MILL CNC MACHINES

A computer numerical control (CNC) milling machine is a mill that uses computer
code to understand where to make cuts.

Like all milling machines, a CNC mill produces a final piece by carving away from
a block of material versus adding layers of material to a blank slate. However, unlike
manual milling, CNC mills do not have to be operated by hand. You simply need
the right computer software and a library of programs to instruct your machine on
how to create the desired product.

CNC milling is just one type of CNC machining process your business could
consider integrating to make your production more accurate and efficient.

Figure 1 The Vital Parts of a CNC Milling Machine.

 Table 1 Difference between CNC milling machine and manual milling machine.

CNC milling machine manual milling machine

CNC milling machine are more versatile than manual milling machine. A number of jobs that are
not possible with manual milling machine can be easily done with CNC mill.
In a CNC milling machine the spindle is Where as in a manual milling machine the
stationary and the table can move parallel as spindle rotates on its axis and the cutters are
well as to the axis of the spindle for the cutting held in it.
process.
The CNC milling machine controls its The manual milling machine is operated by
movement by the numerical control controller, manual operation. The result is that the error is
which makes his machining more precise. very large.
CNC milling machine can work 24 hours a day Manual milling machine needs manual non-
by writing programs, and no one is on duty. stop operation, and cannot achieve automation.
Work done with CNC milling machine is faster Less work pieces can be made because of
than a manual milling machine so more work manual operation.
pieces can be made in less time.

CNC milling machines can automatically Manual milling machines can only change the
change tools so that it is more efficient. tool manually.

The CNC milling machine structure is the manual milling machine is the work table
different from the manual milling machine. moving up and down to complete the work.
The CNC milling machine Z axis can move up
and down

The standard CNC milling machine is a 3-axis Manual milling can only achieve 2 axis linkage.
linkage. We can also expand into a 4 axis and
5 axis linkage.

Because CNC milling machines use computer Manual milling machines can’t do this.
programming, even if they manufacture large
quantities of parts, their size and surface are
the same.

Since the CNC milling machine adopts program the manual milling machine can only operate
control, one can operate multiple machines one machine.

CNC milling machines require trained Ordinary people can operate manual milling
engineers to complete the operation. machines
CNC milling machines are less prone to errors Manual milling machines are more prone to
due to program control. errors due to the need for manual operation.

Figure 3 CNC milling machine.

Figure 2 manual milling machine.

(mohamed wael)
Types Of CNC Milling Machine.

a) Vertical CNC Milling Machine

• Structure: The spindle is oriented vertically, allowing for workpieces to be

positioned horizontally or at various angles.
• Uses: Primarily used for die sinking, mold making, and precision cutting.
• Features: Can handle most types of milling jobs, from face milling to
surface finishing.

Figure 4 vertical cnc milling machine

b) Horizontal CNC Milling Machine

• Structure: The spindle is placed horizontally, allowing the cutters to remove material
more efficiently on the side.
• Uses: Ideal for cutting grooves, slots, and other complex shapes in large workpieces.
• Features: Excellent for heavy-duty or high-volume work.

Figure 5 Horizontal cnc machine

Lathe cnc machine
The way CNC lathe machines operate is by rotating the material of the workpiece
about a primary axis. The lathe cutting tools remove the material from the workpiece
and shape it as needed.
Number of Axes in CNC Lathe Machines
CNC lathe machines are used in various applications and are typically available in
the following configurations:
• 2 Axes (X and Z): This is the basic configuration used for simple turning
operations.
• 3 Axes (X, Y, Z): Adds a third axis (Y) for more complex operations,
allowing for side cutting.
• 4 Axes: Introduces a rotational axis (Axis A), enabling work on more
complex shapes.
• 5 Axes: Allows for advanced machining capabilities with two additional
rotational axes.

Figure 6 lathe cnc machine

 Table 1-2 CNC and Conventional Lathe Machines

CNC Lathe Machines Conventional lathe Machines

Precision: Offer high precision, often achieving Rely on the skill of the operator,
tolerances of ±0.01 mm or less, thanks which can lead to variations in
to digital control. precision.
Efficiency: Can operate automatically for Require an operator for ongoing tasks,
extended periods without human leading to potential downtime and
intervention, increasing productivity. increased labor costs.
They can run for long hours without
the need for monitoring.
Repeatability: Can produce identical parts May experience slight differences
repeatedly with high accuracy, between produced parts due to
making them ideal for mass manual adjustments.
production.
Automated The movements are preprogrammed Typically require manual input for
Control: using G-code, minimizing human adjustments, increasing the likelihood
error and allowing for complex of mistakes.
operations.
Productivity: Capable of performing multiple Often require manual setup and
operations without the need for tooling changes, which can slow
manual tool changes, contributing to down production
higher productivity.

• 1-"Fundamentals of CNC Machining" by Robert E. Krull: (pola)

Drilling cnc machine
The Drilling machine is one of the most popular CNC machines found in most CNC
machine shops. the drilling CNC machine uses a specialized cutting tool called drill
bits or drill. It is ideal for drilling holes in many materials
Number of Axes in CNC Drilling Machines
CNC machines vary in the number of axes based on their applications:
• 3-Axis Machines: Move in three directions (X, Y, Z). This type is the most
common for drilling operations.
• 4-Axis Machines: Add an additional rotational axis (Axis A), allowing the
machine to rotate the part around the X-axis.
• 5-Axis Machines: Add two more axes (Axis A and Axis B), allowing for more
complex movements and multiple angles.
Components of a CNC Drilling Machine
a) Frame:
The frame serves as the primary structure that supports all the machine components.
It is designed to provide stability and reduce vibrations during operation, which is
crucial for maintaining precision.
b) Motors:
CNC drilling machines use various types of motors, including stepper motors and
servo motors, to control the movement of the axes. These motors ensure accurate
positioning and speed control, which is essential for achieving precise drilling
operations.
c) Controller:
The controller is the brain of the CNC drilling machine. It receives commands from
the computer or programming software and translates them into specific actions for
the motors and other components. The controller often includes interfaces for user
input, monitoring, and adjustments.
d) Spindle:
The spindle is the part of the machine that holds and rotates the cutting tools. It is
designed to achieve high rotational speeds, which is crucial for effective drilling.
The spindle speed can vary depending on the material being drilled and the type of
tool used.
e) Axes:
The axes of a CNC drilling machine provide movement in different directions. Most
CNC drilling machines operate with three axes (X, Y, Z), while more advanced
machines may include additional axes (like A and B) for more complex movements,
allowing for intricate drilling patterns and angles.
f) Software:
CNC machines rely on specialized software for programming. This software allows
operators to create and edit machining programs, which are then converted into
machine-readable code (G-code). This code directs the machine’s movements and
operations, ensuring accuracy and efficiency.
 Table 1-3 CNC and Conventional Drilling Machines

CNC Drilling Machines Conventional Drilling Machines

Precision and CNC machines offer extremely high In contrast, conventional machines
Control: precision, often achieving tolerances depend heavily on the skill and
of 0.01 mm or even less. This level of experience of the operator. While
accuracy is made possible by digital skilled operators can produce high-
control systems that use computer quality parts, variability in their
algorithms to guide the movement of technique can lead to inconsistencies
the machine. CNC systems typically and a higher likelihood of errors.
employ servo motors that provide
precise feedback on the position,
which enhances control during
operations.
Efficiency: These machines can operate Operators must constantly oversee
continuously for extended periods conventional machines, leading to
(24/7) with minimal human potential interruptions in production.
intervention. This capability This manual oversight can result in
significantly increases overall increased labor costs and longer lead
efficiency and reduces downtime. times.
Once a job is set up, CNC machines
can run automatically without the
need for constant monitoring.
Repeatability: One of the standout features of CNC Although they can produce quality
machines is their ability to produce parts, conventional machines often
identical parts repeatedly with high suffer from variability in output.
precision. This repeatability is crucial Small differences in setup or operator
for industries that require large technique can lead to variations in
quantities of uniform components, part dimensions, making them less
such as automotive or aerospace suitable for high-volume production
manufacturing. runs.
Automated The movement of CNC machines is These machines typically require
Control: pre-programmed using computer manual input for adjustments and
software, such as G-code, which operations, increasing the chance for
defines each step of the machining human errors and inconsistencies.
process. This programming
minimizes human error and allows for
complex operations that would be
challenging to execute manually.
Productivity: CNC machines can perform multiple These machines often require manual
operations without the need for setup and tooling changes, which can
manual tool changes, which slow down the production process and
contributes to higher productivity. limit throughput.
They can also work faster and more
accurately than traditional machines,
 which translates into shorter cycle
times and higher output.
1-"Fundamentals of CNC Machining" by Robert E. Krull:
2- MACHINING TECHNOLOGY MACINE TOOLS AND OPERATIONS
BY HELMI A.YOUSSEF HASSAN EL HOFY
(Pola)
Grinding machine
Grinding is an abrasive machining process used for fine machining and finishing of
workpieces. It can be performed manually or using grinding machines. As with all
abrasive procedures, excess material is removed from the workpiece in the form of
chips. The cutting is actually performed by the edges of microscopically small hard
mineral crystals in the grinding tool.
Grinding meets today's production needs as it guarantees high quality and output at
reduced cost per workpiece. Grinding is available for:
• High dimensional and form accuracy
• A defined surface quality
• Machining of difficult-to-cut materials
External cylindrical grinding
External cylindrical grinding is used for the production of cylindrical or tapered
workpieces, such as the grinding of shafts, axles and spindles as used in the general
machine tool, automotive and aerospace industries. The circumference of the
grinding wheel is used to remove material from the circumference of the workpiece.
This can be done in the radial (plunge grinding) or axial (traverse gringing) modes.
To allow for greater accuracy in clamping, workpieces are usually mounted between
centers. Multiple idle strokes (spark-outs) are used to improve the form accuracy and
surface quality.

Figure 7 External Cylindrical Grinding Machine

Internal cylindrical grinding
Internal cylindrical grinding is primarily used for machining cylindrical or tapered
bores. During internal cylindrical grinding, the longitudinal feed movement is
typically carried out by the grinding wheel, with the radial infeed movement during
internal cylindrical grinding handled by the wheelhead or the work head, depending
on the design of the machine. Basically, the same kinematic relationships apply as
with external cylindrical grinding. The contact area between grinding wheel and
workpiece is however considerably larger, which makes the removal of chips and
the cooling of the process more difficult.

Figure 8 internal Cylindrical Grinding

Number of Axes in CNC Grinding Machines

CNC grinding machines are available in several configurations:
• 3-Axis Machines: Move in three directions (X, Y, Z). These are commonly
used for basic operations.
• 4-Axis Machines: Add a rotational axis (Axis A), allowing for more
complex operations.
• 5-Axis Machines: Include two additional axes (Axis A and Axis B),
enabling the machine to process parts from different angles.
 Figure 9 Axis of Grinding Machine

Process controls these days ranges over the following categories:

-manual control
-switching control
-CNC
-intelligent control
Manual Control
An example of manual control is where a human operator provides a feed motion.
This may be as simple as providing an increment of crossfeed or down-feed in
surface grinding or as complex as following a contour when grinding a form tool on
an optical profile grinder. The feature that distinguishes manual control is that a
human being has control of measurement, decision making, and actuation. An
important decision is deciding when the workpiece has reached its finish size. This
implies the use of some measurement device such as a micrometer or a reading on a
leadscrew scale. Early grinding machines were all manually operated. Many
machines are still manually controlled but almost all machines incorporate elements
of automation such as automatic traverse reversal for traverse grinding
Switching control
Switching control is one of the simplest forms of machine control, used to reverse
the feed motion in traverse grinding. It relies on switches that are set to determine
the switching point. This can be achieved through PLCs or low-cost computers with
position measurement tools like encoders or linear scales.
In more advanced systems, servo drives and ball screws are used for feed motion,
allowing for easier adjustment of switching positions in more complex feed cycles.
Automatic retraction can also be incorporated when a measuring device detects that
the final size has been reached.
Computer Numerical Control (CNC)
Modem CNCs vary from low-cost computers that basically provide switching
control using servo-drives to full three-axis contouring control that allows complex
shapes to be generated. The example shown is an easy set-up machine produced by
Jones & Shipman Precision Ltd. Other CNCs in the product range provide far more
advanced control features. The process engineer produces a process sheet that
specifies the stages in the production of a part together with critical dimensions and
the type of feed cycle to be employed. These instructions are fed into the CNC using
a code format acceptable to the CNC. After validation of the code, and machine set-
up, the CNC operates automatically to produce a part or batch of parts.
Intelligent Control in CNC Machines
Intelligent control refers to a machine's ability to automatically adjust its operating
settings to improve the process based on real-time data collected from sensors. This
means that instead of the machine working with fixed settings throughout the
process, it can change operating parameters, such as feed rate or tool position,
depending on the information it receives during operation.
For example, if a machine is grinding a part and using a measurement device, such
as a diameter gauge, it can automatically adjust the position of the part or the tool to
achieve the required size with precision.
Table 1-4 Advantage and disadvantage of Grinders CNC Machining

Advantages of Grinders CNC Machining Disadvantages of Grinders CNC

Machining

• Grinders can achieve very tight • Grinders produce a lot of noise

tolerances • Grinders produce a lot of dust
• Grinders can create very intricate and debris
designs • Grinders are expensive machines
• Grinders are very versatile • Grinders require regular
machines- they can be used for a maintenance
variety of different materials • Operators of grinders need to
• Grinders are relatively fast wear personal protective
machines equipment (PPE) such as
• Grinders require very little setup earplugs, safety glasses, and
time respirators
• Operators of grinders do not • Workpieces that are being
need to have a lot of experience machined on grinders need to be
or training securely clamped down so that
they do not become dislodged
during the machining process

"Principles of Modern Grinding Technology" by W. Brian Rowe

(pola)
(Zead)

CNC Laser Cutting

A CNC laser cutter is a piece of computer numerical control (CNC) equipment that
uses a focused, high-powered laser beam to mark, cut, or engrave a material to
form custom shapes. Its unique design and operation make it highly accurate,
especially when cutting intricate shapes and small holes.

Types of CNC Laser Cutting Machines

a) CNC CO2 laser cutter
b) CNC crystal laser cutter
c) CNC fiber laser cutter

a) CNC CO2 Laser Cutter

The CO2 laser cutter is a type of gas laser that employs carbon dioxide as the active
laser medium. They are the most common type of laser cutters primarily because of
their high-power output capability and efficiency.
CO2 laser cutters generate a power output of up to 15 kW and an efficiency of up to
30% (the highest of all the gas laser cutters). They are ideal for cutting fine features
and acute angles, especially in sheet metals or metals with a thickness of less than
10 mm. Higher powered CO2 laser cutters can also deliver good cut quality on
thicker metal surfaces.

b) CNC Fiber Laser Cutter

Fiber laser cutters are a more recent laser technology that uses a bank of diodes to
create the beam, which is focused through a fiber-optic cable. Fiber laser cutters
allow you to achieve a faster and cleaner cutting process than CO2 laser cutters,
especially in materials with a thickness of less than 5 mm.
Although fiber lasers are compatible with a broad range of materials, you must pay
special attention to silver.
Silver retains heat from the laser and starts to warp during cutting operations, making
it challenging to achieve the desired machined part. As a result, top-tier machine
shops typically use a bracket as a heat sink to transfer heat away from the silver
workpiece during fiber laser cutting operations.

c) CNC Crystal Laser Cutter

CNC crystal laser cutters use beams made from crystals like neodymium-doped
yttrium aluminum garnet (Nd:YAG) and neodymium-doped yttrium ortho-vanadate
(Nd:YVO).
Crystal laser cutters generally have higher intensity (or laser power) than CO2 laser
cutters, meaning you can use them to cut through thicker metals. These cutters also
have a broad range of material compatibility, including metals, glass, wood, and
plastics.
Material Removal
As the laser beam moves along the programmed path, it melts or vaporizes the
material. The molten or vaporized material is expelled from the kerf (the cut path),
leaving behind the desired shape or pattern.

Cooling and Solidification

As the laser cuts through the material, it generates a significant amount of heat.
Cooling mechanisms, such as water or air jets, are often employed to prevent the
material from overheating and to aid in solidification.
Numbers of axis of laser cutting cnc machines

• 2-Axis CNC Laser Cutting

A 2-axis CNC laser cutter operates in a flat, 2D plane. This machine can move its
laser head horizontally (X-axis) and vertically (Y-axis), which is optimal for cutting
flat sheet materials like metal and wood.

• 3-Axis CNC Laser Cutting

In addition to the capabilities of the 2-axis machine, a 3-axis CNC laser cutter can
move its laser head up and down (Z-axis), providing a greater depth of cut. This is
especially useful for engraving applications.

• 4-Axis CNC Laser Cutting

A 4-axis CNC laser cutter can perform all movements of a 3-axis machine, but also
rotates the workpiece around one axis, usually the X or Y-axis. This additional
rotation allows for the creation of complex geometries and shapes.

• 5-Axis CNC Laser Cutting

5-axis CNC laser cutters offer even more flexibility, with the ability to rotate the
workpiece around two separate axes simultaneously. This offers a great deal of
control and precision in creating multi-dimensional, intricate shapes.

• 6-Axis CNC Laser Cutting

The 6-axis CNC laser cutter is the most advanced, featuring all the capabilities of
the 5-axis machine plus another rotational axis. This allows the machine to cut from
almost any angle, delivering extremely complex and precise cuts.
some sectors that frequently utilize cnc laser cutting

• Automotive Industry: CNC laser cutting is critical in vehicle manufacturing, used

for precise shaping of sheet metal parts, cutting car body panels, and creating
small components with intricate designs.
• Aerospace Industry: In the aerospace sector, precision is paramount. CNC laser
cutting machines are employed to produce accurate parts with narrow tolerances,
making the most of their ability to cut exotic metals and composites commonly
used in the industry.
• Electronics Industry: From etching circuit boards to creating smartphone
components, CNC laser cutters are versatile tools in electronics production.
• Medical Equipment Manufacturing: CNC laser cutters facilitate the production of
surgical tools, medical devices, and orthopedic implants, where detail and
accuracy are of the utmost importance.
• Jewelry Industry: Creating intricate designs with high precision, CNC laser
cutting is used extensively in jewelry making for cutting and engraving purposes.
• Construction Sector: Large-scale CNC laser cutting machines assist in cutting
structural components for buildings, bridges, and other construction projects.

The advantages of using CNC laser cutting

• Higher Quality Edges: The non-contact nature of laser cutting reduces the chance
of mechanical distortion, resulting in cleaner edges with little to no burring.
• Narrower Kerfs: Compared to traditional cutting methods, CNC laser cutters
produce a much smaller cut width (kerf), which allows for intricate cuts and
maximizes material usage.
• Smaller Heat-Affected Zone (HAZ) and Less Material Distortion: As lasers
produce a smaller HAZ, there is less chance of thermal distortion of the material.
• Less Contamination and Waste: The precision of the CNC laser cutter results in
less waste material, and since it’s a contactless process, there’s reduced risk of
material contamination.
• Less Maintenance Required: CNC laser cutters often require less maintenance
than their mechanical counterparts due to their non-contact nature.
• Less Repair Costs: Fewer mechanical parts mean there are fewer components that
can wear out or break, thus reducing repair costs.
• Greater Operator Safety: The operation of a CNC laser cutter is generally
automated and enclosed, reducing risks to the operator compared to manual
cutting methods.

Types of materials can be cut using a CNC laser cutting machine

• Metals: These include steel, aluminum, and other metals. Laser cutters are perfect
for precision cutting metal sheets, with the power output and laser type
influencing the cut quality and thickness handled.
• Plastics: Both thermoplastics and non-thermoplastics can be laser cut, though
caution is needed due to potentially harmful fumes. Types include acrylic, ABS,
and polycarbonate.
• Thermoplastics: These are a type of plastic that becomes moldable when heated.
Examples include nylon, polyethylene, and polyvinyl chloride.
• Rubber: Laser cutters can precisely cut rubber, making them ideal for producing
gaskets, seals, and other custom rubber parts.
• Leather: Whether for fashion, upholstery, or crafts, laser cutting machines can
provide precise cuts on leather, including complex patterns and designs.
• Ceramics: CNC lasers can cut and engrave ceramics, though caution is needed to
prevent cracking or breakage.
• Wood: From hardwoods to softwoods and plywood, laser cutters offer precise cuts
and intricate detailing.
• Acrylic: Laser cutting is an excellent method for working with acrylic, providing
clean edges and intricate designs.
• Foam: Ideal for packaging, insulating materials, and crafts, foam can be cleanly
and efficiently cut with a laser cutter.
• Textiles: From cotton to polyester and even delicate fabrics like silk, laser cutters
offer precise and fray-free cuts.
• Paper: Whether for crafts, model-making, or packaging, laser cutters can handle
paper of various thicknesses.
• Composites: Composites like fiberglass and carbon fiber can be cut with a CNC
laser, though special care is needed due to the risk of harmful particles.
• Stone: Laser cutters can engrave stone but cutting through is usually not possible
due to the high thickness and hardness.
• Glass: Like stone, laser cutters are more commonly used to engrave glass rather
than cut it.
(Zead)
CNC PLASMA CUTTER
A plasma cutter is a thermal cutting tool used to cut various metals, producing clean
and accurate cuts. Common users of plasma-cutting machines include fabrication
shops, manufacturers, and automotive repair.
Depending on the machine, a plasma machine can cut a wide range of materials,
particularly electrically conductive metals, such as steel, aluminum, stainless, brass,
and copper.

Figure 10 2D CNC plasma

Advantages of CNC Plasma Cutting

The key advantages of CNC plasma cutting include:
a) Comparatively cheap
b) Faster cutting than oxyfuel cutting
c) Offers accuracy and repeatability
d) Can cut in water to mitigate heat-affected zone
 Figure 11 3D CNC plasma
(zead)
Water Jet Cutting CNC machine
Water jet cutting is a manufacturing process that employs high-pressure jets of water,
generated by pressurizing pumps, to deliver a supersonic stream for cutting and
shaping various materials. Water in water jet cutting is pressurized up to 392 MPa
and directed through a small precision nozzle. Upon exiting the nozzle, the water
reaches speeds three times faster than the speed of sound.

Figure 11 water jet CNC machine

Pure water jet cutting, which uses only water as its medium, is designed for soft
materials such as wood, plastics, foam, paper, and rubber. When an abrasive is added
to the water stream, the cutting process becomes more aggressive, enabling it to cut
through hard materials like titanium, stainless steel, aluminum, glass, ceramic, and
concrete.

Figure 12 water jet process

How water jet cutting works?

The water jet cutting process can be carried out in various ways, with most methods
incorporating an abrasive into the water to facilitate cutting through the workpiece.
This versatile manufacturing technique can cut, shape, and design a workpiece to
meet precise specifications.
The shaping method used in water jet cutting offers several advantages over other
cutting processes like plasma or laser cutting. Water jet cutting provides superior
accuracy, can handle complex designs, and is suitable for thermally sensitive
surfaces. The abrasive, akin to sandpaper, erodes the material being cut without
heating it or altering its temper. As a result, the cut edges are clean and ready for
welding without the need for additional processing.
Abrasive flow machining (AFM)
Abrasive flow machining (AFM) is used for interior surface finishing, particularly
for deburring and honing parts that are difficult to reach with traditional methods.
By using a mixture of water and abrasive, AFM effectively erodes raised surfaces
inside a workpiece, similar to the action of a grinder or sandpaper, to remove
unwanted particles and achieve a smooth finish.

Figure 13 abrasive flow machining

The abrasive jet machining process is a key aspect of abrasive water jet cutting. It
involves a high-pressure stream of water mixed with abrasive particles that blast and
erode the workpiece, removing particulate matter, burrs, and other materials. This
technique uses extremely fine particles applied at high velocity and is particularly
effective for cutting and shaping brittle, thin, and hard materials. Abrasive jet
machining excels in creating intricate shapes and achieving smooth, even edges.

Figure 14 abrasive jet machining

High pressure water cutting
Intensifiers are used to dramatically increase the pressure of pure water, allowing it
to shape and form soft materials without leaving behind water residue. Hydraulic
pumps play a crucial role in this process, converting the force of the water into
mechanical energy to achieve the required high pressure.

A significant advancement in high-pressure water jet cutting was the introduction of

corundum elements in the cutting head, including varieties such as rubies and
sapphires. Corundum is renowned for its hardness, toughness, and stability, being
resistant to acids and the second hardest mineral on Earth.

CNC Water Jet Cutting

CNC water jet cutting utilizes high-pressure water in a programmable manner to
perform multiple operations in a single pass. It is particularly useful for materials
that are sensitive to high-temperature processes. CNC water jet machines can handle
various operations such as cutting, forming, deburring, reaming, and honing, making
them ideal for tasks requiring precision and minimal thermal impact.

Most CNC water jet cutting machines operate on three axes: X (left to right), Y (front
to back), and Z (up and down). Recent advancements include five-axis models that
add rotational capabilities. The A axis allows rotation around the X axis, and the B
axis provides rotation around the Y axis, offering greater flexibility and precision in
cutting complex shapes.

SOUECE :IQS directory (amir nagy)

Electric Discharge Machining (EDM)
Electrical Discharge Machining Computer Numerical Control, namely EDM CNC,
is a special machining method that uses the electrical erosion effect produced by the
pulse discharge between electrodes in the working liquid to remove the conductive
materials. It is also called discharge machining or electrical erosion machining.

Figure 15 Electro Discharge Machine

How does EDM works?

In EDM, the tool electrode and the workpiece are connected to the two poles of the
pulse power supply respectively, and immersed in the working liquid, or the working
liquid is charged into the discharge gap. The tool electrode is fed to the workpiece
through the gap automatic control system. When the gap between the two electrodes
reaches a certain distance, the pulse voltage applied on the two electrodes will break
down the working fluid and produce spark discharge.
 Figure 16 EDM working principle

what is CNC EDM used for?

CNC EDM machine is mainly used for machining various kinds of molds, precision
parts and other complex cavity and curved shape of various kinds of conductive
materials
Types of EDM

a. Sinker EDM (also known as Die Sinking):

- The electrode is shaped to create a specific cavity in the workpiece.

- Used for creating molds, dies, and complex shapes.
 Figure 17 sinker EDM

b. Wire EDM:

- Uses a thin, electrically charged wire as the electrode.

- The wire moves along a predetermined path, allowing for intricate cutting
and machining of shapes.
- Ideal for producing small parts with tight tolerances.

Figure 18 wire EDM machine

 Table 1-5 Advantage and Disadvantage of EDM

Advantages of EDM Disadvantages of EDM

• Precision: Capable of producing • Speed: Generally slower than

complex shapes with tight tolerances traditional machining processes.
(up to ±0.001 mm). • Cost: The initial setup can be
• Material Versatility: Can machine expensive due to equipment and
hard materials, including titanium, electrode materials.
steel, and carbide. • Surface Finish: While EDM can
• Minimal Mechanical Stress: The produce fine finishes, the surface may
process does not apply mechanical require additional processing (e.g.,
force, reducing the risk of warping or polishing) for critical applications.
damaging the workpiece.
• No Tool Wear: The electrode wears
down but is often replaceable or
recyclable.

References: 1. "Electrical Discharge Machining" by J. S. Choudhury and A. K. Gupta.

2. Machining Technology Machine Tools and Operation.

(Youssef housny)

SOUECE: DMNC (amir nagy)

CNC Router Machine
A CNC router can be controlled by a computer, it’s like a traditional router with a
modern-day upgrade. To control it, the machine’s servo motors are fed a set of
instructions in a language they can understand: G-code. The instructions tell the
machine exactly how and where to move and, once it has read them, the router gets
to work moving a high-speed rotating cutting tool to make the carvings. The process
falls under the subtractive manufacturing category as it removes material to make
parts, unlike 3D printing, a.k.a. additive manufacturing, which adds layers.

These routers typically have a gantry-style construction (with a horizontal support

beam or structure) where the spindle (the main cutting tool) will move in two
directions left and right along the x-axis, and back and forth on the y-axis to cut or
carve material in the right shape and design. Depending on the material you’re
working with and the shape you want the CNC router to carve, there are different
cutting tools available. These can be manually swapped out, but some of the more
advanced models feature an automatic tool changer so you don’t have to physically
get involved.

Unlike standard CNC mills, these routers don’t have much range of motion up and
down (along the z-axis), so won’t be able to make deeper cuts or holes on tall parts
or very thick materials without struggling or making mistakes. They can be used to
engrave lettering onto harder materials like granite, though. In general, CNC routers
are best for use on flatter and softer materials (think: MDF, plywood, acrylic, and
polyurethane foam/sheet), and metals like brass and aluminum.

CNC routers are used a lot in woodworking to make everything from cupboard doors
to 3D sculptures. They can create wooden patterns for sand molds used in metal
casting and cut foam into custom shapes to be used in packaging. The advertising
industry uses CNC routers to engrave custom signs and lettering on wood or plastic
for various promotional products
 Figure 18 CNC Router Machine

Key Components of a CNC Router Machine:

Bed: This is where you’ll put the material that you want to cut. Some beds have
multiple holes or attachment points to make it easier to mount clamping hardware
so that the workpiece can stay in place during cutting.

Controller: This part houses all the electronics, including the stepper or servo
motors, that control the machine’s speed and how and where it cuts.

Motors: The stepper or servo motors operate each of the three motion axes. Steppers
are usually found on cheaper hobbyist routers, whereas servos, which are found on
more expensive machines, are used in professional-grade models because they offer
more precision. There’s also a separate high-speed motor that rotates the cutting tool.

Spindle/Router: This is what holds and rotates the cutting tool at the set speed. It’s
usually mounted on the gantry above the bed and moves as needed along the axes.

The below diagram shows the different parts of a CNC router.

 Figure 19 CNC Router component

Materials That Can Be Processed:

- Wood: Used in furniture making, cabinetry, and decorative work.
- Plastics: Common in sign-making, prototyping, and industrial components.
- Metal: Certain CNC routers can work with aluminum, brass, and softer metals,
though specialized CNC machines are typically used for harder metals.
- Foam and Composites: Often used in model-making, packaging, or light-duty
industrial work.
Applications of CNC Routers:
c. Woodworking: Used to cut shapes, profiles, and intricate patterns for cabinets,
furniture, and artistic wood carvings.
d. Signage: Engraving and cutting letters, logos, and patterns in materials like
wood, plastic, or acrylic.
e. Furniture Making: Creating detailed parts and components for furniture
design.
f. Rapid Prototyping: Used in engineering and design for quickly making
prototypes out of wood, plastic, or foam.
g. Mold Making: CNC routers can be used to create molds from materials like
wood or plastic for various manufacturing processes.

Advantages of CNC Routers:

- Precision: Achieve intricate and detailed designs with high repeatability.
- Automation: CNC routers can run automatically once programmed, reducing the
need for manual labor.
- Versatility: They can work on a wide range of materials and applications.
- Efficiency: Faster than manual routing or cutting processes, making them ideal for
mass production.

Software Used in CNC Routers:

CNC routers typically use CAD (Computer-Aided Design) and CAM (Computer-
Aided Manufacturing) software. Popular examples include:
- AutoCAD: Widely used for designing parts in 2D and 3D.
- Fusion 360: Provides both CAD and CAM capabilities for 3D design and
manufacturing.
- VCarve Pro: Commonly used for sign-making and woodwork designs.
- Aspire: Great for 3D modeling and detailed CNC carving projects.
How to develop a CNC router?
Upgrading a CNC Router can include a variety of improvements, from improving
performance and cutting techniques to updating software. Here are some steps and
guidelines for upgrading a CNC Router:
a. Improving the design and structure:
- Re-evaluating the frame: Make sure the frame is strong and stable. You can use
more rigid materials such as steel or aluminum.
- Adding additional support Use additional supports or bases to reduce vibrations
and increase accuracy.
b. Upgrading the electronic system:
- High-quality motors: Replace existing motors with high-quality stepper motors or
servo motors to improve accuracy and speed.
- Better drivers: Use improved motor drivers for better performance.
c. Improving cutting tools:
- Using new bits: Try different types of bits, such as carbide bits or diamond bits,
which provide better performance.
- Varying cutting speeds: Try different speeds to increase productivity and reduce
wear on tools.
d. Software Update:
- CAM/CAD Software Change: Use modern design software that provides advanced
features such as 3D simulation.
- G-code Improvements: Ensure that the software generates efficient G-code to
reduce cutting time.
e. Add New Features:
- Remote Control: You can add smart controllers to control the machine remotely.
- Sensors: Integrate sensors such as height sensors to improve accuracy and reduce
errors.
 f. Periodic Maintenance:
- Cleaning and Maintenance: Ensure that the machine is cleaned regularly and
damaged parts are replaced.
- Engine Oil: Use appropriate oils for engines and moving components to ensure
smooth movement.
g. Training and Professional Development:
- Operator Training: Invest in training operators to use software and tools better.
- Workshops: Join workshops or online courses to enhance technical skills.
h. Performance Evaluation:
- Testing of parts: Perform periodic tests of parts to ensure quality is maintained.
- Analyzing the results: Collect and analyze data on performance to discover any
areas for improvement.
i. Communicating with the community:
- Join forums: Participate in CNC forums to get tips and suggestions from other
professionals.
- Seek partnerships: Collaborate with technicians or engineers to improve
performance.
j. Research and Development:
- New Technology: Stay up to date on the latest technologies and innovations in the
CNC field.
- Experiencing new ideas: Don’t hesitate to try new ideas to improve productivity
and quality.
By implementing these steps, you can improve the performance of your CNC Router
and develop it to better meet your needs.
References and Resources:
1. Woodweb (www.woodweb.com): Provides resources and discussions on CNC routers
for woodworking and furniture making.
2. CNCZone (www.cnczone.com): An online forum that discusses CNC router
machines, software, and accessories.
 3. Practical Machinist (www.practicalmachinist.com): Offers advice and information
for metalworkers using CNC routers and similar equipment.
4. CNC Cookbook (www.cnccookbook.com): Covers tutorials, buyer guides, and
software tips for CNC routing and machining.
5. Vectric Software (www.vectric.com): Creators of VCarve Pro and Aspire, offering
extensive tutorials and support for CNC router users.

(Yousef housny)
3D PRINTER
3D printing: is a process that creates three-dimensional objects by building them
layer by layer from a digital model.

Key Features
a. Layered Construction: Objects are created by adding material layer by
layer, allowing for complex geometries and detailed designs.
b. Digital Design: 3D printing uses CAD (Computer-Aided Design) software
to create digital models, which are then sliced into layers for printing.
c. Material Versatility: Various materials can be used, including plastics,
metals, ceramics, and even biological materials.
d. Customizability: 3D printing allows for the production of highly
customized products tailored to specific needs.

Types of 3D Printing Technologies

a. Fused Deposition Modeling (FDM):

- Process: Thermoplastic filament is heated and extruded through a nozzle,

building the object layer by layer.
- Applications: Prototyping, hobbyist projects, and educational purposes.
- Materials: PLA, ABS, PETG, and other thermoplastics.

Figure 20 Fused Deposition Modeling

b. Stereolithography (SLA):

- Process: A UV light source cures liquid resin layer by layer to create

solid objects.
- Applications: High-detail prototypes, jewelry, and dental applications.
- Materials: Photopolymer resins.

Figure 21 Stereolithography 3D printer

c. Selective Laser Sintering (SLS):

- Process: A laser fuses powdered material (typically nylon or polymers)

layer by layer.
- Applications: Functional prototypes, low-volume production, and
complex geometries.
- Materials: Nylon, metals, and composite powders.
 Figure 22 selective laser sintering

d. Digital Light Processing (DLP):

- Process: Similar to SLA, but uses a digital light projector to cure resin.
- Applications: High-speed printing of high-resolution objects.
- Materials: Photopolymer resins.

Figure 23 Digital light processing

Applications of 3D Printing

• Prototyping: Rapid prototyping for product design and testing.

• Manufacturing: Low-volume production of custom parts.
• Medical: Prosthetics, dental implants, and anatomical models.
• Aerospace: Lightweight components and parts for aircraft.
• Education: Teaching concepts in design, engineering, and manufacturing.
• Arts and Crafts: Creating sculptures, jewelry, and artistic pieces.

Advantages of 3D Printing

• Customization: Ability to create bespoke designs tailored to individual

needs.
• Reduced Waste: Additive manufacturing minimizes material waste
compared to subtractive methods.
• Speed: Rapid production of prototypes and parts compared to traditional
methods.
• Complex Geometries: Capability to produce intricate shapes that would be
difficult or impossible to manufacture using conventional techniques.

• Reference: • 3D Printing: Principles and Applications by Chee Kai Chua and Kui Y.
Lim.
• • The 3D Printing Handbook: Technologies, Design and Applications by Ben Redwood,
Filemon Schoffer, and Brian Garret.

(Yousef housny)