Title: CNC Milling (Non Traditional Machining)

Objective
To acquaint trainees or students with NC programming, CNC Milling Machine and produce a
product through the process.
Introduction (Background & Theory)
Non-traditional manufacturing processes is defined as a group of processes that remove
excess material by various techniques involving mechanical, thermal, electrical or chemical
energy or combinations of these energies but do not use a sharp cutting tools as it needs to be
used for traditional manufacturing processes. Extremely hard and brittle materials are
difficult to machine by traditional machining processes such as turning, drilling, shaping and
milling. Non Traditional Machining processes, also called advanced manufacturing processes,
are employed where traditional machining processes are not feasible, satisfactory or
economical due to special reasons.
Numerical control (NC) refers to the automation of machine tools that are operated
by abstractly programmed commands encoded on a storage medium, as opposed to manually
controlled or mechanically automated via cams alone. The first NC machines were built in
the 1940s and '50s, based on existing tools that were modified with motors that moved the
controls to follow points fed into the system on paper tape. These early servomechanisms
were rapidly augmented with analog and digital computers, creating the modern computer
numerical controlled (CNC) machine tools that have revolutionized the design process. In
modern CNC systems, end-to-end component design is highly automated using CAD/CAM
programs. The programs produce a computer file that is interpreted to extract the commands
needed to operate a particular machine, and then loaded into the CNC machines for
production. Since any particular component might require the use of a number of different
tools, modern machines often combine multiple tools into a single cell.
CNC machine have several advantages with emphasis on machine tool applications.
When the production application satisfies the characteristics needed, CNC yields many
benefits over manual production methods. The benefits translate into economic saving for the
user company. Some of the advantages are:

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Nonproductive time is reduced through fewer setup, less setup time, less

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workpiece handling time, and automatic tool changes

Greater accuracy and repeatability
Low scrap produce
Inspections requirements are reduced
More complex part geometries are possible
Engineering changes can be accommodated more gracefully
Simple fixtures are needed
Shorter manufacturing lead times
Reduced parts inventory
Less floor space required
Operator skill level requirements are reduced

Figure 1.0: CNC Milling Machine

Apparatus
1.
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4.

NC Program
Machine controller
Rough stock
CNC milling machine

5. Work holding devices

6. Cutting tool
Industrial Apparatus
1. 5-axis CNC vertical milling machine

2. Dental CAM milling machine (5 axes)

Experimental Procedures
1. The drawing of the workpiece (car tyres rim) is showed by the instructor.
2. The parameter such as cutting speed, wire diameter, feeder and the usage of cutting
speed is set up by the instructor and the command is transferred to the CNC milling
machine.

3. The workpiece is setup on the vice.

4. The CNC milling machine start to cut the workpiece to desired shape and it left for a
while until it is finished.
5. The results of the workpiece is discussed.

References
1. About CNC Milling Machines (n.d). Retrieved from
http://heartwoodfarmscoop.com/2013/08/12/about-cnc-milling-machines-a-brief-andfast-introduction-about-cnc-milling-machines-for-newbies-2/

2. Breton - Natural & Compound Stone Division (n.d). Retrieved from

http://www.directindustry.com/prod/breton-natural-compound-stone-division/5-axiscnc-vertical-milling-machines-69464-632922.html
3. OROTIG S.r.l (n.d). Retrived from http://www.medicalexpo.com/prod/orotigsrl/dental-cam-milling-machines-5-axes-73540-480296.html#
4. P. N. Rao, CAD/CAM Principles and Applications, 2nd edition, Mc Graw Hill,2004
5.

Serope Kalpakjian, W.R. Schmid, Manufacturing Technology and Fundamental,5th

edition, Prentice Hall, 2004