CNC

HISTOY:
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

 CNC (computer numerical control) machining is a process in manufacturing where

programmed computer software directs the motions of plant machinery and tools.
 The application can be used to automate a range of manufacturing
techniques such as milling, water jet cutting, and laser cutting materials. Instructions
are fed into the CNC machine through a CAD file and transposed into a precise set of
sequential instructions.
USES:
 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 repeatable accuracy
 Unmanned machining operations

ADVANTAGESD OF CNC:
 Easier to program;
 - Easy storage of existing programs;
 - Easy to change a program
 - Avoids human errors
 - NC machines are safer to operate
 - Complex geometry is produced as cheaply as simple ones
 - Usually generates closer tolerances than manual machines

CNC TYPES: The reference to axes is used to describe CNC machines which operate along
multiple axis points. CNC machining is the process of removing material from a workpiece
until the desired shape is configured. These machines have at least a 3 axes and operate
along an XYZ plane: X axis (vertical), Y axis (horizontal), and a Z axis (depth). The 4 th axis
denotes the inclusion of an A axis (rotation around the X axis), and the 5th axis denotes the B
axis (rotation around the Y axis).
The number of axes on a CNC machine determines the type of work it can do, the level
of detail it can cut, and the workpiece locations it can manipulate.
 3 Axis
 4 axis
 5 axis
3 Axis
3 axis machining implies that the workpiece remains in the same position while the
cutting tool operates along the XYZ plane to trim away material. This is suitable for parts
that don’t require a lot of depth and detailing. 3 axis machining is most commonly used to
produce mechanical components and is best suited for:
 Automatic/interactive operation
  Milling slots
 Drilling holes
 Cutting sharp edges
4 axis
4 axis machining implies that a workpiece is processed in the same way it would be with a 3
axis machine, but has an additional rotary movement around the X axis, which is named the
A axis. This rotation allows the workpiece to be cut around the B axis. This method is
beneficial when holes or cuts need to be made on the sides of a workpiece. The addition of a
fourth axis (A axis) allows a workpiece to be automatically flipped over, so the machine can
remove material from both sides. 4 axis machining is multifunctional and can be used for:
 Intermittent cutting
 Continuous cutting
 Engraving curved surfaces
5 axis
5 Axis machining implies that a workpiece can be automatically manipulated from five sides
at one time. In addition to automatic movements along the X, Y, and Z axes, 5 axis CNC
machines can select two of the three rotational axes (A,B,C) to use. The A, B, and C axes
perform a 180° rotation around the X, Y, and Z axes, correspondingly. This type of
machining is used in the automobile, aerospace, and boating industries. Application is
commonly favored for extremely complex components that are solid and would otherwise
have to be cast. 5 axis machining requires greater CNC programming preparation time to
accommodate complex rotatory movement, but allows one workpiece to be worked on all
five sides during one operation. 5 axis machining is beneficial when components require a
great deal of intricacy and quick precision. This includes:
 Feature accuracy
 Increased productivity
 Higher quality finishes
 Cutting intricate details
 Machining complex shapes

Codes used in CNC LATHE Programming

G codes:
G00 - Rapid traversing
G01 - Linear interpolation
G02 - Circular interpolation CW
G03 - Circular interpolation CCW
G21 - Metric data input
G28 - Reference point return
G71 - Stock removal in Turning Cycle
 G98 - feed/min
G70 - Finishing cycle
M codes:
M00 - Program stop
M01 - Optional stop
M03 - Spindle toward
M06 - Execute tool change either automatically or manually
M05 - Spindle stop
M30 - End of tape toward

ZEROS OF SYSTEM:
THE REFERENCE OS THE SYSTEM IS DEVISED AS
 FIXED ZERO or MANUFACTURERS ZERO
 FLOATING ZERO OR USER DEFINED ZERO

WORK ZERO may on either left face or right face

COORDINATE SYSTEM
 Absolute system
 Incremental System
Absolute Incremental
System System

Sample Program:
[ BILLET X15 Z30;
G21 G98;
G28 U0 W0;
M06 T0404;
M03 S1200;
G00 X15 Z1;
G71 U0.2 W0 R1;
G71 P10 Q20 U0.1 W0 F60;
N10 G01 X5;
X10 Z-5;
N20 Z-20
G70 P20 Q40;
G28 U0 W0;
M05;
M30;

[ BILLET X20 Z60;

G21 G98;
G28 U0 W0;
M06 T0404;
M03 S1200;
G00 X20 Z1;
G71 U0.2 W0 R1;
G71 P10 Q20 U0.1 W0 F60;
N10 G01 X0;
G02 X8 Z-5 R5;
G01 Z-10;
X12;
Z-15;
G03 X17 Z-20 R10;
G01 Z-25;
X20 Z-35;
N20 Z-45;
G70 P10 Q20;
G28 U0 W0;
M05;
M30;

Part Program:

[ BILLET X22 Z60;

G21 G98;
G28 U0 W0;
M06 T0404;
M03 S1200;
G00 X23 Z1;
G71 U0.2 W0 R1;
G71 P10 Q20 U0.1 W0 F50;
N10 G01 X0;
Z0;
G02 X6 Z-5 R5;
G01 Z-10;
X12;
Z-15;
G03 X17 Z-20 R10;
G01 Z-25;
X22 Z-35;
N Z-45;
G70 P10 Q20;
G28 U0 W0;
M05;
M30;

Codes used in CNC MILL Programming :

G-CODES

G00 Rapid Travel G83 Peck Drilling cycle

G01 Linear Position G68 Rotation
G02 Clock wise G69 Rotation cancel
G03 Counter Clock wise G90 Absolute
G04 Dwell Time (seconds) G91 Incremental
G16 Polar coordinate G86 Boring Cycle
G15 Polar coordinate cancel G41 Tool Compensation Left
G80 Cycle cancellation G42 Tool Compensation Right
G81 Center drill G40 Tool Compensation Cancel

M-CODES

M98 Sub Program call M20 Arm Insert

M99 Sub Program Continued M21 Arm release
M03 Spindle on M22 Tool Release
M05 Spindle Off M23 Tool Clamp
M06 T01 Auto Tool Calling M28 Door Open
M10 vice Open M27 Door closed
M11 Vice Closed M30 Program Rewind

MAX MILL - Accessories

Compressor – Pneumatic Operations
 Door Opening and Closing
 Vice Opening and Clamping
 Tool Arm Inside and Releasing
 Clamp tight and Release
Air Pressure to be maintained at 6 bar
Stabilizer
 3 Phase 6 KVA
 Input Voltage : 295 V to 465 V
 Output: 415 V ± 1%
 Air Cooled
Coolant
 Design Centre – Computer with Mastercam Mill Version & RS 232 Port
Communicator
Interacting With CNC MAX MILL
The Machine Control Unit can be Interacted in 2 modes,
 Jog Mode
 Handle Mode
 Display Unit Provided with Keypad
STEPS TO BE FOLLOWED WHILE STARTING MAX MILL:

 Switch Main ON.

 Stabilizer is switched on, press RESET button.
 Switch the machine control ON.
 Release Emergency button by rotating it.
 Release alarm by pressing RESET+CANCEL keys simultaneously in interface
keypad.
 Press reference return button to set machine home position by selecting appropriate
axes(Press X -, Y - , and Z - )
 Press Jog mode then press Z -, Y -, X + slightly.
 Press MDI mode, using M10 and M11 cycles, open the vice then fix the work piece
and close the vice.
 Using Jog and Handle mode bring the tool to work offset position/work zero.
 To create a new program, go edit mode, open a new file by typing O (file number)
then press insert.
 Write the program and after verifying, press AUTO mode and then press CYCLE
START.
 After completing job, remove the job from the vice using M10 cycle.
 Press emergency button then switch the machine control OFF and stabilizer, main
turned OFF to shut down the machine properly.

Sample Program:
[ BILLET X90 Y90 Z10;
[ EDGEMOVE X0 Y0;
[ TOOLDEF T6 D6;
O 0001;
G0 G90 G80 G40 G15 G69;
G0 G55 X0 Y0;
G0 G43 H1 Z50;
M06 T1
M03 S1200;
G00 Z2 F1000;
G00 Z2 F50;
G01 X20 Y20 F20;
G01 z-1.5
G01 X 70;
G01 X70 Y70;
G01X20 Y70;
G01X20 Y20;
G0 Z100;
M05;
G91 G28 Z0;
G28 X0 Y0;
M30;
Part Program:
[ BILLET X90 Y90 Z10;
[ EDGEMOVE X0 Y0;
[ TOOLDEF T6 D6;
O0002
G0 G90 G80 G40 G15 G69;
M06 T01;
G0 G54 X0 Y0;
G0 G43 H1 Z50;
M03 S1200;
G01 Z2 F1000;
G01 Z2 F50;
G01 X15 Y15 F20;
G01 Z-1.5 F20;
G01 X35;
G02 X35 Y15 R10;
G01 X75 Y15;
G01 X75 Y35;
G02 X75 Y55 R10;
G01 X75 Y75;
G01X55 Y75;
G02 X35 Y75 R10;
G01 X15 Y75;
G01 X15 Y55;
G02 X15 Y35 R10;
G01 X15 Y15;
G0 Z100;
M05;
G91 G28 Z0;
G28 X0 Y0;
M30;

Part Program:

O0104
[BILLET X90 Y90 Z10]
G0 G90 G80 G40 G15 G69;
M06 T01;
G0 G54 X30 Y30;
G0 G43 H4 Z50;
M03 S1200;
G83 R3.0 Q3.0 Z-3.5 F100;
G91 Y60.00 K5;
G0 G80 G15 G90 Z50;
M05;
M28;
M30;