC?

CNC stands for Computer Numerical Control. A CNC machine is a sophisticated

metal (material) removing computerized machine on which we can make any
complex shapes, which was not possible before, with high accuracy, repeatability,
better quality, less rejection and mass production. Before NC and CNC machine,
engineers cannot machine same product again and again with all the above qualities
[1].
1.2 Types of CNC Machines

1.2.1 Milling CNC machine

A computer numerical control (CNC) milling machine is a mill that uses computer
code to understand where to make cuts[10].

Like all milling machines, a CNC mill produces a final piece by carving away from
a block of material versus adding layers of material to a blank slate. However, unlike
manual milling, CNC mills do not have to be operated by hand. You simply need
the right computer software and a library of programs to instruct your machine on
how to create the desired product [10].

CNC milling is just one type of CNC machining process your business could
consider integrating to make your production more accurate and efficient [10].

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 Fig 1.1 The Vital Parts of a CNC Milling Machine.

Table 1-1 Difference between CNC milling machine and manual milling machine.

CNC milling machine manual milling machine

CNC milling machine are more versatile than manual milling machine. A number of jobs that are
not possible with manual milling machine can be easily done with CNC mill.
In a CNC milling machine the spindle is Where as in a manual milling machine the
stationary and the table can move parallel as spindle rotates on its axis and the cutters are
well as to the axis of the spindle for the cutting held in it.
process.
The CNC milling machine controls its The manual milling machine is operated by
movement by the numerical control controller, manual operation. The result is that the error is
which makes his machining more precise. very large.
CNC milling machine can work 24 hours a day Manual milling machine needs manual non-
by writing programs, and no one is on duty. stop operation, and cannot achieve automation.
Work done with CNC milling machine is faster Less work pieces can be made because of
than a manual milling machine so more work manual operation.
pieces can be made in less time.

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CNC milling machines can automatically Manual milling machines can only change the
change tools so that it is more efficient. tool manually.

The CNC milling machine structure is the manual milling machine is the work table
different from the manual milling machine. moving up and down to complete the work.
The CNC milling machine Z axis can move up
and down

The standard CNC milling machine is a 3-axis Manual milling can only achieve 2 axis linkage.
linkage. We can also expand into a 4 axis and
5 axis linkage.

Because CNC milling machines use computer Manual milling machines can’t do this.
programming, even if they manufacture large
quantities of parts, their size and surface are
the same.

Since the CNC milling machine adopts program the manual milling machine can only operate
control, one can operate multiple machines one machine.

CNC milling machines require trained Ordinary people can operate manual milling
engineers to complete the operation. machines

CNC milling machines are less prone to errors Manual milling machines are more prone to
due to program control. errors due to the need for manual operation.

Fig 1.3 CNC milling machine.

Fig 1.2 manual milling machine.

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Types Of CNC Milling Machine.

a) Vertical CNC Milling Machine

• Structure: The spindle is oriented vertically, allowing for workpieces to be

positioned horizontally or at various angles.
• Uses: Primarily used for die sinking, mold making, and precision cutting.
• Features: Can handle most types of milling jobs, from face milling to
surface finishing [10].

Fig 1.4 vertical CNC milling machine

b) Horizontal CNC Milling Machine

• Structure: The spindle is placed horizontally, allowing the cutters to remove material
more efficiently on the side.
• Uses: Ideal for cutting grooves, slots, and other complex shapes in large workpieces.
• Features: Excellent for heavy-duty or high-volume work [10].

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 Fig 1.5 Horizontal CNC machine

1.2.2 Lathe CNC machine

The way CNC lathe machines operate is by rotating the material of the workpiece
about a primary axis. The lathe cutting tools remove the material from the workpiece
and shape it as needed [10].
Number of Axes in CNC Lathe Machines
CNC lathe machines are used in various applications and are typically available in
the following configurations:
• 2 Axes (X and Z): This is the basic configuration used for simple turning
operations.
• 3 Axes (X, Y, Z): Adds a third axis (Y) for more complex operations,
allowing for side cutting.
• 4 Axes: Introduces a rotational axis (Axis A), enabling work on more
complex shapes.
• 5 Axes: Allows for advanced machining capabilities with two additional
rotational axes [10].

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 Fig 1.6 lathe CNC machine
Table 1-2 CNC and Conventional Lathe Machines

CNC Lathe Machines Conventional lathe Machines

Precision: Offer high precision, often achieving Rely on the skill of the operator,
tolerances of ±0.01 mm or less, thanks which can lead to variations in
to digital control. precision.
Efficiency: Can operate automatically for Require an operator for ongoing tasks,
extended periods without human leading to potential downtime and
intervention, increasing productivity. increased labor costs.
They can run for long hours without
the need for monitoring.
Repeatability: Can produce identical parts May experience slight differences
repeatedly with high accuracy, between produced parts due to
making them ideal for mass manual adjustments.
production.
Automated The movements are preprogrammed Typically require manual input for
Control: using G-code, minimizing human adjustments, increasing the likelihood
error and allowing for complex of mistakes.
operations.
Productivity: Capable of performing multiple Often require manual setup and
operations without the need for tooling changes, which can slow
manual tool changes, contributing to down production
higher productivity.

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1.2.3 Drilling CNC machine
The Drilling machine is one of the most popular CNC machines found in most CNC
machine shops. the drilling CNC machine uses a specialized cutting tool called drill
bits or drill. It is ideal for drilling holes in many materials [11].
Number of Axes in CNC Drilling Machines
CNC machines vary in the number of axes based on their applications:
• 3-Axis Machines: Move in three directions (X, Y, Z). This type is the most
common for drilling operations.
• 4-Axis Machines: Add an additional rotational axis (Axis A), allowing the
machine to rotate the part around the X-axis.
• 5-Axis Machines: Add two more axes (Axis A and Axis B), allowing for more
complex movements and multiple angles [10].
Components of a CNC Drilling Machine
a) Frame:
The frame serves as the primary structure that supports all the machine components.
It is designed to provide stability and reduce vibrations during operation, which is
crucial for maintaining precision.
b) Motors:
CNC drilling machines use various types of motors, including stepper motors and
servo motors, to control the movement of the axes. These motors ensure accurate
positioning and speed control, which is essential for achieving precise drilling
operations.
c) Controller:
The controller is the brain of the CNC drilling machine. It receives commands from
the computer or programming software and translates them into specific actions for
the motors and other components. The controller often includes interfaces for user
input, monitoring, and adjustments.
d) Spindle:
The spindle is the part of the machine that holds and rotates the cutting tools. It is
designed to achieve high rotational speeds, which is crucial for effective drilling.

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The spindle speed can vary depending on the material being drilled and the type of
tool used.
a) Axes:
The axes of a CNC drilling machine provide movement in different directions. Most
CNC drilling machines operate with three axes (X, Y, Z), while more advanced
machines may include additional axes (like A and B) for more complex movements,
allowing for intricate drilling patterns and angles.
b) Software:
CNC machines rely on specialized software for programming. This software allows
operators to create and edit machining programs, which are then converted into
machine-readable code (G-code). This code directs the machine’s movements and
operations, ensuring accuracy and efficiency [11].

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 Table 1-3 CNC and Conventional Drilling Machines

CNC Drilling Machines Conventional Drilling Machines

Precision and CNC machines offer extremely high In contrast, conventional machines
Control: precision, often achieving tolerances depend heavily on the skill and
of 0.01 mm or even less. This level of experience of the operator. While
accuracy is made possible by digital skilled operators can produce high-
control systems that use computer quality parts, variability in their
algorithms to guide the movement of technique can lead to inconsistencies
the machine. CNC systems typically and a higher likelihood of errors.
employ servo motors that provide
precise feedback on the position,
which enhances control during
operations.
Efficiency: These machines can operate Operators must constantly oversee
continuously for extended periods conventional machines, leading to
(24/7) with minimal human potential interruptions in production.
intervention. This capability This manual oversight can result in
significantly increases overall increased labor costs and longer lead
efficiency and reduces downtime. times.
Once a job is set up, CNC machines
can run automatically without the
need for constant monitoring.
Repeatability: One of the standout features of CNC Although they can produce quality
machines is their ability to produce parts, conventional machines often
identical parts repeatedly with high suffer from variability in output.
precision. This repeatability is crucial Small differences in setup or operator
for industries that require large technique can lead to variations in
quantities of uniform components, part dimensions, making them less
such as automotive or aerospace suitable for high-volume production
manufacturing. runs.
Automated The movement of CNC machines is These machines typically require
Control: pre-programmed using computer manual input for adjustments and
software, such as G-code, which operations, increasing the chance for
defines each step of the machining human errors and inconsistencies.
process. This programming
minimizes human error and allows for
complex operations that would be
challenging to execute manually.
Productivity: CNC machines can perform multiple These machines often require manual
operations without the need for setup and tooling changes, which can
manual tool changes, which slow down the production process and
contributes to higher productivity. limit throughput.
They can also work faster and more
accurately than traditional machines.

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1.2.4 Grinding machine
Grinding is an abrasive machining process used for fine machining and finishing of
workpieces. It can be performed manually or using grinding machines. As with all
abrasive procedures, excess material is removed from the workpiece in the form of
chips. The cutting is actually performed by the edges of microscopically small hard
mineral crystals in the grinding tool [12].
Grinding meets today's production needs as it guarantees high quality and output at
reduced cost per workpiece. Grinding is available for:
• High dimensional and form accuracy
• A defined surface quality
• Machining of difficult-to-cut materials
External cylindrical grinding
External cylindrical grinding is used for the production of cylindrical or tapered
workpieces, such as the grinding of shafts, axles and spindles as used in the general
machine tool, automotive and aerospace industries. The circumference of the
grinding wheel is used to remove material from the circumference of the workpiece.
This can be done in the radial (plunge grinding) or axial (traverse gringing) modes.
To allow for greater accuracy in clamping, workpieces are usually mounted between
centers. Multiple idle strokes (spark-outs) are used to improve the form accuracy and
surface quality [12].

Fig 1.7 External Cylindrical Grinding Machine

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Internal cylindrical grinding
Internal cylindrical grinding is primarily used for machining cylindrical or tapered
bores. During internal cylindrical grinding, the longitudinal feed movement is
typically carried out by the grinding wheel, with the radial infeed movement during
internal cylindrical grinding handled by the wheel head or the work head, depending
on the design of the machine. Basically, the same kinematic relationships apply as
with external cylindrical grinding. The contact area between grinding wheel and
workpiece is however considerably larger, which makes the removal of chips and
the cooling of the process more difficult [12].

Fig 1.8 internal Cylindrical Grinding

Number of Axes in CNC Grinding Machines

CNC grinding machines are available in several configurations:
• 3-Axis Machines: Move in three directions (X, Y, Z). These are commonly
used for basic operations.
• 4-Axis Machines: Add a rotational axis (Axis A), allowing for more
complex operations.
• 5-Axis Machines: Include two additional axes (Axis A and Axis B),
enabling the machine to process parts from different angles.

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 Fig 1.9 Axis of Grinding Machine

Process controls these days ranges over the following categories:

-manual control
-switching control
-CNC
-intelligent control

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Manual Control
An example of manual control is where a human operator provides a feed motion.
This may be as simple as providing an increment of cross feed or down-feed in
surface grinding or as complex as following a contour when grinding a form tool on
an optical profile grinder. The feature that distinguishes manual control is that a
human being has control of measurement, decision making, and actuation. An
important decision is deciding when the workpiece has reached its finish size. This
implies the use of some measurement device such as a micrometer or a reading on a
leadscrew scale. Early grinding machines were all manually operated. Many
machines are still manually controlled but almost all machines incorporate elements
of automation such as automatic traverse reversal for traverse grinding [12].
Switching control
Switching control is one of the simplest forms of machine control, used to reverse
the feed motion in traverse grinding. It relies on switches that are set to determine
the switching point. This can be achieved through PLCs or low-cost computers with
position measurement tools like encoders or linear scales.

In more advanced systems, servo drives and ball screws are used for feed motion,
allowing for easier adjustment of switching positions in more complex feed cycles.
Automatic retraction can also be incorporated when a measuring device detects that
the final size has been reached [12].
Computer Numerical Control (CNC)
Modem CNCs vary from low-cost computers that basically provide switching
control using servo-drives to full three-axis contouring control that allows complex
shapes to be generated. The example shown is an easy set-up machine produced by
Jones & Shipman Precision Ltd. Other CNCs in the product range provide far more
advanced control features. The process engineer produces a process sheet that
specifies the stages in the production of a part together with critical dimensions and
the type of feed cycle to be employed. These instructions are fed into the CNC using
a code format acceptable to the CNC. After validation of the code, and machine set-
up, the CNC operates automatically to produce a part or batch of parts [12].

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Intelligent Control in CNC Machines
Intelligent control refers to a machine's ability to automatically adjust its operating
settings to improve the process based on real-time data collected from sensors. This
means that instead of the machine working with fixed settings throughout the
process, it can change operating parameters, such as feed rate or tool position,
depending on the information it receives during operation.
For example, if a machine is grinding a part and using a measurement device, such
as a diameter gauge, it can automatically adjust the position of the part or the tool to
achieve the required size with precision [12].

Table 1-4 Advantage and disadvantage of Grinders CNC Machining

Advantages of Grinders CNC Machining Disadvantages of Grinders CNC

Machining

• Grinders can achieve very tight • Grinders produce a lot of noise

tolerances • Grinders produce a lot of dust and
• Grinders can create very intricate debris
designs • Grinders are expensive machines
• Grinders are very versatile machines- • Grinders require regular maintenance
they can be used for a variety of • Operators of grinders need to wear
different materials personal protective equipment (PPE)
• Grinders are relatively fast machines such as earplugs, safety glasses, and
• Grinders require very little setup time respirators
• Operators of grinders do not need to • Workpieces that are being machined on
have a lot of experience or training grinders need to be securely clamped
down so that they do not become
dislodged during the machining
process

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1.2.5 Laser cutting CNC machine

A CNC laser cutter is a piece of computer numerical control (CNC) equipment that
uses a focused, high-powered laser beam to mark, cut, or engrave a material to form
custom shapes. Its unique design and operation make it highly accurate, especially
when cutting intricate shapes and small holes [19].

Types of CNC Laser Cutting Machines

a) CNC CO2 laser cutter
b) CNC crystal laser cutter
c) CNC fiber laser cutter

a) CNC CO2 Laser Cutter

The CO2 laser cutter is a type of gas laser that employs carbon dioxide as the active
laser medium. They are the most common type of laser cutters primarily because of
their high-power output capability and efficiency.
CO2 laser cutters generate a power output of up to 15 kW and an efficiency of up to
30% (the highest of all the gas laser cutters). They are ideal for cutting fine features
and acute angles, especially in sheet metals or metals with a thickness of less than
10 mm. Higher powered CO2 laser cutters can also deliver good cut quality on
thicker metal surfaces [19].

b) CNC Fiber Laser Cutter

Fiber laser cutters are a more recent laser technology that uses a bank of diodes to
create the beam, which is focused through a fiber-optic cable. Fiber laser cutters
allow you to achieve a faster and cleaner cutting process than CO2 laser cutters,
especially in materials with a thickness of less than 5 mm.
Although fiber lasers are compatible with a broad range of materials, you must pay
special attention to silver [19].

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Silver retains heat from the laser and starts to warp during cutting operations, making
it challenging to achieve the desired machined part. As a result, top-tier machine
shops typically use a bracket as a heat sink to transfer heat away from the silver
workpiece during fiber laser cutting operations.

c) CNC Crystal Laser Cutter

CNC crystal laser cutters use beams made from crystals like neodymium-doped
yttrium aluminum garnet (Nd:YAG) and neodymium-doped yttrium ortho-vanadate
(Nd:YVO).
Crystal laser cutters generally have higher intensity (or laser power) than CO2 laser
cutters, meaning you can use them to cut through thicker metals. These cutters also
have a broad range of material compatibility, including metals, glass, wood, and
plastics [19].
Material Removal
As the laser beam moves along the programmed path, it melts or vaporizes the
material. The molten or vaporized material is expelled from the kerf (the cut path),
leaving behind the desired shape or pattern [20].

Cooling and Solidification

As the laser cuts through the material, it generates a significant amount of heat.
Cooling mechanisms, such as water or air jets, are often employed to prevent the
material from overheating and to aid in solidification [20].

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Numbers of axis of laser cutting cnc machines

• 2-Axis CNC Laser Cutting

A 2-axis CNC laser cutter operates in a flat, 2D plane. This machine can move its
laser head horizontally (X-axis) and vertically (Y-axis), which is optimal for cutting
flat sheet materials like metal and wood.

• 3-Axis CNC Laser Cutting

In addition to the capabilities of the 2-axis machine, a 3-axis CNC laser cutter can
move its laser head up and down (Z-axis), providing a greater depth of cut. This is
especially useful for engraving applications.

• 4-Axis CNC Laser Cutting

A 4-axis CNC laser cutter can perform all movements of a 3-axis machine, but also
rotates the workpiece around one axis, usually the X or Y-axis. This additional
rotation allows for the creation of complex geometries and shapes.

• 5-Axis CNC Laser Cutting

5-axis CNC laser cutters offer even more flexibility, with the ability to rotate the
workpiece around two separate axes simultaneously. This offers a great deal of
control and precision in creating multi-dimensional, intricate shapes.

• 6-Axis CNC Laser Cutting

The 6-axis CNC laser cutter is the most advanced, featuring all the capabilities of
the 5-axis machine plus another rotational axis. This allows the machine to cut from
almost any angle, delivering extremely complex and precise cuts [20].

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 Fig 1.10 axis of laser cut machine

some sectors that frequently utilize CNC laser cutting

• Automotive Industry: CNC laser cutting is critical in vehicle manufacturing, used

for precise shaping of sheet metal parts, cutting car body panels, and creating
small components with intricate designs.
• Aerospace Industry: In the aerospace sector, precision is paramount. CNC laser
cutting machines are employed to produce accurate parts with narrow tolerances,
making the most of their ability to cut exotic metals and composites commonly
used in the industry.
• Electronics Industry: From etching circuit boards to creating smartphone
components, CNC laser cutters are versatile tools in electronics production.

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• Medical Equipment Manufacturing: CNC laser cutters facilitate the production of
surgical tools, medical devices, and orthopedic implants, where detail and
accuracy are of the utmost importance.
• Jewelry Industry: Creating intricate designs with high precision, CNC laser
cutting is used extensively in jewelry making for cutting and engraving purposes.
• Construction Sector: Large-scale CNC laser cutting machines assist in cutting
structural components for buildings, bridges, and other construction projects
[19].

The advantages of using CNC laser cutting

• Higher Quality Edges: The non-contact nature of laser cutting reduces the chance
of mechanical distortion, resulting in cleaner edges with little to no burring.
• Narrower Kerfs: Compared to traditional cutting methods, CNC laser cutters
produce a much smaller cut width (kerf), which allows for intricate cuts and
maximizes material usage.
• Smaller Heat-Affected Zone (HAZ) and Less Material Distortion: As lasers
produce a smaller HAZ, there is less chance of thermal distortion of the material.
• Less Contamination and Waste: The precision of the CNC laser cutter results in
less waste material, and since it’s a contactless process, there’s reduced risk of
material contamination.
• Less Maintenance Required: CNC laser cutters often require less maintenance
than their mechanical counterparts due to their non-contact nature.
• Less Repair Costs: Fewer mechanical parts mean there are fewer components that
can wear out or break, thus reducing repair costs.
• Greater Operator Safety: The operation of a CNC laser cutter is generally
automated and enclosed, reducing risks to the operator compared to manual
cutting methods [20].

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 Types of materials can be cut using a CNC laser cutting machine
• Metals: These include steel, aluminum, and other metals. Laser cutters are perfect
for precision cutting metal sheets, with the power output and laser type
influencing the cut quality and thickness handled.
• Plastics: Both thermoplastics and non-thermoplastics can be laser cut, though
caution is needed due to potentially harmful fumes. Types include acrylic, ABS,
and polycarbonate.
• Thermoplastics: These are a type of plastic that becomes moldable when heated.
Examples include nylon, polyethylene, and polyvinyl chloride.
• Rubber: Laser cutters can precisely cut rubber, making them ideal for producing
gaskets, seals, and other custom rubber parts.
• Leather: Whether for fashion, upholstery, or crafts, laser cutting machines can
provide precise cuts on leather, including complex patterns and designs.
• Ceramics: CNC lasers can cut and engrave ceramics, though caution is needed to
prevent cracking or breakage.
• Wood: From hardwoods to softwoods and plywood, laser cutters offer precise cuts
and intricate detailing.
• Acrylic: Laser cutting is an excellent method for working with acrylic, providing
clean edges and intricate designs.
• Foam: Ideal for packaging, insulating materials, and crafts, foam can be cleanly
and efficiently cut with a laser cutter.
• Textiles: From cotton to polyester and even delicate fabrics like silk, laser cutters
offer precise and fray-free cuts.
• Paper: Whether for crafts, model-making, or packaging, laser cutters can handle
paper of various thicknesses.
• Composites: Composites like fiberglass and carbon fiber can be cut with a CNC
laser, though special care is needed due to the risk of harmful particles.
• Stone: Laser cutters can engrave stone but cutting through is usually not possible
due to the high thickness and hardness [20].

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1.2.6 Plasma cutting CNC machine

A plasma cutter is a thermal cutting tool used to cut various metals, producing clean
and accurate cuts. Common users of plasma-cutting machines include fabrication
shops, manufacturers, and automotive repair.
Depending on the machine, a plasma machine can cut a wide range of materials,
particularly electrically conductive metals, such as steel, aluminum, stainless, brass,
and copper [21].

Fig 1.1 2D CNC plasma

Advantages of CNC Plasma Cutting

The key advantages of CNC plasma cutting include:
a) Comparatively cheap
b) Faster cutting than oxyfuel cutting
c) Offers accuracy and repeatability
d) Can cut in water to mitigate heat-affected zone

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 Fig 1.12 3D CNC plasma

1.2.7 Water jet cutting CNC machine

Water jet cutting is a manufacturing process that employs high-pressure jets of water,
generated by pressurizing pumps, to deliver a supersonic stream for cutting and
shaping various materials. Water in water jet cutting is pressurized up to 392 MPa
and directed through a small precision nozzle. Upon exiting the nozzle, the water
reaches speeds three times faster than the speed of sound [21].

Fig 1.13 water jet CNC machine

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Pure water jet cutting, which uses only water as its medium, is designed for soft
materials such as wood, plastics, foam, paper, and rubber. When an abrasive is added
to the water stream, the cutting process becomes more aggressive, enabling it to cut
through hard materials like titanium, stainless steel, aluminum, glass, ceramic, and
concrete [21].

Fig 1.14 water jet process

How water jet cutting works?

The water jet cutting process can be carried out in various ways, with most methods
incorporating an abrasive into the water to facilitate cutting through the workpiece.
This versatile manufacturing technique can cut, shape, and design a workpiece to
meet precise specifications [21].

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The shaping method used in water jet cutting offers several advantages over other
cutting processes like plasma or laser cutting. Water jet cutting provides superior
accuracy, can handle complex designs, and is suitable for thermally sensitive
surfaces. The abrasive, akin to sandpaper, erodes the material being cut without
heating it or altering its temper. As a result, the cut edges are clean and ready for
welding without the need for additional processing [21].
Abrasive flow machining (AFM)
Abrasive flow machining (AFM) is used for interior surface finishing, particularly
for deburring and honing parts that are difficult to reach with traditional methods.
By using a mixture of water and abrasive, AFM effectively erodes raised surfaces
inside a workpiece, similar to the action of a grinder or sandpaper, to remove
unwanted particles and achieve a smooth finish [21].

Fig 1.15 abrasive flow machining

29
The abrasive jet machining process is a key aspect of abrasive water jet cutting. It
involves a high-pressure stream of water mixed with abrasive particles that blast and
erode the workpiece, removing particulate matter, burrs, and other materials. This
technique uses extremely fine particles applied at high velocity and is particularly
effective for cutting and shaping brittle, thin, and hard materials. Abrasive jet
machining excels in creating intricate shapes and achieving smooth, even edges [21].

Fig 1.16 abrasive jet machining

30
High pressure water cutting
Intensifiers are used to dramatically increase the pressure of pure water, allowing it
to shape and form soft materials without leaving behind water residue. Hydraulic
pumps play a crucial role in this process, converting the force of the water into
mechanical energy to achieve the required high pressure.

A significant advancement in high-pressure water jet cutting was the introduction of

corundum elements in the cutting head, including varieties such as rubies and
sapphires. Corundum is renowned for its hardness, toughness, and stability, being
resistant to acids and the second hardest mineral on Earth [21].

CNC Water Jet Cutting

CNC water jet cutting utilizes high-pressure water in a programmable manner to
perform multiple operations in a single pass. It is particularly useful for materials
that are sensitive to high-temperature processes. CNC water jet machines can handle
various operations such as cutting, forming, deburring, reaming, and honing, making
them ideal for tasks requiring precision and minimal thermal impact.

Most CNC water jet cutting machines operate on three axes: X (left to right), Y (front
to back), and Z (up and down). Recent advancements include five-axis models that
add rotational capabilities. The A axis allows rotation around the X axis, and the B
axis provides rotation around the Y axis, offering greater flexibility and precision in
cutting complex shapes [21].

31
1.2.8 Electric Discharge Machining (EDM)
Electrical Discharge Machining Computer Numerical Control, namely EDM CNC,
is a special machining method that uses the electrical erosion effect produced by the
pulse discharge between electrodes in the working liquid to remove the conductive
materials. It is also called discharge machining or electrical erosion machining [13].

Fig 1.17 Electro Discharge Machine

How does EDM works?

In EDM, the tool electrode and the workpiece are connected to the two poles of the
pulse power supply respectively, and immersed in the working liquid, or the working
liquid is charged into the discharge gap. The tool electrode is fed to the workpiece
through the gap automatic control system. When the gap between the two electrodes
reaches a certain distance, the pulse voltage applied on the two electrodes will break
down the working fluid and produce spark discharge [13].

32
 Fig 1.18 EDM working principle

what is CNC EDM used for?

CNC EDM machine is mainly used for machining various kinds of molds, precision
parts and other complex cavity and curved shape of various kinds of conductive
materials [13].
Types of EDM

a. Sinker EDM (also known as Die Sinking):

- The electrode is shaped to create a specific cavity in the workpiece.

- Used for creating molds, dies, and complex shapes.

33
 Fig 1.19 sinker EDM

b. Wire EDM:

- Uses a thin, electrically charged wire as the electrode.

- The wire moves along a predetermined path, allowing for intricate cutting
and machining of shapes.
- Ideal for producing small parts with tight tolerances [13].

Fig 1.20 wire EDM machine

34
 Table 1-5 Advantage and Disadvantage of EDM

Advantages of EDM Disadvantages of EDM

• Precision: Capable of producing • Speed: Generally slower than

complex shapes with tight tolerances traditional machining processes.
(up to ±0.001 mm). • Cost: The initial setup can be
• Material Versatility: Can machine expensive due to equipment and
hard materials, including titanium, electrode materials.
steel, and carbide. • Surface Finish: While EDM can
• Minimal Mechanical Stress: The produce fine finishes, the surface may
process does not apply mechanical require additional processing (e.g.,
force, reducing the risk of warping or polishing) for critical applications.
damaging the workpiece.
• No Tool Wear: The electrode wears
down but is often replaceable or
recyclable.

35
1.2.9 Router CNC machine
A CNC router can be controlled by a computer, it’s like a traditional router with a
modern-day upgrade. To control it, the machine’s servo motors are fed a set of
instructions in a language they can understand: G-code. The instructions tell the
machine exactly how and where to move and, once it has read them, the router gets
to work moving a high-speed rotating cutting tool to make the carvings. The process
falls under the subtractive manufacturing category as it removes material to make
parts, unlike 3D printing, a.k.a. additive manufacturing, which adds layers [14].

These routers typically have a gantry-style construction (with a horizontal support

beam or structure) where the spindle (the main cutting tool) will move in two
directions left and right along the x-axis, and back and forth on the y-axis to cut or
carve material in the right shape and design. Depending on the material you’re
working with and the shape you want the CNC router to carve, there are different
cutting tools available. These can be manually swapped out, but some of the more
advanced models feature an automatic tool changer so you don’t have to physically
get involved [14].

Unlike standard CNC mills, these routers don’t have much range of motion up and
down (along the z-axis), so won’t be able to make deeper cuts or holes on tall parts
or very thick materials without struggling or making mistakes. They can be used to
engrave lettering onto harder materials like granite, though. In general, CNC routers
are best for use on flatter and softer materials (think: MDF, plywood, acrylic, and
polyurethane foam/sheet), and metals like brass and aluminum [14].

CNC routers are used a lot in woodworking to make everything from cupboard doors
to 3D sculptures. They can create wooden patterns for sand molds used in metal
casting and cut foam into custom shapes to be used in packaging. The advertising
industry uses CNC routers to engrave custom signs and lettering on wood or plastic
for various promotional products [14].

36
 Fig 1.21 CNC Router Machine

Key Components of a CNC Router Machine:

Bed: This is where you’ll put the material that you want to cut. Some beds have
multiple holes or attachment points to make it easier to mount clamping hardware
so that the workpiece can stay in place during cutting [15].

Controller: This part houses all the electronics, including the stepper or servo
motors, that control the machine’s speed and how and where it cuts [15].

Motors: The stepper or servo motors operate each of the three motion axes. Steppers
are usually found on cheaper hobbyist routers, whereas servos, which are found on
more expensive machines, are used in professional-grade models because they offer
more precision. There’s also a separate high-speed motor that rotates the cutting tool
[15].

Spindle/Router: This is what holds and rotates the cutting tool at the set speed. It’s
usually mounted on the gantry above the bed and moves as needed along the axes.

The below diagram shows the different parts of a CNC router [15].

37
 Fig 1.22 CNC Router component

Materials That Can Be Processed:

- Wood: Used in furniture making, cabinetry, and decorative work.
- Plastics: Common in sign-making, prototyping, and industrial components.
- Metal: Certain CNC routers can work with aluminum, brass, and softer metals,
though specialized CNC machines are typically used for harder metals.
- Foam and Composites: Often used in model-making, packaging, or light-duty
industrial work [15].

38
Applications of CNC Routers:
c. Woodworking: Used to cut shapes, profiles, and intricate patterns for
cabinets, furniture, and artistic wood carvings.
d. Signage: Engraving and cutting letters, logos, and patterns in materials like
wood, plastic, or acrylic.
e. Furniture Making: Creating detailed parts and components for furniture
design.
f. Rapid Prototyping: Used in engineering and design for quickly making
prototypes out of wood, plastic, or foam.
g. Mold Making: CNC routers can be used to create molds from materials like
wood or plastic for various manufacturing processes [16].

Advantages of CNC Routers:

- Precision: Achieve intricate and detailed designs with high repeatability.
- Automation: CNC routers can run automatically once programmed, reducing the
need for manual labor.
- Versatility: They can work on a wide range of materials and applications.
- Efficiency: Faster than manual routing or cutting processes, making them ideal for
mass production [16].

Software Used in CNC Routers:

CNC routers typically use CAD (Computer-Aided Design) and CAM (Computer-
Aided Manufacturing) software. Popular examples include:
- AutoCAD: Widely used for designing parts in 2D and 3D.
- Fusion 360: Provides both CAD and CAM capabilities for 3D design and
manufacturing.
- VCarve Pro: Commonly used for sign-making and woodwork designs.
- Aspire: Great for 3D modeling and detailed CNC carving projects [17].

39
How to develop a CNC router?
Upgrading a CNC Router can include a variety of improvements, from improving
performance and cutting techniques to updating software. Here are some steps and
guidelines for upgrading a CNC Router:
a. Improving the design and structure:
- Re-evaluating the frame: Make sure the frame is strong and stable. You can use
more rigid materials such as steel or aluminum.
- Adding additional support Use additional supports or bases to reduce vibrations
and increase accuracy.
b. Upgrading the electronic system:
- High-quality motors: Replace existing motors with high-quality stepper motors or
servo motors to improve accuracy and speed.
- Better drivers: Use improved motor drivers for better performance.
c. Improving cutting tools:
- Using new bits: Try different types of bits, such as carbide bits or diamond bits,
which provide better performance.
- Varying cutting speeds: Try different speeds to increase productivity and reduce
wear on tools.
d. Software Update:
CAM/CAD Software Change: Use modern design software that provides advanced
features such as 3D simulation.
G-code Improvements: Ensure that the software generates efficient G-code to reduce
cutting time.
e. Add New Features:
- Remote Control: You can add smart controllers to control the machine remotely.
- Sensors: Integrate sensors such as height sensors to improve accuracy and reduce
errors.

40
 f. Periodic Maintenance:
- Cleaning and Maintenance: Ensure that the machine is cleaned regularly and
damaged parts are replaced.
- Engine Oil: Use appropriate oils for engines and moving components to ensure
smooth movement.
g. Training and Professional Development:
- Operator Training: Invest in training operators to use software and tools better.
- Workshops: Join workshops or online courses to enhance technical skills.
h. Performance Evaluation:
- Testing of parts: Perform periodic tests of parts to ensure quality is maintained.
- Analyzing the results: Collect and analyze data on performance to discover any
areas for improvement.
i. Communicating with the community:
- Join forums: Participate in CNC forums to get tips and suggestions from other
professionals.
- Seek partnerships: Collaborate with technicians or engineers to improve
performance.
j. Research and Development:
- New Technology: Stay up to date on the latest technologies and innovations in the
CNC field.
- Experiencing new ideas: Don’t hesitate to try new ideas to improve productivity
and quality [18].

41
1.3 Advantage and disadvantage

1.3.1 Advantage of CNC Machines:

A. Setup time reduction

In many cases, the setup time for a CNC machine can be reduced, sometimes quite
dramatically. It is important to realize that setup is a manual operation, greatly
dependent on the performance of CNC operator, the type of fixturing and general
practices of the machine shop [5].

To keep the setup time to a mini- mum should be one of the primary considerations
of any machine shop supervisor, programmer and operator. Because of the design of
CNC machines, the setup time should not be a major problem [5].

Modular fixturing, standard tooling, fixed locators, automatic tool changing, pallets
and other advanced features, make the setup time more efficient than a comparable
setup of a conventional machine. With a good knowledge of modern manufacturing,
productivity can be increased significantly. The number of parts machined under one
setup is also important, in order to assess the cost of a setup time. If a great number
of parts is machined in one setup, the setup cost per part can be very insignificant
[5].

B. Reduced lead time

The time between the receipt of a design drawing and manufacturer getting ready to
start production on the shop floor, including the time needed for planning, design
and manufacture of jigs, etc. is called lead time. Since special jige and fixtures are
often entirely eliminated in CNC machines, the whole of the time needed for their
design and manufacture is saved. Consider the position of two manufacturers, one
equipped with conventional machines and the other with CNC machine tools. For a
job requiring special jigs and fixtures and cutting tools, the manufacturing unit with
conventional machines will have to spend considerable time in design and
manufacture of special tooling before taking up the production of components
whereas the unit with CNC machines can start production within a short period of
the work being planned and material being available [6].

42
 C. Estimation of operator’s error
The machine is controlled by programme of instructions stored in the memory of the
computer. The programme is checked before it goes to the machine so no errors will
occur in the job. Fatigue, boredom or inattention by an operator will not affect the
quality or duration of the machining [6].

D. Operator activity
The operator is relieved of tasks readily performed by the machine and is free to
attend to matters for which his skills and abilities are essential. Pre-setting of tools,
setting of components and preparation and planning of future jobs fall into this
category. It is possible for two work-stations to be prepared on a single machine
table, even with small batches. Two setting positions are used, and the operator can
set up one station while machining takes place at the other. The two jobs need not be
identical. Also, it is possible for one operator to attend to more than one CNC
machine at a time [6].

E. lower labor cost

Actual cutting time in the CNC machines is more than conventional machines since
the setting time, etc. are lower. Also, one operator can run two or more machines or
multiple pallet ma- chines are used resulting in reduced labor cost [6].

F. Smaller Batches
By the use of pre-set tooling and pre-setting techniques, downtime between batches
is kept at a minimum. Periodic machining of small batches is found to be economical
and brings about a rapid stock turnover. Larger storage facilities for work-in-
progress are not required. Machining centers eliminate some of the set-ups needed
for successive operations on one job and time spent in waiting until each machine
for successive operations is free. The components circulate round the machine shop
in a shorter period, interdepartmental transport costs are saved and 'Progress
Chasing' is reduced [6].

G. Longer tool life

Tools can be used at optimum speeds and feeds because these functions are
controlled by the part programme. Programmed speeds and feeds can be overridden
by the operator if difficulty in machining is encountered, for example, operator can
change the speed and feed if the material has different properties [6].

43
 H. Elimination of Special Jigs and Fixtures
Standard locating fixtures are often not used on CNC machines, and cost of special
jigs and fixtures is frequently eliminated. The capital cost of jig storage facilities is
also reduced. The storage of a part programme is very simple matter, it may be kept
for many years and the manufacture of spare parts, repeat orders or re- placements
is made much more convenient [6].

I. Flexibility in Changes of Component Design

The modification or changes in component design can be readily accommodated by
re-programming and altering the concerned instructions. There are no jigs and
fixture to be altered, hence, savings are affected in time and cost [6].

J. Reduced Inspection
The time spent on inspection and in waiting for inspection to begin is greatly
reduced. Normally, it is necessary to inspect the first component only. If there is any
difference in the dimensions of the machined component, the programme is checked
and corrected, if needed [6].

K. Less scarp
Since the operator errors are eliminated; a proven part programme results in an
accurate component. However, tool set- tings, as in a boring bar, do not come under
the control of the part programme and periodic checks must be made to ensure that
the settings remain correct. Drill or tap breakages are not unknown, but since the
tools are operating under controlled optimum conditions, the incidence of breakages
should be very small [6].

L. Accurate Costing and Scheduling

In CNC machines, the time taken in machining is predictable, consistent and results
in a greater accuracy in estimating and more consistency in costing. Consistent
operation enables the accurate compilation of shop loading schedules and thus
results in a balanced loading and a more predictable output [6].

44
1.3.2 Disadvantage of CNC Machines:

A. Higher Investment Cost

CNC machine tools represent a more sophisticated and complex technology. This
technology costs more to buy than its non - CNC counterpart. The higher cost
requires manufacturing management to use these machines more aggressively than
ordinary equipment. High machine utilization is essential in order to get reasonable
returns on investment, Machine shops must operate their CNC machines two or three
shifts per day to achieve this high utilization [6].

B. Higher Maintenance Cost

Because CNC is a more complex technology and machines are used harder, the
maintenance problem becomes more acute [6].

C. Costlier CNC Personnel

Certain aspects of CNC machine operations require a higher skill level than
conventional operations. Part programming and CNC maintenance are two areas
where personnel with the required skill are in short supply, The problems of finding,
hiring and training these people must be considered a disadvantage to the CNC shop
[6].

D. Planned Support Facility

Since most of the preparatory work for CNC operation is done away from the
machine, planned support facilities will be essential e.g. part programming, tape
preparation and tool pre-setting are fundamental services that must be considered.
However, the advantages of CNC systems outweigh the disadvantages considerably
and the CNC machines have been widely accepted by the industry, CNC is being
used in drilling, turning, boring, milling and grinding machines. In addition to metal
re- moving operations, CNC is used on machines like pipe bending, coil winding,
flame cutting, welding, wire-cut EDM and many other areas [6].

45
1.4 Different Between DNC, CNC, NC

1.4.1 Numerical control (NC):

Is a form of programmable automation in which the mechanical actions of a machine

tool or other equipment are controlled by a program containing coded alphanumeric
data. The alphanumeric data represent relative positions between a work head and a
work part as well as other instructions needed to operate the machine. The work head
is a cutting tool or other processing apparatus, and the work part is the object being
processed. When the current job is completed, the program of instructions can be
changed to process a new job. The capability to change the program makes NC
suitable for low and medium production. It is much easier to write new programs
than to make major alterations in the processing equipment [7].

Basic Components of an NC System: an NC system consists of three basic

components: (1) a part program of instructions, (2) a machine control unit, and (3)
processing equipment. The part program is the set of detailed step-by-step
commands that direct the actions of the processing equipment. In machine tool
applications, the person who prepares the program is called a part programmer. In
these applications, the individual commands refer to positions of a cutting tool
relative to the worktable on which the work part is fixtured [7].

Additional instructions are usually included, such as spindle speed, feed rate, cutting
tool selection, and other functions. The program is coded on a suitable medium for
submission to the machine control unit [7].

1.4.2 Computer Numerical Control (CNC)

Is the process of using a computer-driven machine tool to produce a part out of solid
material in a different shape, depends on digital instructions usually made on
Computer Aided Manufacturing (CAM) or Computer Aided Design (CAD) software
like SolidWorks or MasterCAM. The software writes G-code that the controller on
the CNC machine can read. The computer program on the controller interprets the
design and moves cutting tools and/or the workpiece on multiple axes to cut the
desired shape from the workpiece [7].

46
the CNC Machine Control Unit: the MCU is the hardware that distinguishes CNC
from conventional NC, The MCU consists of the following components and
subsystems in fig [1.1]: (1) central processing unit, (2) memory, (3) I/O interface,
(4) controls for machine tool axes and spindle speed, and (5) sequence controls for
other machine tool functions. These subsystems are interconnected by means of a
system bus, which communicates data and signals among the components of the
network [7

Fig 1.2 configuration of CNC machine control unites

Central Processing Unit (CPU):

The Central Processing Unit is the brain of the Machine Control Unit (MCU). It
manages the other components in the MCU based on software contained in main
memory. The CPU can be divided into three sections:
1. Control section
2. Arithmetic-Logic Unit (ALU)
3. Immediate access memory

Memory:
The immediate access memory in the CPU is not intended for storing CNC software.
A much greater storage capacity is required for the various programs and data needed
to operate the CNC system. As with most other computer systems, CNC memory
can be divided into two categories:
1. Main memory

47
2. Secondary memory
Input/Output Interface:
The I/O interface provides communication between the various components of the
CNC system, other computer systems, and the machine operator. As its name
suggests, the I/O interface transmits and receives data and signals to and from
external devices. The operator control panel is the basic interface by which the
machine operator communicates with the CNC system [7].

Controls for Machine Tool Axes and Spindle Speed:

These are hardware components that control the position and velocity (feed rate) of
each machine axis as well as the rotational speed of the machine tool spindle. Control
signals generated by the MCU must be converted to a form and power level suited
to the particular position control systems used to drive the machine axes [7].

Sequence Controls for Other Machine Tool Functions:

In addition to control of table position, feed rate, and spindle speed, several
additional functions are accomplished under part program control. These auxiliary
functions generally involve on/off (binary) actuations, interlocks, and discrete
numerical data. The functions include cutting fluid control, fixture clamping,
emergency warnings, and interlock communications for robot loading and unloading
of the machine tool [7].

1.4.3 Distributed Numerical Control (DNC( :

A system was developed in which machine tools were controlled by a remote

mainframe computer that transmitted instructions to a machine control unit (MCU)
in real time. The first model of this system was demonstrated in 1966. General
Electric and Cincinnati Milling Machine were pioneers in the development of direct
numerical control (DNC). In the 1970s, with the development of integrated circuit
technology, it became possible to use dedicated computers as controllers, and this
system was later called computer numerical control (CNC). This section describes
two approaches: (1) direct numerical control and (2) distributed numerical control
[7].
48
DNC Components:
The system consisted of four components: (1) central computer, (2) bulk memory at
the central computer site, (3) set of controlled machines, and (4) telecommunications
lines to connect the machines to the central computer [7].

Fig 1.3 General configuration of a DNC system. Connection to MCU is behind the tape reader.
Key: BTR = behind the tape reader, MCU = machine control unit

49
 1. Numerical Control 2. Computer 3. Direct Numerical 4. (DNC) (Modern
(NC): Numerical Control Control (DNC): Context):
(CNC):
Definition: NC refers to a system CNC is a more DNC is a centralized In modern usage, DNC
in which machine tools advanced system that control system where a also refers to
are controlled by a uses a computer to single computer (often Distributed Numerical
program stored on control machine tools. a mainframe) controls Control, where part
Summary compare:

physical media like Programs are stored multiple CNC programs are stored on
punched tape. The digitally in the machines by sending a central server but
instructions are fed machine’s memory programs in real time. downloaded to
into the machine in a and executed individual CNC
sequence. automatically. machines for
execution.

Control: The control is done The machine has an The central computer Machines execute the
through hardwired onboard computer sends the part programs locally after

50
logic and (CPU) that interprets programs directly to downloading from the
electromechanical and runs the program the CNC machines in server, which allows
devices that read stored in its memory. real-time, rather than for more independence
instructions from the program being than Direct Numerical
punched tapes. stored locally on each Control.
machine.
Table 1-1 difference between NC, CNC, DNC

Storage: No internal storage for Internal memory, The part programs are Part programs are
part programs. Each allowing easy reuse stored on the central stored both centrally
operation requires a and modification computer and (on the server) and
new punched tape with without physical transmitted to locally (on the
the program for that media like tapes. machines as needed. machines), ensuring
task. Machines do not store more flexibility in
the programs operation.
independently.
 Technology: Developed in the 1940s Emerged in the 1970s Developed in the late Common in today’s
and 1950s, relying on with the development of 1960s and early 1970s. manufacturing setups
analog systems and microprocessors and Utilized mainframe with networked CNC
mechanical components. integrated circuits. computers and large machines.
networks of CNC
machines.

Flexibility: Limited flexibility, as any Highly flexible. More flexible than NC Highly flexible, as
modification requires Programs can be easily but less flexible than programs can be easily
creating a new punched modified, uploaded, and modern CNC systems distributed, modified, and
tape. stored in the machine or a because machines still executed across multiple
computer network. rely on the central machines.
computer for
instructions.

51
Reliability: Less reliable due to More reliable than NC, Reliable as long as the More reliable than earlier
mechanical wear and with fewer mechanical central computer is DNC systems as the
complexity of physical components involved and functioning; if the machines can continue to
media like tapes. higher accuracy. mainframe fails, all operate independently
connected machines stop. after receiving the part
programs

Additional CNC machines offer high DNC is useful in large

Features and precision, can execute manufacturing facilities
Usage: complex operations, and where many machines
integrate with are controlled from a
CAD/CAM systems. central location.
1.5 controllers

1.5.1 CNC Controller Board Manufacturers in World

• FANUC – Japan
• Siemens – German
• HuazhongCNC – China
• Heidenhain – Germany
• Mazak – Japan
• Mitsubishi – Japan
• Haas – America
• Fagor – Spain
• NUM – France
• Bosch Rexroth – German

1.6 Codes M-G General

1.6.1 What are G Codes?

Generally, G-codes are used in CNC programming for machining of different profile
like turning, boring, facing, step turning, threading, chamfer, radius profile, profile
turning etc. G-codes are used with numerical numbers like G01, G02, G21, etc. We
can say, these codes are used in material removing operations, parameter settings
and tool geometry offsets, etc. [1].
G Codes are of Two Types
A. Model Command
G codes of this group will be effective in CNC program until replaced by another G
code or another G code will not activate. Examples G01, G00, etc.
B. Non-Model Command
G codes of this group are effective only once when it is used or when it occurs. It
will not effective in the next line, if it is not used again. Examples G02, G03, G04,
etc [1].

52
Addresses
N refers to the block number
G refers to the G code (Preparatory function).
X refers to the absolute distance travelled by the slide tool in the X axis direction.
U refers to the incremental distance travelled by the slide tool in the X axis direction.
Z refers to the absolute distance travelled by the slide tool in the Z axis direction.
W refers to the incremental distance travelled by the slide tool in the Z axis direction.
F refers to the feed rate.
M refers to the M code (Miscellaneous function).
S refers to the spindle speed.
T refers to the tooling management.

Summary of G-Codes
GOO / Rapid positioning
GOl /Linear interpolation
G02 /Clockwise circular/helical interpolation
G03 /Counterclockwise circular/helical interpolation
G04 /Dwell
G I O /Coordinate system origin setting
G12 /Clockwise circular pocket
G13 /Counterclockwise circular pocket
G15/G16 /Polar coordinate moves in GOO and GOl
G17 /XY plane select
G18 /XZ plane select
G19 /YZ plane select
G20/G21 Inch/millimeter unit
G28 /Return home
G28.1/ Reference axes
G30 /Return home
G31 /Straight probe
G40 /Cancel cutter radius compensation
G41/G42 /Start cutter radius compensation left/right
G43 /Apply tool length offset (plus)
G49 /Cancel tool length offset
G50 /Reset all scale factors to 1.0
G51 /Set axis data input scale factors
G52 /Temporary coordinate system offsets

53
G53 /Move in absolute machine coordinate system
G54 /Use fixture offset 1
G55 /Use fixture offset 2
G56-58/ Use fixture offset 3, 4, 5
G59 /Use fixture offset 6/use general fixture number
G61/G64/ Exact stop/Constant velocity mode
G68/G69 /Coordinate system rotation
G73 /Canned cycle - peck drilling
G80 /Cancel motion mode (including canned cycles)
G81/ Canned cycle - drilling
G82 /Canned cycle - drilling with dwell
G83 /Canned cycle - peck drilling
G85 /Canned cycle - boring, no dwell, feed out
G86 /Canned cycle - boring, spindle stop, rapid out
G88 /Canned cycle - boring, spindle stop, manual out
G89 /Canned cycle - boring, dwell, feed out
G90 /Absolute distance mode
G91 /Incremental distance mode
G92 /Offset coordinates and set parameters
G92.X /Cancel G92 etc.
G93 /Inverse time feed mode
G94 /Feed per minute mode
G95 /Feed per rev mode
G98 /Initial level return after canned cycles
G99 /R-point level return after canned cycles.

1.6.2 What is m code?

The “M” references miscellaneous or machine code, and covers all the major
instructions not covered by the G-code. Rather than geometric alphanumeric
movements, M-codes instruct the CNC machine to start and stop certain actions or
programs outside the G-code’s domain.

These instructions include when to use coolant, when to open the machine doors,
when to change the direction the spindle spins in, or to change tools [8].
M Code Meaning

54
MO: Program stops
Ml: Optional program stops
M2: Program end
M3/4: Rotate spindle clockwise/counterclockwise
M5: Stop spindle rotation
M6: Tool change (by two macros)
M7: Mist coolant on
M8: Flood coolant on
M9: All coolant off
M30: Program end and rewind
M47: Repeat program from first line
M48: Enable speed and feed override
M49: Disable speed and feed override
M98: Call subroutine
M99: Return from subroutine/repeat [8].

1.7 Different softwares

1.7.1 Computer Aided Design (CAD)

Engineers and draftsmen use computer-aided design software to create illustrations
or 3D models. While most engineers should be proficient with CAD, the amount of
time they spend using it may depend on their specific role and level of experience.
For example, in some environments, designers may be responsible for creating the
initial design in a CAD program, while analysis and release engineers will review
and analyze it to make sure there are no errors [9].

Best CAD Software for Engineers

Which CAD software tool is used can vary based on an engineer’s specialty, the
industry they work in or specific employer requirements. There are a variety of
highly specialized tools, with some software designed for specific industries. A few
of the popular CAD tools for professional engineers include:
• AutoCAD
• Inventor
• CATIA

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 • Fusion 360
• NX Core Designer
• SolidWorks
• Creo 10
A 2023 report from market research firm Grand View Research also highlights the
growing trend of utilizing cloud-based CAD software, or outsourcing certain design
projects. However, the company expects continued demand for 3D CAD software
due to growing adoption of 3D printing. If outsourcing portions of design becomes
more commonplace, engineers will likely be more focused on providing conceptual
design ideas and interfacing with vendors to review final designs [9].

1.7.2 Computer Aided engineering (CAM)

Computer-aided Manufacturing (CAM) is commonly defined as the use of software

to automate manufacturing processes. CAM software is able to translate CAD
designs into instructions for machines, increasing the efficiency of producing parts
and optimizing the amount of materials used [9].
Best CAM Software
Because CAM is so intertwined with CAD, some software companies produce both
types of applications. SolidWorks, for example, offers a full-suite of tools for CAD,
CAM and other engineering processes. Similarly, companies like AutoDesk offer
combined CAD and CAM tools. Some of the leaders in CAM software include:
• SolidWorks CAM
• Fusion 360
• NX CAM
• SolidEdge
• CAMWorks
• Mastercam

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1.7.3 Computer Aided manufacturing (CAE)

Computer-aided engineering refers to the use of software to simulate the effects of

different conditions on the design of a product or structure using simulated loads and
constraints. CAE tools are often used to analyze and optimize the designs created
within CAD software. Major categories of CAE tools include finite element analysis
(FEA), computational fluid dynamics (CFD) and multi-disciplinary design
optimization (MDO). These tools are used to perform design iterations using virtual
prototypes (sometimes called “digital twins”) prior to building physical prototypes.
This saves companies significant time and money in product development while
often yielding higher quality designs that meet multi-disciplinary and multi-
functional requirements [9].
CAE Software Leaders
There are dozens of CAE software tools used within the field of engineering. A few
of the leaders include:
• Ansys Fluent
• NX Advanced Simulation
• SimScale
• Inventor
• HyperWorks
• LS-DYNA
• MATLAB Simulink
The best CAE product choice will depend to some extent on the skills you want to
build and your specific career path. For example, niche products like OpenFOAM
are open source, which can provide a great deal of flexibility. However, many users
feel the software could be improved because it relies solely on a command line and
has no graphical user interface (GUI) [9].

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References:
1. Pawan Negi ،Mangey Ram ،Om Prakash Yadav“ Basics of CNC
Programming” ,2019
2. M. Sheen, NC Machining: Precision, Process, and Tools
Explained, Power publishing, 2024
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5. Peter smid ‘CNC programming handbook’, second edition, 2003
6. B. S. Pabla ،M. Adithan ‘CNC Machines’, first edition ,2005
7. Groover, M. P. Automation, Production Systems, and Computer-
Integrated Manufacturing. Fourth edition,2007.
8. Alan Overby, CNC machine,2010.
9. Michigan State University
10.Robert E. Krull, Fundamentals of CNC Machining
11.Helmi A. Youssef Hassan EL Hofy, Machining Technology
Machine Tools and Operations
12.W. Brian Rowe, Principles of Modern Grinding Technology
13.J. S. Choudhury and A. K. Gupta, Electrical Discharge Machining
14. Woodweb (www.woodweb.com): Provides resources and discussions on CNC
routers for woodworking and furniture making.
15. CNCZone (www.cnczone.com): An online forum that discusses CNC router
machines, software, and accessories.
16. Practical Machinist (www.practicalmachinist.com): Offers advice and
information for metalworkers using CNC routers and similar equipment.
17. CNC Cookbook (www.cnccookbook.com): Covers tutorials, buyer guides, and
software tips for CNC routing and machining.
18. Vectric Software (www.vectric.com): Creators of VCarve Pro and Aspire,
offering extensive tutorials and support for CNC router users.
19.Mary-Lane Kamberg, Creating with Laser Cutters and Engravers
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21.Eddie Paul, Plasma Cutting Handbook,2011
22.

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