ADVANCED

MANUFACTURING
TECHNOLOGY
CREDITS: 3+1

Dr. Richa
Agrawal
Course
Objectives
•To familiarize with subtractive manufacturing processes
in particular CNC systems.

•To familiarize with various additive manufacturing

processes

•To familiarize with principle and working of non-traditional

manufacturing

•To introduce to them the Intelligent manufacturing in the

context of Industry 4.0

•To acquaint with basic process of developing 3D model using

biomedical data. Dr. Richa 2
Agrawal
Course
Outcomes
Learner will be able to
•Develop and execute CNC part program for various machining
operations.
•Understand the generation of tool paths through different
approaches.
•Identify the additive manufacturing process for development of a
component.
•Illustrate principles and working of non-traditional
manufacturing and select the proper process for the purpose of
manufacturing.
•Understand the manufacturing technologies enabling Industry
4.0 Dr. Richa 3
Agrawal
•Develop a 3D model using available 2D images.
COMPUTER
AIDED
MANUFACTURING
MODULE 1 Dr. Richa
Agrawal
4
MODULE 1: COMPUTER AIDED
MANUFACTURING
•Introduction
•NC/CNC/DNC machines
•Machining Centers
•Coordinate system
•CNC machining practices and
programming:
• Manual part programming method
• Canned Cycles for milling, turning

Dr. Richa 5
Agrawal
 Product Life
Cycle Computer Computer
CA
Aided Aided
Design Engineeri Drafting
ng

Product Design Drafting

Engineering
Concept
Customer Process
Market New Equip. Planning CAPP
Tooling

Quality Production
Production
Control Scheduling
- Computerized Scheduling,
Computer CAM, NC MRP
Aided Q.C. Robotics - Shop
6
FlooDrr.CRoicnhtaroAl
grawal
CAD – Computer Aided Design
CAD can be defined as the use of computer systems to
perform certain functions in the design process.

CAM – Computer Aided Manufacturing

CAM is the use of computer systems to plan, manage
and control the operations of manufacturing plant
through either direct or indirect computer interface
with the plant’s production resources.
Dr. Richa 7
Agrawal
Manufacturing

•Subtractive Manufacturing: https://

www.youtube.com/watch?v=i-PgeWbDgq4

•Additive Manufacturing: ttps://

www.youtube.com/watch?v=m_QhY1aABsE

•Formative Manufacturing

https://
www.youtube.com/watch?v=LfNC1iIay3Y
Dr. Richa 8
Agrawal
NC/CNC/DNC
•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
•The program is translated into the appropriate
electrical signals for input to motors that run the
machine.
•Machine functions controlled electronically, Dr. Richa
Agrawal
9

hydraulically or pneumatically
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 (spindle speed)
with a feed rate of over 600 ipm and an accuracy of .0001 (1980)
Dr. Richa 10
Agrawal
Elements of Numerical
Control

Dr. Richa 11
Agrawal
Elements of Numerical
Control
TAPE ND A
CODING A FORM T

Dr. Richa 12
Agrawal
 Elements of Numerical
Control
• Tape punch: convertswritten instructions into a corresponding hole pattern. The
hole pattern is punched into tape which is passed through the tape punch.
Much older units used a typewriter device called a Flexowriter, and later
devices included a microcomputer coupled with a tape punch unit.
• Tape reader: reads the hole pattern on the tape and converts the pattern to a
corresponding electrical signal code.
• Controller:
receives the electrical signal code from the tape reader and
subsequently causes the NC machine to respond.
• NC machine: responds to programmed signals from the controller. Accordingly, the
machine executes the required motions to manufacture a part (spindle rotation
on/off, table and or spindle movement along programmed axis directions,
etc.).
Dr. Richa 13
Agrawal
 Advantages of CNC over NC Machines

•Part Program storage memory

•Part program editing, downloading and
uploading
•Part program simulation using tool path
•Additional part programming facilities –
Macros and subroutines

Dr. Richa 14
Agrawal
 CNC Application
Characteristics
•Batch production (small and medium lot size, from 1 to several
hundred units)
•Repeated orders
•Complex part geometry.
•Much metal needs to be removed from the workpart.
•Many separate machining\ operations on the part.
•Expensive part.
•Close tolerance.
•Engineering design change is likely.
•Required Dr. Richa Agrawal
inspection. 15
 Application of CNC
Machines
•Machine tool
application
•Non machine tool
application.

Multidimensio CNC Plasma Automotive Medical

nal Cutting Design Industry

Dr. Richa 16
Agrawal
 Advantages of CNC
Machines
•Production in less time, therefore less expensive. Lead time can
be reduced
• By reducing no. of steps
• By reducing set up time
• By reducing work piece handling time
• By reducing tool changing time
•Parts prepared more accurately even for small batches.
•Less scrap due to operators errors.
•Need of expensive jigs and fixtures is reduced.
•Inspection time is reduced. Cont…
Dr. Richa 17
Agrawal
 Advantages of CNC
Machines
•No. of machine tolls required is reduced.
•Set up time is reduced due to datum surface
location.
•Machining time cost is predictable.
•No operator fatigue.
•Tools can be used at optimum feeds ad
speeds.
•Modifications can be easily translated.
•Capability (MRR) is high.
Dr. Richa 18
Agrawal
 Limitations of CNC
Machines
•Cost of CNC m/c and tooling is high. (5-10 times).
Necessity for large utilization.
•Cost and skill of the people required to operate is high.(part
programmers, tool setters, maintenance staff etc.)
•Special training needs to be given.
•High maintenance cost (trained in mechanical, hydraulic,
pneumatic and electronics).
•High running cost. Conditioned environment adds to it.

Dr. Richa 19
Agrawal
 DNC - Direct Numerical
Control
•Provides a central digital repository for all manufacturing and NC data,
and to make this data available to the shop floor.
•Features of a complete DNC solution include:
• Central management and revision control of NC programs and related CAM data;
• Direct connection from the data repository to CNC machines on the shop floor;
• Configuration options to support specific requirements and preferences of each
manufacturer.

Dr. Richa 20
Agrawal
CNC
Machine
CNC
Lathe
Lathe

CNC
Milling
Mill

Dr. Richa 21
Agrawal
Work Coordinate System: Milling
Machines

Dr. Richa 22
Agrawal
Machining
Centers
Vertical Machining Horizontal Machining
Center Center

VMC HMC

Machining
Centre
Dr. Richa 23
Agrawal
NC
Words
N refers to the block number.
G refers to the G code (Preparatory function).

X refers to the distance travelled by the slide tool in the X

axis direction. Y refers to the distance travelled by the slide
tool in the Y axis direction. Z refers to the distance travelled
by the slide tool in the Z axis direction.
F refers to the feed rate.
M refers to the M code (Miscellaneous function).
S refers to the spindle speed.
T refers to the tooling management. Cont…. Dr. Richa 24
Agrawal
 NC
Words
A. Rotation about x-axis
B. Rotation about y-axis
C. Rotation about z-axis
I. Interpolation parameter/thread pitch
parallel to x-axis
J. Thread pitch parallel to y-axis
K. Thread pitch parallel to z-axis
U,V & W 2nd movement parallel to x, y and z axis

Dr. Richa 25
Agrawal
 Word Address
Format

Sequence and format of words:

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

K1.4
Sequence Destinatio Dist to center of To
Feed
no n circle ol
rate
coordinat Spindle
Preparatory es speed
function Miscellaneous
function

Dr. Richa 26
Agrawal
Word Address
Format
The words in a block are usually given in the following
order (although the word address format allows
variations in the order)
1. Sequence number (N-word)
2. Preparatory word (G-word)
3. Coordinates (X-, Y-, Z-words for linear axes, A-B-C-
words for rotational axes)
4. Feed rate (F-word)
5. Spindle speed (S-word)
6. Tool selection (T-word)
7. Miscellaneous command (M-word)
8. End-of-block (EOB symbol)
Dr. Richa 27
Agrawal
 NC
Words
• SEQUENCE NUMBER (N code): This is used to identify the block within an NC
program and provides a means by which NC commands may be
rapidly located.
• PREPARATORY WORD (G code): This word is used to prepare the controller for
instructions that are to follow. For example, the word G02 is used to
prepare the NC controller unit for circular interpolation along an arc in the
clockwise direction. The preparatory word is needed so that the controller
can correctly interpret the data that follow it in the block.
 Two numerical digits following the G prefix
 More than one G code can be in a block but from diff erent groups.
• COORDINATES (x-, y-, and z-words): These give the coordinate positions of the
tool. In a two- axis system, only two of the words would be used. In a four-
or five-axis machine, additional a-words and/or b-words would specify the
angular positions.
• FEED RATE (F code): This specifies the feed in machining operation.Dr.Units
Richa 28
are inches per minute (ipm) by convention. Agrawal
NC
Words
• CUTTING SPEED (S code): This specifies the cutting speed of the process,
the rate at which the spindle rotates.

• TOOL SELECTION (T code): This code would be needed only for machines
with a tool turret or automatic tool changer. The t-word specifies which tool
is to be used in the operation.

• MISCELLANEOUS FUNCTION (M code): The M code is used to specify

certain miscellaneous or auxiliary functions, which may be available on
the machine tool. Of course, the machine must possess the function that
is being called. The miscellaneous function is the last word in the
block.

• EOB: To identify the end of the instruction, an end-of-block EOB symbol

Dr. Richa 29
is used. Agrawal
 Part Programming
Methods
Part programming can be accomplished using a variety of procedures
ranging from highly manual to highly automated methods.

The methods are:

• Manual part programming

• Computer-Assisted Part Programming
• Part Programming using CAD/CAM
• Manual data input

Dr. Richa 30
Agrawal
 Manual Part
Programming
G Codes
•Motion Group:
 Positioning (G00)
 Linear interpolation (G01)
 Circular interpolation (G02,
G03)
•Dwell: G04
•Active plane selection group:
•*G17 (X,Y)
•G18 (X,Z)
•G19 (Y,Z) Dr. Richa 31
Agrawal
 Manual Part
Programming
G Codes
•Units group:
 *G20 Inch Selection,
 G21 Metric Selection
•Hole making canned cycle group: G80
– G89
•Co-ordinate system group:
 *G90 absolute positioning,
 G91 incremental positioning
•Preset: G92 Dr. Richa 32
Agrawal
 Manual Part
Programming
Motion Commands
• G00:
G00 is used for a point-to-point rapid traverse movement of coordinat
the tool to the specified in the command; for example, es
G00 X050 Y86.5 Z100;
specifies a rapid traverse motion from the current location to the location
defined
 This command would be appropriate for NC drilling machines in which a
rapid move is desired to the next hole location, with no specification on
the tool path.
 The velocity with which the move is achieved in rapid traverse
mode is set by parameters in the MCU and is not specified
numerically in the instruction block.
Dr. Richa 33
 The G00 code is not intended for contouring operations. Agrawal
 Manual Part
Programming
Motion Commands
•G01:
Linear interpolation mode is accomplished by the G01 code. This is used
when it is desired for the tool to execute a contour cutting operation
along a straight line path. For example, the command
G01 G94 X50 Y86.5 Z100 F40 S800 ;
specifies that the tool is to move in a straight line from its current
position to the location defined by x=50.0mm, y=86.5mm, and
z=100.0mm, at a feed rate of 40mm/min and spindle speed of 800
rev/min.
•G94 – Feed rate/ min
Dr. Richa 34
Agrawal
 Manual Part
Programming
Motion Commands
•G02 & G03:
The G02 and cod are used for
G03 circular interpolation,
es clockwise
and Thus, the
respectively. counter-clockwise,
instruction
G02 G17 X88 Y40 R28 F30 ;
moves the tool along a clockwise trajectory in
the x-y plane to the final coordinates defined
by x=88mm and y=40mm at a feed rate of
30 mm/min. The radius of the circular arc is
28mm.
Dr. Richa 35
Agrawal
 Manual Part
Programming
Preset G92
With the tool in position, the G92 code is used by the programmer
to define the origin as follows:
G92 X0 Y-050.0 Z010.0;
Units – G21
Our x, y, and z values are specified in mm, and this would have to
be explicitly stated. Thus, a more-complete instruction block would
be the following:
G21 G92 X0 Y-050.0 Z010.0;
Where the G21 code indicates that the subsequent coordinate
values are in mm.
Dr. Richa 36
Agrawal
 Manual Part
Programming
Cutter
Offset

• The tool path is separated from the part perimeter by a distance

equal to the cutter radius.
• To invoke cutter offset compensation,
the G41 code is used to follow the clockwise
Dr. Richa 37
path, and G42 is used to follow the counterclockwise path.Agrawal
 Manual Part
Programming
Cutter Offset
The instruction for profile milling the bottom edge of the part,
assuming that the cutter begins along the bottom left corner, would
read:
G42 G01 X100.0 Y040.0 D05;

where D05 refers to the cutter radius value stored in MCU memory.
Certain registers are reserved in the control unit for these cutter offset
values. The D-code references the value contained in the identified
register. D05 indicates that the radius offset distance is stored in the
number 5 offset register in the controller. Dr. Richa 38
Agrawal
Manual Part
Programming

Dr. Richa 39
Agrawal
Manual Part
Programming

•Absolute
Programming
From A to B
G01 X60 Y15

•Incremental
Programming
From A to B
G01 X15 Y15

Dr. Richa 40
Agrawal
 G
Codes
G Code Milling Function ( may vary depending on the controller)
G00 Rapid Travel – axis motion at maximum speed
G01 Linear Interpolation – straight linear axis motion at a controlled federate
G02 Clockwise circular motion using two axes in a single program block
G03 Anticlockwise circular motion using two axes in a single program block
G04 Dwell, stoppage of axis motion , for a programmed length of time
G10 Tool length Offset value
G17 XY plane selection
G18 ZX plane selection
G19 YZ plane selection
G20 Inch Programming
G21 Metric Programming
G28 Return to reference point

Dr. Richa 41
Agrawal
G
Codes
G Code Milling Function ( may vary depending on the controller)
G40 Cancel Cutter Diameter Compensation
G41 Cutter Diameter Compensation, left
G42 Cutter Diameter Compensation, right
G43 Tool Length Compensation (+ve) ON
G44 Tool Length Compensation (-ve) ON
G45 Tool Length Compensation OFF
G90 Absolute Positioning
G91 Incremental Positioning
G92 Repositioning or resetting the origin point
G94 Per minute Feed rate
G95 Per revolution Feed Rate

Dr. Richa 42
Agrawal
 G
G Codes
Code Milling Function ( may vary depending on the controller)
G76 Fine Boring Cycle
G80 Cancel Canned Cycle
G81 Drilling Cycle
G82 Counterboring Cycle
G83 Deep Hole or Intermittent Peck Drilling Cycle
G84 Tapping Cycle
G85 Boring or Reaming
G86 Rapid Boring (rapid return to reference level)
G87 Boring Back
G88 Boring Manual Dwell
G89 Boring Dwell
G98 Return to Initial Level
G99 Return to reference Level

Dr. Richa 43
Agrawal
 M
Codes
M Code Function ( may vary depending on the controller)
M00 Program Stop – would terminate the auto operation
M01 Optional or Planned Stop
M02 End of Program
M03 Spindle ON – Clockwise Rotation
M04 Spindle ON – Anticlockwise Rotation
M05 Spindle OFF
M06 Tool Change
M07 Coolant ON (flood)
M08 Coolant ON (mist)
M09 Coolant OFF
M13 Spindle Clockwise and Coolant ON
M14 Spindle Anticlockwise and Coolant ON
M19 Spindle Orient and Stop
M30 End of Tape – will rewind automatically Dr. Richa Agrawal 44
 Part Programming
Examples
Example 1: Point-to-Point
Drilling

Dr. Richa 45
Agrawal
 Part Programming
Examples
Example 1: Point-to-Point
Drilling

Dr. Richa 46
Agrawal
 Part Programming
Examples
Example 1: Point-to-Point Drilling
•Example presents the NC part program in word address format for drilling the three holes in the sample part.
•Assume that the outside edges of the starting workpart have been rough cut (by jig sawing) and are slightly
oversized for subsequent profile milling.
•The three holes to be drilled in this example will be used to locate and fixture the part for profile milling in the
following example.
•For the present drilling sequence, the part is gripped in place so that its top surface is 40 mm above the surface of
the machine tool table to provide ample clearance beneath the part for hole drilling.
•The x-, y-, and z-axes will be defined as shown in the figure.
•A 7.0-mm diameter drill, corresponding to the specified hole size, has been chucked in the CNC drill press.
•The drill will be operated at a feed of 0.05 mm/rev and a spindle speed of 1000 rev/min (corresponding to a
surface speed of about
0.37 m/ s, which is slow for the aluminum work material).

•At the beginning of the job, the drill point will be positioned at a target
point located at x=0, y=-50, and z=+10 (axis units are mm).
•The program begins with the tool positioned at this target point. Dr. Richa 47
Agrawal
 Part Programming
Examples
NC Part Program Code Comments

N001 G21 G90 G92 X0 Y-50 Define origin of axe

Z10; N002 G00 X70 Y30; s hole
Rapid move to first
N003 G95 G01 Z-15 F0.05 S1000 location Drill the first hole
M03; N004 G01 Z10; Retract drill from hole
N005 G00 Y60; Rapid move to second hole
N006 G95 G01 Z-15 location Drill second hole
F0.05; N007 G01 Z10; Retract drill from hole
N008 G00 X120 Y30; Rapid move to third hole
N009 G95 G01 Z-15 location Drill third hole
F0.05; N010 G01 Z10; Retract drill from hole
N011 G00 X0 Y-50 Rapid move to target
M05; N012 M30; point
End of program, stop
machine
Dr. Richa 48
Agrawal
 Part Programming
Examples
Example 1: Two axis milling
• The three holes drilled in the previous example can be used for locating and holding the workpart to
completely mill the outside edges without re-fixturing.

• The axis coordinates are the same coordinates as in the previous drilling sequence.
• A 20-mm diameter end mill with four teeth will be used. The cutter has a side tooth engagement length of 40 mm.
• Throughout the machining sequence, the bottom tip of the cutter will be positioned 25 mm below the part top
surface, which corresponds to z=-25mm.

• Since the part is 10mm thick, the z-position will allow the side cutting edges of the milling cutter to cut the full
thickness of the part during profile milling.

• The cutter will be operated at a spindle speed=1000 rev/min (which corresponds to a surface speed of about 1.0
m/s) and a feed rate
= 50mm/ min (which corresponds to 0.20 mm/ tooth).

• The tool path to be followed by the cutter is shown in the following figure, with numbering that corresponds to the
sequence number in the program.

• Cutter diameter data has been manually entered into offset register 05. Dr. Richa 49
Agrawal
Part Programming
Examples

Dr. Richa 50
Agrawal
 Part Programming
Examples
Example 1: Two Axis
Milling

Dr. Richa 51
Agrawal
 Part Programming
Examples
NC Part Program Code Comments

N001 G21 G90 G92 X0 Y-50 Define origin of axe

Z10; N002 G00 Z-12 S1000 s
Rapid to cutter depth, turn
M03; N003 G01 G94 G42 Y0 spindle ON Engage part, start
D05 F40; N004 G01 X160; cutter offset
N005 G01 Y60; Mill lower part edge
N006 G17 G03 X130 Y90 Mill right straight
R30; N007 G01 X35; edge
N008 G01 X0 Y0; Circular interpolation
N009 G40 G00 X-40 around arc Mill upper part
M05; N010 G00 X0 Y- edge
50 Z 10; N011 M30; Mill left part edge
Rapid exit from part, cancel
offset Rapid move to target
Dr. Richa 52
point
Agrawal
End of program, stop
machine
Milling
Exercise 1

•Write a manual Part program to machine the contour as shown

in Figure. The component is 12mm thick.

X15,
Y15

Dr. Richa 53
Agrawal
Milling
Exercise 1
NC Part Program Code

N010 G21 G90 G92 X0 Y0

Z10; N020 T01 M06;
N030 G43 H01
M07; N040 G00 Z-
14;
N050 S800 M03;
N060 G94 G17 G41 G01 X15 Y15 D01
F40; N070 G01 Y65 ;
N080 G02 X35 R10;
N090 G03 X65
R15;
N100 G01 X75;
N110 G01 Y30;
N120 G01 X60 Y15;
N130 G01 X15;
N140 G40 G00 X0 Y0 Z10 M05 Dr. Richa Agrawal
54
M09; N150 M30;
Drilling Canned
Cycle
N10 G81 G99 X20 Y20 Z-10 R2
F200;
N10 – Sequence no.
G81 – G code for drilling Cycle
G99 – Specifies that the spindle should return to
reference level when retracting out of the
hole.
X20 Y20 – Location of the point to begin drilling
(reached in rapid mode)
Z-10 – Instruction to feed the Z axis by 10mm
R2 – Specifies the Z coordinate where the
spindle is to begin feeding, till it reaches
this plane, the spindle moves in rapid
To cancel a canned cycle, G80
F Dr.motion
– Feed rate for the Z axis Richa Agrawal
is 200
used.
55
 Milling
Exercise 2
Y

Z
X

Dr. Richa Agrawal

56
Milling
Exercise
• Spindle Speed 2
and Feed Calculation:
Drilling:
Drill Diameter, D = 10mm
For Cast Iron, cutting speed, V = 18m/ min
Spindle Speed , RPM = 320V/ D = 576 rpm ~ 580 rpm
Feed = 0.2 mm/rev = 0.2 * 580 = 116 mm/min ~ 120 mm/min
Milling:
Cutter Diameter, D = 10mm
For Cast Iron, cutting speed, V =
15m/ min Spindle Speed , RPM =
320V/ D = 480 rpm
For end Mill Cutter feed per tooth f, f = 0.15
mm/ tooth, Assuming no. of flutes as 4 , Z
Dr. Richa 57
= 4 Agrawal
Feed (MMPM) = RPM x Z x f = 480 x 4 x 0.15
= 288 mm/min ~ 290 mm/min
 Milling
Exercise 2
• N010 G21 G90 G92 X-20 Y-20 Z10;
• N015 T01 M06;
• N020 S580 M03;
• N025 G43 H01 M07;
• N030 G94 G81 G99 X25 Y10 Z -28 R2
F120;
• N035 X50;
• N040 X75;
• N045 G49 G80 G00 X-20 Y-20 Z10 M05
M09;
• N050 T02 M06;
• N055 G43 H02 S480 M03 M07;
• N060 G00 Z-28;
Dr. Richa 58
• N065 G94 G42 G01 X0 Y0 D02 F290; Agrawal
Milling
Exercise 2
•N070 G01 X100;
•N080 G01 Y20;
•N090 G02 X40 Y80 R60;
•N100 G01 X15;
•N110 G01 X0 Y30;
•N120 G01 X0 Y0;
•N130 G40 G49 G00 X-20 Y-20 Z10 M05
M09;
•N140 M30;
Dr. Richa 59
Agrawal
 Milling
Exercise 3
Write a CNC program using G and M codes for contouring a component of
thickness 10 mm. Also make drill of 16 mm diameter hole, as shown.
Solution:
Assuming
1.Drilling
Tool - Drill - T01 – Dia.
16mm, Register Value -
D01, H01
Speed - 400
rpm Feed – 0.2
mm/rev
2.Milling
Tool – End Mill - T02 – Dia.
10mm Register Value - D02,
H02
Speed - 500 rpm Dr. Richa 60
Agrawal
Feed – 0.15
mm/rev