1.

Introduction to CNC Machine Tools

The History of Computer Numerical Control (CNC)

Computer numerical control is a modern concept in the manufacturing and production industries.
However, the concept of CNC harkens back to the basic idea of NC, or numerical control.
The idea of numerical control started when the automation of machine tools originally
incorporated specific concepts of programmable logic. In the beginning, the first NC machines
were built back in the 1940s. Slightly more advanced machines came along in the 1950s. These
manufacturing machines were constructed based on existing tools that were modified with
motors designed to move the controls of the machine. These controls followed specific points
that were fed into the machine on punched tape. These early mechanisms were soon improved
with both analog and digital computers. The introduction of computer technology into the
concept of numerical control led to what we now know as computer numerical control.

Early MIT Research on Numerical Control

After World War II, John Parsons researched ways to improve aircraft by creating stiffened skins
for them. This eventually led to a series of important Air Force research projects, which were
conducted at the Massachusetts Institute of Technology (MIT). This research began in 1949.
After the early planning and research phases, an experimental milling machine was designed at
MIT. Professor J.F. Reintjes and his team of researchers were involved in this project.

The First CNC Machine

Before the MIT projects, Parsons Corporation in Traverse City, Michigan developed a system to
produce templates for helicopter blades. John Parsons, who founded the company, discovered
how to calculate airfoil coordinates on an IBM 602A multiplier. He then fed these data points
into a Swiss jig borer. To date, this was considered the first true numerical control machine as it
manufactured goods – helicopter blade templates, in this case – by feeding punched cards into a
system, and the system then read and produced the parts based on preprogrammed information.
As numerical control technology moved into the 1960s and 1970s, a very familiar form of a
CNC machine that most would recognize today started taking shape. Digital technology then
entered the fray, and automation in production processes became more efficient than ever. In
fact, many individuals can purchase – and even design – their own homemade CNC machines.
Because of how advanced computers are nowadays, it’s more common than ever to find CNC
machines in all industries.

Staples of CNC Technology

While there has been tremendous change in the history of CNC technology, there are a few
cornerstones that have remained unchanged. All automated motion control manufacturing
machines,, from bare-bones concepts of the early days to highly advanced systems today, still
require 3 primary components. These include a command function, a drive/motion system, and a
feedback system.
CNC has had a long and interesting history. As technology evolves in the future, there may be
even more incredible elements to add to its history as manufacturing continues to promote the
use of robotic and automated processes in nearly every field.

PRINCIPLE OF CNC MACHINE

CNC Stands for Computer Numerical Control or Computerized Numerical Control. CNC
machine is an Computer Numerical Controlled machine which executes tasks with help of an
inbuilt computer which extracts an computer file based on the commands and codes written.
Then this command is loaded into post processor which gives electric inputs to the axes drives
and spindle which executes the machining requirements.

So this is an basic concept of CNC machine working

So the input is given in the form of G Codes and M Codes thru an Human Machine Interface
Device. This commands are read by an reader and stores into the memory. This memory is in
turn converted into Binary codes which gives electric pulses to the Servo drives which actuates
the motors and spindle.

Basically tool is fed into an spindle either vertically or horizontally. And the workpiece is held
into the table by an vice or fixtures. So the rotational motion is thru the spindle and feed motion
is thru the table. There are three basic axes X,Y,Z.

It shows the basic configuration of an CNC machine with its axes. And nowadays all machines
consists of an fourth by the use of an rotary table and fifth axes is also added based on
requirements. For machining complex parts this fifth axis machines are used.

CNC machines can further categorised into

1. DTC’s - Drill tap centres which does the non accurate operations such as drill and tap
and roughing operations.
2. Machining centres - Machines which are used for finishing operations. Can be further
divided into 1) Vertical machining centres 2) Horizontal machining centres
3. Turning centres - CNC lathe machine which is used mostly for rotational jobs
4. CNC grinding machines - for grinding operations
5. CNC special machines - Controlled by CNC system for special purpose/ specific
operations. Can do only Indented operations where as general machines can be used
for all opertions
6. Turn mill centre - combined lathes for turning and Milling/ drilling opertions.
 Classification of CNC control systems

The CNC control systems can be classified based on below types:

1. Motion type CNC
1.1. Contouring systems
1.2. Point to point systems

2. Control loop CNC

2.1. Closed loop system
2.2. Open loop system

3. Number of axis type CNC

3.1. 2-axis machines
3.2. 2.5 axis machines
3.3. 3 axis machines
3.4. 4 axis machines
3.5. 5 axis machines and above.

1. Motion type CNC Control:

Based on the basic difference of the machine to be controlled there are two types of
machine tools and control system. “Contouring systems” and “Point to point control system”.

1.1 Contouring system:

This type of machine tools works in a continuous path by cutting the material and following a
contour of the part. These machine tools are known as contouring machines which includes
Milling, lathe and routing machines. These contouring machines are also capable of doing the
work same as point to point system. These contouring system machines require simulations
movement of the tool and the work piece i.e., the positions of the work piece and the tool are
simultaneously controlled by a control system. These machines are uneconomical if it’s used as
only point to control without continuous motions. The contouring motion works as below shown
in figure.

1.2 Point to point control system:

The work piece and the tool are placed in the position and the tool does its work. These types of
machines are called point to point systems. The drilling, tapping and boring machines are
characterized under these types. The work piece is not moved until the tool finishes the job and
retracts to the safety. The point to point control system works as shown in the below figure.
 2. Loop control CNC systems:
Based on the looping system the CNC systems are classified into two categories, “Open loop
system” and “closed loop system”.

2.1 Closed Loop system:

Since this type of system has feedback from the control system to the actual and the programmed
input we call it as closed loop system. The CNC systems works on servo mechanism and it’s a
closed loop principle. The feedback can be measured by analog or the digital systems. The
analog systems measure the physical variables such as position and velocity in terms of voltage
levels and digital systems monitor by electrical pulses. These closed loop systems are accurate
and powerful because of their capability of monitoring operational condition through feedback
systems and automatically adjusting the variations in real time.

2.2 Open Loop system:

Open loop system are the systems in which instructions of program are sent into the controller
through the input device and then these instructions are converted to the signals by the controller
and sent to the servo amplifiers to energize the servo motors. The open loop systems are usually
used in the point to point control systems where the accuracy doesn’t matter much and in few
continuous path control system since there is no feedback from the system the result may deviate
from the actual.

3. Number of axis type CNC Control:

3.1 Two axis control system:

Two axis control system is a machine which give access to only two axis. The best example is
the lathe machine. The machine driven with the servo motor allows you only 2 axis, i.e., X and
the z Axis. Here in lathe the job will be rotating and the tool will be moving in 2 directions,
indicating the depth Z and the cut in X direction. So the program is done with x and the Z
direction, where as in lathe universally use U and V which is implies same as X and Y.

3.2 Two and half axis control system:

Two and half axis control system is also a three axis machine but the movement will not be 3
dimensional. These are the best example for drilling and tapping machines. First the X and the Y
axis are moved to the position and then the third axis comes to effect. In some of the machines
the first X movement is made and the Y movement to reach the XY destination when it is in
rapid, But while in feed or machining mode it does its work with 2 dimensional moving along x
and y simultaneously, These type of machines may also called as two and half axis machines or
2.5 axis machine.

3.3 Three axis control system:

Three axis control systems are the machines which moves in three dimensional i.e., X, Y and Z
axis move simultaneously. These are the most popular machines which can produce high
accurate precision parts with three axis machines. The servo motor control the movements as per
the instructions are given. The three axis has verity of machines based on their bed lengths. As
the bed length increases the cost of the machine increases. The number of setups increases and
the cost also increases, three axis machines are limited for simple jobs and straight forward 3
axis jobs.

3.4 Four axis control system:

In Four axis control system is a three axis machine with an extra rotation on B-axis, four axis can
be a vertical machine or an horizontal machine.
In vertical CNC machine the rotary head is added on the side of the machine bed. The
machine works as the three axis machine but it has a rotary head for example if the holes have be
machined on the tube, the tube can be mounted on the rotary B-axis and the drilling in the
required angle. But vertical 4-axis machines are limited for the small jobs.
Horizontal 4-axis machines are used worldwide for successful machining of big parts in a
single setup, where it takes 2-3 setups in a 3-axis machine. The part is mounted on the bed which
has 360 rotations around Y direction i.e., B-Axis giving chance for the tool to cut on the angled
faces in a single setup.

3.5 Five axis control system:

Five axis control system are the three axis machines with an extra rotation along Y and Z
directions which are called B-axis and A-axis. As in Four axis machines B rotation is given by
the bed and the A-axis rotation is given by the spindle movement called PIVOT point. Using a
five axis machine reduces the cycle time by machining the complex parts in a single setup and
improves the accuracy on the positional errors by eliminating the setups.
Five axis machining gives improved access to the under cuts and deep pockets by
tilting the tool and also gives good surface finish and the tool life by tilting the tool to maintain
optimum tool to part contact all the times.

There are more than five axis control systems in the world making aerospace and automobile
industries to achieve their accuracy and meet the requirements.

The Benefits of Computer Numerical Control (CNC)

Computer numerical control, also called CNC, is a manufacturing concept in which machines are
automated to perform certain functions based on the instructions fed to those machines. There
are many great benefits to utilizing a CNC machine compared to other forms of manufacturing
and production. These benefits include:

1. Saving on manufacturing costs

 By using a CNC machine, you can take complete advantage of all raw materials involved in the
manufacturing process. Because of how accurate CNC machines can operate, they significantly
reduce waste. This helps the CNC machine operator minimize any losses they may incur and,
thus, increase profitability over the course of time.

2. Increased speed of production

CNC machining is an extremely efficient process. Because of this, the production process of a
CNC machine cuts down on the number of steps it takes to produce a specific part. Therefore,
you can produce multiple parts – or items – in a much shorter amount of time than using other
manufacturing processes.

3. Increased safety
The entire fabrication process within a CNC machine is automated. So, the machine operator is
not even involved in the production process. This fosters a safe environment as the machine does
all the work without anyone having to be present. Some production involves potentially
dangerous materials like metal or steel. CNC machining is so accurate that it will rarely pose any
safety risks.
4. Increased efficiency of production
A CNC machine is considered perhaps the most efficient system for designing components. This
is because most CNC machines are equipped with quality assurance protection measures built
within them. As such, any time there is a problem in the production process, the machine detects
it and either shuts down to prevent further problems or fixes the issue internally.

5. Reduced production costs

A properly functioning CNC machine should work flawlessly over a long period of time without
the need of fixing parts or repairing the machine in any other fashion. With a well-oiled
production process in place from the beginning and minimal repair work due to rare flaws,
production costs are very low. Manufacturing can take a tremendous bite out of any company’s
budget. But with CNC machinery, this process can be a significant money saver.
It is very clear that CNC machining is a fantastic way of manufacturing a wide array of items.
While other manufacturing processes and equipment each have their own advantages, the
benefits of CNC machines tend to outweigh any competition because of how efficient these
machines are.

Advantages of CNC Machining

As you can imagine, CNC machining provides a variety of advantages to users as well as the
customers to whom they are catering.

 Precise Component Machining: Computer Aided Design (CAD) software is used to create the
3D designs of the final component. When this is fed into the CNC machine’s computer, the
machine is able to carve out the product from the material to exact specifications. Components of
complex shapes can be created easily without consuming too much time.
 Range of Materials: CNC machining can be used to manufacture products from a variety of
materials. These include bronze, steel, aluminum, as well as gold and silver. Polymers such as
ABS, polycarbonate, and PTFE can be used with the machine as well.
 Repeatability: Once a design has been fed into the computer, the CNC machine can repeat the
manufacturing process multiple times. Also, you will always get a high level of precision and
intricacy in the component.

Types of CNC Controls

CNC machining is the computer-controlled process of forming metal into fabricated

components. CNC actually stands for "computer numerical control” and is aptly named—the
computer directs the cutting tool based on a series of numeric codes that can be altered using
computer software.

CNC machining changed the metal fabrication industry by enabling easier production of 3-D
structures and reducing the level of human involvement in metal forming. Since the introduction
of CNC machining, improvements in quality and consistency have increased

When multiple CNC machines manufacture a part that requires multiple operations, designers
refer to that group of machines as a "cell." Today, CNC machines are typically automatons, as
they have the ability to perform without human assistance. The software packages that control
these CNC machines are CAM (Computer-aided Manufacturing) programs.

CNC Machining Software Origins

NC (Numerically Controlled) machining preceded CNC machining—these earlier machines

featured unalterable, fixed hard-wired operating parameters. NC machines were controlled by
"G-Codes," which are punched-tape applications fed into the machine's computer.

CAM Software

Specific files created by CAM software control today's CNC machines. CAM software reduces
production time by eliminating the need to produce a drafted paper drawing of the desired
manufactured component.

With CAM software controlling the CNC machine, the machine is capable of producing a high
volume of parts without human assistance. CNC machines controlled by CAM software also
feature lasers capable of detecting even slight imperfections in the finalized product. When the
laser detects a problem, the computer automatically phones the operator's cell phone and notifies
him of the situation.

CAD Software

CAD (Computer-Aided Design) software is the program used to design the product that the
CAM software program will eventually produce. Most of today's CAD programs feature 2D
vector base drafting systems or 3D solid and surface modelers.

CAD software provides designers with the freedom to create their product on the computer
screen and save it for later editing and printing, which cuts down on design and production time.
Other capabilities of CAD software include:

-3D parametric feature based modeling

-Solid modeling
-Freeform surface modeling
-Reuse of design components
-Wire frame geometry creation
-Automated design of assemblies

-Calculation of mass properties of assemblies and parts

-Aid visualization with shading and rotating
-Bi-directional parametric association
-Cable routing
-Electrical component packaging
-Inclusion of programming code in a model to relate and control the desired attributes of the
model
-Programmable design optimization

-Sophisticated visual analysis routines

-Verification of designs against design rules and specifications
-Automatic generation of standard design components
-Simulation of designs without building a physical prototype
-Maintenance of libraries of parts and assemblies
-Output of design data directly to manufacturing facilities
-Output directly to a Rapid Prototyping or Rapid Manufacture Machine for industrial prototypes

CAE Software
CAE (Computer-Aided Engineering) tools assist engineers in the analysis, design, simulation,
planning, manufacture, diagnosis, and repair of machining activities. CAE tools manage tasks in
three phases: Pre-Processing, Analysis and Post-Processing. The areas addressed by CAE
applications include:

- Stress analysis on components and assemblies using Finite Element Analysis

- Thermal and fluid flow analysis
- Kinematics
- Mechanical event simulation (MES)
- Analysis for process simulation for operations such as casting, die press forming and molding
- Optimization of the process or product

CAD/CAE/CAM Software

Some software companies have merged all three aspects of CNC controlling applications into
one, manageable software package, labeled CAD/CAE/CAM. These software programs handle
the entire fabrication process: the original design created in CAD, the analysis performed by the
CAE, and the final manufacturing as controlled by CAM software.

Types of CNC Controllers

Manufacturers, Factories and companies of CNC machine tool adopt various systems or
controllers as used are mentioned below.
 Electron per their requirement and easiness. Controllers mostly
 Kirloskar – 15T, 150M,200T
 Sinumeric – HMT/810T/810M
 Hind Numeric
 Fanuc O-T,O-IT
 Siemens
 Duckle
 Ferera

Industrial OEM CNC Controllers

Industrial OEM CNC Controllers are the ones used on Industrial CNC Machines like
Haas. They’re the very hind end of the market.
These are not very common for DIY projects due to their expense. Not only is the controller
itself expensive and fairly hard to come by (though one does see them from time to time on
eBay), but Industrial OEM Controllers expect premium sub-components too. Industrial Quality
Servo Drives, Home / Limit Switches, and all the rest really run up a hefty price tag in a hurry.
 While these controls are expensive, lately I’ve seen controls such as the low-end of the Siemens
line coming down in price in places like eBay. It looks like they’re testing the low-end
market. If they keep coming down, these controls may make more sense on a DIY CNC Project
than it seems.
I’m not going to talk further about these controls as they’re a pretty advanced topic. You might
find the article I did that analyzes what features Hobby CNC Controllers are missing compared
to industrial controls intersesting.
CNC Retrofit Controllers
Just a small step down from Industrial OEM Controllers are CNC Retrofit Controllers
like Centroid.
These controllers are marketed for converting manual machines to CNC, for example, a
Bridgeport manual milling machine. They’re also sold as a way to update obsolete controls on
industrial CNC Machines to bring the more up-to-date features and performance.
They’re still not cheap, but they’re starting to fall into the range of what a DIY CNC’er might
afford.
PC Based CNC Controllers
There are three main players in this market:
 Mach 3 & Mach 4
 LinuxCNC
 FlashCut
All three have good reputations with varying trade-offs of features, functionality, price, and ease
of use.
Mach 3

Art Fenerty founded ArtSoft in 2001 and launched Mach 3, which was based on an offshoot of
the original EMC (which is now LinuxCNC) code base. Art wanted a CNC Controller that runs
on Microsoft Windows PC’s rather than Linux, so it took a major rewrite and the two don’t share
much in common any more.
According to our 2017 Survey, Mach 3 is the most popular CNC Controller at the low-end, with
47% market share. The next closest was LinuxCNC.
LinuxCNC (My personal favorite!)

LinuxCNC has its origins in NIST’s “Enhanced Machine Controller” project, hence its original
name “EMC” and “EMC 2”. Since the EMC corporation owns the trademark, the name was
changed to LinuxCNC in
LinuxCNC is Open Source software, which means you can actually obtain the latest source code
should you wish to understand or modify it. It also means that a much larger audience, including
companies like Tormach, can contribute to LinuxCNC.
While it’s extremely cool that LinuxCNC is Open Source, it’s the contributions of Tormach, and
the PathPilot “flavor” of LinuxCNC that made it my favorite choice. Having used Mach 3 for
years, I can tell you that Tormach made a good decision when they moved from Mach 3 to
LinuxCNC.
PathPilot is simply more stable, more powerful, and more user friendly than Mach 3, and there’s
not much more you could ask for.
Now, getting your own PathPilot CNC Controller up and running for your own DIY CNC may
not be quite as straightforward. You’ll have to assemble a controller that matches Tormach’s
and get a copy of PathPilot up and running on it. There are various articles out there that purport
to help. I haven’t verified any of them yet, but if it can be done, you’ll have a sweet setup.
FlashCut

FlashCut is a very nifty plug-and-play CNC Controller. The company was started back in 1993,
so it’s been around a long time and the design is very mature.
While its Market Share isn’t as big as Mach3 or LinuxCNC, I’ve heard nothing but good about
FlashCut. Here’s a great video by Dave DeCaussin (one of the original founders of FADAL)
showing how easy it is to set up a FlashCut system:
I’ve heard some folks say they think the FlashCut is too expensive compared to other
solutions. I put pencil to paper one time comparing it to a Mach3 system and I found that if you
configure a system with all the capabilities of FlashCut (like a USB pulser for Mach3) that the
premium isn’t as high as you may think.
Having a completely engineered turnkey system that’s plug-and-play is worth a bit of premium if
you ask me.
Mach 4

Mach 4 is the newest solution in this category, and has by far the smallest market share. It’s
almost a start over from scratch rewrite of Mach 3. The developers claim it shares less than 1%
of Mach 3’s code.
It’s quite a bit more expensive, but in theory, should be better. From my perspective, the jury is
still out–not enough market share or experience to bet on it when the competition is well
entrenched and has far larger installed bases.
Microcontrollers: USB, Arduino, Rasperry Pi, TinyG, & More
Microcontrollers allow CNC Controllers to be built that are cheap and fit into a small space.
 CNC Microcontrollers are a relatively new development made possible by continued advances in
miniaturization and software. The idea is to put everything you need on one small circuit board,
or perhaps a microcontroller board with a daughterboard commonly called a “Shield”.
Here’s a quick list of all the most popular CNC Microcontrollers:
Grbl
Grbl (pronounced gerbil) runs on an Arduino microcontroller. It’s open source, and in use by a
lot of different firms including:

That’s pretty much an all-star cast, so you can be sure GRBL has a vibrant ecosystem of products
and people who can help and also that it has a bright future. The Shapeoko people told me they
evaluated a bunch of these and felt GRBL was head and shoulders the winner for their needs.
TinyG / TinyG2

TinyG is another microcontroller-based system. It’s related to grbl, but it’s not the same. The
TinyG codebase was forked from grbl in 2010 and has been going its own way ever
since. TinyG claims to do some things better or differently:
 While grbl is 3-axis (XYZ), TinyG is 6-axis so can support additional rotary axes. By default,
TinyG controllers have 4 stepper motor drivers while gShield (used with grbl) has 3.
 TinyG claims some fancy motion control algorithms, specifically “jerk” acceleration profiles for
smoother motion.
 TinyG claims its implemented on a higher performance microcontroller that has more memory.
PlanetCNC

PlanetCNC is a single-board CNC Controller that hails from Slovenia, Europe. Like TinyG, it’s
also a 4-axis solution. In our 2017 CNC Controller Survey, GRBL had #1 market share,
PlanetCNC #2, and TinyG #3 among the microcontrollers.

Characteristics of CNC machining

CNC machining technology is an application technology accompanied by the emergence of
CNC machine tools, continuous development and gradually improvement. The direct study
objects are the numerical controlequipment CNC devices, control systems, numerical control
procedures and preparation methods. CNC machining process comes from the traditional
processing technology. It combines the traditional processing technology, computer numerical
control technology, computer-aided design and auxiliary manufacturing technology.

When the programmers receive a NC programming task of one component or product, the main
works include:

1, CNC machining process feasibility study in accord with design drawings and related technical
documents , to determine the CNC machining parts processing methods;
2, Select the type of CNC machine tools and the specifications;
3, Select the fixture and its supporting tools;
4, Select the tool and tool clamping system;
5, CNC machining programs and process planning;
6, Determine the processing area;
7, Design of CNC machining process content;
8, Coding CNC programs;
9, NC program debugging and process validation;
10, Finally complete all the NC process file and archive all the documents.
CNC programming can be from the beginning of the comprehension of the design drawings to
the completion of coding the NC process.
Ordinary processing technology is the basis of NC machining technology. Because of the using
of computer automatic control for machining process, CNC machining process has the following
characteristics:

1, CNC machining process is more complex than the common mechanical processing
CNC machining process need to consider the process of processing parts, the positioning of the
workpiece and clamping methods, also need to select the tool, build the process routes, cutting
methods and process parameters, which can be simplified in the conventional process. The
diversification of numerical control processing technology is a characteristic of CNC machining
process, and it is significant different with the traditional processing technology.
2, CNC machining process design must be very structured
Due to the automation of CNC machining, so the self-adaptive ability of CNC machining is poor.
And the influence factors of NC processing are more complex, designing of the CNC machining
process must be careful, rigorous, without errors.
3, The transitivity of CNC machining process is better
The CNC Machining process which is after debugging, verification and test cutting process
verification and have a good performance in the NC machining practice, can be used as a
template for subsequent processing of similar parts, so not only time can be saved, but also
ensuring the quality.
4, Before guiding production, CNC machining process must be OK in reality testing
Due to the high degree of automation, safety and quality are paramount important in CNC
Machining. Before guiding production, CNC machining process must be OK in reality testing.
But in general mechanical process, the process files can be used in production line directly.

Linear Interpolation
Linear interpolatiion can be mixed with independent axis commands as desired by the
programmer. To make an axis do interpolation, the axis must be told two things:
1) the destination and
2) the longest move (in pulses) any axis will move during the coordinated move.
Circular Interpolation
This section could be called sinusoidal motion since that would be a true representation of the
motion of each axis. In reference pulse systems a pulse train of varying frequency is output to the
servo control module. The servo system for an axis causes an incremental displacement along the
axis, for each pulse. As mentioned before, this can cause a speed limitation for the CNC,
depending on the execution speed of the interpolation loop. In contrast, in reference word
interpolation systems the maximum velocity is not limited by the execution speed of the
processor. . The interpolation subroutines continuously provide velocity set points to the servo
system, which realizes it through the drive. In this lesson we discuss a circular interpolation
using the reference word method. This require the use of a “controlled speed drive” rather then a
“position servo”

Direct numerical control

(DNC), also known as distributed numerical control (also DNC), is a
common manufacturing term for networking CNC machine tools. On some CNC
machine controllers, the available memory is too small to contain the machining program (for
example machining complex surfaces), so in this case the program is stored in a separate
computer and sent directly to the machine, one block at a time. If the computer is connected to a
number of machines it can distribute programs to different machines as required. Usually, the
manufacturer of the control provides suitable DNC software. However, if this provision is not
possible, some software companies provide DNC applications that fulfill the purpose. DNC
networking or DNC communication is always required when CAM programs are to run on some
CNC machine control.

Applications of CNC Machines.

These days the CNC machines are found in almost all industries, from a small scale industry to
big companies. There is hardly any facet of manufacturing that is not touched by the automated
CNC machining center. Everyone involved in the manufacturing should know what a CNC
machine can do for their company. Due to extensive applications of CNC machines in various
industries, there is a great surge in the demand of the CNC programmers. To meet these demands
a number of schools have come up that teach the operation and programming of the CNC
machines.
 2&3:-CNC Programming
Co-ordinate System: The Cartesian coordinate system is the fundamental system used to
describe the motion of the tool and workpiece within a three-dimensional space. CNC
machines use numbers to locate a particular point along the X-, Y-, and Z-axes. They
perform a series of instructions, one after another, to machine the workpiece and create
incrediblyaccurate dimensions.
CNC machines use either incremental or absolute coordinates to move from
one location to the next. With incremental coordinates, the current position acts as the
origin for the next position. With absolute coordinates, the origin stays in a fixed location,
and each new location is calculated from that fixed position. Most CNC machines can move
along multiple axes at once to perform contour operations.
The axes on any CNC machine are determined by set standards. The Z-axis is always
parallel to the machine spindle. On a machining center, the spindle holds the cutting tool.
On a turning center, the spindle holds the rotating workpiece. Nowadays, CNC machines
can create complex shapes such as circles, curves, and cones.
Fundamentals of APT programming: APT (Automatically Programmed Tool) is a language
for defining tool paths on CNC machines. It was the predecessor to today’s CAM software,
created in the late 1950s to define complex tool paths in the aerospace industry in the US. It was
developed in MIT labs, the same place where the first NC machine was invented.
APT was created before graphical user interfaces were available, and so it is based on text to
specify the geometry and toolpaths needed to machine a part. It has English-like commands:
GOLFT for Go Left, TANTO for Tangent to, etc.

Manual part programming-structure of part programme: A CNC program is composed of

a series of sequential instructions related to the machining of a part. Each instruction is
specified in a format the CNC system can accept, interpret and process. Each instruction
must also conform to the machine tool specifications. This input method of a program can
be defined as an arrangement of the machining and related instructions, written in the
format of the CNC system and aimed at a particular machine tool.

Requirements of computer to be used in CIM system:

Subsystems-
A computer-integrated manufacturing system is not the same as a "lights-out factory", which
would run completely independent of human intervention, although it is a big step in that
direction. Part of the system involves flexible manufacturing, where the factory can be quickly
modified to produce different products, or where the volume of products can be changed quickly
with the aid of computers. Some or all of the following subsystems may be found in a CIM
operation:
Computer-aided techniques:

 CAD (computer-aided design)

 CAE (computer-aided engineering)
 CAM (computer-aided manufacturing)
 CAPP (computer-aided process planning)
 CAQ (computer-aided quality assurance)
 PPC (production planning and control)
 ERP (enterprise resource planning)
 A business system integrated by a common database.
Devices and equipment required:

 CNC, Computer numerical controlled machine tools

 DNC, Direct numerical control machine tools
 PLCs, Programmable logic controllers
 Robotics
 Computers
 Software
 Controllers
 Networks
 Interfacing
 Monitoring equipment
Technologies:

 FMS, (flexible manufacturing system)

 ASRS, automated storage and retrieval system
 AGV, automated guided vehicle
 Robotics
 Automated conveyance systems
Others:

 Lean manufacturing
CIMOSA
CIMOSA (Computer Integrated Manufacturing Open System Architecture), is a 1990s European
proposal for an open systems architecture for CIM developed by the AMICE Consortium as a
series of ESPRIT projects.[8][9] The goal of CIMOSA was "to help companies to manage change
and integrate their facilities and operations to face world wide competition. It provides a
consistent architectural framework for both enterprise modeling and enterprise integration as
required in CIM environments".[10]
CIMOSA provides a solution for business integration with four types of products:[11]

 The CIMOSA Enterprise Modeling Framework, which provides a reference architecture

for enterprise architecture
 CIMOSA IIS, a standard for physical and application integration.
 CIMOSA Systems Life Cycle, is a life cycle model for CIM development and deployment.
 Inputs to standardization, basics for international standard development.
CIMOSA according to Vernadat (1996), coined the term business process and introduced the
process-based approach for integrated enterprise modeling based on a cross-boundaries
approach, which opposed to traditional function or activity-based approaches. With CIMOSA
also the concept of an "Open System Architecture" (OSA) for CIM was introduced, which was
designed to be vendor-independent, and constructed with standardised CIM modules. Here to the
OSA is "described in terms of their function, information, resource, and organizational aspects.
This should be designed with structured engineering methods and made operational in a modular
and evolutionary architecture for operational use".

Database requirements of CIM

A major challenge facing the implementation of CIM is to establish the type of data needed to
bridge the mechanical design and manufacturing function. Following is the list of varied tasks
one might expect to accomplish in a CIM environment.
1.Designing assemblies and performing tolerance analysis on those assemblies.
2. Preparing production drawings of assemblies, invidual parts, tooling, fixtures and other
manufacturing facilities.
3. Creating analytical models of parts for structural, kinematics and thermal analysis (FEM,
MeM etc., )
4. Calculating weights, volumes, centres of gravity (mass properties) and costs of
manufacturing (cost estimation). Classifying existing parts according to shape, function and the
process by which they are manufactured and retrieving these pans from the parts library on
demand (Group technology and coding).

1. Preparing parts lists and bill of materials (BOM).

2. Preparing process plans for individual part manufacture and assembly (Variant or
Generative).
3. Programming CNC machines for processing complete parts (CAM).
4. Designing work cells and programming the movement of components in those
cells using work handling devices like robots, conveyors, AGVS/ RGVs, etc.,
(Cellular manufacture).
5. Controlling engineering changes and maintaining associativity between design and
manufacturing (concurrent associativity).
6. Preparing programs to handle components or manipulate production equipment (like
welding torches or robots).
7. Preparing inspection programs including programs for CNC co-ordinate measuring
machines {CNC- CMMS}.
The exchange of graphic information has been advanced with increasing acceptance of Initial
Graphics Exchange Specification (IGES) and STEP.
Design and development environment:

Computer-aided design (CAD) involves creating computer models defined by geometrical

parameters. These models typically appear on a computer monitor as a three-dimensional
representation of a part or a system of parts, which can be readily altered by changing relevant
parameters. CAD systems enable designers to view objects under a wide variety of
representations and to test these objects by simulating real-world conditions.

Computer-aided manufacturing (CAM) uses geometrical design data to control automated

machinery. CAM systems are associated with computer numerical control (CNC) or direct
numerical control (DNC) systems. These systems differ from older forms of numerical control
(NC) in that geometrical data are encoded mechanically. Since both CAD and CAM use
computer-based methods for encoding geometrical data, it is possible for the processes of design
and manufacture to be highly integrated. Computer-aided design and manufacturing systems are
commonly referred to as CAD/CAM.

Advance modeling techniques:

The Advanced Modelling part of the CAD*I project aimed at the development of a new
generation of modelling techniques as a basic functionality of future CAD/CAM systems. The
methodology and concepts for advanced modelling techniques, their availability in the
communication interface of a CAD/CAM system and their influence on internal interfaces in the
software architecture of a CAD/CAM system are fundamental results of advanced modelling
work. These results form the basis for the development of a new generation of CAD/CAM
systems which are called product modelling systems. CAD/CAM systems today mainly support
the geometric description of a technical part or its description as a technical drawing. Advanced
geometric modelling capabilities deal with parametric design functions embedded into
CAD/CAM systems. However, development strategies for future CAD/CAM systems are
directed toward the following: 1. The development of product modelling systems and 2. the
development of integrated systems based on CAD, CAP (Computer Aided Planning), CAM and
other CIM (Computer Integrated Manu facturing) functionalities.

ESPRIT:-

ESPRIT is a powerful, full-spectrum CAM system for CNC programming, optimization,

and simulation — supporting the entire manufacturing process from CAD file to machined
part. With factory-certified post processors delivering machine-optimized G-code and
ESPRIT's ability to solve unique challenges with automation solutions built using the
software's API, ESPRIT is the smart manufacturing solution for any machining
application. When you combine these benefits with world-class technical support that
allows programmers to get started quickly and keep running at top efficiency, it’s clear
that ESPRIT is the only CAM software you'll ever need.

MASTER CAM:-
CNC programming and machining is a very complex and diverse skill set. The career path
requires a vision for lifelong learning. What was considered "state of the art" just a few years ago
is not enough to stay competitive in today's market. This career field is never boring and there is
always room for innovation. Top dollar employers require knowledge of materials, software, and
very expensive complex machinery. This is not a trade for "good enough" thinking.
Because of this complexity, CNC Software, Inc. offers many different curricula, baseline testing
and Certifications for each product. The Certifications are typically classed into modules based
on the number of axis used to complete the scope of work. The tests are not specific to an
industry or application type such as injection molds or furniture.
Within curricula sets there are two testing and Certification levels. The Mastercam Associate
Level Certification is strictly comprehensive testing based on the latest technologies. The
Mastercam Professional Level Certification includes the comprehensive testing combined with a
practical application component.

FANUC CNC:- controls are fully compatible with all previous versions and can be adapted
to suit any configuration of machine in a very short time. Easy-to-operate standard setups
and smart simulation tools such as the FANUC NCGuide make setting up the FANUC
CNC straightforward, ensuring you are usually up and running within just a few days.
Offering everything you need for your specific application, they are easily adaptable to
your machines – and if you need help, the best support on the market is always close at
hand.

Heidenhain and Sinumeric control system:-

HEIDENHAIN CNC Control’s History

1968 VRZ 59.4 bidirectional counter for one axis
1974 HEIDENHAIN 5041 numerical position display unit
1976 TNC 110 and TNC 120 numeric positioning controls for 3 axes
1979 TNC 131 / TNC 135 numerical straight cut controls
1981 TNC 145 numeric contouring control for 3 axes
1984 TNC 155 numerical contouring control for 4 axes with graphic simulation of workpiece
machin .
1995 EnDat synchronous serial interface for absolute position encoders
1996 TNC 426 contouring control with digital drive control for 5 axes
1996 TNC 410 MA HEIDENHAIN complete package with inverters and motors
2004 iTNC 530 contouring control with alternative operating mode smarT.NC
2007 TNC 620 contouring control with HSCI, the serial controller interface.
2011 TNC 640 contouring control for combined milling and turning operations
Shorter product launch times and the increasing individualization of products strongly influence
the production processes using machine tools. Superior productivity is more important than ever
for machine builders and operators. In this context, the optimal interaction between automation
respectively CNC solutions and sophisticated technology is important – together with the
effective integration of digital solutions. This concerns all areas: From machine design and
building through to operation and service. SINUMERIK combines automation, technology
competence and digitalization to form a unique range of solutions, thus increasing the
productivity. SINUMERIK CNC systems are the optimum solution for individual parts or mass
production, for simple or complex workpieces.

4:-Tooling for CNC Machines

Cutting tool materials:-

Different cutting tool materials used for cutting operations in practice are high carbon steel, high
speed steel, non -ferrous cast alloys, cemented carbides, ceramics and sintered oxides, ceremets,
diamond, cubic boron nitride, UCON and sialon.
1. High Carbon Steel tools
 Its composition is C = 0.8 to 1.3%, Si = 0.1 to 0.4% and Mn = 0.1 to 0.4%.
 It is used for machining soft metals like free cutting steels and brass and used as
chisels etc.
 These tool loose hardness above 250°C.
 Hardness of tool is about Rc = 65.
 Used at cutting speed of 5m/min.
2.High speed steel (H.S.S)
General use of HSS is 18-4-1.
18- Tungsten is used to increase hot hardness and stability.
4 – Chromium is used to increase strength.
1- Vanadium is used to maintain keenness of cutting edge.
In addition to these 2.5% to 10% cobalt is used to increase red hot hardness.
Rest iron
 H.S.S is used for drills, milling cutters, single point cutting tools, dies, reamers etc.
 It looses hardness above 600°C.
 Some times tungsten is completely replaced by Molybdenum.
 Molybdenum based H.S.S is cheaper than Tungsten based H.S.S and also slightly
greater toughness but less water resistance.
3. Non – ferrous cast alloys
It is an alloy of
Cobalt – 40 to 50%,
Chromium – 27 to 32%,
Tungsten – 14 to 29%,
Carbon – 2 to 4%
 It can not heat treated and are used as cast form.
 It looses its hardness above 800°C
 It will give better tool life than H.S.S and can be used at slightly higher cutting
speeds.
 They are weak in tension and like all cast materials tend to shatter when subjected to
shock load or when not properly supported.
4. Cemented carbides
 Produced by powder metallurgy technique with sintering at 1000°C.
 Speed can be used 6 to 8 times that of H.S.S.
 Can withstand up to 1000°C.
 High compressive strength is more than tensile strength.
 They are very stiff and their young’s modulus is about 3 times that of the steel.
 High wear resistance.
 High modulus of elasticity.
 Low coefficient of thermal expansion.
 High thermal conductivity, low specific heat, low thermal expansion.
According to ISO the various grades of carbide tool materials grouped as
1. For cutting CI and non ferrous metals are designated as K10 to K50
2. For cutting steel are designated as p10 to p50
3. For general purpose application are designated as M10 to M50.
The advantages of carbide tools are
 They have high productivity capacity.
 They produce surface finish of high quality.
 They can machine hardened steel.
 Their use leads to reduction in machining costs.
5. Ceramics and sintered oxides
 Ceramics and sintered oxides are basically made of Al2O3, These are made by
powder metallurgy technique.
 Used for very high speed (500m/min).
 Used for continuous cutting only.
 Can withstand upto 1200°C.
 Have very abrasion resistance.
 Used for machining CI and plastics.
 Has less tendency to weld metals during machining.
 Generally used ceramic is sintered carbides.
 Another ceramic tool material is silicon nitride which is mainly used for CI.
6. Cermets
 Cermets is the combination of ceramics and metals and produced by Powder
Metallurgy process.
  When they combine ceramics will give high refractoriness and metals will give high
toughness and thermal shock resistance.
 For cutting tools usual combination as Al2O3 + W + Mo + boron + Ti etc.
 Usual combination 90% ceramic, 10% metals.
 Increase in % of metals reduces brittleness some extent and also reduces wear
resistance.
7. Diamond
 Diamond has
1. Extreme hardness
2. Low thermal expansion.
3. High thermal conductivity.
4. Very low coefficient of friction.
 Cutting tool material made of diamond can withstand speeds ranging from 1500 to
2000m/min.
 On ferrous metals diamond are not suitable because of the diffusion of carbon atoms
from diamond to work-piece.
 Can withstand above 1500°C.
 A synthetic (man made) diamond with polycrystalline structure is recently
introduced and made by powder metallurgy process.
8. Cubic Boron Nitride (CBN)
 The trade name is Borozone.
 Consists of atoms of Nitrogen and Boron and produced by power metallurgy
process.
 Used as a substitute for diamond during machining of steel.
 Used as a grinding wheel on H.S.S tools.
 Excellent surface finish is obtained.
9. UCON
 UCON is developed by union carbide in USA.
 It consists of Columbium 50%, Titanium 30 % and Tungsten 20%.
 This is refractory metal alloy which is cast, rolled into sheets and slit into blanks.
though its hardness is only 200 BHN, it bis hardened by diffusing nitrogen into
surface producing very hard surface with soft core. It is not used because of its
higher costs.
10. Sialon (Si-Al-O-N)
 Sialon is made by powder metallurgy with milled powders of Silicon, Nitrogen,
Aluminium and oxygen by sintering at 1800°C.
 This is tougher than ceramics and so it can be successfully used in interrupted cuts.
Cutting speeds are 2 to 3 times compared to ceramics.
 At present this is used for machining of aerospace alloys, nickel based gas turbine
blades with a cutting speed of 3 to 5 m/sec.

Carbide inserts classification:-

Preset Tools:-

The setting of tools in advance at a place away from the machine tool or offline, in special
holders is known as preset tools. A presetting device is used to preset axial and radial
positions of the tool tip on the tool holder. Once this is done, the tool holder is ready to be
mounted on the machine and produce a known dimension. Presetting devices to various
levels of sophistication are available like optical projector. Tool length and tool diameter
compensation facilities available in the present day CNC machines have brought down the
importance of presetting. Since the generation of actual geometry is taken care of by the
CNC part program, which is essentially the coordinates through which the cutting tool tip
moves, it is important to know the actual dimensions of the tool when it is placed in the
spindle. The relationship of the tool with reference to the tool holding mechanism requires
a special attention during CNC machining process. The actual point to be programmed in a
CNC part program is the tip of the tool whereas the axes will be moving with respect to a
known point in the spindle, e.g. the centre of the spindle in case of machining centres. It
becomes therefore necessary to know precisely the deviation of the tool tip from the gauge
point on the spindle.

Qualified Tools:-

Tool which fits into a location on the machine, where its cutting edge is accurately
positioned within close limits relative to a specified datum on the tool holder or slide, is
known as qualified tool. The cutting tools satisfy the following requriements : (a) Tools
need not be measured individually. (b) No presetting device is used. (c) The dimensions of
the tool holder which are fixed and known. (d) Set up time is reduced. (e) Control
dimensions of the tool are nominal and fixed. (f) Higher control on resharpening e.g. drills,
reamers. (g) Cutter for better size control e.g. end mills, teamers. (h) Chip breaking
facilities incorporated in tool. (i) Impoved designs.

Semi-qualified Tools:-

The qualified tools which can be adjusted to the dimensions by using several adjustable
buttons on the tool shank are known as semi qualified tools. These tools demand regular
maintenance and calibration for accurate dimensioning.

Cooling fed tooling system:-

Coolant-Fed Tooling Products

CFT Systems designs, develops and provides coolant-fed tooling and accessories from the finest
materials ensuring consistent quality and long-lasting performance. Our products are specifically
designed for the speeds, feeds, and temperature extremes of today’s machining process in a cost-
effective manner. Coolant-fed technology can extend tool life, increase speeds and feeds, and
improve accuracy. CFT Systems tools and accessories are manufactured to meet or exceed
industry specifications.

Special Tooling Needs

CFT Systems is able to custom-design coolant-fed tooling and systems for highly specialized
applications. When ordering special tools, please supply a print of the desired tool or holder or
give a detailed, accurate description along with necessary dimensions and specifications.

New products are continuously being designed and developed by CFT Systems team to
further benefit the coolant-fed technology industry. Please periodically check our site for
new coolant-fed tools and accessories

Quick change tooling system:-

Quick change tooling is a modular system that enables tools to be changed very fast on the
machine during:
1. Initial part setup
2. Tool change due to tool wear

The system dramatically reduces machine downtime for tool change during setup changes, and
for changing worn out inserts during machining.

A normal tool is clamped by inserting it in a slot in the turret and tightening screws to hold it
firmly. While doing this, care must be taken to seat the holder properly against available butting
surfaces. Finally, the tool offsets must be taken by touching the part or taking skin cuts. The
whole process can take 5 to 10 minutes.

With a quick change tool, you do not clamp the tool directly in the turret. The tool is replaced by
an interchangeable cutting unit. You insert the cutting unit into a standardized locking unit.
There are different locking units for internal and external tools, and the locking units remain on
the turret forever – there is no need to keep removing them for every part. The interface between
the units is such that the cutting unit will only sit in a particular position in the locking unit, and
will sit accurately every time. Because of the high precision of the coupling and self-centering
design, repeatability can be as high as +/- 2 microns for the same cutting unit in the same female
receiver.
When doing the setup for a new part, you just quickly insert and clamp a new set of cutting units
into the appropriate locking units. The tool offsets are pre-determined for each cutting unit, and
remain the same every time that you put in the unit. Tool change time is 30 seconds, against 5 to
10 minutes for normal tooling.

Quick change tooling is more important on lathes than machining centers. This is because tool
setup is anyway done offline, on pre-setters. You are not bothered so much about the time of
changing tools because there is no machine down time involved in this

Tooling system for machining centre and turning center:-

A machining center, illustrated in Figure 1, is a highly automated machine tool capable of

performing multiple machining operations under computer numerical control in one setup
with minimal human attention. Workers are needed to load and unload parts, which usually
takes considerable less time than the machine cycle time, so one worker may be able to tend
more than one machine. Typical operations performed on a machining center are milling and
drilling, which use rotating cutting tools.

Fig.1 A universal machining center. Capability to orient the work head makes this a five-axis
machine. (Courtesy of Cincinnati Milacron, Batavia, Ohio.)

The typical features that distinguish a machining center from conventional machine tools and
make it so productive include:

Multiple operations in one setup:

Most work parts require more than one operation to totally machine the specified geometry.
Complex parts may require dozens of distinct machining operations, each requiring its own
machine tool, setup, and cutting tool. Machining centers are capable of performing most or all of
the operations at one location, thus minimizing setup time and production lead time.

Automatic tool changing:

To change from one machining operation to the next, the cutting tools must be changed. This is
done on a machining center under CNC program control by an automatic tool-changer designed
to exchange cutters between the machine tool spindle and a tool storage carousel. Capacities of
these carousels commonly range from 16 to 80 cutting tools. The machine in Figure 1 has two
storage carousels on the left side of the column.
Pallet shuttles:

Some machining centers are equipped with pallet shuttles, which are automatically transferred
between the spindle position and the loading station, as shown in Figure 1. Parts are fixtured on
pallets that are attached to the shuttles. In this arrangement, the operator can be unloading the
previous part and loading the next part while the machine tool is engaged in machining the
current part. Nonproductive time on the machine is thereby reduced.

Automatic work part positioning:

Many machining centers have more than three axes. One of the additional axes is often designed
as a rotary table to position the part at some specified angle relative to the spindle. The rotary
table permits the cutter to perform machining on four sides of the part in a single setup.

Machining centers are classified as horizontal, vertical, or universal. The designation refers to
spindle orientation. Horizontal machining centers normally machine cube shaped parts, in which
the four vertical sides of the cube can be accessed by the cutter. Vertical machining centers are
suited to flat parts on which the tool can machine the top surface. Universal machining centers
have work heads that swivel their spindle axes to any angle between horizontal and vertical, as in
Figure 1.

Success of CNC machining centers led to the development of CNC turning centers. A modern
CNC turning center, Figure 2, is capable of performing various turning and related operations,
contour turning, and automatic tool indexing, all under computer control.

Fig.2 Computer numerical control, four-axis turning center.

In addition, the most sophisticated turning centers can accomplish

(1) work part gaging (checking key dimensions after machining),

(2) tool monitoring (sensors to indicate when the tools are worn),

(3) automatic tool changing when tools become worn, and even

(4) automatic work part changing at the completion of the work cycle.

Another type of machine tool related to machining centers and turning centers is the CNC mill-
turn center. This machine has the general configuration of a turning center; in addition, it can
position a cylindrical work part at a specified angle so that a rotating cutting tool (e.g., milling
cutter) can machine features into the outside surface of the part, as illustrated in Figure 3. An
ordinary turning center does not have the capability to stop the work part at a defined angular
position, and it does not possess rotating tool spindles.

Fig.3 Operation of a mill-turn center: (a) example part with turned, milled, and drilled surfaces;
and (b) sequence of operations on a mill-turn center: (1) turn second diameter, (2) mill flat with
part in programmed angular position, (3) drill hole with part in same programmed position, and
(4) cutoff.

Further progress in machine tool technology has taken the mill-turn center one step further by
integrating additional capabilities into a single machine.

Tool holders:-
 Techleader toolholders for CNC machining centers have become one of the premier
toolholder lines in North America. Our toolholders are available in CT, BT, NMTB & R8
Shanks. HSK tooling upon request. They are being used not only by many of the largest
corporations but also by small and medium sized job machining shops. Many of these
companies are longtime users and customers. This customer loyalty is based on three solid
reasons... a standard of accuracy and finish second to none, very competitive pricing, and fast
delivery.

If you haven't tried Techleader CNC toolholders up to now, give us a chance to prove why
thousands of other companies always ask for us by name.
"Techleader, the best CNC toolholder money can buy".

VIEW THE CNC TOOLHOLDERS CATALOGUE

 Milling Chucks
LEARN MORE

 ER/ECX Collet Chucks w/ DIN 69871 Form B Coolant Through The Flange
LEARN MORE
 ER/ECX Collet Chucks w/ Mini Nuts
LEARN MORE

 TG Collet Chucks
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 End Mill Holders

LEARN MORE

 Nuts and wrenches for TG, DA & ECX/ER Collet Chucks

LEARN MORE

 Morse Taper Holders

LEARN MORE

 Integral Shank Keyless Drill Chucks

LEARN MORE

 Tappers
LEARN MORE
 Boring Head Adapters
LEARN MORE

 BT & CT Retention Studs

LEARN MORE

 ER/ECX Collet Chucks

LEARN MORE

 ER/ECX & No. 25 (SYOZ25) HSK63F Collet Chucks for CNC Routers
LEARN MORE

 ER/ECX Extensions
LEARN MORE

 DA Collet Chucks
LEARN MORE

 Shell Mill Holders

LEARN MORE
 Jacobs Taper Holders
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 Jacob Drill Chucks

LEARN MORE

 Precision Keyless Drill Chucks

LEARN MORE

 Syncrolize Tappers
LEARN MORE

 Boring Bar Blanks

LEARN MORE

ASSEMBLY ON CNC MILLING MACHINES

 1. Assemble the tool directly on a Weldon fitting (we recommend one with an
internal supply);
2. Position the selector on MDI and place the machine in spindle configuration
(for example Fanuc M19);
3. Place the aligner plate in the insert housing and, using a gauge or comparator,
slide the axis along the flat surface of the plate until you achieve perfect
alignment, parallel to the direction of operation;
4. Tighten the bolts on the Weldon fitting so as to clamp the tool on, then remove
the aligner plate and put the insert in place.

Tool magazines:-

Bamboo-hat type tool magazine for CNC machining center

Mechanical arm type tool magazine for CNC machining center

Synchronous –action type tool magazine for CNC machining center

Clamp –armtype tool magazine for CNC machining center

Flying-saucer type tool magazine for CNC machining center

ATC mechanisms:-

An Automatic tool changer or ATC is used in computerized numerical control (CNC) machine
tools to improve the production and tool carrying capacity of the machine. ATC changes the tool
very quickly, reducing the non-productive time. Generally, it is used to improve the capacity of
the machine to work with a number of tools. It is also used to change worn out or broken tools. It
is one more step towards complete automation
A chain type automatic tool changer with swiveling arm and two grippers, installed on a
mill.

An Automatic Tool Changer for press brakes, used to set up rearrange, and remove
punches and dies. Tooling is stored in a motorized tool rack (right) and is placed in the
desired position by the shuttle (blue/grey/white on center).

Tool management:-

Tool management is needed in metalworking so that the information regarding the tools on
hand can be uniformly organized and integrated. The information is stored in a database
and is registered and applied using tool management. Tool data management consists of
specific data fields, graphics and parameters that are essential in production, as opposed to
managing general production equipment.

4.Robotics

A robot is a re programmable multi-function manipulator designed to move

material parts, tools or specialised devices, through variable programmed motions for the
performance of a variety of task. (Robotic Institute of America, 1979)

An industrial robot is a re-programmable device designed to both manipulate and transport

parts, tools or specialised manufacturing implements through variable programmed motions
for the performance of specific manufacturing tasks.
(British Robots Association)

Robotics is the engineering science and technology of robots, and their design,
manufacture, application, and structural disposition. It requires a working knowledge of
electronics, mechanics, and software.
1. Robots must not injure humans
2. Robots must obey orders
3. Robots must protect their own existence

Industrial Robot Applications :-

Historically, there have been two main streams for the development of robotics. One
application area is the traditional industrial robot, employed for assembly line tasks such as
welding, painting, and materials handling. The other application area is teleportation for The
other application area is teleportation for hazardous environments, such as handling nuclear
materials. More recently, the domain of application for robotics has expanded. Here are the most
10 industrial robot application.
1) Material Handling (see slide 12).
2) Polishing (see slide 12).
3) Punching (see slide 13).
4) Welding (see slide 13).
5) Palletizing.
6) Assembly.
7) Laser Cutting.
8) Spray Painting.
9) Inspection.
10) Deburring.
Percentages of industrial robot uses in worldwide are (60% welding and painting ,20%
pick and place and 20% others)

Advantages &Benefits of Industrial Robots

1. Increased output rates. 2. Improved product quality

3. Reduced material wastage. 4. Accident reduction.
5. Reduced labor turnover. 6. Greater flexibilityandre-programmability.

Dis-advantages of Industrial Robot

1) Replacement of human labor.
2) Robots are an expensive initial cost.
3) Can only do what it is instructed to do; nothing more, nothing les
4) Greater unemployment

Robot anatomy:-

The manipulator of an industrial robot consists of a series of joints and links. Robot anatomy
deals with the study of different joints and links and other aspects of the manipulator's physical
construction. A robotic joint provides relative motion between two links of the robot. Each joint,
or axis, provides a certain degree-of-freedom (dof) of motion. In most of the cases, only one
degree-of-freedom is associated with each joint. Therefore the robot's complexity can be
classified according to the total number of degrees-of-freedom they possess.

Each joint is connected to two links, an input link and an output link. Joint provides controlled
relative movement between the input link and output link. A robotic link is the rigid component
of the robot manipulator. Most of the robots are mounted upon a stationary base, such as the
floor. From this base, a joint-link numbering scheme may be recognized as shown in Figure
7.5.1. The robotic base and its connection to the first joint are termed as link-0. The first joint in
the sequence is joint-1. Link-0 is the input link for joint-1, while the output link from joint-1 is
link-1—which leads to joint-2. Thus link 1 is, simultaneously, the output link for joint-1 and the
input link for joint-2. This joint-link-numbering scheme is further followed for all joints and
links in the robotic systems.