CNC Machines, Types, Tools,

Applications and Importance

Group No:

Sarmad Rasheed AU-026

Muhammad Maavia Asghar AU-003

Nikhil Raj AU-045 Submitted to:

Syed Kashif Ahmed AU-020 Dr. Faraz Akbar

Mankind has always found new ways to cut metals into their desired shapes over the
time. Machining process have evolved over the time too. Machining is a part of the
manufacture of many metal products, but it can also be used on materials such as
wood, plastic, ceramic, and composites. As the industry evolved, humans invented new
ways to machine metals with less effort. Similar is an interesting invention that led to
evolution of machining of metals and other hard elements as well as composites. It is
called CNC Machine.

Introduction to CNC Machines

What is a CNC Machine?

CNC stands for computer numeric controlled. It refers to any machine tool (i.e. mill,
lathe, drill press, etc.) which uses a computer to electronically control the motion of one
or more axes on the machine.

The development of NC machine tools started from a task supported by the US Air
Force in the early 1950’s, involving MIT and several machine-tool manufacturing
companies. The need was recognized for machines to be able to manufacture complex
jet aircraft parts.

 As computer technology evolved, computers replaced the more inflexible

controllers found on the NC machines; hence the dawn of the CNC era.
 CNC machine tools use software programs to provide the instructions necessary
to control the axis motions, spindle speeds, tool changes and so on.
 CNC machine tools allow multiple axes of motion simultaneously, resulting in 2D
and 3D contouring ability.
 CNC technology also increases productivity and quality control by allowing
multiple parts to be produced using the same program and tooling.

Typical CNC Machine Operation:

History of CNC Machines:
To understand where CNC Machining first appeared, it is important to note that the said
machine’s advent can be traced back to the invention of the NC (numerical controlled)
machine made by John T. Parsons during the 1940s-1950s. The NC was a breakthrough
invention that led the way towards modern automated machines.

Together with Frank L. Stulen, Parsons first utilized computer methods to crack
machining setbacks, especially the accurate interpolation of the curves that is found in
helicopter blades. Stulen got an idea from his brother to employ stress calculations on
the rotors. Parsons observed what Stulen was experimenting on with punched card
machines generating an outline with 17 points and then inquired if it was possible for
Stulen to generate an outline with 200 points.
 CNC Machines used to be as big as size of a room.

In the process of developing smoother rotors, they managed to generate an early

version of the NC, where generating numbers for complex and précised outputs was
possible. At that point, Parsons considered a fully automated tool that can surpass the
performance of the current NC. In 1949, he turned to Gordon S. Brown’s
Servomechanisms Laboratory at MIT to develop a feedback system that can gauge how
far the controls had turned.

With enough resources to back the project, the system was displayed in September
1952. The MIT’s system was a triumph, so that it was now possible to come up with any
complex cut that cannot be copied manually. Yet due to its complexity, its reliability in a
production setting is reduced, not to mention its cost that is worth more than
$2,641,727.63 in today’s currency.

The Air Force halted its funding in 1953, but Giddings and Lewis Machine Tool Co.
resumed the project by producing NC that can reduce the expenses and improve quality
and efficiency. With their direction of the project, the Numericord controller was
created, replacing punch type readers with magnetic tape readers.

Woman operating a CNC Turning Lathe VTI Machine

The CNC machine first appeared when John Runyon managed to produce punch tapes
under computer control. This showed dramatic results in terms of time, reducing the
normal production duration of 8 hours to 15 minutes. In June 1956, the Air Force
accepted the proposal to produce a generalized “programming” language for NC.

Eventually, the Air Material Command at the Wright-Patterson Air Force Base and the
Aircraft Industries Association (AIA) collaborated with MIT in 1957 to generate a fully
computer controlled NC system. The invention of CNC machines paved the way for
automated tools that meant cost efficient production for manufacturers.

CNC mills have very little differences with its predecessor in terms of its concept. The
modern CNC mill still functions in machines to produce outputs in three dimensional
directions: X and Y axes, and depth. Examples of CNC systems applied in various
industries include laser cutting, welding and ultrasonic welding among others.
 The Different Types of CNC Machines:
When CNC was first invented it was a technology that was adapted to fit existing
machines. Today CNC technology is still being retrofitted to various machine tools but
there are also many machines which are created for the sole purpose of being CNC
machines.

 Milling Machine
A mill uses rotary cutters to shave, cut or slice sections off of a work piece. CNC
technology enables far greater precision in milling than when the operation is
performed manually. The CNC milling machine can be programmed to vary in depth,
angle and direction of cut. A 3-axis machine operates along both the X and Y horizontal
axes, as well as the Z vertical axis. A 4-axis machine includes a rotary dimension to its
linear capability, which allows it to cut along an arc.

Mills use gyratory cutters to cut an assortment of manufacturing materials and use CNC
commands to dictate the direction, depth, and angle of the incision. The accuracy of a
cut has improved using CNC technology, rather than when these machines were used by
hand.
 Typical Milling Machine & its parts

Features of a Milling Machine:

 High speed drilling
To further improve cycle times on high-speed drilling, boring and tapping processes, the
best machines come equipped with smart functions that allow the drilling tool to leave
its path and take the fastest route between points.
  Peck drilling hard materials
Peck drilling cycles make drilling hard materials and deep holes easy by removing swarf
and protecting the drill from breaking or overheating.

 High speed tapping

On some machines, high speed rigid tapping as standard enables tapping speeds of up
to 8000 rpm.

 One pass precision tapping

By controlling the maximum acceleration power of the spindle motor, better quality
milling centers achieve precision rigid tapping across a wide range of diameters from M
0.8 to M 24 in just one pass.

 Multi step boring

Machines that can produce torque peaks of up to 100 Nm for 1 to 2 seconds are ideal
for multistep boring applications.

 CNC Lathe Machine

Lathes used in turning centers operate by rotating the material rapidly on a spindle.
While the material is turning, a cutting tool is used to shape the piece into its desired
form. CNC lathes are ideal for manufacturing symmetrical objects that have conical,
spherical or cylindrical shapes.

A lathe machine is generally used in metalworking, metal spinning, woodturning, and

glass working. The various operations that it can perform include the following: sanding,
cutting, knurling, drilling, and deforming of tools that are employed in creating objects
which have symmetry about the axis of rotation. Some of the most common products of
the lathe machine are crankshafts, camshafts, table legs, bowls, and candlestick holders.
 Parts of a CNC Lathe Machine

Features of a CNC Lathe Machine:

 Bed and Ways
The bed is the base for the working parts of the lathe. The main feature of the bed is the
ways which are formed on the bed’s upper surface and which run the full length of the
lathe. The tailstock and carriage slide on the ways in alignment with the headstock. The
headstock is normally permanently bolted at one end (at the operator’s left).
  Headstock
The headstock carries the head spindle and the mechanism for driving it. In the belt-
driven type headstock, the driving mechanism consists merely of a cone pulley that
drives the spindle directly or through the back gears. When the spindle is driven directly,
it rotates the cone pulley. When the spindle is driven through the back gears, it rotates
more slowly than the cone pulley, which in this case turns freely on the spindle. Thus
two speeds are available with each position of the belt on the cone; if the cone pulley
has four steps, eight spindle speeds are available.

 Tailstock
The primary purpose of the tailstock is to hold the dead center to support one end of
the work being machined between centers. However, it can also be used to hold live
centers, tapered shank drills, reamers, and drill chucks. The tailstock moves on the ways
along the length of the bed to accommodate work of varying lengths. It can be clamped
in the desired position by the tailstock clamping nut.

The dead center is held in a tapered hole (bored to a Morse taper) in the tailstock
spindle. The spindle is moved back and forth in the tailstock barrel for longitudinal
adjustment. The handwheel is turned which turns the spindle-adjusting screw in a
tapped hole in the spindle. The spindle is kept from revolving by a key that fits a spline,
or keyway, cut along the bottom of the spindle.

 Carriage
The carriage carries the crossfeed slide and the compound rest which in turn carries the
cutting tool in the toolpost. The carriage slides on the ways along the bed.

 Apron
The apron is attached to the front of the carriage. It contains the mechanism that
controls the movement of the carriage for longitudinal feed and thread cutting. It
controls the lateral movement of the cross-slide. One should thoroughly understand the
construction and operation of the apron before attempting to operate the lathe. In
general, a lathe apron contains the following mechanical parts: (a) A longitudinal feed
handwheel for moving the carriage by hand along the bed. This handwheel turns a
pinion that meshes with a rack gear that is secured to the lathe bed.

 CNC Drilling Machines

Sophisticated drilling machines can be programmed using CNC technology to ensure
precise positioning of holes in materials. With thick material, a process called peck, or
interrupted cut drilling is used to drill the hole in a stepwise procedure.CNC turret
drilling machines have several drill bits and cutting tools mounted on a turret.
Automation enables the required tool to be indexed quickly and accurately into position
for drilling.

Computer Numerical Control (CNC) Drilling is commonly implemented for mass

production. The drilling machine, however, is often a multi-function machining center
that also mills and sometimes turns. The largest time sink for CNC drilling is with tool
changes, so for speed, variation of hole diameters should be minimized. The fastest
machines for drilling varying hole sizes have multiple spindles in turrets with drills of
varying diameters already mounted for drilling. The appropriate drill is brought into
position through movement of the turret, so that bits do not need to be removed and
replaced. A turret-type CNC drilling machine is shown below.

A variety of semi-automated drilling machines are also used. An example is a simple drill
press which, on command, drills a hole of a set depth into a part set up beneath it.

In order to be cost-effective, the appropriate type of CNC drilling machine needs to be

applied to a particular part geometry. For low-volume jobs, manual or semi-automated
drilling may suffice. For hole patterns with large differences in sizes and high volume, a
geared head is most appropriate. If holes are close to each other and high throughput is
desired, a gearless head can locate spindles close together so that the hole pattern can
be completed in one pass. For further reference for CNC processes, please refer to the
CNC, metal forming section.
 CNC Drilling Machine

 CNC Grinding Machine

A grinding machine, often shortened to grinder, is any of various power tools or
machine tools used for grinding, which is a type of machining using an abrasive wheel as
the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from the
workpiece via shear deformation.

Grinding is used to finish workpieces that must show high surface quality (e.g., low
surface roughness) and high accuracy of shape and dimension. As the accuracy in
dimensions in grinding is of the order of 0.000025 mm, in most applications it tends to
be a finishing operation and removes comparatively little metal, about 0.25 to 0.50 mm
depth. However, there are some roughing applications in which grinding removes high
volumes of metal quite rapidly.
 CNC Griding Machine

 CNC Plasma Cutters

A plasma cutting torch is a commonly used tool for cutting metals for a wide variety of
purposes. A hand-held plasma torch is an excellent tool for quickly cutting through sheet
metal, metal plates, straps, bolts, pipes, etc. Hand-held plasma torches also make an
excellent gouging tool, for back-gouging weld joints or removing defective welds. A
hand torch can be used for cutting small shapes from steel plate, but it’s impossible to
get good enough part accuracy or edge quality for most metal fabrication. That is why a
CNC plasma is necessary.
A simple 4' x 4' plasma table - Click for larger viewA “CNC plasma” system is a machine
that carries a plasma torch, and can move that torch in a path directed by a computer.
The term “CNC” refers to “Computer Numerical Control”, which means that a computer
is used to direct the machines motion based on numerical codes in a program.

Parts of the system

The CNC may be an actual controller designed for machine tools, with a proprietary
interface panel and a specially designed control console, such as a Fanuc, Allen-Bradley,
or Seimens controller. Or it could be as simple as a Windows based laptop computer
running a special software program and communicating with the machine drives
through the Ethernet port. Many entry level machines, HVAC machines, and even some
precision unitized machines use a laptop or desktop computer as the controller.

To cut parts from steel plate, the motion of the torch is controlled by the CNC. A part
program, usually just a text file with “M-codes” and “G-codes”, describes the contours
of the part and when to turn the torch on and off. Part programs are usually created by
a piece of software called a “post-processor”, which can take a part geometry from a
CAD file and translate it into M-codes and G-codes that the CNC can read.

A large CNC plasma system in a shipyard - Click for larger viewA CNC plasma machine
also requires a drive system, consisting of drive amplifiers, motors, encoders, and
cables. There will be at least two motors, one for the X-axis and one for the Y-axis. There
is a drive amplifier for each motor, which takes a low-power signal from the CNC and
turns it into a higher-powered signal to move the motor. Each axis has a feedback
mechanism, usually an encoder, which creates a digital signal indicating how far the axis
has moved. Cables take the power from the amplifier to the motor, and carry the
position signals from the encoder back to the CNC.

How CNC Machines Work?

CNC stands for computer numerical control. A computer and a CAM program are used
to control and automate date, the process being enabled by the digitalization of data.
CNC machines can be anything from welders to grinders, waterjet cutters, to a standard
milling machine. The computer used to control the machine in question will generally be
an on-board computer. In the case of a hobbyist machine, an external PC will be used.

The smaller machines that are controlled by an external PC or laptop computer are
generally known as desktop CNC machines. They are smaller and lighter weight than
industrial machines. What this means is that they are also less rigid, less precise, and
less expensive. They are perfect for making objects out of soft materials such as foam or
wax, and for hobbyists who are fulfilling their passion as opposed to making the most
precision parts. Some desktop machines will work similarly to a printer; others will have
their own dedicated CAM software. Some desktop machines are advanced enough to
except G-Code, and these are machines like those found in industrial desktop
engineering.

How CNC Machines Work : CAM

CAM stands for computer aided machining or manufacturing. It refers to the software
packages that are used to create the NC and toolpaths based on the data given.
Computer aided machining can be used together with computer aided design. When the
two run together they are known are CAD/CAM.

It is important here to not get confused and think that CAM runs the CNC machine. It
does not. It simply creates the code for it to follow. In order to run a CNC machine
requires experience from the controller, the developer, and the machine itself. In order
to run a CNC machine successful requires knowledge of what tools and operations to
use for each individual situation. CNC machines will run on several axes, and the
movements can be linear or rotary. The most advanced five axes machine will have
three linear axes and two rotary.

Limitations of CNC Machines

Depending on their age and sophistication, CNC machines can be limited to the
capabilities of their control and drive systems. Most CNC controllers only understand
straight line movements and circular arcs. In many machines, the arcs are restricted to
the principal XYZ planes as well. Rotary axis movements can be considered like linear
movements, just degrees instead of distance. To create arc movements or linear
movements that are at an angle to the principal axes, two or more axes must
interpolate (move precisely in a synchronized manner) together. Linear and rotary axes
can also interpolate simultaneously. In the case of five axis machines, all five must be
perfectly synchronized – no easy task.

The speed at which the machine controller can receive and process the incoming data,
transmit commands to the drive system, and monitor the machine’s speed and position
is critical. Older and less expensive machines are obviously less capable in this, much in
the same way that an older computer will work less well and more slowly (if at all) on
demanding tasks than a newer one.

What Tools does a CNC Machine Use?

CNC turning tools are used by CNC machines in the precision engineering industry to
create precision engineered parts. CNC machining has overtaken manual input on the
factory floor in the past decades, and it is now commonplace to see factory floors that
are entirely deserted of human beings. To understand how computer numerical
controlled technology works it is important to take a look at the different CNC turning
tools that are used. Below, are some of the more commonly used CNC turning tools that
you will find on a production line and on the factory floor.

 CNC Machine Drills

CNC machine drills work in the same way that a hand held drill works; the difference
between the two however is that in CNC a software platform is controlling the position
of the cut as opposed to the human hand. The CAD software used in CNC can control
the depth and position of the cut, and a CNC machine drill can repeatedly drill hundreds
of parts to the exact same depth and parameters.

 CNC Lathes
A CNC lathe is another of the most common CNC turning tools and CNC turning services
used. A lathe is a machine that spins a part whilst a cutting blade removes excess
materials. CNC lathes are used for sanding, drilling, deforming, cutting, and knurling. In
order to make the process free from human intervention, cutting fluid will be used to
remove the debris produced. A common example of a part that is made by a CNC lathe
is a crankshaft.
  Electrical Discharge Machining Machines
When minute and complex cuts or contours are required, electrical discharge machining
can be used. EDMs are only used on ferrous alloys, and are only effective on electrical
conductors. Rapid bursts of electricity from an electrode are used to melt or vaporize
materials, the debris that is made being flushed away by the use of dielectric fluids.

 CNC Milling Machines

CNC milling machines are used to make complex shapes from solids and metals. A CNC
milling machine uses a work piece that is fixed to a moveable table, the material being
guided around the rotating cutter. Inversely, the cutter can be made moveable across a
stationary table, and some machines will include a spindle across the z axis. These types
of CNC turning tools are commonly used in engraving.

 CNC Plasma Cutting Machines

CNC plasma cutting machines use a plasma torch to cut material on a CNC table. Plasma
cutting can handle thick pieces of material, and is often used in the cutting of ducts and
vents.

 Water Jet Cutting Machines

Water jet cutters in CNC provide a stream of highly pressurized water, acting as an
erosive. This type of CNC machining is used when the material being cut would become
heat damaged by other techniques.

 Laser Cutting Machines

Lastly, when learning about the different CNC turning tools used in CNC and precision
engineering, you should explore laser cutting machines. When a laser cutter is used it
will melt or vaporize the excess material that is produced during the cutting process,
allowing for a very high quality finish. CNC lasers provide the highest form of accuracy of
all CNC tools.
 Introduction to G and M Codes:

Coordinate Geometry Basics

G – Code Programming originally called the “Word Address” programming format.

Processed one line at a time sequentially.
Reserved Code Words Worksheet

N – Sequence or line number

G – Preparatory function

Word Address 1

N – (Sequence or line number) A tag that identifies the beginning of a block of code. It is
used by operators to locate specific lines of a program when entering data or verifying
the program operation.

G – (Preparatory function) “G words” specify the mode in which the milling machine is
to move along its programmed axes.

Word Address 2

Dimension Words: - X – Distance or position in X direction

                                    Y – Distance or position in Y direction

                                    Z – Distance or position in Z direction

M – Miscellaneous functions M words specify CNC machine functions not related to

dimensions or axial movements.

 Word Address 3

F – Feed rate (inches/minute or millimeters/ minute) “Rate at which cutting tool moves
along an axis.”

S – Spindle speed (rpm – revolutions per minute) “Controls spindle rotation speed.”

T – Tool number (Specifies tool to be selected.)

Word Address 4

I – Circular cutting reference for x axis

J – Circular cutting reference for y axis

K – Circular cutting reference for z axis

G  Words: - G words or codes tell the machine to perform certain functions. Most G
words are modal which means they remain in effect until replaced by another modal G
code.
CNC Programming Basics
 CNC instructions are called part program commands.
 When running, a part program is interpreted one command line at a time until all
lines are completed.
 Commands, which are also referred to as blocks, are made up of words which
each begin with a letter address and end with a numerical value.
“G” AND “M” CODES
 Each letter address relates to a specific machine function. “G” and “M” letter
addresses are two of the most common. A “G” letter specifies certain machine
preparations such as inch or metric modes, or absolutes versus incremental modes.
 An “M” letter specifies miscellaneous machine functions and work like on/off
switches for coolant flow, tool changing, or spindle rotation. Other letter addresses
are used to direct a wide variety of other machine commands.

CNC programming Important things to know: -

 Coordinate System
 Units, incremental or absolute positioning
 Coordinates: X,Y,Z, A,Y,Z
 Feed rate and spindle speed
 Coolant Control: On/Off, Flood, Mist
 Tool Control: Tool and tool parameters
 Programming consists of a series of instructions in form of letter codes
 Preparatory Codes:
 G codes- Initial machining setup and establishing operating conditions
 N codes- specify program line number to executed by the MCU
 Axis Codes: X,Y,Z  - Used to specify motion of the slide along X, Y, Z direction
 Feed and Speed Codes: F and S- Specify feed and spindle speed
 Tool codes: T – specify tool number
 Miscellaneous codes – M codes  For coolant control and other activities
Programming Key Letters
 O - Program number (Used for program identification) 
  N - Sequence number (Used for line identification) 
 G - Preparatory function 
 X - X axis designation 
 Y - Y axis designation 
 Z - Z axis designation 
 R - Radius designation 
 F – Feed rate designation 
 S - Spindle speed designation 
 H - Tool length offset designation 
 D - Tool radius offset designation 
 T - Tool Designation 
 M - Miscellaneous function

Why CNC machines are Important?

 Improved Efficiency
One reason to find a company with a CNC machine shop for your production needs is
efficiency. The use of computer means that all the main operations are automated and
that increases the speed and quality of products. When a technician does not have to
drill manually, it takes less time. CNC machines don’t have to be turned off, except for
maintenance, meaning production goes on continuously.

Machines don’t have to deal with interruptions or fatigue, making the production a
seamless process. Procedures that would otherwise require various machines and a lot
of hands need only one. This advantage is not one you get with manual operations.

 Better Accuracy
Accuracy is another reason CNC machining has taken over manufacturing. With the use
of CNC machines, manufactured parts are made identical and with the highest level of
accuracy. Design and specifications are programmed into computers, leaving very little
room for error.

Minimal errors during production mean that there is no unnecessary waste. If a business
needs identically manufactured parts, CNC machining provides that. The high level of
accuracy makes it less complicated to duplicate the same products. It is also possible for
CNC machines to come up with products that may otherwise be difficult to produce
manually, even with the highest level of expertise.

 For Fabrication
CNC machines are vital when it comes to fabrication. Fabrication involves a lot of
operations such as shearing, welding metal sheets, flame cutting, and punching holes,
which can all be done with CNC machines. CNC allows for the fabrication of large
machines of any specifications. The fact that CNC machines are flexible and allow
reprogramming makes them highly suitable for fabrication. A company can easily find
experts in large fabrication in Ontario for different types of equipment, such as Central
Machine and Marine.

CNC machining has improved a lot of sectors from manufacturing to woodwork. Find a
CNC machine shop in Ontario when you need to get CNC machining services.

Conclusion
CNC machining is the result of computer use in manufacturing and other sectors. CNC
refers to Computer Numerical Control – the manipulation of traditional machines by
computer. Conventional equipment like millers, routers, centre lathes, and drills operate
with the help of computers.

A lot of industries now use CNC machining in their production jobs, which offers some
advantages. For a company in Ontario in need of machining services, there are several
benefits why you should get it.