CNC Machining and other

CNC Applications
 Lesson Outcomes
By the end of this lesson, students should be able to:
Understand the concept of Computer Numerical
Control System and its applications
Understand the fundamental components of an
CNC system
Understand aspects of CNC motion control
Understand aspects of CNC codes
Understand the advantages and disadvantages of
CNC control systems
 What is Computer Numerical
Control (CNC)?
(Definition:) A form of programmable
automation in which the mechanical actions of
a machine tool or other equipment are
controlled by a program.
Program of instructions (numbers, letters
symbols) used to control a process
Main advantage: Flexibility (easy to change
program of instructions for different parts)
 Applications of CNC Control
Technology
1. Machine tool applications to control the
relative motion between cutting tool and
workpiece.

Examples:
CNC Lathe CNC EDM
CNC Milling CNC Grinder
CNC Machining Ctr CNC Laser-cut
CNC Turning Center CNC Water-jet
CNC Wire-cut CNC Punch & Blanking
CNC Drilling & Boring
 Applications of CNC Control
2. Non-Machine Tool Applications
Examples:
-Assembly
(CNC used to control assembly machines)
-Drafting
(Once a CAD drawing is completed, CNC is used to
control a plotter to generate an engineering drawing)
-Robotics
(CNC is used to control the motors that move robotic arms)
-Quality Control and Inspection
(eg CNC CMM)
 Components of an CNC System
1. Program of instructions or part program
2. Machine control unit
3. Processing equipment
 Components of an CNC System
1. Program of instructions:
The detailed step by step commands that
direct the actions or movements of the
machine

Program written manually & key-in or via

CAD/CAM
 Components of an CNC System
2. Machine Control Unit (MCU):
Microcomputer and control hardware that
read and interprets the program of instructions
and converts it into signals to the processing
equipment.

Diskette / RS232C/ CPU/CRT/HDD/RAM

buffer/CPU convert CNC program into
electronic pulses to drive various motors
 Components of an CNC System
3. Processing equipment:
The part of the CNC System that performs the
useful work

Examples are:
Worktable, spindle and motors in a machine tool
Motors and linkages in a robotic system
This machine tool/ production process designed to
give high level of repeatability and precision
 CNC Motion Control
Systems

Three aspects of CNC Motion Control

Systems:
1. Point-to-point
2. Interpolation methods (Continuous Path
Control)
3. Absolute vs. Incremental positioning
 NC Motion Control Systems
1. Point to point system:
Tool movement is arbitrary as long as the final
destination is reached
A tool may move through a number of different
points before reaching the final destination.
Examples: drilling and spot welding operations
Processing action is performed after location is
reached
 NC Motion Control Systems
2. Interpolation methods (Continuous path control
system)

Some shapes such as circles and ellipses are

continuous.
NC control system, however, is digital.
Therefore, a circle or ellipse must be divided
into straight segments to approximate the curve.
This leads to a very large number of points
Interpolation methods calculate the intermediate
points and generate a smooth continuous points
 NC Motion Control Systems
2. Interpolation methods (Continuous path control
system:
The path followed by the tool is continuously
controlled to get the desired geometrical feature
Movement of worktable by continuously and
simultaneously controlling two or more axes.
Provides control of the tool path.
Processing action is performed during
movement.
Allow for generation of 2D and 3D contours
 CNC Motion Control Systems
2. Absolute vs. Incremental Positioning

Absolute positioning:
Positions are defined with respect to the origin
of coordinate system

Incremental positioning:
Positions are defined relative to the previous
location
CNC Co-ordinate System
 Floating zero point system
This feature allows the user to place a
secondary coordinate system anywhere on
the machine table.
This makes it easy to develop the part
program & machine the workpiece
 CNC Codes
CNC Code (forms the
program of instructions)
Types of CNC Code:
Sequence/block number (N
Code)
Preparatory Codes (G
Codes)
Miscellaneous Codes (M
Codes)
Feed and Speed Codes
Tools Codes

Source: MTAB
 CNC Codes
Sequence/Block
number (N
Codes)
Describes the
block of codes in
a program

Source: MTAB
 CNC Codes
Source: MTAB
Preparatory Codes (G Codes)
Relevant G Codes:
G00 G28
G01 G90
G02 G91
G03 G92
G20 G94
G21
 CNC Codes
Preparatory Codes (G Codes)

G00 Rapid Traverse of fast Traverse

A G00 causes the tool to move to the specified
position at maximum speed.
(for non-cutting movements)
Example: G00 X20 Y30 Z1
Here the tool is moved to X 20mm, Y 30mm, and
Z 1mm (for metric system)
 CNC Codes
Preparatory Codes (G Codes)

G01 Linear Interpolation

A G01 causes linear motion to the given
position.
Example: G01 X20 Y30 F45
Here the tool is moved to X 20mm, Y 30mm
 CNC Codes
Preparatory Codes (G Codes)

G02 Clockwise Circular Interpolation

Arcs can be specified by either radius or by centre.
Example: G02 X30 Y20 R15
In this example the tool is moved to X 30mm and Y
20mm. The arc has a radius of 15mm.
I and J specifies the arc centre relative to the arc
start. If the value-+ is 0 then it need not be specified.
Example: G02 X30 Y20 I15 J0
 CNC Codes
Preparatory Codes (G Codes)

G03 Counter-Clockwise Circular Interpolation

G03 causes counter-clockwise circular motion
Similar to G02
 CNC Codes
Preparatory Codes (G Codes)

G20 Imperial Units

All future instruction parameters will be taken
as imperial values.
 CNC Codes
Preparatory Codes (G Codes)

G21 Metric Units

All Future instruction parameters will be taken
as metric values.
 CNC Codes
Preparatory Codes (G Codes)

G28 Automatic Zero Return

Send spindle to home position
Usually used for tool change or setting up for a
new program
Milling: Lathe:
N020 G91 G28 Z0 N020 G28 U0 W0
N030 G28 X0 Y0
 CNC Codes
Preparatory Codes (G Codes)

G40 Cancel cutter compensation

G41 and G42 are used to locate the tool on
either left or right side of the profile
G40 is used to cancel this tool compensation
 CNC Codes
Preparatory Codes (G Codes)

G90 Absolute Movement

All future movements will be absolute until
overridden by a G91 instruction
Example: G90
G01 X30 Y0
The new position becomes X30 Y0
 CNC Codes
Preparatory Codes (G Codes)

G91 Incremental Movement

All future movements will be incremental until
overridden by a G90 instruction.
Example: G90
G01 X15
G91
G01 X2
The position becomes X17
 CNC Codes
Preparatory Codes (G Codes)

G92 Programming of the coordinate system

Defines a coordinate system
Example: G00 X30.0 Y40.0
G92 X0.0 Y0.0
Converts the position that was X30 Y40 to X0
Y0
 CNC Codes
Miscellaneous Codes (M Codes)
Relevant M Codes:
M03
M05
M06
 CNC Codes
Miscellaneous Codes (M Codes)
Relevant M Codes:

M03 Start Spindle

An M03 instruction starts forward spindle motion.
Example: M03 S2200
The spindle should be switched on before any
movement below the component surface.
 CNC Codes
Miscellaneous Codes (M Codes)
Relevant M Codes:

M05 Stop Spindle

An M05 instruction stops spindle rotation.
M05 is issued before a tool change, and at the
end of a program.
 CNC Codes
Miscellaneous Codes (M Codes)
Relevant M Codes:

M06 Change Tool

The M06 instruction causes the a change to a
different tool. The tool changing operation should be
done in the home position only.
Example: M06 T1
Changes to the tool in turret 1
 CNC Codes
Miscellaneous Codes (M Codes)
Relevant M Codes:

M30 End of Program

Rewind program and reset memory
 CNC Codes
Feed and Speed Codes
Feed code (F code)
Specifies the tool motion feed rate
Unit can be in mm/min, in/min, mm/rev or in/rev
Example: F50
Speed code (S code)
Specifies the rate of tool revolution
Unit is in RPM
Example: S1200
 CNC Codes
Tool code (T code)
Refers to a location on tool turret
Example: M06 T1
 CNC Machine tools:
Program of Instructions example (Milling)

F Feed code (F
code)
S Speed code
(S code)
T Tool code (T
code)

G00 Rapid Traverse of fast Traverse G40 Cancel cutter G94 Feed rate in mm/min
compensation in/min (G98 performs the s
G01 Linear Interpolation function in the CNC lathe)
G71 Rough out profile by
G02 Clockwise Circular Interpolation G95 Feed rate in mm/rev
turning
G03 Counter-Clockwise Circular in/rev
G70 Finishing Cycle
Interpolation M03 Start Spindle
G90 Absolute Movement
G20 Imperial Units M05 Stop Spindle
G91 Incremental Movement
G21 Metric Units M06 Change Tool
G92 Programming of the
G28 Automatic Zero Return M30 End of Program
coordinate system
Program of Instructions example (Milling)

Source: MTAB
G00 Rapid Traverse of fast Traverse
G01 Linear Interpolation
F
G02 Clockwise Circular Interpolation E D
C B
G03 Counter-Clockwise Circular
Interpolation A
G20 Imperial Units
G21 Metric Units
G28 Automatic Zero Return
G40 Cancel cutter compensation
M03 Start Spindle
G71 Rough out profile by turning
M05 Stop Spindle
G70 Finishing Cycle
M06 Change Tool
G90 Absolute Movement
M30 End of Program
G91 Incremental Movement
F Feed code (F code)
G92 Programming of the coordinate system
S Speed code (S code)
G94 Feed rate in mm/min or in/min (G98
performs the same function in the CNC T Tool code (T code)
lathe)
Source: MTAB
G95 Feed rate in mm/rev or in/rev
CNC Program of Instructions example (Lathe)

Z1

Source: MTAB
 CNC Codes:
Summary of relevant codes
G00 Rapid Traverse of fast Traverse G94 Feed rate in mm/min or
in/min (G98 performs the same
G01 Linear Interpolation
function in the CNC lathe)
G02 Clockwise Circular Interpolation
G95 Feed rate in mm/rev or
G03 Counter-Clockwise Circular in/rev
Interpolation
G20 Imperial Units
M03 Start Spindle
G21 Metric Units
M05 Stop Spindle
G28 Automatic Zero Return
M06 Change Tool
G40 Cancel cutter compensation
M30 End of Program
G71 Rough out profile by turning
F Feed code (F code)
G70 Finishing Cycle
S Speed code (S code)
G90 Absolute Movement
T Tool code (T code)
G91 Incremental Movement
G92 Programming of the coordinate system
Advantages of CNC Control systems
1. Reduce nonproductive time
2. Greater accuracy and repeatability
3. More complex part geometeries are
possible
4. Lesser operator skill-level is required
5. Easy to make engineering changes
(flexible).
6. Less floor space requirement
 Disadvantages of CNC
Control Systems

1. Higher cost of initial investment

2. Higher maintenance cost
3. Requires part programming (conventional
machining does not require any
programming)
 Summary
CNC is a form of programmable automation
The three components of an CNC system are the
program of instructions, MCU, and the
processing equipment
Three aspects of CNC motion control are Point-
to-point vs. Continuous Path Control,
Interpolation methods and Absolute vs.
Incremental positioning
Alphanumeric CNC codes (G&M) codes are
used for tool motion control and miscellaneous
parts