INTRODUCTION TO
CNC AND METAL
CUTTING (PART 1)
HISTORY
US Air Force commissioned MIT to develop the
first "numerically controlled" machine in 1949.
It was demonstrated in 1952.
At 1970-1972 first Computer Numeric Control
machines were developed.
Today, computer numerical control (CNC)
machines are found almost everywhere, from
small job shops in rural communities to
companies in large urban areas.
2
DEFINITION
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.
3
CNC APPLICATIONS
Machining
2.5D / 3D
Turning ~ Lathes, Turning Centre
Milling ~ Machining Centres
Forming 2.5 D
2D
Plasma and Laser Cutting
Blanking, nibbling and punching
3D
Rapid Prototyping
4
3D
CNC TURNING
5
CNC MILLING
6
CNC LASER CUTTING
7
CNC PLASMA CUTTING
8
CNC PRESS
9
CNC RAPID PROTOTYPING
10
AEROSPACE INDUSTRY
AIRCRAFT TURBINE MACHINED BY
5-AXIS CNC MILLING MACHINE
11
FUNDAMENTAL OF
METAL CUTTING
15
The metal cutting operations ( also called
machining ) is one of the most important
manufacturing processes in industry today
Machining is the removal of materials in
forms of chips from the workpiece by shearing
with a sharp tool.
16
Machine tool provides:
• work holding
• tool holding
• relative motion between tool and
workpiece
primary motion
secondary motion
18
PRIMARY MOTION SECONDARY MOTION
Relative motion
between tool and Feed motion
workpiece
Feed rate
Cutting motion
Cutting speed 19
BASIC
COMPONENTS OF
CNC SYSTEMS
20
RIGHT HAND RULE
VERTICAL MACHINE HORIZONTAL MACHINE
21
STANDARD LATHE
COORDINATE SYSTEM
24
STANDARD MILLING
MACHINE
COORDINATE SYSTEM
25
STEPPING MOTORS
26
RECIRCULATING BALL SCREWS
27
RECIRCULATING BALL SCREWS
Accuracy of CNC
machines depends on
their rigid construction,
care in manufacturing, and
the use of ball screws
to almost eliminate slop in
the screws used to move
portions of the machine.
28
COMPONENTS OF
RECIRCULATING BALL SCREWS
CNC PROGRAMMING
Manual
Write code directly
Computer-assisted
Draw cutter path
CAD/CAM
Draw the part
Cutter path is generated
CNC MACHINES
CUTTING TOOLS (CUTTERS)
31
CNC CUTTERS
Turning center cutters
Machining center cutters
32
TURNING CENTER CUTTERS
Types of cutters used on CNC turning centers
Carbides (and other hard materials) insert
turning tools
Ceramics
High Speed Steel (HSS) drills and taps
33
STANDARD INSERT
SHAPES
V – used for profiling, weakest
insert, 2 edges per side.
D – somewhat stronger, used for
profiling when the angle allows
it, 2 edges per side.
T – commonly used for turning
because it has 3 edges per side.
C – popular insert because the
same holder can be used for
turning and facing. 2 edges per
side.
W – newest shape. Can turn and
face like the C, but 3 edges per
side.
S – Very strong, but mostly used
for chamfering because it won’t
cut a square shoulder. 4 edges
per side.
R – strongest insert but least 34
commonly used.
TYPICAL TURNING,
THREADING AND PARTING
TOOLS
35
MACHINING CENTER CUTTING
TOOLS
Most machining centers
use some form of HSS or
carbide insert endmill as
the basic cutting tool.
Insert endmills cut many
times faster than HSS,
HSS endmills leave a
better finish when side
cutting.
36
MACHINING CENTER CUTTING
TOOLS ( CONT ’ D )
Facemills flatten
large surfaces
quickly and with an
excellent finish.
Notice the engine
block being finished
in one pass with a
large cutter.
37
MACHINING CENTER CUTTING
TOOLS ( CONT ’ D )
Ball endmills (both
HSS and insert) are
used for a variety of
profiling operations
such as the mold
shown in the picture.
Slitting and side
cutters are used
when deep, narrow
slots must be cut.
38
MACHINING CENTER CUTTING
TOOLS ( CONT ’ D )
Drills, Taps, and Reamers
Common HSS tools such as
drills, taps, and reamers are
commonly used on CNC
machining centers. Note that
a spot drill is used instead of a
centerdrill. Also, spiral point
or gun taps are used for
through holes and spiral flute
for blind holes. Rarely are
hand taps used on a
machining center.
39
TOOL HOLDERS
All cutting tools must be held in a holder
that fits in the spindle. These include
end mill holders (shown), collet holders,
face mill adapters, etc. Most machines in
the USA use a CAT taper which is a
modified NST 30, 40, or 50 taper that
uses a pull stud and a groove in the
flange. The machine pulls on the pull
stud to hold the holder in the spindle,
and the groove in the flange gives the
automatic tool changer something to
hold onto. HSK tool holders were
designed a number of years ago as an
improvement to CAT tapers, but they
are gaining acceptance slowly.
40
CNC PROGRAMMING
41
