Lab Report=09

“Manufacturing Processes: Introduction to

Computerized Numeric Control (CNC) Machines”

Name: Muhammad Abdullah Zafar Ghauri

Class: ME-14

Section: C

CMS ID: 405642

Subject Code ME-322

Subject: Manufacturing Processes

Submitted To: Sir Khayyam Ahmed

Due Date: 25th November 2024

 Manufacturing Processes: Introduction to Computer Numeric
Control (CNC) Machines

Muhammad Abdullah Zafar Ghauria

a
School of Mechanical and Manufacturing Engineering (SMME), National University
of Science and Technology (NUST), Islamabad Capital Territory (ICT), H-12, 44000, Pakistan
[email protected]

18th November 2024

Abstract
This lab is aimed at providing throughout introduction to Computer Numeric Control (CNC) ma-
chines, both central lathe and milling machines capable of working in two and three axes respectively.
The lab predominantly aims a providing much deeper insights of controlling the actions and pro-
ducing high-quality final product, with deep introduction to control panel buttons controlling every
movement concerned.
Keywords: Computer Numeric Control (CNC); central lathe; milling

1 Objectives
The main objectives of this lab are as follows:
• Introduction to CNC machines.
• Distinguishing between Milling and Lathe CNC machines on the basis of operations.
• Developing understanding regarding control operations extensively involved.
• Develop acquaintance with practical application of G and M codes in manufacturing final parts.
• Understanding the necessary standard operation procedures (SOPs) and safety precautions necessary for
safe operation of machines.

2 Overview of Laboratory Analysis

2.1 Computerized Numeric Control (CNC) Machines: Types and Implica-
tions
Computerized Numeric Control (CNC) Machines In manufacturing processes, numeric control (NC),
or more commonly referred to as Computerized Numeric Control (CNC) is the automated control of machine tools
by means of computers and software. CNC machines tend to operate on wide variety of tools such as drills, lathes,
mills, grinders, routers etc. It is effectively used to transform a piece of material such as metal, plastic, wood,
ceramic, stone, or composite into a specified shape through a sophisticated coded programming instructions in-
structions sans involvement of manual operator by directly controlling the machining operation.
Usually a CNC machine is controlled by a motor and comprises of motorized maneuverable tool and sometimes
a motorized platform (which is commonly referred to as a bed), which are both effectively controlled by a com-
puter, according to specific input instructions. Series of G and M codes serve as instructions to CNC machines
programmed appropriately in a sequential manner which are later on executed. The programs based on G and M
codes, are either manually devised line by line, or generated from 2D/3D CAD (Computer Aided Design) model
devised in modeling software such as SOLIDWORKS, Autodesk Innovator, Catia V6 etc.
Pertaining to the involvement of 3D printers, the part has to be initially sliced before appropriate instructions
are generated, as G and M codes are themselves extensively used by 3D printers.

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Types of Computerized Numeric Control (CNC) Machines There are many different types of CNC
machines, which are discussed as follows:
• CNC Lathe Machine
• CNC Milling Machine
• CNC Plasma Cutting Machine
• CNC Electric Discharge Machine (CNC EDM)
• CNC Water-powered jet cutter
• CNC Punch Press

Figure 1: Typical 2-axis Central Lathe CNC machine

CNC Milling Machine CNC Milling machines are commonly used in manufacturing industry, usually 3-axis
vertical CNC machines are extensively used. They are generally instructed by means of sequential G and M codes
embedded into system either by manual programming or generating G and M code file from 3D CAD model
devised in any particular designing software. A CNC milling machine performs its due action by translation of
programs comprising of G and M codes in order to maneuver the spindle or workpiece in various locations and
depths. Usually for a 3-axis Vertical CNC machine, the workpiece remains stationary while the tool rotates/moves.
However apart from Vertical orientation, machines, Horizontal CNC machines are also available in the market
and industry.
3-axis Milling CNC machines are super powerful machines and are capable of serving may important operations
such as face milling, shoulder milling, tapping, drilling and some even offer turning. Today, CNC mills can have
3 to 6 axes. Most CNC mills require placing the workpiece on or in them and must be at least as big as the
workpiece, but new 3-axis machines are being produced that are much smaller.

CNC Lathe Machine Likewise a milling CNC machine, the Lathe machine serves to cut different workpiece
of desired dimensions by rotation. Usually 2-axis lathe machines are available in market and are extensively used
in different manufacturing industries. CNC lathe machines have the capability of making fast, precision cuts,
using traditional indexable and adjustable tools and drills. Again CNC lathe machines are programmed using
sequential arrangement of G and M codes, and they are capable of executing such complicated programs and
manufacturing of complex geometries which otherwise are difficult to be accomplished using typical manual lathe
machines. Most modern lathes have live tooling, allowing for limited milling operations to take place without
having to remove the part from the lathe spindle. Second operations can be completed by using a sub-spindle,
which is co-axial to the main spindle, but faces the other direction. This allows the part to be removed from the
main spindle, and for additional features to be machined in the back side of the part.

CNC Electric Discharge Machine (CNC EDM) Electric Discharge Machine(EDM), or more com-
monly known as spark machining, spark eroding, burning, die sinking, or wire erosion, is a manufacturing process
in which the desired shape is obtained using electrical discharges (sparks). CNC EDM machines tend to perform

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their due action by removal of material from workpiece by series of rapid electric discharges which initiate sparking
between two electrodes of strong and hard metal which are usually separated from each other by a dielectric fluid
and subject to an electric voltage. The involved electrodes are generally of same metal as workpiece and they are
referred to as tool electrode and workpiece electrode.
Wire EDM operates by using a thin conductive wire, typically brass, as the electrode, and discharging as it runs
past the part being machined. This is useful for complex profiles with inside 90 degree corners that would be
challenging to machine with conventional methods.

3 Laboratory CNC Machines: Operations and Specifications of

Machines
3.1 Vertical 3-Axis Milling CNC Machine
The very particular machine used in CNC machine lab is YDPM MV-1060 manufactured in People’s Republic of
China having the capability to work in three major axes, respectively in longitudinal, cross and vertical movement
in X, Y, Z axes. The control panel is operated by operating system developed by FANUC series O1-MC. The
Vertical 3-Axis Milling Machine used in the lab is depicted as follows:

Figure 2: YDPM MV-1060 3-Axis Vertical Milling Machine

This particular CNC machine chuck and spindle are pneumatic empowered, making this machine an important
device within the laboratory and in the university. Some major specifications of this machine are as follows

Table 1: Specifications of YDPM MV-1060 3-Axis Vertical Milling Machine

Series Parameter Specification
1 Maximum Travelling Range 1060mm (X-axis) 630 mm (Y and Z axes)
2 Maximum Loading Capacity 1000 kg
3 Spindle Taper ISO 40
4 Maximum Traverse of X,Y,Z axes 30 M/min
5 Maximum Tool Capacity STD: 24 Pieces
6 Maximum Adjacent Tool Diameter x Length Dia 80x250 L
7 Maximum Tool Gauge 6 kg
8 Maximum Spindle Speed STD 8000 rpm
9 Automatic Tool Change System Hydraulic System

Control Panel Interface The control panel, for any machine, holds a significant importance as it is respon-
sible for all actions performed by the machine. With adequate control, the final product has optimum significance

3
of requirements. The control panel for this device is as follows:

Figure 3: Control Panel of YDPM MV-1060 3-Axis Vertical Milling Machine

The control panel usually comprises of twelve sub-control panels which are used as per requirement. Those
sub-panels are listed as follows:
• Mode
• Axis Direction
• Chip Conveyor
• APF
• Coolant
• Light
• Buzzer
• Emergency
• NC
• Function
• Override
• Spindle Control
• Rapid Override

Mode Mode is one of key sub control panel which is extensively used before and during initiation of machining
process. Some important buttons mounted are as follows:
1. EDIT
2. MEM
3. MDI
4. TAPE
5. JOG
6. HANDLE

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 7. ZRN
8. MOD1
EDIT is generally used for editing the commands as depicted on display screen. Editing can be done manually
before initiation of machining process.
MEM is used to upload G-M code file from the memory card inserted in its due slot. Usually this command is
used when a program has been stored in portable SD card suited for computer.
MDI stands for Manual Data Input. This command is used when the coding is to be done manually by the
operator before initiating machining process.
HANDLE is used when manual control remote is used to initiate the axis movement in concerned axes.
ZRN is generally used for setting the zero reference point for initiating machining process. Usually reference is
always input with positive value with movements of axis are initiated in opposite (negative) direction.

Axis Direction Axis direction interface is concerned with movement of axes in both positive and negative
direction. Some important buttons mounted are as follows:
1. +Z Axis
2. -Z Axis
3. +Y Axis
4. -Y Axis
5. +X Axis
6. -X Axis
7. +4 Axis
8. -4 Axis
9. RPD
+Z Axis For upward movement
-Z Axis For downward movement.
+Y Axis For rightward cross movement of bed.
-Y Axis For leftward cross movement of bed.
+X Axis For longitudinal movement of bed in positive direction.
-X Axis For longitudinal movement of bed in negative direction.
+4 and -4 Axis Usually used when four degrees of freedom are taken into account.

Chip Conveyor Initiates chip removal from workpiece. The chip removal is typically carried out in either
forward ore reverse direction as per requirement. Two buttons respectively as FWD and REV are concerned
with the action.

Coolant Activates inflow of coolant during machining process. Coolant is used to cool down both the tool
and workpiece. Usually there are two different types of coolants, water soluble coolant and immersible coolant.
Immersible coolant is commonly used due to ease of availability and long-term usage capability.

Light Activates light within the working environment. Lightning helps to envision the machining process
properly.

Buzzer Buzzer cretaes sounding effect during and prior to machining process. Usually buzzer is turned off to
prevent nuisance.

EMG EMG command is an emergency command initiated when overriding of axes is endangered.

NC Ready This command initiates automatic lubrication of all movement parts attached directly or indirectly
to machine.

Function Function panel comprises of different commands which can be initiated as per requirement. The
function sub panel comprises of following buttons:
1. SRN
2. BDT
3. DRN
4. SBK
5. OSP
6. MLK
7. Z MLK

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Override and Rapid Override Override is concerned with the movement of working bed. It is often a
multi-position (10, 25, 50 and 100 percent) switch that is used during setup to slow rapid motion rate during
each tool’s initial approach to the workpiece. Once a program is verified and the machine begins a production
run, rapid override should be set to 100 percent. Override on this machine can be initiated by mechanical knob
rotated at specific points and through button mounted on control panel as well.

Emergency Stop Emergency Stop is a knob when pulled breaks the entire circuitry and the machine ceases
to operate. Usually emergency stop is initiated at very rare circumstances when any catastrophe is eminent.

3.2 2-Axis Horizontal CNC Lathe Machine

The very particular machine used in CNC machine lab is YDPM ML-300 manufactured in People’s Republic
of China having the capability to work in two major axes, respectively in longitudinal and vertical movement in
Y, Z axes. The control panel is operated by operating system developed by FANUC series O1-TC. The Vertical
3-Axis Milling Machine used in the lab is depicted as follows:

Figure 4: Enter Caption

This particular CNC machine is hydraulic system initiated, with the chuck and tools held by hydraulic system
rather than pneumatic system as used in milling machine. Some major specifications for this machine are as
follows

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 Table 2: Specifications of YDPM ML-300 2-Axis Horizontal Lathe Machine
Serial Number Parameter Specification
1 Maximum Turning Diameter (Facing) 300 mm
2 Maximum Turning Length 600 mm
3 Z-Axis Rapid Movement 30 m/min
4 X-Axis Rapid Movement 30 m/min
5 Z-Axis Rapid Travelling 560 mm
6 X-Axis Rapid Travelling 240 mm
7 Maximum Spindle Speed 3500 rpm
8 Maximum Clamping Diameter 254 mm
9 Minimum Clamping Diameter 15 mm
10 Chuck Jaws Travelling Diameter 7.4 mm-8.8 mm
11 External Cutting Tools 5
12 Internal Cutting Tools 5
13 Machine Accuracy Position X-Axis: 0.015/100 and 0.025/300

Control Panel Interface The control panel, for any machine, holds a significant importance as it is respon-
sible for all actions performed by the machine. With adequate control, the final product has optimum significance
of requirements. The control panel for this device is as follows:

Figure 5: Control Panel Interface of YDPM ML-300 2 Axis Horizontal Lathe Machine

The major commands as present on control panel are much similar to those of 3 axis vertical milling CNC
machine. Highlighting some important aspects as follows:

Mode Mode is one of key sub control panel which is extensively used before and during initiation of machining
process. Some important buttons mounted are as follows:
1. EDIT
2. MEM
3. MDI
4. TAPE
5. JOG
6. HANDLE
7. ZRN

7
 8. MOD1
EDIT is generally used for editing the commands as depicted on display screen. Editing can be done manually
before initiation of machining process.
MEM is used to upload G-M code file from the memory card inserted in its due slot. Usually this command is
used when a program has been stored in portable SD card suited for computer.
MDI stands for Manual Data Input. This command is used when the coding is to be done manually by the
operator before initiating machining process.
HANDLE is used when manual control remote is used to initiate the axis movement in concerned axes.
ZRN is generally used for setting the zero reference point for initiating machining process. Usually reference is
always input with positive value with movements of axis are initiated in opposite (negative) direction.

Axis Direction Axis direction interface is concerned with movement of axes in both positive and negative
direction. Some important buttons mounted are as follows:
1. +Z Axis
2. -Z Axis
3. +Y Axis
4. -Y Axis
5. +X Axis
6. -X Axis
7. +4 Axis
8. -4 Axis
9. RPD
+Z Axis For upward movement
-Z Axis For downward movement.
+X Axis For longitudinal movement of bed in positive direction.
-X Axis For longitudinal movement of bed in negative direction.
+C and -C Axis Usually used when three degrees of freedom are taken into account.

Chip Conveyor Initiates chip removal from workpiece. The chip removal is typically carried out in either
forward ore reverse direction as per requirement. Two buttons respectively as FWD and REV are concerned
with the action.

Coolant Activates inflow of coolant during machining process. Coolant is used to cool down both the tool
and workpiece. Usually there are two different types of coolants, water soluble coolant and immersible coolant.
Immersible coolant is commonly used due to ease of availability and long-term usage capability.

Light Activates light within the working environment. Lightning helps to envision the machining process
properly.

Buzzer Buzzer cretaes sounding effect during and prior to machining process. Usually buzzer is turned off to
prevent nuisance.

EMG EMG command is an emergency command initiated when overriding of axes is endangered.

NC Ready This command initiates automatic lubrication of all movement parts attached directly or indirectly
to machine.

Function Function panel comprises of different commands which can be initiated as per requirement. The
function sub panel comprises of following buttons:
1. SRN
2. BDT
3. DRN
4. SBK
5. OSP
6. MLK
7. Z MLK

8
Override and Rapid Override Override is concerned with the movement of working bed. It is often a
multi-position (10, 25, 50 and 100 percent) switch that is used during setup to slow rapid motion rate during
each tool’s initial approach to the workpiece. Once a program is verified and the machine begins a production
run, rapid override should be set to 100 percent. Override on this machine can be initiated by mechanical knob
rotated at specific points and through button mounted on control panel as well.

Emergency Stop Emergency Stop is a knob when pulled breaks the entire circuitry and the machine ceases
to operate. Usually emergency stop is initiated at very rare circumstances when any catastrophe is eminent.

3.3 Standard Operation Procedures (SOPs) for CNC Machines

For smooth operation of any machine there is a dire requirement for adequate SOPs which govern the operation
in an effectively. Highlighting some important SOPs for smooth operation are as follows:
• Adequate strategy has to be adopted for programming. It is optimum to use computer software for ma-
chining complex geometries involving complex codes which otherwise cannot be manually input through
MDI mode or through memory card which is quite a volatile medium for data storage.
• Compressors and all pneumatic systems should be protected from external elements and it is most optimum
to store them in open atmosphere. High pressure pneumatic systems are dangerous and can lead to serious
injuries if manhandled.
• Adequate choice of tool should be made before initiating machine as once machining begins there is no way
back, and improper tool can either destroy the workpiece or render it unusable in future.
• The code once devised should be free of errors. Usually, CNC machines display error messages in such
circumstances.
• There should be an adequate choice of coolant, as generally both water miscible and water immersible
are available in market. Water immiscible oil as coolant is extensively used owing to long shelf-life and
economically viable.
• For rightward path of tool, the spindle rotates in clockwise direction and for leftward path of tool, the
spindle rotates in anticlockwise direction.
• There should be an adequate rpm for spindle rotation. Rapid rotation can destroy the finish of product
concerned.
• Tools should be removed with care as discussed above, mishandling with pneumatics and hydraulic system
can lead to injuries. Tools should be sharpened as per necessity.
• It is of utmost necessity to keep a strict check and balance on lubrication oil and coolant as both hold
significant importance in proper functioning of machine.

3.4 Conclusion
In conclusion, it can be asserted that CNC machines play a significant role in any manufacturing industry,
primarily concerned with production of large goods on large scale with improved accuracy and surface finish and
efficient logistics. However, there is a necessity for adequate skills for effective operation of such machines as small
errors can result in improper operation. There should be a significant knowledge regarding G and M codes and
how they can be coupled together to produce optimum operational code.

Supplementary Files (optional)

Referring to this lab report, no AI has been brought into account and majority portion of the information has
not been sourced from any search engine or website. Figure 1 and information regarding CNC machines has been
sourced from https://en.wikipedia.org/wiki/Numerical control.