Non-Traditional Machining and

Automation
(MET 255)
B.Tech. (4th Sem) Spring 2021
Department of Mechanical Engineering
NIT Srinagar

Course Incharge
Dr. Noor Zaman Khan
Course Outcomes
At the end of the course, a student should be able to:

• CO1: Analyze and access the importance of automation and industrial automated systems.

• CO2: Identify and Analyze functions and functioning of CNC machines.

• CO3: Recognize the need of non-traditional machining processes and understand the working of high energy
beam machining.

• CO4: Illustrate underlying mechanisms in non-traditional machining processes along with their applications
 Syllabus of Unit 2
• Computer numeric control (CNC) machines

• Open loop & closed loop CNC machines

• Classification, advantages and applications of CNC machines

• Introduction to CNC programming

• G-codes and M-codes

• Absolute and Incremental coordinate system

• Adaptive control

• Material Handling Equipment

• Automated Guided vehicles (AGVs)

• Analysis of AGVs
 Coordinate System in CNC Machines
• Two type of coordinate system are used in CNC machines to define and control the position
of tool related to the work piece.
1. Absolute coordinate system:
• Tool/work locations are always defined with respect to the origin of the axis system.
• The coordinates of a point are always referred with the same origin.
• It is very easy to check and correct the program written with absolute coordinate system.
2. Incremental coordinate system:

• The coordinate points are calculated with reference to previous point. The next tool/work
position is defined relative to the present location.
• It is difficult to check and modify a program written in incremental coordinate system
Absolute Vs Incremental Coordinate System

Points Absolute C S Incremental C S

1 X=10, Y=10 X=10, Y=10

2 X=30, Y=20 X=20, Y=10

3 X=50, Y=30 X=20, Y=10

 Interpolation
• It is the method by which contouring machine tool move from one point to the next
point.
• Contouring path consist of circular arcs and other smooth nonlinear shapes.
• A fundamental problem in generating contour using NC equipment is that they are
continuous, whereas NC is digital.

• To cut along a circular path, the circle must be divided into a series of straight line
segments that approximate the curve

• The tool is commanded to machine each line segment in succession so that the machined
surface closely matches the desired shape.
 Interpolation
• The maximum error between the nominal (desired) surface and
the actual (machined) surface can be controlled by the lengths of
the individual line segments.

• Approximation of a curved path in NC by a series of straight line

segments as shown in Fig.

• In (a) the tolerance is defined on only the inside of the nominal

curve.

• In (b) the tolerance is defined on only the outside of the desired

curve.

• In (c) the tolerance is defined on both the inside and outside of

the desired curve.
 Interpolation methods
• A number of interpolation methods are available to deal with the various problems
encountered in generating a smooth continuous path in contouring. They include:

1. Linear interpolation,

2. Circular interpolation,

3. Helical interpolation,

4. Parabolic interpolation,

5. Cubic interpolation.
 Interpolation methods
(1) Linear interpolation: This is the most basic and is used when a straight line path is to be
generated in continuous path NC. The programmer specifies the beginning point and end point of
the straight line and the feed rate to be used along the straight line

(2) Circular interpolation: This method permits programming of a circular arc by specifying the
following parameters: (a) the coordinates of the starting point, (b) the coordinates of the
endpoint, (c) either the center or radius of the arc, and (d) the direction of the cutter along the arc.

(3) Helical interpolation: This method combines the circular interpolation scheme for two axes
described above with linear movement of a third axis.

(4) Parabolic interpolation and (5) Cubic interpolation: These routines provide approximations of
free form curves using higher order equations. They generally require considerable computational
power and are not as common as linear and circular interpolation
 Adaptive Control
• It is a type of Artificial intelligence.

• Controls the feed rate of the tool (increase or decrease) to maintain

vibrations in workpiece.

• Stops the operation if the cutting force increases or decreases abruptly.

• If tool wear occur during operation then it compensate the tool path.
 Basics of CNC Programming
• Word Address format: Words in an instruction block are intended to convey command
needed for machine tool to execute specific operation.
• Sequence of word in a block
➢Sequence No. ------------------------------- N
➢Preparatory word--------------------------- G
➢Coordinates (X, Y, Z—Linear & A, B, C-----Rotation)
➢Feed rate------------------------------------- F
➢Spindle rotation---------------------------- S
➢Tool selection-------------------------------T
➢Miscellaneous command-----------------M
➢End of block--------------------(EOB symbol ‘;’)
 G00 Point-to-point positioning (Rapid Traverse)
This provides point-to-point positioning of the feed drives at a rapid traverse rate of the machine
Common a-words tool along an uncontrolled random path.
(Preparatory Word) G01 Linear Interpolation with feed rate
G02 Circular Interpolation (CW): An arc generated by the coordinated motion of the two axes in which the
tool moves CW, when viewing the plane of motion in the negative direction of the axis perpendicular to
the plane of motion.
• G03 Circular Interpolation (CCW): An arc generated by the coordinated motion of the two axes in which the
tool moves CCW, when viewing the plane of motion in the negative direction of the axis perpendicular
to the plane of motion.
G17 Selection of the X, Y plane: Used to identify the plane for such functions as circular interpolation, cutter
compensation, and other functions as required.
G18 Selection of the Z, X plane : Used to identify the plane for such functions as circular interpolation, cutter
compensation, and other functions as required.
G19 Selection of the Y, Z plane : Used to identify the plane for such functions as circular interpolation, cutter
compensation, and other functions as required.
G41 Cutter diameter compensation left of the workpiece contour
G42 Cutter diameter compensation right of the workpiece contour
G70 Mode for programming in imperial (inch) units.
G71 Mode for programming in metric (mm) units.
G90 Absolute programming.
G91 Incremental programming
G94 Specify Feed in mm/min (or inch / min)
G95 Specify Feed in mm/rev (or inch / rev)
Common M-words Used in Word Address Format
M02 End of program
It indicates completion of machining cycle. Stops spindle, coolant, and feed after
the completion of all commands in the last NC block.

M03 Start spindle CW

M04 Start spindle CCW
M05 Spindle Stop
M06 Tool Change
M08 Coolant ON
M09 Coolant OFF
M30 End of program
It stops feed, spindle, and cutting fluid and rewinds the NC program to the beginning.
 To perform slotting operation on CNC Milling machine
• N001 G90 G71 G94;

• N002 G00 Z10;

• N003 X20 Y20;

• N004 Z2;

• N005 M03 S1000;

• N006 G01 Z-0.5 F100;

• N007 G01 Y60;

• N008 G01 X40;

• N009 G01 X60 Y 40;

• N010 G01 Y20;

• N011 M30;
Thank You