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DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY

Computer Aided Manufacturing

EMG 4104

Department of Mechanical Engineering

Lecture Notes
Table of contents

1. Coordinate Systems
2. CNC Programming Language
3. CNC Tools
4. CNC Operation
5. 2D Milling Toolpaths
6. CNC Turning
The general workflow to go from CAD model to machined CNC part is:
1. Begin with CAD model.
2. Establish Job parameters including CNC coordinate system and stock shape/size.
3. Select CNC process.
4. Select cutting tool and machining parameters.
5. Select driving CAD geometry.
6. Verify toolpath.
7. Post Process.
8. Transfer G-­‐code program to CNC machine.
9. Set up and operate CNC machine to make part.

Computer numerically controlled machines (CNC)


Computer numerical control (CNC) is a method for automating control of machine tools through
the use of software embedded in a microcomputer attached to the tool. It is commonly used in
manufacturing for machining metal and plastic parts.
Advantages of CNCs
• Constant use with Minimal Maintenance
Manual machining can only occur as long as skilled workers are present. When the workers take a
break, progress stops. However, CNC machines can operate 24 hours a day. Depending on the
project’s design, the operator can program the computer and set the machine to create the required
part. The machine then automates the part manufacturing, allowing the programmer to move to set
up another machine. By freeing up operators, CNC machines require fewer workers and increase
machine shop production. CNC machines also allow for rapid changes in production. If the operator
needs to produce small orders of various parts, all they need to do after completing one design is to
change the program to set the next form. With this increased flexibility compared to other
manufacturing methods, CNC machine shops can fulfill many orders, from large batches of the
same parts to individual prototypes.
• Precision
A machine’s precision refers to how fine a tolerance it can produce. Not all CNC machines are
capable of high precision. Discuss the precision capabilities of any CNC machine shop you work
with. Typically, aerospace and defense industries frequently rely on high-precision, machined parts.
Creating these parts to their specifications could save lives due to their potential installation in
aircraft, automobiles or defense equipment.
• Accuracy
How closely the produced part matches the plans reflects the project’s accuracy. With human
machinists, mistakes can create minor differences in precision that could cause significant problems.
Applications that require parts to meet strict design guidelines may fail with even small deviations
from the correct design. Automating production with CNC machining reduces accuracy problems,
but the operator still has some control over the process.
Machining projects’ accuracy depends heavily on the operator. Because the operator plays such a
pivotal role, finding a machine shop that puts extra effort into projects is critical to getting the results
you want.
• Versatility
With alternatives to CNC machining, such as 3D printing, you will encounter limitations in the
types of materials you can choose from for your parts. However, CNC machining can occur with
various materials for example, plastics, metals
• More Capability
When paired with continuously advancing computer and design software, CNC machines can create
products that even the most experienced engineers couldn’t replicate. Advanced software allows
CNC machines to produce a wider range of shapes, sizes and textures than manual or conventional
machines.
• High Production and Scalability
Once the CNC machine’s operator has programmed the design specifications, the only thing
stopping it is the user. Once started, CNC machines are highly productive and can produce many
parts in no time. Plus, CNC machines offer a wide range of scalability. Unlike other manufacturing
methods, CNC milling allows machine shops to produce large quantities or a single model. CNC
machines don’t limit you to how many parts you can have manufactured at once, allowing you to
use your money and resources more efficiently.
• Uniform Product
There is always room for error with manual production, and each product could vary slightly due
to human inaccuracies. CNC machining allows for uniform outputs. CNC machines can perfectly
match the design specifications every time they create a part. This precision ensures you’re getting
parts that will fit your application, reducing the risk of damaging your equipment or slowing your
operations.

Disadvantages of CNC machine

CNC machine has many advantages, but there are also disadvantages.
1. Expensive Machines; The cost of the machine is expensive, and the maintenance cost is
also high.
2. Limited Materials: The material selection is limited for certain CNC machine, mainly
metal materials can be processed by CNC machine, but the material selection for CNC
machinery is not as wide as that for conventional machining tools.
3. Machining Precision: The precision performance of CNC machines is relatively low in
some situations: when the surface roughness of the workpiece surface is too high, the cutting
accuracy of CNC machines will be greatly reduced; when there are too many holes in a
workpiece or when there are many corners on a workpiece, it will be difficult to process
with CNC machines; when cutting thin materials such as sheet metal or aluminum plate, it
is easy to have deformation issue.
4. Need skilled workers: Workers who operate the CNC machine will not be able to learn new
skills if they want to change their job in the future because their skills are very specific for
one type of work only, which is operating CNC machines or machining parts with CNC
machines, so they will have difficulties finding another job that suits them well in this field.
5. Low production speed: CNC machining is only suitable for small to middle volume
production, but not suitable for high volume batch manufacturing production because its
cost is higher than other machining like casting, injection molding, stamping etc.
Features of CNC Machine
1. Machine Control Unit
The machine control unit is where the device takes instructions to perform its functions. This is like
the CPU of the CNC machine. The instructions include decoding instructions and generating axis
motion commands. Consequently, the machine control unit makes the CNC machine more accurate
than humans.
2. CNC Tools
3. Feedback System
The feedback system has the machine’s sensors. Which provide data to the operator on the
condition of the machine as well as the errors that might occur during machining.
4. CNC Input Devices
The CNC needs commands to give the correct output. The input devices include a computer and a
tape reader that users utilize to issue commands.
5. CNC Driving Systems
These parts of the CNC machine ensure the movements of the various sections. The parts include
motors, circuits, and ball lead screws.
6. CNC Display Unit
This is the part of the machine where you can see the programs, commands, and other useful data.

CNC Tools

A wide range of tool types and configurations are available for CNC milling machines. However,
in this chapter, we only introduce the most commonly used tools for prototype and short run
production machining.
• End mills (Flat, Ball, Bull and Chamfer) Face mill
• Corner Rounding tools
• Slot Tools
• Spot-­‐Center Drill
• Twist Drill
• Tap
• Reamer
• Counterbore
a. End Mill

Milling tools include flat, ball, bull nose and chamfer.

Figure 1: Nose type mill tools


Flat nose mills are used for milling 2D contours and pockets. Ball nose mills are used for 3D
milling. Bull nose end mills have a radius corner. They are used to create a fillet on the bottom of
a wall. Because they are sturdier than an end mill, they are also sometimes used for roughing
operations. Chamfer mills have an angled nose used to create a chamfer or to deburr parts.
Number of Flutes
Milling tools usually have either two or four cutting flutes. Two flute cutters provide more chip
clearance when milling in close areas. Four flute mills are more rigid, can be fed faster, and are
preferred when greater chip clearance is not required, such as when milling an outside contour.
Center Cutting End Mills
Milling tools are either center cutting or non-center cutting. Center cutting mills can plunge straight
down into material, while non-center cutting tools cannot.
Figure 2 below shows the cutting end view of a center cutting and non-­‐center cutting end mill.
Notice that the cutting edges of the center cutting end mill continues to the center of the tool. The
center of the other has a small hole at the center. Non-­‐center cutting end mills require a pilot
hole, ramping or helical motion to plunge into material.

Figure 2 End View of Center and Non-Center Cutting End Mill


Face Mill
A face mill has cutting inserts that are replaced when worn. They are rigid, may have up to eight or
more cutting edges, and can remove material quickly. They are often used for the first machining
operation to quickly create a flat finished face on the part.
Figure 3: Face Mill
Corner Radius Tool
Corner radius (also called Corner Round) tools are used to place a fillet on the outside corner of a
part.

Figure 4: Corner radius tool


Slot Mill/Slotting Saw
Slot mills include side milling cutters, slitting saws, and Woodruff keyset cutters. Slitting saws and
side milling cutters are installed on a special arbor. Woodruff cutters are single piece tools used for
creating slots and undercuts that can be held in a standard tool holder.
Hole Making Tools
Center Spot Drills
Center (spotting) drills are short and very rigid drills used to create a conic on the face of the part.
Because they come to a sharp point and resist bending, they locate the hole precisely. The conic
helps prevent the subsequent drill from wobbling and ensure the drill is located precisely and drills
straight down.
Countersink drills are used to create the conical face for a machine screw. Combined spotting
countersinks are used to create a screw clearance hole and countersink in one operation.

There are many different sizes and tip angles of center, countersink, and combined drills. Be sure
the tip angle of the countersink matches the included angle of the machine screw, and that the drill
diameter is greater than the screw head diameter.

Twist Drill
Twist drills are available in many diameters and lengths. Usually made of high-speed steel, carbide,
or cobalt, they may also be coated with titanium nitride (TiN) for longer life. The tip angle of most
twist drills is 118 degrees. Other tools include taps, reaming tools and counter sinking tools.
Cutting Tool Fundamentals
All tools (except left-­‐handed taps) rotate clockwise (M3) when viewed from the machine spindle
looking down at the part.

Chip Formation
Cutting tools remove metal by shearing action as illustrated in Figure 11 below. As the tool
advances into the material, it causes a small amount of the material to shear away, forming a chip.

Chip Formation Diagram


Chip Load

The thickness of material sheared away by each cutting tooth is called the feed per tooth, or
chip load. As the chip is ejected from the work area it carries with it some of the heat generated
by the shearing process.
One of the best ways to validate cutting speeds and feeds is to observe the chips created
by the machining process. Chips should be curled and may change color due to heating.
Cutting Speeds and Feeds Formulas
The tool moves through the material at a specified rotational speed, defined in revolutions per
minute (RPM), and feed rate, defined in inches per minute (IPM).
CNC mills require calculating speeds and feeds in advance. These speeds and feeds can, and often
are, adjusted at the machine based on chip shape and color, cutting sound, and machine horsepower
meter readings.
Speed Formula
Milling machine cutting speeds are derived from the following formula

Where;
• Speed is the rotational frequency of the tool (Spindle Speed) in revolutions per minute
(RPM).
• SFM (Surface Feet per Minute) is the speed at which the material moves past the cutting
edge (outside diameter) of the tool in feet per minute. SFM values depend on the tool type,
tool material, and material being machined.
• Circumference is the circumference of the cutting tool in feet.
Because cutting tools are defined by their diameter in inches, the cutting speed formular can be
rewritten as:

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