MANUFACTURING TECHNOLOGY

UNIT 1
What is CNC machining?

• It is a manufacturing process
where computers control how
machines will manufacture
parts.
Concept of CNC machining process

• CNC stands for Computer Numerical control.

• CNC machining is a manufacturing process where
preprogrammed software and codes tell the machine
how to manufacture parts. Once a program is fed into
the machine software, CNC machine will operate on its
own following the program. The speed, position and
change of tools needed to produce a part will happen
automatically according to the program fed to the
machine.
• CNC machining control a variety of machinery such as
grinders, drills, mills, lathes and so forth.
 Computer-aided process planning (CAPP)

• CAPP is the process of using computer software to plan and optimize CNC
machining operations.
• CAPP uses computer software to help determine the sequence of operations
and settings needed to machine a part on a CNC machine.
• Essentially, it's the blueprint for how the CNC machine will transform a
designed part from CAD into a finished product.
How CAPP interacts with CNC machines
1. Planning the Process: CAPP systems analyze the CAD design and,
based on knowledge of manufacturing processes and available equipment
(including CNC machines), determine the most efficient sequence of
operations (e.g., milling, drilling, turning) to produce the part.

2. Generating CNC Programs: CAPP systems can generate G-code (a

programming language for CNC machines) or other programming formats
that instruct the CNC machine how to perform each operation.
3. Optimizing Parameters: CAPP can help optimize various parameters
like cutting speeds, feeds, toolpaths, and material removal rates for each
operation, ensuring efficient and accurate machining on the CNC machine.
4. Reducing Errors:
• CAPP systems can help to standardize and optimize the process,
reducing the potential for errors and inconsistencies in machining,
especially when dealing with complex parts.
5. Improving Productivity:
• By automating the process planning and code generation, CAPP can
streamline the manufacturing process, saving time and reducing the
workload on human operators, thus improving overall productivity.
 NC, CNC & DNC machines
https://youtu.be/OZpfxKxlR3k?si=Caz87KIQ3NZNMkOU

NC Machines

• NC (numerical control) machines use punched

cards or tapes to control machine operations

Key features
• Early automation: NC machines were the first
to use numerical control.
• Punched cards/tapes: Programs were stored on
punched cards or tapes.
• Limited flexibility: Changing programs was
cumbersome.
CNC machines

• CNC (computer numerical control)

Machines are Computer-controlled
machines that use computers to
control machine operations.

Key features
• Computerized control: CNC machines
use computers for control.
• Programmability: Easy to program and
reprogram.
• Flexibility and precision: CNC
machines offer high precision and
flexibility.
DNC machines

• DNC (Direct Numerical Control) Machines are

a network of machines.

Key features
• Centralized control: DNC systems connect
multiple machines to a central computer.
• Real-time monitoring: Enables real-time
monitoring and control.
• Optimized production: DNC systems optimize
production and reduce downtime.
 CNC control system: open &closed system

• In CNC machines, open-loop

systems control movement
without feedback, while closed-
loop systems use feedback to
ensure precise positioning and
correct errors.
Open loop system
• In an open-loop system, the CNC controller sends a command to the
motor to move the tool to a specific position, but it doesn't receive
feedback on whether the tool has reached that position.
• If the tool doesn't reach the desired position due to friction, backlash, or
other factors, the system won't detect or correct the error.
• Open-loop systems are less precise but can be simpler and more
economical.
• They are often used in simpler machining operations or when high
accuracy is not crucial.
Closed loop system
• In a closed-loop system, the CNC controller sends a command to the motor, and a
feedback device (like an encoder) constantly monitors the tool's position.
• The feedback device sends information back to the controller, allowing it to compare
the actual position with the desired position.
• If there's a discrepancy, the controller can adjust the motor's movement to correct the
error and ensure the tool reaches the exact position.
• Closed-loop systems offer higher precision and reliability but are more complex and
expensive.
• They are essential for high-precision machining where accuracy is paramount.
 Construction and operation of CNC machines

• CNC machines are constructed with four main units: a computer system
for control, drive motors for movement, a machine tool for the
machining process, and feedback devices for monitoring.
• They operate by a closed-loop system, where a computer reads a
program, translates it into machine-readable language, and sends
commands to drive motors, which in turn position the machine tool.
• Feedback devices continuously monitor the machine's operation,
ensuring accuracy and providing error messages if needed.
1. Computer and Control System:
• Machine Control Unit (MCU): The
"brain" of the CNC machine, responsible for
reading and interpreting the CNC program,
translating it into instructions for the
machine.
• CNC Program: A pre-programmed
sequence of instructions, often in G-code
format, that tells the machine how to move,
what tools to use, and what operations to
perform.
• Input Devices: These allow operators to
input commands or load CNC programs into
the MCU.
2. Drive System
• Drive Motors:
Motors, often servo motors, are used to
control the movement of the machine's axes
(e.g., X, Y, Z).
• Servo Drives:
These amplifiers translate the control signals
from the MCU into the necessary power to
drive the motors.
• Feed Drives:
These systems control the movement of the
machine table and spindle, often using ball
lead screws.
3. Machine Tool
• Spindle: The rotating part of the machine
that holds and spins the cutting tool.
• Table or Workpiece Holder: Holds the
material being machined.
• Cutting Tools: Depending on the machine
type (milling, lathe, etc.), these tools are
used to remove material and shape the
workpiece.
2. Drive System
• Drive Motors:
Motors, often servo motors, are used to
control the movement of the machine's axes
(e.g., X, Y, Z).
• Servo Drives:
These amplifiers translate the control signals
from the MCU into the necessary power to
drive the motors.
• Feed Drives:
These systems control the movement of the
machine table and spindle, often using ball
lead screws.
 CNC Tooling

Cutting tools
• These specialized tools designed to
remove material from a workpiece in
CNC machine. These tools, controlled
by computer-generated instructions,
are used to shape, turn, drill, and
perform other machining operations.
Work holding or fixtures
• CNC work holding refers to any
device or apparatus used to
keep a workpiece properly
positioned and
immobile during the machining
process.
• Work holding for CNC lathe are
chucks, dead center, live
center etc.
• Work holding for CNC milling
are hydraulic vices and other
customized fixtures
Automatic tool changer (ATC)
• An Automatic Tool Changer (ATC) is a
system that automatically swaps tools on
a CNC machine tool without manual
intervention.
• It improves production by allowing the
machine to quickly change to different
tools, as needed, reducing downtime and
increasing efficiency.
• ATCs typically include a tool magazine
(where tools are stored), a gripper arm,
and a support arm, all working together
to transfer tools between the magazine
and the spindle.
CNC motion control
Point-to-Point (PTP) Motion Control: PTP, also known as positioning
control, moves the tool to a designated point and stops before performing
an action (e.g., drilling).
Functionality: Each axis moves independently, and the programmed
motion is typically at a rapid traverse speed.
Applications: PTP is well-suited for simple machining operations like
drilling, punching, or simple milling.
Advantages: Simple to implement, low computational demands.
Disadvantages: Limited to simple applications, does not provide
continuous movement or smooth contouring.
Continuous Motion (CM) Control: CM allows the tool to move
continuously along a predefined path without stopping at intermediate
points.
Functionality: The tool moves in any number of axes simultaneously, and
the control system interpolates intermediate points to ensure the tool
follows the path.
Applications: CM is used in applications requiring complex shaping,
contouring, and smooth movements.
Advantages: Minimizes cycle times, enhances productivity, reduces
mechanical strain, and increases equipment lifespan.
Disadvantages: More complex to implement, requires more sophisticated
control systems.
Interpolation
Part program
• A part program is a series of coded instructions required to
produce a part.
• A part program controls the movement of the machine tool
and on/off control of auxiliary functions such as spindle
rotation and coolant.
• A part program is a composed of letters, numbers and
symbols.
• A part program is commonly referred to as a G code program