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CNC MILLING CHP 3

The document discusses the history and evolution of CNC milling from the 1940s to modern times. It describes the key elements, programming, and applications of CNC milling. The advantages include easier programming and avoiding human errors, while disadvantages include higher costs and loss of some manual machining skills.

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Prathamesh Magadum
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33 views28 pages

CNC MILLING CHP 3

The document discusses the history and evolution of CNC milling from the 1940s to modern times. It describes the key elements, programming, and applications of CNC milling. The advantages include easier programming and avoiding human errors, while disadvantages include higher costs and loss of some manual machining skills.

Uploaded by

Prathamesh Magadum
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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C N C M IL L I N G

CONTENTS
HISTORY
INTRODUCTION TO CNC-MILLING
ELEMENTS OF CNC MACHINE
HOW CNC WORKS
CNC PROGRAMMING
ADVANTAGES AND DISADVANTAGES OF CNC
APPLICATIONS OF CNC
HISTORY

THE FIRST NC MACHINES WERE BUILT IN THE 1940S AND 1950S BY PROF. JOHN T PARSON.

CNC MACHINE CAME INTO EXISTENCE AFTER EVOLUTION OF COMPUTER AROUND 1980 BY USING COMPUTER TO LINK DIRECTLY TO CONTROLLER.

MODERN CNC MACHINE ARE IMPROVING FURTHER AS THE TECHNOLOGY IS CHANGING WITH A VARIETY OF FUNCTIONS ACCORDING TO APPLICATIONS.

BY 1990'S, DNC MACHINES ARE INTRODUCED.


INTRODUCTION
NUMERICAL CONTROL (NC) IS THE AUTOMATION OF MACHINE TOOLS THAT ARE OPERATED BY PRECISELY
PROGRAMMED COMMANDS ENCODED ON A STORAGE MEDIUM, AS OPPOSED TO CONTROLLED MANUALLY.

MOST NC TODAY IS COMPUTER NUMERICAL CONTROL (CNC), IN WHICH COMPUTERS PLAY AN INTEGRAL PART
OF THE CONTROL.

IN MODERN CNC SYSTEMS, END-TO-END COMPONENT DESIGN IS HIGHLY AUTOMATED USING COMPUTER-
AIDED DESIGN (CAD) AND COMPUTER-AIDED MANUFACTURING (CAM) PROGRAMS.
WHAT IS CNC?

COMPUTER NUMERICAL CONTROL (CNC) IS ONE IN WHICH THE FUNCTIONS AND MOTIONS
OF A MACHINE TOOL ARE CONTROLLED BY MEANS OF A PREPARED PROGRAM CONTAINING
CODED ALPHANUMERIC DATA.

CNC CAN CONTROL THE MOTION OF THE WORK PIECE OR TOOL, THE INPUT PARAMETERS
SUCH AS FEED. DEPTH OF CUT, SPEED, AND THE FUNCTION SUCH AS TURNING SPINDLE
ON/OFF, COOLANT ON/OFF.
WHAT IS MILLING?
MILLING IS THE MACHINING PROCESS OF USING ROTARY CUTTERS TO REMOVE MATERIAL FROM A WORK
PIECE ADVANCING (OR FEEDING) IN A DIRECTION AT AN ANGLE WITH THE AXIS OF THE TOOL.

IT COVERS A WIDE VARIETY OF DIFFERENT OPERATIONS AND MACHINES, ON SCALES FROM SMALL
INDIVIDUAL PARTS TO LARGE, HEAVY-DUTY GANG MILLING OPERATIONS.

IT IS ONE OF THE MOST COMMONLY USED PROCESSES IN INDUSTRY AND MACHINE SHOPS TODAY FOR
MACHINING PARTS TO PRECISE SIZES AND SHAPES.
TYPES OF MILLING
Vertical Milling Horizontal Milling
ELEMENTS OF CNC

•CNC MACHINE • Input device


Machine Control Unit (MCU)
CONSIST OF •
• Machine Tool
FOLLOWING 6 • Driving System
MAJOR • Feedback Devices
• Display Unit
ELEMENTS:
BLOCK DIAGRAM OF ELEMENTS OF CNC
MACHINE
HOW CNC WORKS?
• CONTROLLED BY G AND M CODES.
• THESE ARE NUMBER VALUES AND CO-ORDINATES.
• EACH NUMBER OR CODE IS ASSIGNED TO A PARTICULAR OPERATION.
• TYPED IN MANUALLY TO CAM BY MACHINE OPERATORS.
• G & M CODES ARE AUTOMATICALLY GENERATED BY THE COMPUTER SOFTWARE.
FEATURES OF CNC MACHINERY
• THE TOOL OR MATERIAL MOVES AUTOMATICALLY.
• TOOLS CAN OPERATE IN 1-5 AXES.
• LARGER MACHINES HAVE A MACHINE CONTROL UNIT (MCU) WHICH MANAGES
OPERATIONS.

• MOVEMENT IS CONTROLLED BY MOTORS (ACTUATORS).


• FEEDBACK IS PROVIDED BY SENSORS (TRANSDUCERS).
• TOOL MAGAZINES ARE USED TO CHANGE TOOLS AUTOMATICALLY.
CARTESIAN AXIS OF CNC MACHINE TOOL
3-5 AXIS MACHINING OPERATION
5-AXIS CNC MACHINE
ADVANTAGES OF 5-AXIS CNC MACHINE
TO MACHINE COMPLEX SHAPES IN A SINGLE SETUP.
REDUCES THE MACHINIST SETUP TIME AND INCREASES PRODUCTION RATES
.BY ELIMINATING MULTIPLE SET-UPS, TIME AND ERRORS ARE REDUCED.
THE FEATURE-TO-FEATURES ACCURACY IS IMPROVED BECAUSE THE SAME ZERO OR DATUM REFERENCE
FRAME IS USED THROUGHOUT THE MANUFACTURING PROCESS.
SINCE SIMULTANEOUS MOVEMENT IS ALLOWED ALONG THE X AND Y AXIS, SHORTER AND MORE RIGID TOOLS
MAY BE USED.
HIGHER SPINDLE/CUTTING TOOL SPEEDS MAY BE ACHIEVED WHILE REDUCING THE LOAD ON THE CUTTING
TOOL.
APPLICATION OF 5-AXIS CNC MACHINE

• IN COMPLEX THREE DIMENSIONAL PROFILES

• FOR IMPELLERS, TURBINE BLADES, AND PLASTIC MOLD TOOLS

• FOR CONVECTIONAL MACHINING OF TILTED SURFACES.


BASICS OF CNC PROGRAMMINGCNC
• INSTRUCTIONS ARE CALLED PART PROGRAM COMMANDS.

• WHEN RUNNING, A PART PROGRAM IS INTERPRETED ONE COMMAND LINE AT A TIME


UNTIL ALL LINES ARE COMPLETED.

• COMMANDS, WHICH ARE ALSO REFERRED TO AS BLOCKS, ARE MADE UP OF WORDS


WHICH EACH BEGIN WITH A LETTER ADDRESS AND END WITH A NUMERICAL VALUE.
COMMON FORMAT OF A BLOCK
CNC PROGRAMMING
Preparatory Codes:
IMPORTANT THINGS TO KNOW:
Gcodes-Initial machining setup and

COORDINATE SYSTEM establishing operating conditions


N codes- specify program line number
GCODES-INITIAL MACHINING SETUP AND UNITS,
to executed by the MCU
INCREMENTAL OR ABSOLUTE
Axis Codes: X,Y,Z
POSITIONING CO-ORDINATEX: X,Y,Z, RX,RY,RZ
Used to specify motion of the slide along
FEED RATE AND SPINDLE SPEED COOLANT X, Y, Z direction
CONTROL: ON/OFF, FLOOD, MIST Feed and Speed Codes: F and S
TOOL CONTROL: TOOL AND TOOL PARAMETERS Specify feed and spindle speed
Tool codes: T-specify tool number
DIFFERENT PROGRAMMING MODES

THE GROUP OF
IMPORTANT AND
ECONOMICAL Absolute Incremental Polar Mode of
Mode of Mode of Programming.
METHODS FOR Programming. Programming.
MANAGING THE CNC-
MACHINES CONSISTS
OF:
KEY LETTERS FOR PROGRAMMING
G-CODES
M-CODES
ADVANTAGES OF CNC
• EASIER TO PROGRAM • CNC MACHINES CAN BE USED CONTINUOUSLY CAN BE
UPDATED BY IMPROVING THE SOFTWARE
• EASY STORAGE OF EXISTING PROGRAMS
• EASY TO CHANGE A PROGRAM • TRAINING IN THE USE OF CNCS IS AVAILABLE THROUGH
THE ME OF VIRTUAL SOFTWARE.
• AVOIDS HUMAN ERRORS
• NO NEED TO MAKE A PROTOTYPE OR A MODEL.
• CNC MACHINES ARE SAFE TO OPERATE
• ONE PERSON CAN SUPERVISE MANY CNC MACHINES
• COMPLEX GEOMETRY IS PRODUCED AS CHEAPLY AS
SIMPLE • BATCH PRODUCTION WITH HIGH ACCURACY
• USUALLY GENERATES CLOSER TOLERANCES THAN MANUAL
MACHINES
DISADVANTAGES

• COSTLY SETUP, SKILLED OPERATORS.


• COMPUTERS, PROGRAMMING KNOWLEDGE REQUIRED.
• MAINTENANCE IS DIFFICULT.
• MORE EXPENSIVE THAN MANUALLY OPERATED MACHINES.
• THE CNC MACHINE OPERATOR ONLY NEEDS BASIC TRAINING AND SKILLS, ENOUGH TO SUPERVISE SEVERAL
MACHINES. IN YEARS GONE BY, ENGINEERS NEEDED YEARS OF TRAINING TO OPERATE CENTRE LATHES,
MILLING MACHINES AND OTHER MANUALLY OPERATED MACHINES. THIS MEANS MANY OF THE OLD SKILLS
ARE BEEN LOST.
APPLICATIONS
Other Applications are:

• AUTOMOTIVE INDUSTRY • CNC water het cutter


• Drilling
• AEROSPACE INDUSTRY • Sheet metal works(turret punch)
• MACHINERY INDUSTRY • Wire bending machines
• Surface grinding
• ELECTRICAL INDUSTRY • Cylindrical grinders
• INSTRUMENTATION INDUSTRY • Submerged welding
• Glass cutting
CONCLUSION
• CNC MILLING :- EXAMPLE OF FALLIBILITY
• CNC :- EXAMPLE OF AUTOMATION.
• THE ADVANTAGE OF A CNC SYSTEM ARE THAT THE OPERATION OF A CONVENTIONAL MACHINE IS REMOVED AND THE PART
PRODUCTION IS MADE AUTOMATIC. IT REDUCES THE LABOR WORK AND HENCE HIGHLY EFFICIENT IN THE
MANUFACTURING PROCESS.

• BHEL GENERALLY USES CNC MACHINES TO ACHIEVE ITS MANUFACTURING TARGETS. FOR MANUFACTURING WORKS OF
LARGE SCALE IT VERY DIFFICULT TO WORK WITH MANUAL MACHINES AS THEY ARE TIME CONSUMING. CNC MACHINES
HAVE THEIR WIDE SCOPE BECAUSE THEY ARE EASY TO HANDLE THE JOBS ARE DONE WITH PERFECTION

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