LIST OF CONTENTS

SL NO CONTENTS
1. ABSTRACT
2. INTRODUCTION
3. DEFINATION OF A CNC MACHINE
4. BASIC CNC PRINCIPLES
5. CNC MACHINES- ADVANTAGES/DISADVANTAGES
6. CNC PROGRAMMING
7. CNC MACHINES AND SAFETY
8. 2D COMPUTER AIDED DESIGN AND MANUFACTURE
9. 3D COMPUTER AIDED DESIGN AND MANUFACTURE
10. INDUSTRIAL PRODUCTION FLOWCHART
11. CONCLUSION

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 ABSTRACT
The introduction of CNC machines has radically changed the manufacturing industry. Curves
are as easy to cut as straight lines, complex 3-D structures are relatively easy to produce,
and the number of machining steps that required human action has dramatically reduced.
With the increased automation of manufacturing processes with CNC machining,
considerable improvements in consistency and quality can be achieved, CNC automation
reduced the frequency of errors and provided CNC operators with time to perform
additional tasks. CNC automation also allows for more flexibility in the way parts are held in
the manufacturing process and the time required to change the machine to produce
different components. In a production environment, a series of CNC machines may be
combined into one station, commonly called a "cell", to progressively machine a part
requiring several operations.

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 INTRODUCTION

CNC (Computer Numerical Control) lathes are advanced machines used in modern
manufacturing industries. They automate machining processes, enabling precision and
consistency in producing cylindrical components. CNC lathes are used in automotive,
aerospace, and general engineering industries for producing parts like shafts, bolts, and
other rotationally symmetrical objects.

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What is a CNC Machine?
CNC: Computer Numerical Control

Conventionally, an operator decides and adjusts various machines parameters like feed,
depth of cut etc depending on type of job, and controls the slide movements by hand. In a
CNC Machine functions and slide movements are controlled by motors using computer
programs.

The Evolution of NC

It was in 1947 when numerical control was born. It began when John C. Parsons of the
Parsons Corporation, Traverse City, Michigan, a manufacturer of helicopter rotor blades,
could not make his templates fast enough. So, he invented a way of coupling computer
equipment with a jig borer. Mr. Parsons used punched cards to operate his digit Ron system.

1949 was the year of another "Urgent need". The U.S. Air Material command realized that
parts for its planes and missiles were becoming more complex. Also, as the designs were
constantly being improved, changes in the drawing were frequently made. Thus, in their
search for methods of faster production, an Air Force study contract was awarded to the
Parsons Corporation. The servo mechanisms laboratory of the Massachusetts Institute of
Technology (MIT) was the subcontractor.

In 1951, MIT took over the complete job, and in 1952, the prototype of today's NC machine,
a modified Cincinnati Hydrotel Milling Machine, was successfully demonstrated. The term
numerical control was originated at MIT.

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TYPES OF CNC MACHINE

There are many different types of CNC Machines used in industry, Such as:

 Mills and Machining Centers

 Lathes and Turning Centers

 Drilling Machines

 EDM Sinker and wire cut Machines

 Flame and Laser-Cutting Machines

 Water Jet Profilers

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 OPERATIONAL FEATURES of CNC MACHINES

 A numerical control, or "NC", system controls many machine functions and

movements which were traditionally performed by skilled machinists.
 Numerical control developed out of the need to meet the requirements of high
production rates, uniformity and consistent part quality.
 Programmed instructions are converted into output signals which in turn control
machine operations such as spindle speeds, tool selection, tool movement, and
cutting fluid flow.

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 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.

Motion control - the heart of CNC

The most basic function of any CNC machine is automatic, precise, and consistent motion
control.

Rather than applying completely mechanical devices to cause motion as is required on most
conventional machine tools, CNC machines allow motion control in a revolutionary manner.
All forms of CNC equipment have two or more directions of motion, called axes. These axes
can be precisely and automatically positioned along their lengths of travel.
The two most common axis types are linear (driven along a straight path) and rotary (driven
along a circular path).

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Basic CNC Principles Coordinates System:

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Work Positioning:
The method of accurate work positioning in relation to the cutting tool is called the
"rectangular coordinate system." On the vertical mill, the horizontal base line is designated
the "X" axis, while the vertical base line is designated the "Y" axis. The "Z" axis is at a right
angle, perpendicular to both the "X" and "Y" axes.
Increments for all base lines are specified in linear measurements, for most machines the
smallest increment is one ten-thousandth of an inch (.0001). If the machine is graduated in
metric the smallest increment is usually one thousandth of a millimeter (.001mm).
The rectangular coordinate system allows the mathematical plotting of points in space.
These points or locations are called "coordinates." The coordinates in turn relate to the tool
center and dictate the "tool path" through the work.

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CNC LATHE:
Automated version of a manual lathe.
Programmed to change tools automatically.
Used for turning and boring wood, metal and plastic.

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How CNC Lathe 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 CAD/CAM by machine operators.
 G&M codes are automatically generated by the computer software.

Features of CNC Lathe:

 The tool or material moves.

 Tools can operate in 1-5 axes.

 Larger machines have a machine control unit (MCU) which manages operations.
 Movement is controlled by a motors.
 Feedback is provided by sensors.

 Tool magazines are used to change tools automatically.

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Limitations:
 High initial cost.

 Requires skilled operators for programming.

 Maintenance can be complex.

Applications:
1. Automotive Industry Manufacturing gears, shafts, and engine components.

2. Aerospace Industry Producing high-precision turbine blades and fittings.

3. Medical Industry Crafting surgical tools and implants.

4. General Engineering Making fasteners, pipes, and fittings.

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 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. Etc
•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:

 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.

 Investment in CNC machines can lead to unemployment

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 CNC PROGRAMMING

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

 D - Tool radius offset designation

 T-Tool Designation
 M- Miscellaneous function

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Explanation of commonly used G codes:
 Goo - Preparatory code to control final position of the tool and not concerned with
the path that is followed in arriving at the final destination.
 G01 - Tool is required to move in a straight line connecting current position and final
position. Used for tool movement without any machining- point to point control.
(linear interpolation)
 Go2 - Tool path followed is along an arc specified by I, J and K codes.(circular
interpolation)

Table of Important G codes:

 Goo Rapid Transverse
 G01 Linear Interpolation
 G02 Circular Interpolation, CW
 G03 Circular Interpolation, CCW
 G17 XY Plane, G18 XZ Plane, G19 YZ Plane

 G20/G70 Inch units

 G21/G71 Metric Units
 G40 Cutter compensation cancel
 G41 Cutter compensation left
 G42 Cutter compensation right

 G43 Tool length compensation (plus)

 G44 Tool length compensation (minus)
 G49 Tool length compensation cancel
 G80 Cancel canned cycles
 G81 Drilling cycle

 G82 Counter boring cycle

 G83 Deep hole drilling cycle
 G90 Absolute positioning
 G91 Incremental positioning

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Program Command Parameters:
Optimum machine programming requires consideration of certain machine operating
parameters including:
• Positioning control

• Compensations
• Special machine features
Positioning control is the ability to program tool and machine slide movement
simultaneously along two or more axes. Positioning may be for point-to-point movement or
for contouring movement along a continuous path. Contouring requires tool movement
along multiple axes simultaneously. This movement is referred to as "Interpolation" which is
the process of calculating intermediate values between specific points along a programmed
path and outputting those values as a precise motion. Interpolation may be linear having
just a start and end point along a straight line, or circular which requires an end point, a
center and a direction around the arc.

Table of Important M codes:

 Moo Program stop
 M01 Optional program stop
 Mo2 Program end
 M03 Spindle on clockwise

 M04 Spindle on counterclockwise

 M05 Spindle stop
 Mo6 Tool change
 Mo8 Coolant on
 M09 Coolant off
 M10 Clamps on
 M11 Clamps off
 M30 Program stop, reset to start

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 CNC MACHINES AND SAFETY
CNC machines are very safe to use as they are designed to be as safe as possible. One of the
main advantages of CNC machines is that they are much safer than manually operated
machines.

1. Most modern CNC machines are designed so that the cutting tool will not start unless the
guard is in position. Also, the best CNC machines automatically lock the guard in position
whilst the cutter is shaping material. The guard can only be opened if the cutter has
stopped.
2. It is essential that pupils/students/machine operators receive 'quality' instruction before
attempting to use any CNC equipment.
3. CNC routers, used for shaping materials such as woods and plastics, have built in
extraction. Dust can be very dangerous if inhaled and can also cause eye irritation. The CNC
Router shown above has an outlet for an extraction unit. As the router is fully enclosed, dust
cannot escape into the atmosphere. If an extraction unit is attached the dust is removed
automatically. Most manually operated machine routers have very limited extraction
systems which leave some dust in the air.

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4. The CNC router above has a single phase electrical supply. Older machines such as
manually operated milling machines and centre lathes have three phase supplies. A single
phase electrical supply can be 'plugged' into any available socket. The electrical supply for
the machine comes through a residual circuit breaker (RCB). If an electrical fault develops
the MCB will cut off electrical power immediately.

5. Single phase CNC machines can be moved more easily because they are simply unplugged
and relocated. Three phase machines are specially wired by an electrician into the electrical
supply and cannot be unplugged.

6. Most CNC machines work behind a guard or even a closed, transparent safety door. This
means that the operated cannot be hurt by 'flying' pieces of sharp/hot material.

7. Commonsense applies to the use of all machines including CNC machines. Basic safety
training regarding working in a workshop and with other machines applies to CNC machines
as well.

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 2D COMPUTER AIDED DESIGN AND MANUFACTURE

There are two types of computer aided design software. 2D design software allows the
designer to design shapes with very limited three dimensional properties. Do not
underestimate the designs that can be achieved through 2D software.

1. The design is drawn using software such as Tec Soft 2D Design. At first appearance
this software looks basic but, depending on the skill of the designer, quite complex
designs can be produced. The example shown is a simple block of material with
initials.

2. When the design is complete the drawing is processed. This converts the drawing
into a detailed series of X, Y and Z coordinates. Processing must take place before
the CNC machine can cut the design from material. When the CNC machine shapes
the material the cutter follows the coordinates, in sequence, until the shape has
been manufactured

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3. Most CAD/CAM software allows the designer to test the manufacture of his/her
design on a computer rather than actually making it. This saves time and materials.
Testing designs is carried out using 'simulation' software. When the design is run
through simulation software the computer displays the manufacturing on the
screen. It also checks whether or not the design can be manufactured successfully.
Many designs have to be altered before they can be made by a CNC machine.

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 3D COMPUTER AIDED DESIGN AND MANUFACTURE
3D Design software allows the designer to produce three dimensional representations of
his/her ideas. When completed the design can be viewed on the screen and it can even be
revolved and examined at any angle. 3D software is much more complex than 2D software
such as Tec Soft 2D design. It requires specialist training before it can be used competently.

1. The designer draws up the design using software. The design can be examined in
detailed and if modifications/alterations are needed they can be made on the
screen. Software of this type allows the designer to model his/her idea on the screen
rather than make/manufacture an expensive model. Good 3D software allows the
designer to design almost any item.

2.The design is processed. When the design has been completed using software it must be
exported as a stereo lithography file. This type of file can be imported into processing
software which converts the drawing into a long list of coordinates. Each set of coordinates
is called a G code & M code.

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3. Most CAD/CAM software allows the designer to test the manufacture of his/her design on
a computer rather than actually making it. This saves time and materials. Testing designs is
carried out using 'simulation' software. When the design is run through simulation software
the computer displays the manufacturing on the screen. It also checks whether or not the
design can be manufactured successfully. Many designs have to be altered before they can
be made by a CNC machine

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4. An advanced CNC machine can be used to manufacture the three dimensional
product. This CNC is both fast and accurate making suitable for school and industrial
use.

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INDUSTRIAL PRODUCTION FLOWCHART

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 CONCLUSION

CNC lathes are indispensable in modern manufacturing due to their precision, efficiency,
and versatility. Despite the initial investment, their ability to streamline production
processes makes them highly valuable for industries that demand high-quality and
consistent machining. Continuous advancements in CNC technology promise even greater
capabilities in the future.

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