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Unit 5 - CNC MACHINE TOOLS AND

PART PROGRAMMING

G.Ravisankar, Asst Prof , Mechanical, Sri

Eshwar college of Engineering , Coimbatore .
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UNIT V - CNC MACHINE TOOLS AND PART PROGRAMMING

Numerical Control (NC) machine tools – CNC types,

constructional details, special features, machining
centre, part programming fundamentals CNC – manual
part programming – micromachining – wafer
machining

1. Hajra Choudhury, "Elements of Workshop Technology", Vol.II., Media

Promoters

2. Rao. P.N “Manufacturing Technology - Metal Cutting and Machine

Tools", Tata McGraw-Hill, New Delhi, 2003.
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An Introduction to -
Computer Numerical Control
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Introduction
• CNC: Computer Numerical Control
• Production of machined parts whose production
is controlled by a computer.
• Computer uses a controller to drive each axis
of the machine tool. (X,Y,Z)
• Controls direction, speed, and length of
time motor rotates.
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Introduction
• A programmed path is loaded into the
computer and then executed.
• Program consists of numeric point data (X,Y,Z),
along with machine control and function
commands.
• Numerical Control (NC) & Computer Numerical
Control (CNC) mean the same.
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Introduction
• A major manufacturing development in past
60 years.
• Resulted in:
▫ new manufacturing techniques
▫ higher production levels
▫ higher quality
▫ stabilization of manufacturing costs
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Evolution of CNC
• Single items produced by crafts people
• Interchangeable Parts
▫ Eli Whitney (Cotton Gin)
▫ Manual labor was still the most cost effective
method.
• WW II manufacturers could not maintain
quantity & quality parts.
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Evolution of CNC
• Machinists could produce superior quality but not
at high volume that was required.
• As quantity increased, quality decreased due
to human factors
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Evolution of CNC
• ENIAC – developed by the United States Army
Ballistic Research Lab & University of
Pennsylvania
• First digital computer.
• Vacuum tube technology. (30,000)
• Used to calculate artillery tables.
• Programming involved setting hundreds
of switches and cables.
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ENIAC
Electronic Numerical Integrator And Computer
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ENIAC
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CNC & WW II
• Need to manufacture large amount of products
for the war.
• Need for quantity and quality.
• U.S. Air Force set up companies to develop and
produce NC systems to handle volume and
repeatability.
• Repeatability: the ability to perform the
same operation over & over within specified
parameters.
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Specific Goals
• Increase production
• Improve quality & accuracy of machined parts.
• Stabilize manufacturing costs.
• Speed up production & assembly operations.
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NC Timeline
• 1949 - First contract awarded for NC machine.
• 1951 - servo system for machines developed.
• 1952 - tape-fed machine was created.
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History
• Development of G codes - Punch tape
input (Cartesian Coordinate System)
• 1970’s Development of computer chips
▫ Cheaper processing power
▫ Smaller computers
▫ More reliable
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Paper Tape Control

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Paper Tape Control

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Paper Tape Control

• Strip of paper tape with holes in it.
• Machine read pattern of holes and performed
the required operation.
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Paper Tape Control

• Disadvantages
▫ Difficult to identify parts of program.
▫ Programs could be quite large.
▫ Stored on large bulky reels.
▫ Fragile, could rip easily.
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CNC
• Further developments in the computer allowed
it to be used to control the machine instead of
the paper tape.
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Definitions
• NC - A method of accurately controlling the
operation of a machine tool by a series of
coded instructions, consisting of numbers,
letters of the alphabet, and symbols that the
machine control unit can understand
• MCU - Machine Control Unit - decodes NC
codes to drive and monitor servo motor
movements.
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Definition
• CNC - Computer Numeric Control -
computer provides machine codes to the
MCU.
• Control Systems
▫ Open loop system - servo motor driven by pulses
without feed back encoders.
▫ Closed loop system - servo motor is driven by
electrical pulses. An encoder provides feedback
to verify machine movements.
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History of CNC

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
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CNC Advantages vs. NC

• Programs could be stored in computer memory.
• Easier to edit.
• More complex parts could be manufactured.
• Use of 3d geometry.
• Networking/file sharing / other computers.
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Advantages of CNC
• Increased productivity after programming is
completed
• Reliability - reduces human error
• Often eliminates need for special jigs
and fixtures
• Reduces location of part features
• Makes possible the machining of complex
shapes requiring simultaneous 3 axis
motion
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Advantages
• Single part and production runs can be
programmed and machined with minimum
effort and cost.
• Programs can readily be altered and re-run
• Reduced inspection costs (more reliable)
• Once programming, setup and verified the
equipment can be operated by a less
skilled operator.
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Disadvantages
• Initial cost of CNC machine tools
• Servicing of equipment
• Larger machines require more space
• Personnel must be trained in the
programming and operation of this
equipment.
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Conventional milling machines

Vertical milling machine

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Conventional milling machines

Vertical Milling machine architecture

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Conventional milling machines

Horizontal Milling machine architecture

How does the table move along X- Y- and Z- axes ?

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NC machines

Motion control is done by: servo-controlled motors

Table
Leadscrew
Encoder A/C Motor
~

Servo Controller

Counter Comparator

Input (converted from analog to digital value)

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NC SYSTEM ELEMENTS

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CNC SYSTEM ELEMENTS

A typical CNC system consists of the following six
elements
• Part program
• Program input device
• Machine control unit
• Drive system
• Machine tool
• Feedback system

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OPERATIONAL FEATURES of CNC MACHINES

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CNC terminology

BLU: basic length unit 

smallest programmable move of each axis.

Controller: (Machine Control Unit, MCU) 

Electronic and computerized interface between operator
and m/c

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

Data Processing Unit:

Input device [RS-232 port/ Tape Reader/ Punched Tape Reader]
Data Reading Circuits and Parity Checking Circuits
Decoders to distribute data to the axes controllers.

Control Loops Unit:

Interpolator to supply machine-motion commands between
data points
Position control loop hardware for each axis of motion
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SAMPLE
CNC MACHINES

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CNC TURNING
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CNC MILLING
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CNC LASER CUTTING

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CNC PLASMA CUTTING

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CNC PRESS

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CNC RAPID PROTOTYPING

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Industrıes Most Benefited by CNC

• Aerospace
• Machinery
• Electrical
• Fabrication
• Automotive
• Instrumentation
• Mold making
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SAMPLE PRODUCTS
OF
CNC MANUFACTURING
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AUTOMOTIVE INDUSTRY
Engine Block Different Products
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AEROSPACE INDUSTRY
Aircraft Turbine Machined by 5-Axis CNC Milling Machine
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CNC MOLD MAKING

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ELECTRONIC INDUSTRY
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RAPID PROTOTYPING PRODUCTS

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Types of CNC machines

Based on Motion Type:

Point-to-Point or Continuous path

Based on Control Loops:

Open loop or Closed loop

Based on Power Supply:

Electric or Hydraulic or Pneumatic

Based on Positioning System

Incremental or Absolute
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Open Loop vs. Closed Loop controls

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Open loop control of a Point-to-Point NC drilling machine

NOTE: this machine uses stepper motor control
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Components of Servo-motor controlled CNC

Motor lead screw rotation table moves

Motor speed control feedback position sensed by encoder

Two types of encoder configurations

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Motion Control and feedback

Encoder outputs: electrical pulses (e.g. 500 pulses per revolution)

Rotation of the motor  linear motion of the table: by the leadscrew

The pitch of the leadscrew: horizontal distance between successive threads

One thread in a screw  single start screw: Dist moved in 1 rev = pitch

Two threads in screw  double start screw: Dist moved in 1 rev = 2* pitch
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Guide Ways and Slide Ways

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Guide Ways and Slide Ways

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Guide Ways and Slide Ways

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Slide Ways
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Slide Ways
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Slide Ways
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Slide Ways
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Slide Ways
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Tool holding and work holding devices

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Tool holding and work holding devices

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Tool holding and work holding devices

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Tool holding and work holding devices

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Tool holding and work holding devices

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ATC
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Tool holding and work holding devices

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ATC
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Manual NC programming

Part program: A computer program to specify

- Which tool should be loaded on the machine spindle;

- What are the cutting conditions (speed, feed,
coolant ON/OFF etc)
- The start point and end point of a motion segment
- how to move the tool with respect to the machine.
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Part program

The RS274-D is a word address format

Each line of program == 1 block

Each block is composed of several instructions, or (words)

Sequence and format of words:

N3 G2 X+1.4 Y+1.4 Z+1.4 I1.4 J1.4 K1.4 F3.2 S4 T4 M2

sequence no destination coordinates dist to center of circle tool

feed rate spindle speed

preparatory function
miscellaneous function
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Manual Part Programming Example

5”
2.5”
p4
p2 p3 p5

1”

Tool size = 0.25 inch,

5” Feed rate = 6 inch per minute,
Cutting speed = 300 rpm,
Tool start position: 2.0, 2.0
Programming in inches
45°

(4, 4)
p1 Motion of tool:
p0  p1  p2  p3  p4  p5  p1  p0
p0 (2, 2)
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1. Set up the programming parameters

5”
2.5”
p4
p2 p3 p5

1”

Programming in inches
5”
Use absolute coordinates

Feed in ipm
45°
N010 G70 G90 G94 G97 M04
(4, 4)
p1
Spindle speed in rpm
p0 (2, 2)
Spindle CCW
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2. Set up the machining condition s

5”
2.5”
p4
p2 p3 p5

1”

Machine moves in XY-plane

5” Use full-circle interpolation

Feed rate

Spindle speed
45°

N020 G17 G75 F6.0 S300 T1001 M08

(4, 4)
p1
Tool no.
p0 (2, 2)
Flood coolant ON
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3. Move tool from p0 to p1 in straight line
 5”
2.5”
p4
p2 p3 p5

Linear interpolation
1”
target coordinates

5” N030 G01 X3.875 Y3.698

45°

(4, 4)
p1

p0 (2, 2)
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4. Cut profile from p1 to p2

5”
2.5”
p4
p2 p3 p5

1”

Linear interpolation
5” target coordinates

N040 G01 X3.875 Y9.125

45°
or
(4, 4)
p1 N040 G01 Y9.125

p0 (2, 2)

X-coordinate does not change  no need to program it

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5. Cut profile from p2 to p3
 5”
2.5”
p2 p3
p4
p5 Linear interpolation

target coordinates
1”

N050 G01 X5.634 Y9.125

5”

y = 9 + 0.125 = 9.125
(6.5 - x)2 + 0.1252 = (1 - 0.125)2
x = 5.634
45° p3
(x, y)
(4, 4)
p1 (6.5, 9)
.125

p0 (2, 2)

1”
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6. Cut along circle from p3 to p4

5”
2.5”
p4
p2 p3 p5

1”

circular interpolation, CCW motion

5”
target coordinates

45° N060 G03 X7.366 Y9.125 I6.5 J9.0

(4, 4) coordinates of center of circle

p1

p0 (2, 2)
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7. Cut from p4 to p5

5”
2.5”
p4
p2 p3 p5

1”

5”

Linear interpolation

45° target coordinates (Y is unchanged)

(4, 4) N070 G01 X9.302

p1

p0 (2, 2)
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8. Cut from p5 to p1

5”
2.5”
p4
p2 p3 p5

1”

5”
Linear interpolation

target coordinates (see step 3)

45°
N080 G01 X3.875 Y3.698
(4, 4)
p1

p0 (2, 2)
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9. Return to home position, stop program

5”
2.5”
p4
p2 p3 p5

1”

Linear interpolation

5” target coordinates (see step 3)

N090 G01 X2.0 Y2.0 M30

45°
end of data
(4, 4)
N100 M00
p1

p0 (2, 2) program stop

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PART PROGRAMMING
• Part program is a sequence of instructions, which
describe the work, which has to be done on a part, in the
form required by a computer under the control of a
numerical control computer program
• Programming is where all the machining data are
compiled and where the data are translated into a
language which can be understood by the control system
of the machine tool.
The machining data is as follows :
(a) Machining sequence classification of process, tool start up
point, cutting depth, tool path, etc.
(b) Cutting conditions, spindle speed, feed rate, coolant, etc.
(c) Selection of cutting tools.
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PART PROGRAMMING
While preparing a part program, need to perform the
following steps :
(a) Determine the startup procedure, which includes the
extraction of dimensional data from part drawings and
data regarding surface quality requirements on the
machined component.
(b) Select the tool and determine the tool offset.
(c) Set up the zero position for the work piece.
(d) Select the speed and rotation of the spindle.
(e) Set up the tool motions according to the profile required.
(f) Return the cutting tool to the reference point
after completion of work.
(g) End the program by stopping the spindle and coolant
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PART PROGRAMMING
Methods of part programming can be of two types
depending upon the two techniques as below :
(a) Manual part programming,
(b) Computer aided part programming

Manual Part Programming

• The programmer first prepares the program
manuscript in a standard format.
• Manuscripts are typed with a device known as flexo
writer, which is also used to type the program
instructions.
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PART PROGRAMMING
Computer Aided Part Programming
• Complex-shaped component requires calculations to
produce the component are done by the
programming software contained in the computer.
• The programmer communicates with this system
through the system language, which is based on
words.
• There are various programming languages
developed in the recent past, such as APT
(Automatically Programmed Tools), ADAPT,
AUTOSPOT, COMPAT-II, 2CL, ROMANCE, SPLIT
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PART PROGRAMMING
Computer Aided Part Programming
A translator known as compiler program is used to
translate it in a form acceptable to MCU.

The programmer has to do only following things

(a) Define the work part geometry.
(b) Defining the repetition work.
(c) Specifying the operation sequence.
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Computer Aided Part Programming

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Terminology
• NC – Numerical Control
• CNC – Computer Numerical Control
• DNC – Direct Numerical Control
• APT – Automatic Programmed Tool
• CAD – Computer Aided Design
• CAM – Computer Aided Manufacturing
• CIM – Computer Integrated Manufacturing
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Direct Numerical Control (DNC)

• Direct numerical simultaneously control the operations of
a group of NC machine tools using a shared computer.
Programming, editing part programs and downloading part
programs to NC machines are main responsibilities of the
computers in a NC system.
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G - Code Programming
• G – Code Programming
• Originally called the “Word Address” programming
format.

• Processed one line at a time sequentially.

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Common Format of a Block

Sequence Preparatory Dimension Feed Spindle Tool Misc.
# Function Words Rate Function Function Function

N50 G90 G01 X1.40Y2.25 F10 S1500 T01 M03

Individual Words
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Word Address 1
• N – Sequence or line number
• A tag that identifies the beginning of a block of code.
It is used by operators to locate specific lines of a
program when entering data or verifying the
program operation.

• G – Preparatory function
• G words specify the mode in which the milling
machine is to move along its programmed axes.
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Word Address 2
• Dimension Words
X – Distance or position in X direction
Y – Distance or position in Y direction
Z – Distance or position in Z direction

• M – Miscellaneous functions
• M words specify CNC machine functions not related
to dimensions or axial movements.
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Word Address 3
• F – Feed rate (inches per minute or millimeters
per minute)
• Rate at which cutting tool moves along an axis.

• S – Spindle speed (rpm – revolutions per minute)

• Controls spindle rotation speed.

• T – Tool number
• Specifies tool to be selected.
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Word Address 4
• I – Circular cutting reference for x axis

• J – Circular cutting reference for y axis

• K – Circular cutting reference for z axis

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G Word
• G words or codes tell the machine to perform
certain functions. Most G words are modal
which means they remain in effect until
replaced by another modal G code.
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Common G Codes
• G00 – Rapid positioning mode
• Tool is moved along the shortest route to
programmed X,Y,Z position.
• Usually NOT used for cutting.
• G01 – Linear Interpolation mode
• Tool is moved along a straight-line path
at programmed rate of speed.
• G02 – Circular motion clockwise (cw)
• G03 – Circular motion counter
clockwise (ccw)
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Common G Codes, con.,

• G17 – XY plane
• G18 – XZ plane
• G19 – YZ plane
• G20 – Inch Mode
• G21 – Metric Mode
• G28 – Return to axis machine Zero (Home)
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G Codes: G90, G91

G90 – Absolute Coordinate Reference
References the next position from an absolute zero
point which is set once for the entire program.

G91 – Incremental Coordinate Reference

References the next position from the previous
position.
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G Codes: Canned Cycles

• G80 – Cancel canned cycle
• G81 – Drilling cycle
• G83 – Peck drilling cycle
• G84 – Tapping cycle
• G85 – Boring cycle
• G86 – Boring cycle

• NOTE: A canned cycle stays in effect

until cancelled by a G80.
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Canned Cycles: G81

• G81 – Drilling Cycle
• Feed to depth, rapid return

Example of program code:

• N35 G81 X.500 Y.500 Z-1.000 R.100 F1.50
• N36 X1.000 Y1.500
• N37 X1.500 Y2.000
• N38 G80
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Canned Cycles: G83, G84

• G83 – Peck Drilling Cycle
• Feed to an intermediate depth, rapid out, rapid back
to just above previous depth, feed to next depth,
rapid out, repeat until reaching full depth.

• G84 – Tapping Cycle

• This cycle creates internal threads in an
existing hole.
• NOTE: One cannot over-ride the feed rate.
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Canned Cycles: G85, G86

• G85 - Boring Cycle
• Feed to depth, feed back out.

• G86 – Boring Cycle

• Feed to depth, rapid out.
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G Codes: Cutter Compensation

• G40 – Cancel cutter diameter compensation.
• G41 – Cutter compensation left.
• G42 – Cutter compensation right.
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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)
G43 Tool length compensation (plus)
G44 Tool length compensation
(minus) G49 Tool length compensation
cancel
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Table of Important G codes

G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning
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M Word
• M words tell the machine to perform certain
machine related functions, such as: turn
spindle on/off, coolant on/off, or stop/end
program.
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Common M words
• M00 – Programmed pause
• Automatically stops machine until operator pushes a
button to resume program.

• M01 – Optional stop

• A stop acted upon by the machine when operator
has signaled this command by pushing a button.

• M02 – End of program

• Stops program when all lines of code are completed. Must be
last command in program.
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Common M words
• M03 – Turn spindle on
• In clockwise direction
• M04 – Turn spindle on
• In counter clockwise direction
• M05 – Stop spindle
• Usually used prior to tool change or at end of program.
• M06 – Tool change
• Stops program and calls for a tool change,
either automatically or manually.
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Common M words
• M08 – Turns Accessory 1 on.
• M09 – Turns Accessory 1 off.

• M10 – Turns Accessory 2 on.

• M11 – Turns Accessory 2 off.

• M30 – End of program

• Similar to M02 but M30 will also “rewind” the program. Must
be last statement in program. If used, DO NOT use M02.
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Zero Points
• Part Zero
▫ Used for absolute programming mode.
▫ Usually a position on the part that all
absolute coordinates are referenced to.
▫ Changes with different parts and programs.

• Machine Zero or Machine Home Position

▫ Fixed for each machine from the manufacturer.
▫ Not changeable.
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Cutter Path Generation

• Cutter path is generated by moving the tool
from point to point. The points are previously
defined from the part drawing dimensions.
• Each line of code will show the destination
point of where the tool will go to.
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Interpolation
• Method of determining intermediate points along
a cutting path.

• Two methods:
• Linear interpolation – cut a path along a specified
angle at a specified feed rate.
• Circular interpolation – cut a path along an arc
or circle at a specified feed rate.
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Interpolation
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Absolute System
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Incremental System
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TYPES OF CNC MACHINES

In every aspects of manufacturing CNC machines are
used. It can be mainly classified in eight classes.
▫ Mills and Machining centers
▫ Lathes and Turning centers
▫ EDM Machines
▫ Grinding machines
▫ Cutting Machines
▫ Fabrication Machines
▫ Welding Machines
▫ Coordinate Measuring Machines
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CNC
• CNC – Turning Center • CNC – Machining Center
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CNC – Turning Center

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CNC – Machining Center

• It is a machine tool capable of multiple
machining operations on a work part in one
setup under NC program control.

Classification
• Machining centres are classified as
vertical, horizontal, or universal.
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CNC – Machining Center

• Vertical MC • Horizontal MC
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CNC – Machining Center

• Horizontal Boring Mill

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CNC – Machining Center

5 Axis - Vertical Axis Machining Center

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CNC – Machining Center

• Reference points and axis on a Milling Machine

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Automatic Part Programming
Software programs can automatic generation of CNC data

Define Tool
 CNC data

Make 3D model
Simulate
cutting
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Automatic part programming and DNC

Very complex part shapes  very large NC program

NC controller memory may not handle HUGE part program

computer feeds few blocks of

NC program to controller

When almost all blocks executed,

controller requests more blocks
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Summary

CNC machines allow precise and repeatable control in machining

CNC lathes, Milling machines, etc. are all controlled by NC programs

NC programs can be generated manually, automatically

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