LAB 11

Objective:-

 To study the Numerical Control (NC) and Computer Numerical Control (CNC) Machines.
 To study the Dimensioning Systems, Zero Points and Functions of CNC Machines.
 To study the CNC Program, types of CNC Program, CRC (Cutter
Radius Compensation) and CNC Program Format.

Theory:-

Introduction:-

NUMERICAL CONTROL (NC)

HISTORICAL DEVELOPMENT :-
15th century - machining metal. 18th century - industrialization, production-type machine tools. 20th
century - F.W. Taylor - Tool metal - HSS Automated production equipment - Screw machines Transfer
lines Assembly lines using cams and preset stops Programmable automation - NC PLC Robots

Definition of NC:-
Numerical Control is a system in which actions are controlled by the direct insertion of numerical data at
some point. IN other words, Programmable automation in which the mechanical actions of a ‘machine
tool’ are controlled by a program or It is defined Method of programmable automation in which various
functions of machine tools are controlled by numbers, letters and symbols.

CNC Machines:-
The term CNC stands for 'computer numerical control', and the CNC machining definition is that it is a
subtractive manufacturing process which typically employs computerized controls and machine tools to
remove layers of material from a stock piece—known as the blank or workpiece—and produces a custom-
designed part. This process is suitable for a wide range of materials, including metals, plastics, wood,
glass, foam, and composites, and finds application in a variety of industries, such as large CNC machining
and CNC machining aerospace parts.
Difference between NC & CNC Machines:-
The various differences between NC and CNC machine in tabular form are as follows:

S.no NC Machine CNC Machine

1. NC stands for Numerical Control CNC stands for Computer Numerical Control.

It is defined as the machine which is It is defined as the machine which is used to

controlled by the set of instructions in the control the motions of the workpiece and tool
form of numbers, letters and symbols. The set with the help of prepared program in computer.
2. of instructions is called as program. The program is written in alphanumeric data.

In CNC machines the programs are fed directly

In NC machine the programs are fed into the into the computer by a small keyboard similar to
3. punch cards. our traditional keyboard.

4. Modification in the program is difficult. Modification in the program is very easy.

5. A high skilled operator is required. A less skilled operator is required.

6. The cost of the machine is less. The cost of the CNC machine is high.

7. Maintenance cost is less The maintenance cost is high.

The programs in the NC machine cannot be In CNC machines, the programs can be stored in
8. stored. the computer and can be used again and again.

It offers less flexibility and computational It offers additional flexibility and computational
9. capability. capability.

The accuracy is less as compared with the

10. CNC. It has high accuracy.

It requires more time for the execution of the

11. job. It takes very less time in the execution of the job.

12. It is not possible to run it continuously. It can be run continuously for 24 hours of a day.
Advantages of CNC Machines:-

 Continuous Use: Unlike manual labor, CNC machinery (barring any malfunction or maintenance
issue) can work continuously over any period of time without a break. This greatly increases
productivity and efficiency.
 Consistency, Precision and Redundancy: With computer software, the design of any given product
only needs to be programmed once. The CNC machine can then perfectly replicate that design, for
any order quantity.
 Low Skill Requirement: CNC machine operators require little training and skill when compared to
manual machine operators.
 Fewer Personnel: Because computer software controls the machinery, fewer technicians are needed
for operation and oversight, cutting overall expenses.
 Flexibility: The software can be reprogrammed quickly and easily to produce different parts,
allowing operations to keep up with shifting customer demands.
 Capability: This technology uses computer precision to go beyond the limitations of manual
capabilities. More complex and intricate operations are possible with CNC machining.

Disadvantages of CNC Machines:-

 Cost: CNC machines are more expensive and require a greater initial investment than machines that
can be operated manually. However, as this technology becomes the standard, supply is increasing
resulting in costs gradually decreasing.
 Skills Loss: As the demand for manual machine operators decreases, fewer and fewer new students
adopt those skills. This could eventually lead to the complete loss of long-preserved skills.
 Unemployment: Automation decreases the need for manpower, and fewer laborers are hired. That
said, the need is now shifting to software engineers and mechanical engineers, and education and
training will have to adjust to meet that need.
Dimensioning Systems:

Two basic types:

Absolute Dimensioning System:

The absolute system in which dimension values of all the co-ordinates are taken from one origin point is
called Absolute Dimensioning System. The G-Code used for this system is G-90.
 Fig.2

Incremental Dimensioning System:

In incremental dimensioning system all the values of co-ordinates are taken from one point
to another point. The G-Code used for this system is G-91.

Fig.3
Zero Points:-
Three types of Zero Points are:

 Machine Zero Point

 Work Piece Zero
Point

Program Zero Point

Machine Zero Point:-
The point at which the co-ordinate values of all the axes of machines are zero is called Machine Zero
Point. It is denoted by Mo.

 It is the origin of machine.

 Machine calculates all the values from it.
 It is selected by machine manufacturer.
 It cannot be changeable, but it can be temporary shifted.

Work Piece Zero Point

The point at which the co-ordinate values of all the axes of work piece are zero is called Work Piece Zero
Point. It is denoted as Wo.

• It is origin of work piece.

• In absolute dimensioning system the co-ordinate values of all the target points are taken from it.
• It is selected by programmer.

Program Zero Point:-

The point which is used to start the contour / profile is called Program Zero Point. It is denoted as Po.

 In the start of any contour tool is positioned at this point.

 It is selected by programmer.
 Depth of cut is given at it.
 It is changeable.

Functions of CNC Machines:-

G-Functions:-
These functions describe the type of slide movement, interpolation and dimensioning system, influence of
time and activation of various operation modes .The G-Functions which only remain active until they are
replaced by a new G-Function in the same group are said to be modally active.
M-Functions:-
The functions which are used to provide machining information in a program are called Miscellaneous
Functions or M-Functions. These functions are part of logic information.
CNC Program:-
1. A computer program is a list of instructions written in the language that the computer understands
and which tells it how to carry out a particular task.
2. CNC programming (Computer Numerical Control Programming) is utilized by manufacturers to
create program instructions for computers to control a machine tool. CNC is highly involved in
the manufacturing process and improves automation as well as flexibility.

Types of CNC Programs:-

There are two types of CNC Program:

Part Program

 Path Information
 Logic Information

Sub Program

Types of CNC Programs:-

Part Program:-
This program consists of path information, logic information and machining cycles.

Path Information:-
The information used to travel the tool on required path is called Path Information. e.g. X, Y, Z etc.

Logic Information:-
The information used to complete the machining operation of required work piece is called Logic
Information. e.g. S, D, F etc. It is denoted by % in maximum 4 digits0-9999. This program ends with M02.
or M30.

Sub Program:-
Any movement or function which is to be repeated for several times can be inputted as a Sub Program. It
only consists of the path information .A sub program can be repeated up to 99 times in a single block. It
also behaves like a loop program.
CNC (Applications):-
 Signage.
 Cabinets and furniture.
 Aluminum and brass machining.
 Prototyping and 3D modeling.
 Musical instruments.
Safety Rules for CNC:-
Below are some general machine safety rules that you can use as a guide only. You might like to
add any other rules that apply to you.

DO:
Always keep the area around the machine clear of obstacles.
Always stack material where you can reach it but where it is clear of the moving
parts of the machine.
Always check that tools are sharp and set correctly.
Always check that the correct tool data is entered into the CNC program.
Always make sure that all guards are in position while the machine is in
operation.
Always make sure that all work and fixtures are clamped securely before starting
machine.
Always make sure spindle direction is correct for right-hand or left-hand
operation.
Always conduct a dry run to ensure the program is correct.
Always follow company policy on correct procedures when handling or lifting
parts or tooling.
DON'T:
Do not use the machine table as a workbench.
Do not use compressed air to blow chips from the parts of the machine, machine
surfaces, cabinets, controls or floor around the machine.
Conclusion:-
In this we will see how the use of programming aids can minimise the length of programs. This may be
an important criterion when one is faced with either a small memory capacity in the CNC, or many parts
already stored in the memory, or a complex part geometry, which might otherwise take up considerable
space in this memory. These programming aids are usually available for most CNC controllers, or may be
offered as "options" from many universal/proprietary builders. Such options are: "mirror-imaging",
"scaling", "angular rotation", "datum shifting", "canned-cycles", "subroutines" and "nested subroutines",
which all reduce the length of the part program considerably, with the secondary benefit of minimising
the expertise necessary in writing such programs. The structure of "word address programs" will be
enlarged upon later - arguably the most cornmon technique used in developing CNC part programs for
both turning and machining centres.
 LAB 12

Objective:-
 To demonstrate the CNC Milling Machine.
 Adapt a CNC Program and construct a job on CNC Milling Machine according to given design /
designs.

Theory:-

Introduction:-

NUMERICAL CONTROL (NC)

HISTORICAL DEVELOPMENT :-
15th century - machining metal. 18th century - industrialization, production-type machine tools. 20th
century - F.W. Taylor - Tool metal - HSS Automated production equipment - Screw machines Transfer
lines Assembly lines using cams and preset stops Programmable automation - NC PLC Robots

Definition of NC:-
Numerical Control is a system in which actions are controlled by the direct insertion of numerical data at
some point. IN other words, Programmable automation in which the mechanical actions of a ‘machine
tool’ are controlled by a program or It is defined Method of programmable automation in which various
functions of machine tools are controlled by numbers, letters and symbols.

CNC Machines:-
The term CNC stands for 'computer numerical control', and the CNC machining definition is that it is a
subtractive manufacturing process which typically employs computerized controls and machine tools to
remove layers of material from a stock piece—known as the blank or workpiece—and produces a custom-
designed part. This process is suitable for a wide range of materials, including metals, plastics, wood,
glass, foam, and composites, and finds application in a variety of industries, such as large CNC machining
and CNC machining aerospace parts.
Advantages of CNC Machines:-

 Continuous Use: Unlike manual labor, CNC machinery (barring any malfunction or maintenance
issue) can work continuously over any period of time without a break. This greatly increases
productivity and efficiency.
 Consistency, Precision and Redundancy: With computer software, the design of any given product
only needs to be programmed once. The CNC machine can then perfectly replicate that design, for
any order quantity.
 Low Skill Requirement: CNC machine operators require little training and skill when compared to
manual machine operators.
 Fewer Personnel: Because computer software controls the machinery, fewer technicians are needed
for operation and oversight, cutting overall expenses.
 Flexibility: The software can be reprogrammed quickly and easily to produce different parts,
allowing operations to keep up with shifting customer demands.
 Capability: This technology uses computer precision to go beyond the limitations of manual
capabilities. More complex and intricate operations are possible with CNC machining.

Disadvantages of CNC Machines:-

 Cost: CNC machines are more expensive and require a greater initial investment than machines that
can be operated manually. However, as this technology becomes the standard, supply is increasing
resulting in costs gradually decreasing.
 Skills Loss: As the demand for manual machine operators decreases, fewer and fewer new students
adopt those skills. This could eventually lead to the complete loss of long-preserved skills.
 Unemployment: Automation decreases the need for manpower, and fewer laborers are hired. That
said, the need is now shifting to software engineers and mechanical engineers, and education and
training will have to adjust to meet that need.

Functions of CNC Machines:-

G-Functions:-
These functions describe the type of slide movement, interpolation and dimensioning system, influence of
time and activation of various operation modes .The G-Functions which only remain active until they are
replaced by a new G-Function in the same group are said to be modally active.

M-Functions:-
The functions which are used to provide machining information in a program are called Miscellaneous
Functions or M-Functions. These functions are part of logic information.
CNC Program:-
3. A computer program is a list of instructions written in the language that the computer understands
and which tells it how to carry out a particular task.
4. CNC programming (Computer Numerical Control Programming) is utilized by manufacturers to
create program instructions for computers to control a machine tool. CNC is highly involved in
the manufacturing process and improves automation as well as flexibility.

Types of CNC Programs:-

There are two types of CNC Program:

 Part Program
 Sub Program

CNC Operation:
Taking digitized data, a computer and CAM program is used to control, automate, and monitor the
movements of a machine. The machine can be a milling machine, lathe, router, welder, grinder, laser or
waterjet cutter, sheet metal stamping machine, robot, or many other types of machines. For larger
industrial machines, the computer is generally an on-board dedicated controller. But for more hobbyist
types of machines, or with some retrofits, the computer can be an external PC. The CNC controller works
together with a series of motors and drive components to move and control the machine axes, executing
the programmed motions. On the industrial machines there is usually a sophisticated feedback system that
constantly monitors and adjusts the cutter's speed and position.

CNC Milling:-
CNC milling, or computer numerical control milling, is a machining process which employs computerized
controls and rotating multi-point cutting tools to progressively remove material from the workpiece and
produce a custom-designed part or product. This process is suitable for machining a wide range of
materials, such as metal, plastic, glass, and wood, and producing a variety of custom-designed parts and
products.
 Fig.5

CNC Machine Operation:-

CNC milling is a machining process suitable for producing high accuracy, high tolerance parts in
prototype, one-off, and small to medium production runs. While parts are typically produced with
tolerances ranging between +/- 0.001 in. to +/- 0.005 in., some milling machines can achieve tolerances
of up to and greater than +/- 0.0005 in. The versatility of the milling process allows it to be used in a wide
range of industries and for a variety of part features and designs, including slots, chamfers, threads, and
pockets. The most common CNC milling operations include:

 Face milling
 Plain milling
 Angular milling
 Form milling
 Fig.6

Basic Codes for CNC Part Programming:

CNC applications:
The applications are as follows:

 Signage
 Cabinets and furniture
 Aluminium and brass machining
 Prototyping and 3D modelling Musical instruments

Mechanical Hazards in CNC:-

Mechanical hazards involve moving machine parts and ways that a worker’s body could come in contact
with those parts. The most common types of mechanical hazards found in machine shops include the
following:

 Single rotating parts, like shafts or couplings, which have a risk of snagging or entanglement.
 Two or more rotating parts working together, such as pulley drives, rollers, or exposed gears, create
nip points and pinch point’s hazard.
 Parts that slide or swivel, including sliding mills or robotic arms, create shearing or crushing hazards.
 Parts that can rupture or fragment, such as in grinders, pose a risk of impact injuries.

Conclusion:-
Although CNC machining demonstrates advantages over other manufacturing processes, it may not be
appropriate for every manufacturing application, and other processes may prove more suitable and
costeffective. While this article focuses on the mechanical CNC machining processes which employ
machine tools to produce the custom-designed part or product, CNC controls can be integrated into a
variety of machines. Other mechanical CNC machining processes include ultrasonic machining, waterjet
cutting, and abrasive jet machining.
 LAB 13
Objective:-
 To demonstrate CNC Lathe Machine. Adapt a CNC Program and construct a job on CNC Lathe
Machine/ CAD CAM Software according to given design.

Theory:-

Introduction:-

NUMERICAL CONTROL (NC)

HISTORICAL DEVELOPMENT :-
15th century - machining metal. 18th century - industrialization, production-type machine tools. 20th
century - F.W. Taylor - Tool metal - HSS Automated production equipment - Screw machines Transfer
lines Assembly lines using cams and preset stops Programmable automation - NC PLC Robots

Definition of NC:-
Numerical Control is a system in which actions are controlled by the direct insertion of numerical data at
some point. IN other words, Programmable automation in which the mechanical actions of a ‘machine
tool’ are controlled by a program or It is defined Method of programmable automation in which various
functions of machine tools are controlled by numbers, letters and symbols.

CNC Machines:-
The term CNC stands for 'computer numerical control', and the CNC machining definition is that it is a
subtractive manufacturing process which typically employs computerized controls and machine tools to
remove layers of material from a stock piece—known as the blank or workpiece—and produces a custom-
designed part. This process is suitable for a wide range of materials, including metals, plastics, wood,
glass, foam, and composites, and finds application in a variety of industries, such as large CNC machining
and CNC machining aerospace parts.

CNC Operation:
Taking digitized data, a computer and CAM program is used to control, automate, and monitor the
movements of a machine. The machine can be a milling machine, lathe, router, welder, grinder, laser or
waterjet cutter, sheet metal stamping machine, robot, or many other types of machines. For larger
industrial machines, the computer is generally an on-board dedicated controller. But for more hobbyist
types of machines, or with some retrofits, the computer can be an external PC. The CNC controller works
together with a series of motors and drive components to move and control the machine axes, executing
the programmed motions. On the industrial machines there is usually a sophisticated feedback system that
constantly monitors and adjusts the cutter's speed and position.

CNC Lathe machine:-

Lathes as the only universal CNC Machine tool because a lathe can make all of the parts needed for another
lathe. A lathe spins the workpiece in a spindle while a fixed cutting tool approaches the workpiece to slice
chips off of it. Because of this geometry, lathes are ideal for parts that have symmetry around some axis
that could be chucked up in the spindle.

Fig.5

CNC Lathes have at the very least the ability to drive the cutting tool under G-code control over 2 axes,
referred to as X and Z. They may have a considerable amount of other functionality as well. The act of
cutting a workpiece (material removal) on a lathe is called "Turning". Due to technological advancements,
CNC lathes are quickly replacing some of the older and more traditionally used production lathes. CNC
lathes come with a number of benefits. They can be easily set up and operated.
They offer tremendous repeatability, along with top-notch accuracy in production.
 Fig.6

A CNC lathe is typically designed to utilize modern versions of carbide tooling and processes. In CNC
Lathe Machines the coded computer file is uploaded to the CNC machine, and the machine will then
automatically produce the desired parts for which it was programmed to design.

Basic Codes for CNC Part Programming:

The basic codes are as follows:
CNC Lathe applications:
The applications are as follows:

• Aluminium and brass machining

• Prototyping and 3D modelling
• A CNC lathe can be used to produce plane surfaces and screw threads or in the case of ornamental
lathes, three-dimensional products that are quite complex
• Some prime examples of finished items as a result of using CNC lathe machines include: Baseball
Bats, Bowls, Camshafts, Crankshafts, Cue sticks, Gun Barrels.

Conclusion:-
A CAD/CAM system without full post processing capabilities is somewhat useless. All of the
programming and toolpath creation is run through a posting engine or translator to generate the g-code
program. The output NC code will have taken everything that the operator input into the CAM – Job Tree
and “Post” it through a configuration file (Post Processor) that will create the exact language required at
the controller. CAD/CAM software providers work hard with their customers and machine tool makers to
create all of the different models that are out in the industry. Many machines have multiple controller
models that all need to receive the g-code program specific to the controllers requirements. Generally Post
Processor configuration files can also be edited and modified by the operator or by the providers’
technicians to be customized.