Unit -3

CNC TECHNOLOGY
CNC TECHNOLOGY
PROFIT increases as COST decreases and as
PRODUCTIVITY increases.

COST through PROCESS OPTIMIZATION

PRODUCTIVITY through AUTOMATION

Limitations of conventional machines
(Reason for low productivity)
To manufacture complex curved geometries in 2D or
3D was extremely expensive by mechanical means
(which usually would require complex jigs to control the
cutter motions)

Machining components with repeatability & accuracy

Unmanned machining operations

History of NC/CNC/DNC
1949:
US Air Force asks MIT to develop a "numerically controlled"
machine.
1952:
Prototype NC machine demonstrated (punched tape input)
1980:
CNC machines (computer used to link directly to controller)

1990:
DNC: external computer “drip feeds” control programmer to
machine tool controller
 NUMERICALLY CONTROLLED (NC)
MACHINE TOOLS:

Numerical control (NC) refers to the

automation of machine tools as opposed to
manually controlled via hand-wheels or levers,
or mechanically automated via cams &
mechanisms.

An NC machine tool is functionally the same as a

conventional machine tool. The difference is in
the way in which various machine functions and
slide motion are controlled by machine control
unit(MCU)
 Basic NC machine tool
PART DRAWING components
&
PART
PROGRAM
PUNCHED TAPE

MCU

MACHINE
TOOL
NC machine tool ELEMENTS
 NC MACHINE TOOL
COMPONENTS(ELEMENTS)
(1)PART DRAWING & PART PROGRAM:
Part drawing is drawing of job/part used for
production.
using the part drawing and cutting parameters,
part program (process plan)is written.
(2) DATA INPUT DEVICE-PROGRAM TAPE:
The part program is entered by punching on
metallic/paper tape or by recording on magnetic
tape/magnetic disk.
(3) CONTROLLER / MACHINE CONTROL UNIT (MCU) 
MCU is Electronic interface between operator and m/c

Tape reader and Controller together form the MCU

A) Tape reader:
1.Punched tape reader
2.Card reader

B ) Controller components:
1. Data Processing Unit (DPU)
2. Control-Loops Unit (CLU)
A)Tape reader

It is device used to read the coded instruction from the

program which is on punched tape or card. It is of two
types.
1.Punched tape reader:
It read the coded instructions on punched tape
2.Card reader:
It read the coded instruction on card
When the punched tape or card passed through a tape
reader, depending upon whether the hole punched at
particular track or not electric connections are either
close or open.
B) Controller components

(1)Data Processing Unit:

•Data Reading Circuits and Parity Checking Circuits
•Decoders to distribute data to the axes controllers.

(2)Control Loops Unit:

•Interpolator to supply machine-motion commands between
data points
•Position & velocity control loop hardware for each axis
of motion
NOTE:BLU: basic length unit smallest programmable move of each axis.
(4) MACHINE TOOL 

Machine tool is operated by the controller of the MCU

Machine tool perform according to command given by MCU

such as -starting or stopping the machine, positioning the
cutting tool tip, coolant on/off etc.
 Data input in NC
• The information of part production has to be
converted into a some form and that must be
stored in storage device.
• There are four different ways through which
data of part program is stored .
• Punched tape:
• Punched card
• Magnetic disk
• Magnetic tape
 Functions controlled by MCU in
NC machines
Some important functions, controlled by MCU in NC system.
• Displacement of machine slides
• Angular rotation of circular table
• Start / Stop of the main spindle
• Changing of spindle speed
• Reverse spindle direction
• Changing the feed rate of machine slides
• Rotate tool turret
• Change tool
• Coolant ON / OFF
• Lock table in position
 Advantages of NC machine tools
over conventional machine
• Less skilled operator is required
• High productivity
• Greater flexibility
• Produce complex shape
• Less fatigue to worker
• Component produced with better accuracy
and repeatability which will reduce inspection
cost.
 limitations of NC machine tools
over conventional machine
• Once program written, Editing of program is
not possible
• Non reliability of punched tape and tape
reader
• Controller is hardwired; so updating is costlier
• Trained operator is required
• Initial investment & maintenance cost is high
 CNC
• CNC stands for Computer Numerical Control.

• It is a versatile system that allows you to control

the motion of tools and parts through computer
programs that use numeric data.

• CNC can be used with any traditional machine.

   
 BASIC FUNCTIONAL ELEMENTS OF
CNC MACHINE
A typical CNC system consists of the following
six elements
• Part drawing & program
• Program input device
• Machine control unit -computer
• Feed drive system
• Machine tool
• Feedback system
 BASIC FUNCTIONAL BLOCKS OF
CNC MACHINE

Part drawing User

& CPU Interface
program (key board, monitor)

Servo Slide Machine Tool

Motor

Encoder
 Applications of NC/CNC
MACHINES with NC/ CNC are as follows:
•Lathe
•Milling machine
•Drilling machine
•Wood routers machine
•Sheet metal works (Turret Punch) press
•Wire bending machines
•EDM
• Hot-wire foam cutters
• Plasma cuttings
• Water jet cutters
• Laser cutting
• Oxy-fuel cutting
• Surface grinders
• Cylindrical grinders
• 3D Printing
• Induction hardening
Advantages of CNC machine tools
over conventional machine
• Less skilled operator is required
• High productivity
• Greater flexibility
• Produce complex shape
• Less fatigue to worker
• Component produced with better accuracy
and repeatability which will reduce inspection
cost.
• Reduced set-up time

• Reduced lead times

• Reduced inventory

• Better machine utilization

 limitations of CNC machine tools
over conventional machine
• Trained operator is required
• High Initial investment & maintenance cost.
• High tooling cost
• High cost of software.
 NC/CNC machines
Vs
Automats/SPMs
• Automats and Special Purpose Machines (SPMs) require
special cams / templates and clutch settings for each part.
Manufacturing of these cams / templates is costly.
• Furthermore, changing over from one part to the other on
these machines also consumes considerable time.
• The high cost and long time of these hard automated
machines to produce parts can be justified only in mass
production. These are avoided with CNC machines
 Control features of CNC machines over
NC machine
• Part Program editing
• Part Program storage
• Flexibility in control
• Fixed cycles and subroutines.
 CLASSIFICATION OF NC/CNC
SYSTEMS
The NC/CNC system can be classified on the
basis of
–Control of path motions
–Feed back
–Method of co-ordinate programming.
Types of NC/CNC machines

[A]Based on Control Loops:

Open loop or Closed loop

[B]Based on Motion Type:

Point-to-Point or Continuous path

Straight cut

[C]Based on co-ordinate Programming method

Incremental or Absolute
[A] BASED ON CONTROLS LOOP

(a)Open Loop Vs (b) Closed Loop controls

 Open loop Control Systems
• Open-Loop Control
– Stepper motor system
– Current pulses sent from control unit to motor
– Each pulse results in a finite amount of revolution
of the motor001” is possible
 Open loop Control Systems
• Open-Loop Limitations
– Due to lower torque motor,this system is more
suitable for cases where the tool force does not
exist
– No positioning compensation
• Open-Loop Advantages
– Less complex, Less costly, and lower maintenance
costs
 Closed-Loop Control Systems
• Closed-Loop Control
– Variable DC motors - Servos
– Positioning sensors -Resolvers
• Feedback to control unit
• Position information compared to target
location
• Location errors corrected
 Closed-Loop Control Systems
• Closed-Loop Advantages
– Closed loop NC/CNC systems are appropriate
when there is a force resisting the movement of
the tool/workpiece.
– DC motors have the ability to reverse instantly to
adjust for position error
– DC motors have higher torque ranges vs..
stepper motors
– Error compensation allows for greater positional
accuracy (.0001”)
• Closed-loop limitations
– Cost
[B]BASED ON MOTION

(a)Fixed position notion control

(b)Continuous path type motion control
[C]CO-ORDINATE PROGRAMMING
METHOD

Points Absolute Incremental

system system
A1 (100,100) (100,100)

A2 (200,300) (100,200)

A3 (300,200) (100,100)
 Difference between Absolute and
incremental
• In absolute position of point is defined w-r-t to
some datum point.
• The absolute system has two significant
advantages over the incremental system:
– In the absolute mode, the tool is automatically
returned to the position if interruptions caused
by, for example, tool breakage
– Easy change of dimensional data
 CNC MACHINES
• CNC LATHE-TURNING CENTRE

• CNC MILLING-MACHINING CENTRE

– HORIZONTAL SPINDLE:HMC
– VERTICAL SPINDLE:VMC
 AXIS DESIGNATION IN CNC
OR
CARTESIAN COORDINATE DESIGNATION FOR CNC
 Axis

Axis is the direction of movements of machine tool

slide.

CNC machine has a minimum of two axes (turning

center -x & z) controlled by the CNC while todays
machining center has maximum 5- axes(Vertical
machining center-X,Y,Z,.B,C)
STANDARD LATHE COORDINATE
SYSTEM
 STANDARD MILLING MACHINE
COORDINATE SYSTEM

Vertical Machine Horizontal Machine

RIGHT HAND RULE
 PARTS OF CNC MACHINES
• Spindle
The part of the machine tool that spins. On the
machining center, the spindle holds a cutting tool.
On the turning center, the spindle holds the work
piece.
• Turret 
This holds the tools required for machining.
Usually on a turret in the rear, most CNC lathes
have 8 to 12 tools on a single, indexing turret. 
 CNC Turning Centers
• Majority of the components machined in the
industry are of the cylindrical shape.

• CNC lathes, called as turning centers are

important machine tools that specializes in
turning, boring, drilling, and threading
operations, all at the same location.
Classification of CNC Turning Centers
(a) Multiple axis turning centers (X,Y,Z,B,C)
(b) Twin turret turning centers
(c) Multiple spindle turning centers
(d) Turn mill centers (X,Z,C)
Multiple Axis Turning Centers
 Twin Turret Turing Centers:

• This turning center consists of two turrets in a turning center.

• This makes it a four axes turning center with both turrets

capable of moving independently, moving in two axes each.

• The main advantage to be gained in such cases is that machining

can be done by two tools which have large tool capacity also.
Multiple Spindle Turning Centers:

• Used for large volume production of small and medium size

parts with standard tolerances.
• In this, the head stock consists of two spindles
• Tail stock has two quills
• These are arranged at a fixed distance from each other
 Turn Mill Centers (X, Z, C):

• The major development in the CNC turning centers is the

development of turn mill center.
• The use of multiple machine tools calls for multiple setups,
which decrease the over all tolerances.
• Also they cause delays in scheduling the jobs on different
machine tools, transportation, storage, etc.
• This calls for the development of a combined machine tool,
which can perform the turning as well as milling operations.
• Such a machine tool is called the CNC turn mill center.
CNC Machining Center
 Machining Centers
•They are capable of carrying out milling, drilling,
reaming, tapping, boring etc.
•They do not need operator intervention for change of
tools and workpiece.
•Machining centers are equipped with automatic tool
changers(ATC).A machining center is characterized by
an indexable tool magazine which can store several
tools. Tools from tool magazine is transferred by tool
changing arm to the machine spindle.
 Machining centers
• Machining centers are often provided with
two or more work tables called pallets.
• Work pieces can be set up in all pallets
• The machine can be programmed to accept a
new pallet when work of a previous pallet is
completed with the help of pallet changer.
 Advantages of Machining
centers
• Due to reduction in non productive time,
machining centers have high productivity
• Reduction in the lead time of production of
complex components.
• This reduces work in process (WIP)
 Classification Of
Machining Centers
(a) Horizontal spindle machining centers.
(HMC)

(b) Vertical spindle machining centers.

(VMC)
HORIZONTAL Spindle Machining Centers
 (a) Horizontal Spindle Machining
Centers:
• Horizontal spindle machining centers are single
spindle machines with automatic tool changer.

• X-axis transverse is provided by table or column.

• The Y-axis transverse is provided by spindle head

• The Z-axis transverse is provided by the saddle,

column, head stock or spindle head.
 (a) Horizontal Spindle Machining
Centers
• These machines are used with a rotary indexing table
and rotary spindle head to facilitate multiphase
matching at different angles in a single set up.

• The axis of rotary table is parallel to Y-axis is called

“B” axis. The axis of rotary spindle is parallel to Z-axis
is called “A” axis.

• The rotation of the table and rotation of spindle can

be used for machining contours on workpiece.
 Advantages of HMC

• This will ensure several hours of uninterrupted

operation of the machine without the need for
operator intervention.
• Another feature of operation on the machining center
is the use of special fixtures.
VERTICAL Spindle Machining Centers
(b) Vertical Spindle Machining Centers
The structural configuration is:

• X-axis traverse is provided by table or column

• Y-axis traverse is provided by the saddle or the column

or ram.

• Z-axis traverse is provided by the head stock

 (b) Vertical Spindle Machining Centers:

• The vertical axis machining centers (VMC) are generally

more versatile.
• They can generate more complex surfaces compared to
the horizontal axis.
• Most of the early CNC machine tools therefore are of
this category.
 (b) Vertical Spindle Machining Centers

Vertical spindle machining centers are also bed type

Machines with:

• Single spindle and auto tool changer & pallet changer

• Multi spindle with turret head (turret machining centers)

 Constructional features of CNC
• Feed drives
• Slide-ways
• Automatic tool changer
• Pallet
• Automatic pallet changer
• Recirculating ball screw
 CNC PROGRAMMING
• What is programming ?
Programming is telling the machine by
‘command data’ through numerical control for
its working of components.

Example :
Movement of Turret..
Rotation of spindle… etc
 Program Number
• Program number
The program no. is used to arrange several
programs in order
The program no is expressed by putting
numerals of 4 digits after the alphabet “O”
Ex O 1234
 Program block

A program block is a combination of functions of

machine tool in a single line.
Example: N01 G01 G91 X0.0 Y10.0 S2000 F100 M03 ;

SEQUENCE END OF BLOCK

NUMBER

Line number is optional

End of block is mandatory
 Codes in program block
Programming consists of a series of instructions in form of letter codes:
•N codes- specify program line number to executed by
the MCU
•Preparatory Codes: G codes- Initial machining setup and
establishing operating conditions
•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
 (1)Sequence Number

• Designated by alphabet N
• Used to identify the blocks
• Not mandatory
• Occupies memory
• Can be used for each process rather than for each block.
 (2)Preparatory code :G codes
• G00 – Preparatory code to control final position of the
tool and not concerned with the path that is followed in
arriving at the final destination.

• G01 – Tool is required to move in a straight line

connecting current position and final position. Used for
tool movement without any machining- point to point
control. (linear interpolation)

• G02 – Tool path followed is along an arc specified by I, J

and K codes.( circular interpolation)
 Table of Important G codes
G00 Rapid Transverse
G01 Linear Interpolation
G02 Circular Interpolation, CW
G03 Circular Interpolation, CCW
G17 XY Plane,G18 XZ Plane,G19 YZ Plane
G20/G70 Inch units
G21/G71 Metric Units
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation (plus)
G44 Tool length compensation (minus)
G49 Tool length compensation cancel
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning
 (3)Spindle speed Function

The spindle speed can be specified by a S code followed by a

Numerical value (rpm).

Syntax :S ;

Example : S2000 ;

Usually S command is associated with M03 or M04 to specify

the direction of rotation CW or CCW
 (4)Feed function

The feed can be specified by F code followed by a Numerical

value (feed per minute or feed per revolution).

Syntax :F ;

Example : G98 F100;

: G99 F0.15;
G98 and G99 are preparatory functions to specify feed
per minute and feed per revolution respectively.
 (5)Tool function
Tool selection
A 2 digit or 4 digit numeric followed by a T code is used to select
the required tool.

Syntax T

Offset number
Tool number
Example T0303; Selects tool 3 with offset Nr.03
T0313; Selects tool 3 with offset Nr.13
 (6)Auxiliary function
M codes
• M codes are used for doing auxiliary
machine functions.
• It is designated by M followed by No.

Example
M08 Coolant On
M06 Tool change
M00 Program Stop Temporary stop of program
M01 Optional Stop Temporary stop of program ( Optional Stop )
M02 Program end Program end and reset
M03 Spindle normal rotation Clockwise rotation of spindle
M04 Spindle reverse rotation Counter clockwise rotation of spindle
M05 Spindle Stop Spindle rotation stop
M06 Tool Change ATC Cycle start
M08 Coolant ON Coolant Discharge
M09 Coolant OFF Coolant shut
M22 Index Forward Turret index clockwise
M23 Index Reversed Turret index counter clockwise
M24 Chuck open Opening of chuck
M25 Chuck close Closing of chuck
M30 Program end and rewind Program end and reset/rewind
M98 Sub-program call Call of a sub-program from a main program
M99 Sub-program end Return from a sub-program to a main program
How to set the machine
Machine ON

Origin

Fixture Mounting

Fixture dialing

Locator/clamp fixing

Tool mtg on the holders

Measure the tool length

Tool pocketing
 Tool offset inputing

Programming

Find work co ordinate

Dry run with out component

/single block

Cutting in single block

Rapid /feed lesser rate

Component inspection

Correction of work co ordiante

Correction of tool offset

Component cutting @
100% feed/ speed/Rapid
Flexible Manufacturing System(FMS)
• A manufacturing system which consist of
CNC workstations (CNC machine
tools)interconnected by automated
material handling system such as AGVs
and robots with automated storage and
retrieval system(AS/RS)
 COMPONENT OF FMS
• CNC workstations
• Automated material handling system
• Automated storage and retrieval system(AS/RS)

CONCEPT USED IN FMS

• Flexible automation
• Group Technology