An Introduction to Machine Tools and

Computer Numerical Control (CNC)

Presented By:
Abeymon Francis

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Machining
MACHINING IS THE REMOVAL OF
MATERIALS IN FORMS OF CHIPS
FROM THE WORKPIECE BY
SHEARING WITH A SHARP TOOL.

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The main function of a machine tool is
to control the workpiece-cutting tool
positional relationship in such a way as
to achieve a desired geometric shape of
the workpiece with sufficient
dimensional accuracy.

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Machine tool provides:

•work holding
•tool holding
•relative motion between tool and
workpiece (primary motion and secondary
motion)

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 Primary motion

Relative motion
between tool and Secondary motion
workpiece

Cutting motion Feed motion

Cutting speed Feed rate

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CLASSIFICATION OF THE CHIP REMOVING METHODS
ACCORDING TO THE RELATIVE MOTION

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CLASSIFICATION OF MACHINE TOOLS

THOSE USING THOSE USING THOSE USING

SINGLE POINT MULTIPOINT ABRASIVE
TOOLS TOOLS TOOLS
lathes drilling m/c’s grinding m/c’s
shapers milling m/c’s honing m/c’s
planers broaching m/c’s etc.
boring m/c’s hobbing m/c’s
etc. etc.

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Computer Numeric Control
(CNC)

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Numerical Control
Numerical control is a method of automatically
operating a manufacturing machine based on a
code of letters, numbers, and special characters.
The numerical data required to produce a part is
provided to a machine in the form of a program,
called part program or CNC program.
The program is translated into the appropriate
electrical signals for input to motors that run the
machine.

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Numerical Control - History
 The concept is credited to John Parson (1947). Using
punched cards he was able to control the position of a
machine in an attempt to machine helicopter blade.
 US Air Force teamed up with MIT to develop a
programmable milling machine (1949).
 In 1952, a three-axis Cincinnati Hydrotel milling machine
was demonstrated. The term Numerical Control (NC)
originated. The machine had an electromechanical
controller and used punched cards.
 A new class of machines called machining centers and
turning centers that could perform multiple machining
processes was developed.
 Modern NC machine has a computer on board, Computer
Numerical Control (CNC). They can run unattended at
over 20,000 rpm (spindler speed) with a feed rate of over
600 ipm and an accuracy of .0001

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Computer Numerical Control (CNC)
A CNC machine is an NC machine with the added feature of
an on-board computer.

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In CNC (Computer Numerical
Control), the instructions are stored as
a program in a micro-computer
attached to the machine. The
computer will also handle much of the
control logic of the machine, making it
more adaptable than earlier hard-
wired controllers.

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Hardware Configuration of CNC Machine
Machine Control Unit (MCU)
the brain of the CNC machine.
The Data Processing Unit (DPU)
reads the part program.
The Control Loop Unit (CLU)
controls the machine tool operation.

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CNC System Elements

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CNC Controllers
The NC controller is the brain of the NC system, it controls all
functions of the machine.
• Motion control deals with the tool position,
orientation and speed.
• Auxiliary control deals with spindle rpm, tool
change, fixture clamping and coolant.

Many different types of controllers are available in the

market (GE, Fanuc, Allen-Bradley, Okuma, Bendix, …).

There are two basic types of control systems:

point-to-point and continuous path.
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Point-to-Point Tool Movements
Point-to-point control systems cause the tool to move to a
point on the part and execute an operation at that point only.
The tool is not in continuous contact with the part while it is
moving.
Drilling, reaming, punching, boring and tapping are examples
of point-to-point operations.

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Continuous-Path Tool Movements
Continuous-path controllers cause the tool to maintain
continuous contact with the part as the tool cuts a contour shape.
These operations include milling along any lines at any angle,
milling arcs and lathe turning.

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Loop Systems for Controlling Tool Movement
Open Loop System
Uses stepping motor to create movement. Motors rotate a fixed
amount for each pulse received from the MCU. The motor sends a
signal back indicating that the movement is completed. No feedback
to check how close the actual machine movement comes to the exact
movement programmed.

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Loop Systems for Controlling Tool Movement
Closed Loop System
AC, DC, and hydraulic servo-motors are used. The speed of these
motors are variable and controlled by the amount of current or fluid.
The motors are connect to the spindle and the table. A position sensor
continuously monitors the movement and sends back a single to
Comparator to make adjustments.

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Flow of Computer-Aided CNC Processing
 Develop or obtain the 3D geometric model of the part,
using CAD.
 Decide which machining operations and cutter-path
directions are required (computer assisted).
 Choose the tooling required (computer assisted).
 Run CAM software to generate the CNC part program.
 Verify and edit program.
 Download the part program to the appropriate machine.
 Verify the program on the actual machine and edit if
necessary.
 Run the program and produce the part.

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 Basic Concept of Part Programming
Part programming contains geometric data about the part
and motion information to move the cutting tool with
respect to the work piece.
Basically, the machine receives instructions as a sequence
of blocks containing commands to set machine parameters;
speed, feed and other relevant information.
A block is equivalent to a line of codes in a part program.
N135 G01 X1.0 Y1.0 Z0.125 T01 F5.0

Coordinates Special function

Block number
G-code Tool number

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 Basic Concept of Part Programming
Preparatory command (G code)
The G codes prepare the MCU for a given operation, typically
involving a cutter motion.
G00 rapid motion, point-to-point positioning
G01 linear interpolation (generating a sloped or straight cut)
G06 parabolic interpolation (produces a segment of a parabola)
G17 XY plane selection
G20 circular interpolation
G28 automatic return to reference point
G33 thread cutting

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Basic Concept of Part Programming
Miscellaneous commands (M code)
M00 program stop
M03 start spindle rotation (cw)
M06 tool change
M07 turn coolant on
Feed commands (F code)
Used to specify the cutter feed rates in inch per
minute.
Speed commands (S code)
Used to specify the spindle speed in rpm.
Tool commands (T code)
Specifies which tool to be used, machines with
automatic tool changer.
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 CNC Machine Axes of Motion
The coordinate system used for the tool path must be identical to the
coordinate system used by the CNC machine. The standards for machine
axes are established according to the industry standard report EIA RS-267A.

Right hand rule

Vertical
milling
machine
Horizontal
milling
machine

CNC machines milling machines can perform

simultaneous linear motion along the three
axis and are called three-axes machines.
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Coordinate system for a Lathe

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More complex CNC machines have the capability of executing
additional rotary motions (4th and 5th axes).

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Five-axis
machine
configurations

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Advantages of CNC
Higher productivity
Quality (more accurate and less scrap)
Reduced inventory (reduces setup time)
Machining complex shapes
Management control (process planning
and product planning)

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Drawbacks of CNC
High capital cost
Machine tools cost $1,50,000 -
$35,00,000
Retraining and recruitment of staff
New support facilities
High maintenance requirements
Not cost-effective for low-level
production on simple parts
Maintenance personnel must have both
mechanical and electronics expertise

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Engine Block made from a single cast
iron block using a CNC machine

2004 30
Aircraft Turbine Machined by
5-Axis CNC Milling Machine

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Thank You

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