Machining is cri cal to the manufacturing of products used across mul ple facets of daily life.

This
controlled process involves using power-driven machine tools to cut raw material from a workpiece to
produce the desired shape and size from materials such as metal, plas c, rubber, wood, paper, and
more.

Machining can be described as conven onal, which requires manual technician promp ng and
manipula on of the cu ng tools, or non-conven onal, such as CNC machining, which relies on
computer automa on to drive the process. While each approach offers dis nct drawbacks and
advantages, both aim to produce the highest quality machined parts.

Conven onal Machining: The conven onal machining process uses a human operator to direct and
control machining tools such as milling, boring, and drilling machines as well as lathes and other sharp
cu ng tools. This individual is responsible for driving the loca on and intensity of tool contact with
the raw material through the use of bu ons, levers, or wheels in order to achieve the intended product
geometry.

Non-Conven onal Machining: Non-tradi onal machining processes can be classified into
categories such as electrical discharge machining (EDM), electrochemical machining (ECM), laser
cu ng, and abrasive water jet machining, each u lizing unique principles for material removal and
shaping.

CNC Machining: Although CNC machining s ll requires operator oversight to manage so ware,
func ons in the CNC process are primarily carried out by pre-programmed computer designa ons that
guide the movements of the machining tools. Tools used in the CNC process do not require contact
with the raw materials.

Difference between Conven onal & CNC Machining:

Parameters Manual Machining CNC Machining

Cost Conven onal machining generally costs CNC machining is more expensive for
less and is more cost-effec ve and efficient small jobs, but provides greater efficiency
for small jobs. and cost savings for larger jobs.
Produc on The quality of the final product is largely Geometry is loaded into the so ware, so
dependent on the skills and abili es of the the risk for human error is minimized in
machine technician or operator. the quality equa on.
Replica on Due to human involvement, it is difficult to Since machines run on computer
guarantee a high level of part consistency, commands, iden cal parts or
making conven onal machining ideal for components can be produced with ease,
small runs or single pieces. making CNC machining ideal for large
quan es of highly consistent products.
Experience Operator experience greatly influences Operators with li le experience can s ll
and Skills part quality and consistency. produce highly consistent and quality
parts due to computer-interven on.
Labor Each machine requires a dedicated Since minimal operator involvement is
Requirements operator, and a high level of technician needed to manage the CNC process, a
involvement is necessary to direct the single operator can oversee mul ple
tools. Operators must be able to produce machines at once with high degrees of
a variety of parts, which requires extensive accuracy and precision, which reduces
knowledge, skills, and experience. labour costs.

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NC: NC stands for Numerical Control. It refers to the automa on of machine tools using programmed
commands that are executed by a computer. Before the advent of CNC, NC machines were controlled
by punched tape or punched cards containing the machine instruc ons.

CNC: CNC stands for Computer Numerical Control. It is an advancement of NC, where the control of
machine tools and processes is automated using a computer. CNC machines use coded instruc ons (G-
codes and M-codes) to control the movement and opera on of the machine. The codes are generated
by computer-aided design (CAD) and computer-aided manufacturing (CAM) so ware, allowing for
precise and efficient machining opera ons.

DNC: DNC stands for Direct Numerical Control. It is a method used to control mul ple CNC machines
from a single computer or host system. In DNC, the part programs (G-code files) are stored in a
centralized computer, and the CNC machines are connected to this computer through a network or
direct cabling. The CNC machines then access the required part programs directly from the DNC system
for execu on. This setup is useful in large-scale manufacturing environments where mul ple CNC
machines need to be managed and coordinated efficiently.

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Difference between NC & CNC Machine:

S.no NC Machine CNC Machine

Here NC stands for Numerical
1 CNC stands for Computer Numerical Control.
Control
It is defined as the machine which is It is defined as the machine which is used to
controlled by the set of instructions control the motions of the workpiece and tool
2 in the form of numbers, letters, and with the help of prepared program in
symbols. The set of instructions is computer. The program is written in
called as program. alphanumeric data.

In CNC machines the programs are fed directly

In NC machine the programs are fed
3 into the computer by a small keyboard similar
into the punch cards.
to our traditional keyboard.

Modification in the program is

4 Modification in the program is very easy.
difficult.
5 A high skilled operator is required. A less skilled operator is required.
6 The cost of the machine is less. The cost of the CNC machine is high.
7 Maintenance cost is less The maintenance cost is high.
In CNC machines, the programs can be stored
The programs in the NC machine
8 in the computer and can be used again and
cannot be stored.
again.
It offers less flexibility and It offers additional flexibility and
9
computational capability. computational capability.
The accuracy is less as compared
10 It has high accuracy.
with the CNC.
It requires more time for the It takes very less time in the execution of the
11
execution of the job. job.
It is not possible to run it It can be run continuously for 24 hours of a
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continuously. day.

Advantages of CNC machining:

 Precision: One of the major advantages of CNC machining is its definiteness and precision.
Because the process is controlled by a computer, the machining can be done with a high level
of accuracy and repeatability.
 More Capability: CNC machining also has a wider range of capabili es compared to tradi onal
machining methods. This includes the ability to produce parts with complex shapes, contours,
and surface finishes.
 High Produc on and Scalability: CNC machines can produce parts quickly and efficiently,
making it possible to produce large quan es of parts in a short period of me.
 Uniform Product: It can produce a uniform product. Because the process is controlled by a
computer, every part produced is iden cal, ensuring that there are no varia ons in quality.
 Time Efficient: CNC machining is also me efficient. Because the process is automated, it is
possible to set up a CNC machine and let it run without the need for constant supervision.

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  Range of Materials: CNC machining can work with a wide range of materials, including metals,
plas cs, and composites. This makes it a versa le solu on for manufacturers who need to
work with different materials.
 Reliability: CNC machining is also reliable process, that ensures func onality. Because the
process is controlled by a computer, there is less room for human error compared to tradi onal
machining methods.

Disadvantages of CNC machining:

 Costly: One of the major disadvantages of CNC machining is its expensiveness. CNC machines
can be costly to purchase and maintain. Apart from this, the cost of programming and se ng
up the machine can also be a significant factor in determining the exorbitant rates.
 Size Restric ons: CNC machines have a fixed size and are not suitable for producing large parts
or products. This can be a limita on for manufacturers who need to produce larger items or
who work with materials that are not easily machined on a smaller scale.
 Material Waste: CNC machining can result in material waste. Because the process involves
removing material to create a finished product, there is o en excess material that is discarded.
 Design Limita ons: CNC machining also has some design limita ons. Because the process
relies on computerized controls, it is not well-suited for producing parts with highly organic or
irregular shapes.
 Opera on Errors: If the machine is not programmed correctly or if there is a problem with the
machine itself, it can result in faulty parts or produc on delays.
 Material Suitability: Some materials, such as certain plas cs or composites, may not be
suitable for CNC machining due the requirement of special tooling or processes.
 Time for Mass Produc on: While CNC machines can produce parts quickly and efficiently, it
can take me to set up the machine and program for mass produc on.
 Trained Operator Required: CNC machining requires a trained operator to set up and run the
machine. This can be a limita on for manufacturers who do not have the resources or
exper se to train an operator or who need to quickly ramp up produc on.

Causes of accidents during opera ng CNC Machine:

 Se ng of wrong tools inside the Automa c Tool Changer (ATC) tool pocket
 Input of wrong tool length when they are exchanged or newly set-up
 Se ng the wrong feed rate (normally too fast for the job)
 Choosing the wrong tool for the job
 Se ng the job wrongly
 Wrong reference point set
 Errors in CNC programming
 Poor maintenance of CNC machine

Safety Precau ons for CNC Machining:

a) Only Operate CNC Machines You have Been Trained to Use: Sounds obvious and simple, but
some companies do allow untrained employees to operate CNC machinery with li le or no
training. Many accidents do happen this way.
b) Always Have at Least One Person Observing the CNC Machine: For some, it is temp ng to
leave the room while the programmed CNC machine does its work. Most likely, nothing will go

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 wrong. But once in a while, CNC machines break or do not work right. It happens. They are
machines. And that’s when injuries can happen too. So, make sure you have every CNC
machine under observa on by at least one person.
c) Always Do These Things Before Opera ng Your CNC Machine:
 Make sure the CNC machine is not opera ng when you load a tool magazine
 Ensure the tools are sharp and free of cracks Double-check to make sure all tools
are set correctly
 Double-check that you have set the right tool data for the program
 Test tools before every new use
 Examine sea ng surfaces for cleanliness before installing new tools
 Set the spindle direc on correctly for right and le -handed operators
 Only use tools within manufacturer limits and ghten them to their recommended
torque
d) A Few Things Never to do Before Opera on: Pre y simple and straigh orward here. Never
use blunt, cracked, or chipped tools. If you no ce tools with damaged ps, do not use those
either.
e) If You Use a CNC Router: Before you operate a CNC router, make sure there are not any screws
in the path of the bit. At best, the bit will get broken and the screw will get embedded into
your project. However, in some cases the screw can shoot off and hit you or another worker.
If, during opera on, you no ce anything unusual with the bit, hit the pause bu on, or the red
emergency bu on for immediate shutdown. Fix the problem before you begin opera ng again.
f) Always Make Sure You are Mentally Focused: If you are not feeling well and it is hard for you
to concentrate because of a sickness, do not use CNC machinery. Supervisors, send your
workers home if you no ce them behaving unusually. Workers, no fy your supervisors if
something does not seem right. Be er to miss a few hours of work that cause an injury to
yourself or someone else. And, be er to leave work than it is to break the machine and cause
costly repairs and down me. Do those things and you and your workers will stay safe.

HMC and VMC:

VMC refers to the ver cal machining centre with the spindle axis perpendicular to the worktable. It
can complete the processes of milling, boring, drilling, tapping, and cu ng threads. The VMC is at least
three-axis and two-linkage, generally three-axis and three-linkage can be realized, and some can be
controlled by five or six-axis.

HMC refers to the horizontal machining centre with a horizontal spindle. It usually has an automa c
indexing rotary table. It generally has 3 to 5 mo on coordinates. The common one is three linear
mo on coordinates plus one rotary mo on coordinate.

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Differences Between VMC and HMC:

 Structure Difference Between VMC and HMC: The main difference between the VMC and HMC is
the Z-axis structure. The Z-axis of the VMC moves ver cally downward to complete the processing,
while the Z-axis of the HMC moves horizontally downward to complete the processing, which is
the main difference between them.
 Workbench Difference Between HMC and VMC: The worktable of the VMC is usually a T-slot
worktable with a cross slide structure. There are two sets of mo on mechanisms responsible for
the ver cal movement of each other. The X-feeding worktable is covered on the Y-feeding guide
rail. The worktable of the HMC is only designed to move in the X or Y direc on. The worktable is
generally a rotary worktable with a dot matrix screw hole table, and it is rela vely easy to choose
an interchangeable double worktable.
 Different Parts Processed by CNC VMC and HMC Machine: The ver cal machining centre is
suitable for processing disk, sleeve, and plate parts. It generally has three linear mo on coordinate
axes, and a rotary table that rotates along the horizontal axis can be installed on the worktable to
process spiral parts. The horizontal machining centre can process parts with more than two sides
or process holes and surfaces arranged radially around, such as box and shell parts; if the posi on
accuracy of the processed parts is high, you should select high-precision horizontal machining
centre.

Advantages and Disadvantages of HMC:

Advantages: Compared with VMC, the HMC is easier to remove chips during the processing of the
workpiece, and it is more advantageous for the processing of complex recesses and the mould cavity.
Due to the structural advantages of the horizontal machining centre, the HMC can process large
workpieces. Workpieces that are difficult or impossible to be processed by ver cal machining centres
can be processed on horizontal machining centres.

Disadvantages: The HMC covers a large area, its structure is complex, and the price is more expensive
than that of the VMC. It is inconvenient to debug the program of the horizontal machining centre. It is
not suitable to observe the tool movement path during processing. The workpiece is inconvenient for
loading and unloading.

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Advantages and Disadvantages of VMC:

Advantages: It occupies a small area with simple structure and rela vely low price. It is more
convenient to set up and adjust the program, and it has a wide range of applica ons.

Disadvantages: It cannot process parts that are of large height. Chips cannot be easily removed when
machining a cavity or a concave profile. In severe cases, it may damage the tool, destroy the processed
surface, and affect the smooth processing. It is more suitable for processing workpieces with rela vely
small dimensions in the height direc on.

Applica ons of CNC Machining in Mechanical Processing:

CNC machining is a modern technology in the field of mechanical processing that uses computer-
controlled movement of axes (usually 3, 4, or 5) to improve the precision and efficiency of part
manufacturing significantly. It is widely applied in various materials such as metal, plas c, wood,
ceramics, etc. Compared to tradi onal machining, CNC machining has apparent advantages. Its main
applica ons in mechanical processing technology include:

 Part Manufacturing: A CNC machine can produce highly complex three-dimensional parts by using
3D models made with CAD or other mechanical design so ware and genera ng CNC programs
through CAM so ware. It can achieve high-precision part manufacturing, thus saving R&D costs
and me and improving produc on efficiency.
 Carving and Decora on: CNC machining can be used for carving and decora on, such as wood,
stone, plas c, etc. Due to its precise control over the tool's curve trajectory, it can achieve complex
carving, such as high relief effects, making it more beau ful.
 Mould Manufacturing: The CNC machining process is the best choice for manufacturing moulds
because moulds require high precision, repeatability, and mass produc on, which are the
strengths of CNC technology. Using CNC machining to manufacture moulds can achieve efficient
produc on and larger produc on batches.
 Part Finishing: In mechanical processing, part finishing usually requires manual processing, such
as using files and sandpaper, which may result in irregular surfaces and complex geometric shapes.
CNC machining can complete these tasks while ensuring smooth surfaces, high precision, and high
efficiency.
 Automated Produc on Processes: CNC machining can also be used in computer-integrated
manufacturing (CIM) or computer-aided manufacturing (CAM) produc on lines. This makes
mechanical produc on completely automated, thereby reducing produc on costs, improving
produc on efficiency and quality, and enhancing the reliability and consistency of part
manufacturing.

The Applica ons of CNC Machining in Different Industries:

CNC machining has various applica ons in various manufacturing industries, including automo ve,
aerospace, medical, and electronics. CNC machines can produce high-precision parts and components
used in mul ple products, from engine blocks to surgical instruments.

 Automo ve Industries: In the automo ve industry, CNC machines produce parts that require ght
tolerances and exact specifica ons, such as engine blocks, transmission housings, and suspension
components. CNC machines can also create custom parts unique to a par cular vehicle model.

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 Aerospace Industries: CNC machines produce aircra , spacecra , and satellite parts in the
aerospace industry. These parts must be lightweight, durable, and withstand extreme condi ons.
CNC machines can create complex shapes and contours that cannot be achieved with tradi onal
machining methods.
 Medical Industry: CNC machines produce surgical instruments, prosthe cs, and implants in the
medical industry. These parts must be precise and reliable to ensure pa ent safety. CNC machines
can have parts with intricate designs and ght tolerances essen al in medical applica ons.
 Electronics Industry: CNC machining is an indispensable technology in the electronics industry,
used to produce a wide range of electronic components and devices with high precision and
accuracy. It is used for cu ng and drilling printed circuit boards, shaping enclosures and
connectors, producing heat sinks, crea ng electronic components, and prototyping.
 Op cal Communica on Industry: CNC machining is used in the op cal communica on industry to
create precise components such as fibre op c connectors, ferrules, op cal filters, and couplers.
These components are cri cal for the efficient transmission of data through op cal fibres.
 Military and Defence Industry: CNC machining is widely used in the defence industry for producing
high-precision components for aerospace systems, weapon systems, armour, vehicle components,
and communica on and electronics equipment. It is cri cal for ensuring the reliability and
performance of these systems.
 Oil and Gas Industry: CNC machining is used extensively in the Oil and Gas industry for various
applica ons, including manufacturing components for drilling equipment, valves, pumps, and
pipelines. It is also used in the fabrica on of offshore structures and the repair and refurbishment
of equipment. CNC machining ensures high precision and reliability of cri cal components in harsh
environments.
 Energy Industry: In the energy industry, CNC machining produces intricate parts for various
applica ons such as turbines, oil and gas drilling equipment, nuclear power plant components,
and solar panel frames. The process guarantees high precision, accuracy, durability, and resistance
to wear and tear.

Some common type of CNC Machines:

CNC Milling Machine: One of the most common types of CNC machines, a CNC mill u lizes computer
controls to cut various materials. Mills can translate specific programs of numbers and le ers in order
to move the spindle in various ways. Many mills use what is known as G-code, which, as men oned, is
a standardized programming language recognized by most CNC machines. A CNC mill can have a wide
array of func ons, such as face milling, shoulder milling, tapping, drilling, and turning. Most CNC mills
come in three to six-axis configura ons.

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A CNC mill is very large compared to other tools and can be quite costly. Some CNC milling machine
manufacturers include Okuma, HAAS and DMG Mori.

CNC Lathe: A lathe is a CNC machine that func ons to cut work pieces as they are rotated. CNC lathes
can make precise cuts quickly by using various tools. These CNC machines are quite effec ve in the
precision they offer compared to manual lathes. They o en have fewer axes than CNC milling
machines, and are therefore smaller in size and more compact.

CNC lathes come with similar controls to those of CNC mills and can read both G-code and other
proprietary programming languages. Some of the most common CNC lathe machine manufacturers
include HAAS, Mori Seiki, and Okuma. The framework of CNC lathes is similar to manual lathes.

CNC Router: A CNC router is a machine that is very similar to the commonly used handheld router
u lized for cu ng various materials. This type of CNC machine can aid in the cu ng of steel, wood,
aluminium, composites, plas c, and foam. A CNC router is similar to a CNC mill. It comes with the
ability to use computer numerical control to route tool paths that enable the machine to func on. CNC
routers reduce waste and increase produc vity by producing various items in a much shorter amount
of me than other machines.

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Most routers can operate on a par cular material in all three dimensions, and are great for smaller
projects and the crea on of prototype models and complex designs. You can also find three axis, four
axis, five axis and six axis routers.

CNC Plasma Cu er: The process of plasma cu ng involves the cu ng of a material using a plasma
torch. This method is most commonly used to cut heavy materials, such as steel and other forms of
metal.

With a CNC plasma cu er, gas is blown at a very high speed from a nozzle. While this is being done, an
electrical arc forms through the gas coming out of the nozzle to the surface that is being cut. This
converts some of the gas into plasma, and these plasma temperatures range from 10,000-50,000
degrees. The plasma is hot enough to melt whatever material is being cut, and it blows away any
molten metal from the site of the cut.

In terms of shape and size, CNC plasma cu ers are very similar to CNC routers. These machines only
work with two-dimensional shapes.

Electric Discharge Machine: Electric discharge machining, or EDM for short, involves crea ng a specific
shape within a certain material by using electrical discharges, or sparks.

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In this process, the material is removed from a specific work piece by a series of recurring electrical
discharges between two electrodes. These electrodes are separated by a dielectric fluid, which o en
receives an electric voltage. In this machine, the material is placed in between two electrodes and the
machine then calculates to see the amount of electrical discharge each electrode needs to produce.

CNC Laser Cu er: Last but certainly not least, there are CNC laser cu ers.

These types of machines are similar to CNC plasma machines—the only difference is that lasers are
mostly used for cu ng and are great when it comes to cu ng metals, plas c, or hardwood. Depending
on the density and strength of the material, the intensity of the laser can be adjusted.

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