Introduction to CNC

Machining
LEARN THE BASICS OF CNC MACHINING

By:

Basilius Inc.
Contents
Introduction .......................................................................................................................................................... 3
Common Aspects of CNC Equipment.................................................................................................................... 5
Machine Axes .................................................................................................................................................... 5
Control System.................................................................................................................................................. 5
Material Holding ............................................................................................................................................... 6
Cooling System.................................................................................................................................................. 6
ATC System ....................................................................................................................................................... 6
Guarding ........................................................................................................................................................... 6
Common CNC Applications ................................................................................................................................... 7
CNC Milling........................................................................................................................................................ 7
CNC Turning ...................................................................................................................................................... 8
EDM .................................................................................................................................................................. 9
Deep Hole Drilling (Gun Drilling) ....................................................................................................................... 9
About Basilius ..................................................................................................................................................... 11
It’s Personal .................................................................................................................................................... 11
Quality Reassurance ....................................................................................................................................... 11
A Simple Source, A Simple Solution ................................................................................................................ 11
From Specialized Assistance to Turn-Key Solutions........................................................................................ 11
Introduction
CNC (computer numeric control) machining is a broad category for describing a material removal process
where a machine is preprogrammed to operate. In most CNC applications, a blank of material is mounted
into a machine, and material is removed until the final shape is complete. That blank could be rough cut via
other machining processes or could be a cast blank. In any case, a machine operator knows what the final
product will be and what material needs to be removed to get there. The first step is plugging that
information into CAM (computer-aided manufacturing) software.

There are several different CAM software manufacturers that, generally speaking, all serve the same
function. That is, creating an intuitive interface between an operator and the CNC machine. Think of CAM
software as a translator. The operator uses the software to create the CNC movements, choose the tooling,
set speeds, collision check, and generally make sure the part comes out as expected. The software then
translates that into a language the CNC machine can understand, known as G-code. Below is a screenshot of
what a popular CAM software looks like for the user, followed by an image of a small amount G-code.
Note: Not all CNC machines require a computer and software to operate. All machines have the
means to create movement, to varying degrees. For some small machines, all the programming may
be done right at the machine without software. These are still CNC machines because they a
preprogrammed.
Common Aspects of CNC Equipment
CNC machining encompasses several different types of machines. They could include mills, lathes, EDMs,
grinders, deep hole drills, water jetting, plasma cutting, routers, and several others. Even though these
machines serve different functions, there are some commonalities between them.

Machine Axes
All CNC machines can move the workpiece, the cutting head, or both. Each direction a machine moves is
called an axis. The vertical mill pictured below is an example of a three-axis machine. The table, which holds
the workpiece, can move left and right (X-axis), forward and backward (Y-axis), can vertically (Z-axis).
Generally speaking, more axes means more capability. The main advantage of adding axes to machines is to
gain greater access to the part and finish more areas of the part without having to change its position in the
machine.

Control System
For most CNC machines, the control system includes a computer, motors, and motor drives. Each axis will
have a motor and a motor drive to control movement. The computer system tells all the drives what to do
and when to do it based on the G-code created in the CAM software. It's then up to the motor drives to
control the motors and confirm the motor is doing what it's supposed to do. This position control and
checking process happens hundreds of times a second to make sure the machines are as accurate as possible.
Material Holding
The material the machine is cutting needs to be held in place (work holding). CNC machines will use various
methods to do this, depending on the application. Work holding may include clamps, vices, chucks (lathes
and OD/ID grinders), magnetic tables, as well as automated clamping systems. Most machines are capable of
using various work holding methods as well.

Cooling System
The material removal process generates heat, and both the cutting equipment and the workpiece can get
extremely hot. Although there are exceptions, most operations require a cooling system to keep everything
from overheating. The cooling liquid is either oil or water-based and also serves as a lubricant for cutting
equipment. Larger machines will have a circulation system for coolant and various means of discharging it
onto the workpiece. In high accuracy applications, some internal mechanical elements of the CNC machine
are cooled to avoid variation due to thermal expansion. These machines are often kept in temperature-
controlled rooms as well.

A Note on accuracy: Accuracy can be a subjective term. If you are building a house and every wall is
within a sixteenth of an inch, that’s accurate. If your running CNC equipment, keeping an accuracy
within a sixteenth of an inch is inaccurate (horribly). For perspective, in most applications, it’s easy for
an operator to maintain an accuracy of +/- .005 inches. When we say “accurate” and “precision” in
CNC machining, we’re usually talking less the .001 inches. Precision CNC equipment has
repeatability/accuracy at the micron level.

ATC System
Since many CNC operations involve complicated procedures, it's unlikely that one cutting tool will complete a
job. For jobs requiring several different cutting tools, CNC machines will have an ATC system (automatic tool
changer). An operator will set-up each tool in advance and preprogram each. A simple example is using a
large tool to rough cut a piece and then a smaller one to produce small details. The machine can be
programmed to change those tools when the time is right.

Guarding
Even small CNC machines can remove material aggressively, causing spent material, sparks, and coolant to fly
out from the cutting area. For the safety of the operator, nearly all CNC machines have guarding and safety
systems built in to avoid flying debris. Some CNC equipment is large enough to walk inside, so you can
imagine how important operator safety is.
Common CNC Applications
CNC Milling
CNC Milling uses a rotating cutting tool
to remove material. The machine
moves both the cutting tool and
material in different directions (axes) to
give the cutting tool access to various
design features. The cutting tools come
in hundreds of different variations to
perform specific actions. Cutting tools
are selected based on the material and
features being cut. For example, the
cutting tools used for rough cutting
aluminum vs. detailing a feature on
titanium are much different. Beyond
that physical design of those cutting
tools, the way an operator programs
them will vary as well.
CNC Turning
Turning is a generic term used in the CNC industry to represent the use of a lathe. A lathe's main function is
to create round parts; however, as you will see, a lathe can have much more functionality. The lathe has a
chuck that holds and spins the workpiece. The tooling is then moved around the workpiece to remove
material. A simple lathe will have tooling that can move in two axes. In more advanced CNC turning
equipment, more axes (directions of movement) are utilized to expand the functionality of the lathe. The
added axes could be multiple chucks for different stages or the addition of milling type components to create
more advanced features.

Like CNC milling, CNC lathes can use various types of tooling to create different features in round parts. These
could be features like o-ring grooves, internal and external threads, face grooves, and so on. Lathes will also
have a tailstock located opposite and in line with the chuck. The tailstock is used for holding a long workpiece
or for completing various drilling functions. The image below is a sectioned (cut in half) part that would be
produced using a CNC lathe. Features include internal threads, external threads, outer diameter groove, inner
diameter groove, and a face groove.
EDM
EDMs (electrical discharge machines) use electrical current to remove material from a workpiece. There are
three main kinds of EDMs; Ram, Wire, and drilling.

Ram EDM
The Ram EDM, sometimes called sinker,
die sinker, or plunger uses an electrode to
produce the desired shape in material via
electrical current. First, a machinist will
use 3D data of the desired part and
design various electrodes around the
part. The electrode is the opposite of the
desired shape in the material. Once the
electrode is made, it's placed into the
Ram EDM. A dielectric oil then surrounds
the material and electrode. The oil is a
critical component in the process as it serves as an ionizer for the current, flushes out the material being
removed, and cools the electrode and workpiece.

Compared to a CNC Mill or Lathe material is moved relatively slowly when common/soft steels are used. The
advantages of the EDM compared to standard CNC machining are the ability to machine extremely hard
materials with ease, produce features that are either difficult or impossible on other equipment, and produce
an array of textures.

Wire EDM
Like the Ram EDM, the wire EDM uses electrical current to remove material. The difference is that instead of
using a machined electrode, a wire is used to cut a narrow channel through material. The wire is continuously
moving so that it does not wear and break due to the corrosive nature of the EDM process. The wire EDM is
extremely accurate and used for making inserts, insert pockets, precision holes, tapered pockets, and small
holes. Like the Ram, the wire can cut hardened material with ease.

Drilling EDM
Often called a "Hole Popper," the drilling EDM functions using a spinning electrode rod to "drill" into
materials. In the most simple form, workpieces are manually moved, and the hole popper is manually aligned
to the desired location. However, much more advanced multi-axis CNC hole poppers have been developed.

Since Wire EDMs require a starting hole, these machines are often used in tandem, where the hole popper
creates a small starting hole that wire EDM can work from as a starting point. Hole poppers can also create
relatively accurate holes.

Deep Hole Drilling (Gun Drilling)

One major aspect of any drilling is how deep a hole can be accurately drilled. The depth limit is typically
measured relative to the diameter of the drill being used. This is represented as a length to depth ratio. For
example, a standard spiral drill is accurate to a length to diameter ratio of 5:1.
The unique design of the gun drilling machine provides the ability to keep the cutting area cool and remove
chips effectively at high l:d ratios. This is due to the high-pressure oil being directed right to the cutting
surface. The oil is used for lubrication and cooling initially, but as the oil comes back out of the hole, it carries
chips with it to keep the hole clean. The chips and oil are then collected in the base of the machine. The oil
gets separated from the chips and recirculated through the process.

Using the gun drilling process, it's possible to get l:d ratios up to 400:1 using specialty gun drilling equipment.
More common for standard gun drilling equipment is hole sizes from .125 to 2.00 inches with l:d ratios off
200:1 or less.
About Basilius
It’s Personal
Basilius Inc. is a family-owned business that has been in operation since 1952. You’ll find hands-on ownership
in every key operation and process. We work as an extension of your team to ensure
absolute quality and efficiency. We are driven by a commitment to customer satisfaction rooted in
accountability, responsiveness, and service excellence.

Quality Reassurance
Basilius Inc. meets international standards for quality and performance. In-house validation processes ensure
that the tooling and parts will meet or exceed your quality standards.

A Simple Source, A Simple Solution

Our centralized facility makes it possible for us to handle every step of the process under one roof,
ensuring consistent quality, continuity, and conformity to your part specifications. Our integrated approach
streamlines solutions to get your parts to market faster.

From Specialized Assistance to Turn-Key Solutions

Basilius Inc. is a full-service plastics part supplier, which can support as much or as little of your project
development as you choose. If you need technical assistance for part design, we have the equipment and
expertise to assist you from step one through project completion. If your design is complete, we can build
molds directly from your part design. If you need machine time for short-term production runs or are looking
for a permanent home for your existing tools, we will meet your injection molding needs. Basilius, Inc. is truly
a one-stop-shop.

Basilius Inc.
4338 South Ave
Toledo Ohio, 43615
419-536-5810
Contact@basilius.com
https://www.basilius.com/contact