CNC Milling- An Introduction

ME 110:Workshop Practice-I

Department of Mechanical Engineering

Indian Institute of Technology Patna
 CNC Machines
Replacement of hard or rigid automation by Flexible automation
by developing and using CNC has made a great break through
since mid seventies in the field of machine tools’ control. The
advantageous characteristics of CNC machine tools over
conventional ones are :
• flexibility in automation
• change-over (product) time, effort and cost are much less
• less or no jigs and fixtures# are needed
• complex geometry can be easily machined
• high product quality and its consistency
• optimum working condition is possible
• lesser breakdown and maintenance requirement
Direct Numerical Control is a system that uses a central computer
to control several machines at the same time.
#Both jigs and fixtures clamp, support and locate the workpiece. A jig also guides the cutting tool. A fixture has a reference point for
setting the cutting tool with reference to the workpiece.
 CNC Machines contd.
• Conventionally, an operator decides and adjusts various
machining parameters like feed , depth of cut etc. depending
upon the type of job, and controls the slide movements by
hand.
• In a CNC Machine functions and slide movements are
controlled electronically by using computer programs rather
than by hands.
• The earliest NC machines performed limited functions and
movements controlled by punched tape# or punch cards#.
• Some of the enhancements that came along with CNC include:
canned cycles, sub programming, cutter compensation, work
coordinates, coordinate system rotation, automatic corner
rounding, chamfering and B–spline interpolation.
#Punched tape or perforated paper tape is a form of data storage, consisting of a long strip of paper in which holes are punched to
store data.
#A punched card, punch card, IBM card, or Hollerith card is a piece of stiff paper that contained either commands for controlling

automated machinery or data for data processing applications.

 Beginning of CNC machines
• In 1940 John Parson developed first machine able to drill
holes at specific coordinates programmed on punch cards.
• In 1951 MIT developed servo‐mechanism
• In 1952 MIT developed first NC machines for milling.
• In 1970 First CNC machines came into picture
• Now‐a‐days modified 1970’s machines are being used.

Languages of CNC machines

While there is a fairly standard set of G and M codes, there is
some variation in their application. For example a GO or GOO
command is universally regarded as the command for rapid
travel. Some older machines do not have a GO command. On
these machines, rapid travel is commanded by using the F
(feed) word address.
 Basic CNC Principles
• All computer controlled machines are able to accurately and
repeatedly control motion in various directions. Each of these
directions of motion is called an axis. Depending on the machine
type there are commonly two to five axes.
• Additionally, a CNC axis may be either a linear axis in which
movement is in a straight line, or a rotary axis with motion
following a circular path. All CNC machining begins with a part
program, which is a sequential instructions or coded commands
that direct the specific machine functions.
• The part program may be manually generated or, more
commonly, generated by computer aided part programming
systems.
• Conversational Control: It lets the programmer use simple
descriptive language to program the part. This control then
displays a graphical representation of the instructions so that
the programmer can verify the tool path.
 Classification of milling machines
• According to nature of purpose of use:
general purpose; single purpose; special purpose
• According to configuration and motion of the work holding
table / bed:
Knee type; bed type; planar type; rotary table type
• According to the orientation of the spindle(s):
Plain horizontal knee type; horizontal axis (spindle) and
swivelling bed type; vertical spindle type; universal head milling
machine
• According to mechanization / automation and production rate:
Hand mill (milling machine);
Planer and rotary table type vertical axis milling machine;
Tracer controlled copy milling machine;
Milling machines for short thread milling;
Computer Numerical Controlled (CNC) milling machine;
CNC Machines- Advantages/Disadvantages
Advantages:
• High Repeatability and Precision e.g. Aircraft parts
• Volume of production is very high
• Complex contours/surfaces need to be machined. E.g.
Turbines
• Flexibility in job change, automatic tool settings, less scrap
• More safe, higher productivity, better quality
• Less paper work, faster prototype production, reduction in
lead times
Disadvantages:
• Costly setup, skilled operators
• Computers, programming knowledge required
• Maintenance is difficult
 Basic Length Unit (BLU)
• In NC machine, the displacement length per one pulse output
from machine is defined as basic length unit (BLU).
• In CNC computer each bit (binary digit) represents 1 BLU.
Bit = BLU
• Example: if one pulse makes a servomotor rotate by 1 degree
and the servomotor moves the table by 0.0001mm, 1 BLU will
be 0.0001mm

Stepper Motor
Special type of synchronous motor which is designed to rotate
through a specific angle (called step) for each electrical pulse
received from the control unit.
 Coordinate systems
The machine tool uses Cartesian coordinate system. First
identify the z-axis, x- and y- axes will then follow using the
Right hand coordinate system.
 Coordinate systems contd.

Absolute Coordinate System Incremental Coordinate System

 Coordinate systems contd.

Machine coordinate system Work part coordinate system

Complex Geometries Machined by CNC
 CNC Movement
• Each axis consists of a mechanical component, such as a slide
that moves, a servo drive motor that powers the mechanical
movement, and a ball screw to transfer the power from the
servo drive motor to the mechanical component.
• These components, along with the computer controls that
govern them, are referred to as an axis drive system.
 Table
Leadscrew
Encoder A/C Motor
~

Servo Controller

Counter Comparator

Input (converted from analog to digital value)

 Encoder
• Movement is controlled by motors (actuators)
• Feedback is provided by sensors (transducers)
• An encoder is a device or transducer that converts
information from one format or signals to another.
• Transducers (such as optical or magnetic encoders) sense
position or orientation for use as a reference or active
feedback to control position:
• A rotary encoder converts rotary position to an analog.
• A linear encoder similarly converts linear position to an
electronic signal.
Such encoders can be either absolute or incremental.
 How CNC Works

• Controlled by G and M codes.

• These are number values and co-ordinates.
• Typed in manually by machine operators or
automatically generated by the computer software.
• Movement is controlled by a motors (actuators).
• Feedback is provided by sensors (transducers)
• Tool magazines are used to change tools
automatically
 Program Input
Different ways of data input are :
•MDI : Manual Data Input
•PROGRAM PREPARATION WITH CAD/CAM
• PROGRAM DATA TRANSFER FROM PC TO CNC M/C
•PROGRAM DATA TRANSFER FROM PC TO DNC OPERATIONS
Mechanical Clamping Devices
Automatic Part Programming by CAD CAM
Software programs can automatic generate CNC data

Define Tool

CNC data

Make 3D model
Simulate
cutting
 CNC programming
Important things to know:
• Coordinate System
• Units, incremental or absolute positioning
• Coordinates: X,Y,Z, RX,RY,RZ
• Feed rate and spindle speed
• Coolant Control: On/Off, Flood, Mist
• Tool Control: Tool and tool parameters
Programming consists of a series of instructions in form of letter codes
• Preparatory Codes:
G codes- Initial machining setup and establishing operating conditions
N codes- specify program line number to executed by the MCU
• Axis Codes: X,Y,Z - Used to specify motion of the slide along X, Y, Z
direction
• Feed and Speed Codes: F and S- Specify feed and spindle speed
• Tool codes: T – specify tool number
• Miscellaneous codes – M codes For coolant control and other
activities
 Programming Key Letters
• O - Program number (Used for program identification)
• N - Sequence number (Used for line identification)
• G - Preparatory function
• X - X axis designation
• Y - Y axis designation
• Z - Z axis designation
• R - Radius designation
• F – Feed rate designation
• S - Spindle speed designation
• H - Tool length offset designation
• T - Tool Designation
• M - Miscellaneous function
 Important G (Preparatory) codes
• G00 Rapid Transverse G00 Rapid move G0 X# Y# Z# up to
• G01 Linear Interpolation 6 axis or G0 Z# X#
G01 Linear feedrate move G1 X# Y#
• G02 Circular Interpolation, CW Z# up to 6 axis or G1 Z# X#
• G03 Circular Interpolation, CCW G02 Clockwise move
• G15 Polar Coordinate System off G03 Counter clockwise move
• G16 Polar Coordinate System on G04 Dwell time
G08 Spline smoothing on, optional L#
• G17 XY Plane,G18 XZ Plane,G19 YZ Plane number of blocks to buffer
• G20/G70 Inch units G09 Exact stop check, spline
• G21/G71 Metric Units smoothing Off
• G28 Return to Reference Point G10 Linear feedrate move with
decelerated stop
• G40 Cutter compensation cancel G11 Controlled Decel stop
• G41 Cutter compensation left G17 X Y Plane
• G42 Cutter compensation right G18 X Z Plane
• G43 Tool length compensation (plus) G19 Y Z Plane
G28 move to position relative to
• G44 Tool length compensation (minus) machine zero
• G49 Tool length compensation cancel G53 Cancel fixture coordinate offsets
• G51.1 - X0 X Mirror on G54-G59 fixture coordinate offsets 1
• G50.1 - X0 X Mirror off through 6
 Important G (Preparatory) codes Contd.
G70 Inch mode
• G51.1 - Y0 Y Mirror on G71 Millimeter mode
• G50.1 - Y0 Y Mirror off G80 Cancels canned cycles
• G53 Work Coordinate System off and modal cycles
• G54 …..G59 Work Coordinate System 1…6 G81 Drill cycle
G82 Dwell cycle
• G68 Rotation on G83 Peck cycle
• G69 Rotation off G84 Tapping cycle
• G73 Peck Drilling Cycle G85 Boring cycle 1 bore
• G80 Cancel canned cycles down, feed out
G86 Boring cycle 2 bore
• G81 Drilling cycle down, dwell, feed out
• G82 Counter boring cycle G88 Boring cycle 3 bore
• G83 Deep hole drilling cycle down, spindle stop, dwell,
• G90 Absolute positioning feed out
G89 Boring cycle 4 bore
• G91 Incremental positioning down, spindle stop, dwell,
• G94 Feed per Minute rapid out
• G95 Feed per Revolution G90 Absolute mode
• G98 Return to Reference point in Drilling Operation G91 Incremental mode
G92 Home coordinate reset
• G99 Return to Initial point in Drilling Operation G93 cancel home offsets
G98 - G199 User-definable G
codes
 Important M (Functional) codes
• M00 Program stop
• M01 Optional program stop
• M02 Program end
• M03 Spindle on clockwise
• M04 Spindle on counterclockwise
• M05 Spindle stop
• M06 Tool change
• M08 Coolant on
• M09 Coolant off
• M10 Clamps on
• M11 Clamps off
• M13 Spindle CW and Coolant On
• M14 Spindle CCW and Coolant On
• M30 Program stop, reset to start
• M98 Sub-Program Call
• M99 Sub-Program Exit
 Profile Milling Example
• G15 G17 G94 G21 G40 G69 G80
• G91 G28 Z0
• G28 X0 Y0
• M06 T1
• M03 S1200
• G90 G00 G54 X-30 Y-20
• G43 H1 Z10
• M08
• G01 Z-1 F120
• G01 Y20
• G02 X-20 Y30 R10
• G01 X20
• G03 X30 Y20 R10
• G01 Y-20
• G01 X20 Y-30
• G01 X-20
• G03 X-30 Y-20 R10
• G00 Z5
• M09
• G91 G28 Z0
• G28 X0 Y0
• M05
• M30