History of CNC

 CNC machines are very accurate and powerful industrial robots developed jointly by Mr. John
Parsons, IBM and MIT Servomechanism Laboratory in the 1950’s.
 Most CNC machine tools use a language set by the Electronics Industry Association (EIA) in the
1960’s.
 The official name of this language is RS-274D, but everyone refers it “G-code” or “G&M Code”
because many of the words of this language begin with the letters G or M.

What is CNC ?
 CNC stands for Computerized Numerical Control.
 It is a computerized manufacturing process in which pre-programmed software and code
controls the movement of production equipment.
 CNC machining is the process of using a computer-driven machine tool to produce a part out of
solid material in a different shape.
 CNC can control the motions of the work piece or tool, the input parameters such as feed, depth
of cut, speed,and the functions such as turning spindle on or off, turning coolant on or off.

Why is CNC Machining necessary?

 To manufacture complex curved geometries in 2D or 3D was extremely expensive by
mechanical means (which usually would require complex jigs to control the cutter motions).

TYPES OF CNC MACHINES

 Milling CNC machine
 Turning CNC machine
 Drilling CNC machine
 Grinding CNC machine
 Laser cutting CNC machine
 Plasma cutting CNC machine
 Electric discharge CNC machine
 Router CNC machine
 CNC machine with automatic tool changes
 5-axis CNC machine

CNC Control Panel

 Siemens Sinumerik
 Fanuc
 Mazatrol
 Mitsubishi
 Heidenhain
 Hass

Advantages of CNC machine

 The CNC machines have high repeatability and accuracy.
 It can manufacture products in large quantity.
 Complex and irregular surfaces need to machine to get a regular surface and CNC machines help
in doing this.
 Consistent quality.
 Reduced manpower.

Limitations oF CNC Machine

 Cost
 Size Limitations of CNC
 Operator Error

CNC INSTRUMENTS
 Surface Table
 Analog Vernier
 Digital Vernier
 Analog Micrometer
 Digital Micrometer
 Depth Vernier
 Height Gauge
 Filler Gauge
 Radius Gauge
 Pin Gauge
 Bore Guage

 Surface Table
 What is Milling Center?
 Milling is the machining process of using rotary cutter to remove material from a workpiece
advancing (or feeding) in a direction at an angle with the axis of the tool.
 It is one of the most commonly used processes in industry and machine shops today for
machining parts to precise sizes and shapes

MACHINE CENTER AXIS DEFINATION

 ISO machine tools mainly having 3 axes for machining conditions.
 X axes which is called as Longitudinal axes.
 Y axes which is called as cross axes.
 Z axes which takes the Tool & Work piece in contact for machining.

Process Planning
The part programmer will often carry out the task of process planning. Process planning
is the procedure of deciding what operation are to be done on the component, in what
order and with what tooling and work holding facilities. Both the process planning and
part programming aspects of manufacturer occur after the detail drawings of a
component have been prepared. The following procedure maybe used as a guide to
assist the programmer by describing each step required in preparing the method of
production.
Receive the part drawing from the part drawing information and check the suitability
of part to be machined against the machine capacity.
Determine a method to driving the component (Chuck type, chuck size, type of jaw,
collect size, face driver etc.) and the method of machining.
Determine the tooling required to suit the method of machining and utilize as much
as possible which are permanently in the turret set upon the machine.
Determine the order of machining and tooling stations
Determine the planned stop (Cycle interrupt procedure, incorporating block delete
codes) for checking dimensional sizes where required by operator.
Determine the cutting speed based on i) component material, method of driving,
rigidity of the component. ii) The tooling selected for roughing and finishing tool
holders with carbide drills, HSS drills and ceramics.
Determine the depth of cut and feed rate for roughing operation based on the
horsepower available for cutting and rigidity of the part.
4Determine form surface finish requirements the cutter nose radius most suited for
finishing operations and determine feed rates.
Allocates tool offsets as required
Complete planning sheet


PART PROGRAMMING GEOMETRY:
2.1 Coordinate System:
Machining of a workpiece by a CNC program requires a coordinate system to be applied
to the machine tool. As all machine tools have more than one slide, it is important that
each slide is identified individually. There are three planes in which movement can take
place.
Each place is assigned a letter and is referred as an axis,
o Longitudinal plane (AXIS X)
o Vertical plane (AXIS Y)
o Transverse plane (AXIS Z)
The three axis is identified by the upper case X, Y and Z and the direction of movement
along each axis is specified in plus (+) or minus (-) and the Z axis is always parallel to the
main spindle of the machine, as shown in the below figure.
The coordinate system for designating the axes is the conventional ‘Right hand
coordinate system’ as shown in figure. A labeling of the axes is a right hand coordinate
system whenever the fingers of the right hand are aligned with the positive X axis and
are then rotated (through the smaller angle) toward the positive Y axis then the thumb
of the right hand points in the direction of the positive Z axis. Otherwise, the orientation
is a ‘Left Hand coordinate system’.
The right hand coordinate system is also known as ‘Clockwise rotating coordinate
system’.
The reason for this is the sequence of the axis definitions. If the X axis is rotating in the
direction of the Y axis, the movement is the name as if a screw is turned in the Z
direction as shown. In programming it must be assumed that the workpiece is stationary
and the tools move in the coordinate system. The workpiece is positioned within the
coordinate system so that the Z axis coincides with the turning center line (axis of
rotation) and the X and Y coordinates always have the same values. Therefore Y is not
used in turning.
2.2 Zero Point and Reference Point:
The CNC machines, tool traverse are controlled by the coordinating systems. Their
accurate position within the machine tool is established by ‘Zero Point’.
2.3 Machine Zero Point (M):
This is specified by the Manufacturer of the Machine. This is the zero point for the
coordinate systems and reference points in the machine. The Machine zero point can be
the center of the table or a point along the edge of the traverse range as shown.
The position of the Machine zero point generally varies from Manufacturer to
Manufacturer. The precise position of the machine zero point as well as the axis
direction must therefore be taken from the operating instructions provided for each
individual machine.
2.4 Reference Point (R):
This point serves for calibrating and for controlling the measuring system of the slides
and tool traverses. The position of the reference point is accurately predetermined in
every traverse axis by the trip dogs and limit switches. Therefore, the reference point
coordinates always have the same, precisely known numerical value in relation to the
machine zero point. After initiating the control system, the reference point must always
be approached from all axes to calibrate the traverse measuring system. If current slide
and tool position data should be lost in control system as for example through an
electrical failure the machine must against be positioned to the reference point to re-
establish the proper position valves.
2.5 Workpiece Zero Point (W):
This point determines the workpiece coordinate system in relation to the machine zero
point. The workpiece zero point is chosen by the programmer and input into the CNC
system when setting up the machine. The workpiece zero point can be freely chosen by
the programmer within the workpiece envelope of the machine. It is however advisable
to place the workpiece zero point in such a manner that the dimensions in the
workpiece drawing can be conveniently converted into coordinate values and
orientation when clamping / chucking, setting up and checking the traverse measuring
system can be effected easily.
For turned parts, the workpiece zero point should be placed along the spindle axis
(center line), in line with the right-hand or left-hand end face of the finished contour.
Occasionally, the workpiece zero point is also called the ‘program zero point’.
2.6 Tool Reference Point (T):
When machining a workpiece it is essential to able to control the tool point or the tool
cutting edges in precise relationship to the workpiece along the machining path. Since
tools have different shapes and dimensions, precise tool dimensions have to be
established beforehand and input into the control system.
The tool dimensions are related to a fixed tool setting point during pre-setting. The tool
setting point E is located at a certain point on the tool holder. This setting point permits
measuring of tools away from the CNC machine. The data thus measured such as tool
length, tool point offset or tool radius are input into the tool data storage (memory) of
the control system. The mate of the tool settings point is the socket point N on the tool
carrier.


TYPES OF MILLING OPERATION

 Face milling
 Pocket milling
 Drilling
 Reaming
 Boring
 Tapping
 Circular Interpolation
 Slot milling

Calculation of Cutting Speed, Spindle Speed and Feed

Its an inbuilt Computer which handles all the elements of machine tools and also
gives feed back each and every axis positions in 3d graphical Display.

Operator can make a program and also execute it in machining mode for
machining the work part on the machine.
Its an inbuilt Computer which handles all the elements of machine tools and also
gives feed back each and every axis positions in 3d graphical Display.
Introduction of Sinumerik 828D Advanced Controller
 Its an inbuilt Computer which handles all the elements of machine tools and also gives feed
back each and every axis positions in 3d graphical Display.

 Operator can make a program and also execute it in machining mode for machining the work
part on the machine.

Why work holding Device?

 Setting up the milling work piece is the most difficult part of the job work.
 Its obviously required critical thinking for some complicated machining angle.
 As a programmer, you must know about the types of work holding devices and their appropriate
use.
 By the good understanding of work holding devices you can fasten the work part to the machine
table, before going for machining.

Temporary work holding Device

 Temporary work holders are general purpose equipments used for immediate and short-term
needs and for non-repetitive task.

Permanent work holding devices

 Permanent work holding devices are also called dedicated work holders which are customized
for same type of job work . They are used in repetitive production work of large quantities.

Three Jaws Chuck Four Jaws Chuck HYDRAULIC VICE LANG VICE

Benefits of Permanent work holding devices

 The permanent work holding devices reduce the setting up time of work part on machine.

 They give surety of easy setup and desired accuracy.

 They are reduce manufacturing cost when identical work part machined.

 They increase the productivity and decrease the manpower dependence.

 They help operation conditions for higher values machine setup.

 They reduces the operators efforts by which they get safety while working on machine.
CNC Tooling Systems
TOOL HOLDER
 Tool Holder act as physical interface between tools and M/C
 The Tool Holder fits into the spindle allowing the machine spindle to transfer rotary motion to
the tool. Parts of Tool Holder:
 Taper Shank
 Flange
 Socket of Collets
 Pull Stud

TYPE OF TOOL HOLDER

Side Lock Holder
Collets Type Holder
Drill Chuck Holder
Shrink Fit Holder
Morse Taper Type Tool Holder
Synchronous Tap Holder

Machine Spindle Taper Shank Specification

A machine taper secures cutting tools and other accessories to machine spindle.
The various types of taper are:
 CAT- It was developed on American standards by Caterpillar.
 BT - It was developed in Japan . Its similar to CAT but uses dual flange pull.
 NMTB- It was developed by the National Machine Tool Builders for quick change.
 HSK- It is hollow shank tool is designed to strengthen the tool grip at speed.
 MORSE - It was invented by Stephen A. Morse. It used to the end of drills & Reamers

Operation Wise Cutting Tool

 Endmill are used in milling applications such as profiling, plunging, slotting, Spigot, Pocket-milling
etc.
 Chamfer tool is used to remove the burs from edge of machined work part or drill hole.It is also
used to remove the sharp edges from the sides of work part.
 Drills are used to create a cylindrical hole in the work piece.
 Tapping is a machining process by which the internal threads are produced with the help of a
tapping tool that has teeth on its periphery to cut threads in a predrilled hole.
 Remer is used to give a high degree of accuracy and surface finish to a pre-drilled hole.
 Face milling is a machining technique used for flattening and smoothing the surface of
workpieces.
 T-slot mill is typically used on work piece holding components.
 Cutting Tool Material
There are different types of cutting tool materials used in CNC machine tool They are:

 HIGH SPEED STEEL (HSS)

 CEMENTED CARBIDE
 COATED CARBIDE

Work offset
 Work offset represents the position of the workpiece at which the all the axis lie at the zero
position.

Tool offset
 Tool offset is the position of cutting tool at which the Z axis is at zero position.

G-Code:
 G-code stands for “Geometric Code”.
 G-code is a software programming language used to control a CNC machine.
 G-code (also RS-274D) is the most widely used in CNC programming language.
 G-code command instruct the machine where to move, how fast to move and what path to
follow.

M-Code
M-code stands for “miscellaneous function”.
M-code is the machine control language for CNC machining.
M-code are related to machine function in all CNC machine like Coolant on/off, machine door
open/close.

G-Code: Geometric Code/Preparatory Code

G00-Rapid positioning
G01- Linear interpolation
G02-Circular interpolation, clockwise
G03-Circular interpolation, counter clockwise
G04-Dwell
G17-XY plane selection
G18-ZX plane selection
G40-Tool radius compensation off
G41-Tool radius compensation left
G42-Tool radius compensation right
G54 Work offset no: 1
G55 Work offset no: 2
G56 Work offset no: 3
G57 Work offset no: 4
G58 Work offset no: 5
G59 Work offset no: 6
G70-Inches mode
G71-Metric mode
G75-Go to home position or Machine reference
G90-Absolute mode
G91-Incremental mode
G94-Feed mm/min
G95-Feed mm/rev(Feed Per Revolution)
G96-Constant cutting speed ON
G97-Constant cutting speed OFF

M Code-Machine code/Miscellaneous function

M00-Compulsory stop
M01-Optional stop
M02-End of program
M03-Spindle on (clockwise rotation)
M04-Spindle on (counterclockwise rotation)
M05-Spindle stop
M06-Automatic tool change (ATC)
M07-Coolant on (mist)
M08-Coolant on (flood)
M09-Coolant off
M30-End of program with return to program top
M17-Subprogram

Program Build Up:Milling Machine

CNC Program can be divided into three parts
o Start-up Program
o Profile Program
o End Program
i) Star-Up Program
G71 G94
G75 Z0
G75 X0 Y0
M06 S1500
G00 G90 G54 X0 Y0 Z5
M08
ii) Profile Program is based on the given part drawing.
iii) End of the program
G00 Z10
G75 Z0
G75 X0 Y0 D0
M05
M09
M30
Safety Precaution:
Safety checks at the same time of machining:
 Do not operate the machine with guard or machine door open.
 Do not open the door while machining is in process.
 Make sure, tools and job is rigidly fixed.
 Make sure, tools are in the right holders.
 Before starting an operation, ensure that the machine is performing correctly; runs
with functions such as low feed rate, single block and simulation.
 Ensure cleaning periodic & preventive care is taken care as per machine instruction
manual.
Safety should continue:
 Don’t do the alternative functionality while machining is in process.
 Maintenance should be done by authorized person only. (MTAB customer service
persons are authorized for this process).
 Stop machining completely while inspection.
General Safety:
 To preventive maintenance, tasks should be carried out as given in this maintenance
manual.
 Follow the safety instruction in the manuals supplied with machine.
 Check the lubrication oil is sufficient in the lubrication tank
 Check the coolant is sufficient in the Coolant tank
 Don’t fail to understand the machine construction, machine functions, machine
operation/machining programs (wrong entry may damage the tool, machine,
workpiece)
 Wrong Programming may cause injury to the user.

Introduction to Turning Center

 Turning utilizes a cutter that moves perpendicularly through the center plane of a rotating work
piece.
 The part shape depends on the shape of the tool and the operations performed to obtain the
finished part

Coordinate System for a CNC Lathe :

 Machining of a workpiece by a CNC program requires a coordinate system to be applied to
the machine tool. As all machine tools have more than one slide, it is important that each
slide is identified individually. There are three planes in which movement can take place.
Each place is assigned a letter and is referred as an axis,
 Longitudinal plane (AXIS X)
 Transverse plane (AXIS Z)
The two axis is identified by the upper case X and Z and the direction of movement along each axis is in
plus (+) or minus ( - ) and the Z axis is always parallel to the main spindle of the machine.

Process Planning :
The part programmer will often carry out the task of process planning. Process planning
is the procedure of deciding what operation are to be done on the component, in what
order and with what tooling and work holding facilities. Both the process planning and
part programming aspects of manufacturer occur after the detail drawings of a
component have been prepared. The following procedure may be used as a guide to
assist the programmer by describing each step required in preparing the method of
production.
 Receive the part drawing from the part drawing information and check the
suitability of part to be machined against the machine capacity.
 Det ermine a method to driving the component (Chuck type, chuck size, type of jaw,
collect size, face driver etc.) and the method of machining.
 Determine the tooling required to suit the method of machining and utilize as much
as possible which are permanently in the turret set upon the machine.
 Determine the order of machining and tooling stations
 Determine the planned stop (Cycle interrupt procedure, incorporating block delete
codes) for checking dimensional sizes where required by operator.
 Determine the cutting speed based on i) component material, method of driving,
rigidity of the component. ii) The tooling selected for roughing and finishing tool holders
with carbide drills, HSS drills and ceramics.
 Determine the depth of cut and feed rate for roughing operation based on the
horsepower available for cutting and rigidity of the part.
 Determine form surface finish requirements the cutter nose radius most suited for
finishing operations and determine feed rates.
 Allocates tool offsets as required
 Complete planning sheet
TYPES OF TURNING OPERATION
 FACING
 TURNING
 GROOVING
 PARTING
 DRILLING
 BORING
 THREADING

Tool Code Key for General Turning

 Insert shape
 Insert clearance angle
 Tolerances
 Insert type
 Insert size
 Insert thickness
 Nose radius
 Cutting edge conditionHand of tool
 Chamfer width
 Chamfer angle
 Manufacture option

Program Build Up For CNC Lathe:

CNC Program can be divided into three parts
o Start-u p Program
o Profile Program
o End Program
i) Star- Up Program
G71 G95
G75 X0 Z0
MO6T1D1
M04S250
G00 X0 Z0
M08
ii) Profile Program is based on the given part drawing.
iii) End of the program
G00 Z5
G75 X0 Z0
M05
M09
M30