ABSTRACT

In Industry it is not efficient or profitable to make everyday products by hand. On a CNC machine it is possible to make hundreds or even thousands of the same items in a day. First a design is drawn using design software, and then it is processed by the computer and manufactured using the CNC machine. This is a small CNC machine and can be used to machine woods, plastics and aluminum. In industry, CNC machines can be e tremely large.

CONTENTS
!. INT"O#$CTION %. &'(NIN) OF CNC *. $+' OF T,-IC(. CNC &(C/IN' 0. -("T+ OF CNC &(C/IN' 1. CNC &(C/IN' 2 IN-$T, -"OC'++, O$T-$T 3. CONTO. -(N'. OF CNC 4. CNC "O$T'" 2 T/' I&-O"T(NT -("T+ 5. CNC &(C/IN' (N# +(F'T, 6. +'TTIN) $- T/' C$TTIN) TOO. TO T/' CO""'CT .'N)T/ !7. (#8(NT()'+ (N# #I+(#8(NT()'+ OF CNC &(C/IN'+ !!. %# CO&-$T'" (I#'# #'+I)N (N# &(N$F(CT$"' !%. *# CO&-$T'" (I#'# #'+I)N (N# &(N$F(CT$"' !*. IN#$+T"I(. -"O#$CTION F.O9C/("T !0. "'F"'NC' :OO;+

INTRODUCTION
The CNC &achine &echanical +eminar "eport describes about the CNC machine which produce hundreds and thousands of one items per day. The designed is made with the design software and it is e ecuted on a computer and made with the help of CNC machine. It is a small CNC machine which is utili<ed for machine plastics, woods, and aluminum. The CNC machines can be very great in industry. The design of the machine is stored into the computer that is connected to the CNC machine. The computer transforms the design in the form of special code that is numerical which controls the method of the CNC for cutting and shaping the material. The parts of the CNC machine are vice, guard, chuck, motor, lathe bed, and cutting tool. The CNC machine includes three steps. They are input, process, and output. The production re=uires three parts of e=uipment. They are computer, an interface, and Computer Numerical Control. Normally, the software and the computer functions the machine. (s a result, the machines include range of controls to utili<e manually. The machine is utili<ed manually like simple functions are performed on cheap or manual machines. If the machine is handled manually then it is utili<ed with its specification and ability. These machines are free from danger to utili<e with the design which is very safe. The important benefit of the machines is they are very safe than operated machines of the man.

CNC MACHINES

CNC means Computer Numerical Control. This means a computer converts the design into numbers which the computer uses to control the cutting and shaping of the material.

Use Of Typical CNC Machine

!. The design is loaded into the computer which is attached to the CNC machine. The computer changes the design into a special code >numerical? that controls the way the CNC cuts and shapes the material.

%. The material to be shaped is taped on to a block with double sided tape. This must be done carefully so that it does not come off the block during machining.

*. The block is then placed in the vice, inside the CNC. It must be tightened up carefully. If it is not secure when the machine starts to cut the material it can come away from the vice. 9hen the machine starts working, the vice moves up, down, right and left according to the design.

0. The guard is placed in position. It protects the machine operator in case the material is pulled out of the vice by the power of the cutter. For safety reasons, if the guard is not in position the motor will not start.

1. The CNC is turned on and the shape is cut from the material. 9hen the cutter has stopped the shaped material can be removed from the vice.

PARTS OF CNC MACHINE

VICE: This holds the material to be cut or shaped. &aterial must be held securely otherwise it may @fly@ out of the vice when the CNC begins to machine. Normally the vice will be like a clamp that holds the material in the correct position.

GUARD: The guard protects the person using the CNC. 9hen the CNC is machining the material small pieces can be @shoot@ off the material at high speed. This could be dangerous if a piece hit the person operating the machine. The guard completely encloses the dangerous areas of the CNC. CHUCK This holds the material that is to be shaped. The material must be placed in it very carefully so that when the CNC is working the material is not thrown out at high speed. MOTOR: The motor is enclosed inside the machine. This is the part that rotates the chuck at high speed. !ATHE BED: The base of the machine. $sually a CNC is bolted down so that it cannot move through the vibration of the machine when it is working. CUTTING TOO!: This is usually made from high =uality steel and it is the part that actually cuts the material to be shaped.

CNC MACHINE " INPUT# PROCESS# OUTPUT

( CNC production facility needs three pieces of e=uipmentA A C$%p&'e( The computer is used to draw the design. /owever, the design is only a picture and the CNC machine cannot use this to manufacture the product. The computer software must also convert the drawing into numbers >coordinates? that the CNC machine can use when it starts to cut and shape the material. An In'e(face ( computer cannot be directly connected to a CNC machine. The computer is connected to an interface. This converts the signals from the computer to a form that the CNC machine understands. The signals are in the form of digital signals when they are sent to the CNC machine. CNC )C$%p&'e( N&%e(ical C$n'($l* Machine The signals from the interface control the motors on the CNC machine. The signals determine the way the vice moves. The vice moves in three directions B, , and C. >/ori<ontally, vertically and depth?. The signals also control the speed of the cutting tool.

 CONTRO! PANE! OF CNC

( CNC machine is normally controlled by a computer and software. /owever, most CNC machines have a range of controls for manual use. It is rare for a CNC machine to be used manually as simple operations are best carried out on cheapDbasicDmanual machines. 9hen a CNC machine is used manually it is been used well below its capability and specification.

RESET BUTTONA The must important control button is usually the reset button. 9hen the CNC machine is turned on, the reset button is pressed by the machine operator. This E<erosF the cutter, moving the cutter to coordinates 7, 7, 7 on

the B, (nd C a is. In simple terms, the reset button moves the cutter to the corner of the machine, above the work table. If the reset button is not pressed, it is possible that the CNC machine will start cutting the material in the wrong place or even miss cutting the material and plunge into the work table. MANUA! CONTRO!A The cutter can be controlled manually although this is rarely needed. The EBF and E,F buttons control the movement of the cutter along the hori<ontal surfaces. The ECF buttons control depth and up D down movement. STOP BUTTONA &ost control panels have stop buttons. 9hen pressed these stop the machine very =uickly. SPEED AND FEEDA On some CNC machines it is possible to manually vary the speed and feed of the cutter.

CNC R$&'e( " The I%p$('an' Pa('s

CNC MACHINES AND SAFET+

CNC machines are very safe to use as they are designed to be as safe as possible. One of the main advantages of CNC machines is that they are much safer than manually operated machines.

!, &ost modern CNC machines are designed so that the cutting tool will not start unless the guard is in position. (lso, the best CNC machines automatically lock the guard in position whilst the cutter is shaping material. The guard can only be opened if the cutter has stopped. %, It is essential that pupils D students D machine operators receive E=ualityF instruction before attempting to use any CNC e=uipment. *, CNC routers, used for shaping materials such as woods and plastics, have built in e traction. #ust can be very dangerous if inhaled and can also cause eye irritation. The CNC "outer shown above has an outlet for an e traction unit. (s the router is fully enclosed, dust cannot escape into the atmosphere. If an e traction unit is attached the dust is removed automatically. &ost manually operated machine routers have very limited e traction systems which leave some dust in the air. 0, The CNC router above has a single phase electrical supply. Older machines such as manually operated milling machines and centre lathes have three phase supplies. ( single phase electrical supply can be EpluggedF into any available socket. The electrical supply for the machine comes through a residual circuit breaker >"C:?. If an electrical fault develops the "C: will cut off electrical power immediately. 1, +ingle phase CNC machines can be moved more easily because they are simply unplugged and relocated. Three phase machines are specially wired by an electrician into the electrical supply and cannot be unplugged. 3, &ost CNC machines work behind a guard or even a closed, transparent safety door. This means that the operated cannot be hurt by @flying@ pieces of sharpDhot material. 4, Commonsense applies to the use of all machines including CNC machines. :asic safety training regarding working in a workshop and with other machines applies to CNC machines as well.

SETTING UP THE CUTTING TOO! TO THE CORRECT !ENGTH

One of the few operations that the machine operator carries out is to change the cutting tool. 'ach CNC machine has a range of cutting tools. +traight cutters chamfer 82groove and radius cutters are some e amples. If a detailed design is being manufactured, it may be necessary to change the cutting tool at least once during the manufacturing process. It is very important that all the cutters are set up to e actly to the same length in the cullet. If this is not done the material being machined will be machined at incorrect depths. ( special depth gauge is used to accurately set up the cutting tools. >+ee diagram below?. This EruleF applies to all CNC machines although different techni=ues may be used depending on the type of the CNC machine.

( pair of spanners is used to loosen the cullet and locking nut. The cutting tool can then be removed and the new tool put in position. Once the depth gauge has be used to check the distance from the end of the cutting tool to the cullet, the spanners are used again to tighten the cullet and locking nut.

ADVANTAGES AND DISADVANTAGES OF CNC MACHINES

CNC >Computer Numerical Control machines? are widely used in manufacturing industry. Traditional machines such as vertical millers, centre lathes, shaping machines, routers etc. operated by a trained engineer have, in many cases, been replaced by computer control machines.

CO&-$T'" N$&'"IC(. CONT"O. &(C/IN' ADVANTAGES !. CNC machines can be used continuously %0 hours a day, *31 days a year and only need to be switched off for occasional maintenance. %. CNC machines are programmed with a design which can then be manufactured hundreds or even thousands of times. 'ach manufactured product will be e actly the same. *. .ess skilledDtrained people can operate CNCFs unlike manual lathes D milling machines etc... 9hich need skilled engineersG 0. CNC machines can be updated by improving the software used to drive the machines 1. Training in the use of CNCFs is available through the use of Evirtual softwareF. This is software that allows the operator to practice using the CNC machine on the screen of a computer. The software is similar to a computer game. 3. CNC machines can be programmed by advanced design software such as -roD#'+;TO-H, enabling the manufacture of products that cannot be made by manual machines, even those used by skilled designers D engineers. 4. &odern design software allows the designer to simulate the manufacture of hisDher idea. There is no need to make a prototype or a model. This saves time and money. 5. One person can supervise many CNC machines as once they are programmed they

&(N$(.., O-'"(T'# C'NT"' .(T/' DISADVANTAGES !. CNC machines are more e pensive than manually operated machines, although costs are slowly coming down. %. The CNC machine operator only needs basic training and skills, enough to supervise several machines. In years gone by, engineers needed years of training to operate centre lathes, milling machines and other manually operated machines. This means many of the old skills are been lost. *. .ess workers are re=uired to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment. 0. &any countries no longer teach pupils D students how to use manually operated lathes D milling machines etc... -upils D students no longer develop the detailed skills re=uired by engineers of the past. These include mathematical and engineering skills.

can usually be left to work by themselves. +ometimes only the cutting tools need replacing occasionally. 6. ( skilled engineer can make the same component many times. /owever, if each component is carefully studied, each one will vary slightly. ( CNC machine will manufacture each component as an e act match.

-D COMPUTER AIDED DESIGN AND MANUFACTURE

There are two types of computer aided design software. %# design software allows the designer to design shapes with very limited three dimensional properties. #o not underestimate the designs that can be achieved through %# software.

!. The design is drawn using software such as Tec +oft %# #esign. (t first
appearance this software looks basic but, depending on the skill of the designer, =uite comple designs can be produced. The e ample shown is a simple block of material with initials.

%. 9hen the design is complete the drawing is processed. This converts the
drawing into a detailed series of B, , and C coordinates. -rocessing must take place before the CNC machine can cut the design from material. 9hen the CNC machine shapes the material the cutter follows the coordinates, in se=uence, until the shape has been manufactured.

*. &ost C(#DC(& software allows the designer to test the manufacture of

hisDher design on a computer rather than actually making it. This saves time and materials. Testing designs is carried out using EsimulationF software. 9hen the design is run through simulation software the computer displays the manufacturing on the screen. It also checks whether or not the design can be manufactured successfully. &any designs have to be altered before they can be made by a CNC machine.

0. (fter all the testing and improvements to the design, it can finally be
manufactured on a CNC machine.

.D COMPUTER AIDED DESIGN AND MANUFACTURE

*# #esign software allows the designer to produce three dimensional representations of hisDher ideas. 9hen completed the design can be viewed on the screen and it can even be revolved and e amined at any angle. *# software is much more comple than %# software such as Tec +oft %# design. It re=uires specialist training before it can be used competently.

!. The designer draws up the design using software. The design can be
e amined in detailed and if modificationsDalterations are needed they can be made on the screen. +oftware of this type allows the designer to model hisDher idea on the screen rather than makeDmanufacture an e pensive model. )ood *# software allows the designer to design almost any item.

%. The design is processed. 9hen the design has been completed using software
it must be e ported as a stereo lithography file. This type of file can be imported into processing software which converts the drawing into a long list of coordinates. 'ach set of coordinates is called a ) code I & code.

*. &ost C(#DC(& software allows the designer to test the manufacture of

hisDher design on a computer rather than actually making it. This saves time and materials. Testing designs is carried out using EsimulationF software. 9hen the design is run through simulation software the computer displays the manufacturing on the screen. It also checks whether or not the design can be manufactured successfully. &any designs have to be altered before they can be made by a CNC machine.

0. (n advanced CNC machine can be used to manufacture the three dimensional

product. This CNC is both fast and accurate making suitable for school and industrial use.

CNC !ATHES PROGRAM CODES

#efault ) codes used on most machines types. $ser customi<able ) codes will change based on application and user definition. ,ou can add, modify, edit, delete and customi<e your own ) and & codes. +pecial characters that can be used from within your program areA > ? 'nter user notes between the two parentheses. J K 'nter math functions between the two braces. )77 "apid move )7 BL ,L CL up to eight a es or )7 CL BL )7! Feed "ate move )! BL ,L CL up to eight a es or )! CL BL )7% Clockwise move )7* Counter Clockwise move )70 #well time )70 .L )75 +pline +moothing On )76 ' act stop check, +pline +moothing Off )!7 ( linear feedrate controlled move with a decelerated stop )!! Controlled #ecel stop )!4 B, -.(N' )!5 BC -.(N' )!6 ,C -.(N' )%5 "eturn to clearance plane )** Threading >.athe? )*1 :ypass error checking on ne t line )07 Tool compensation off )0! Tool compensation to the left

)0% Tool compensation to the right )0* Tool length compensation 2 negative direction )00 Tool length compensation 2 positive direction )06 Tool length compensation cancelled )1* Cancel work coordinate offsets )102)16 9ork coordinate offsets ! through 3 )3! +pline contouring with buffering mode off )30 +pline contouring with buffering mode on )31 &ill out rectangular pocket )33 &ill out circular pocket )34 Flycut )35 &ill out rectangular pocket with radius corners )47 Inch mode )4! &illimeter mode )40 -eck drilling >.athe? )5* CL BL "L )5! #rill cycle )5! BL ,L CL "L )5% #well cycle )5% BL ,L CL "L )5* -eck cycle )5* BL ,L CL "L )50 Tapping cycle )50 BL ,L CL "L CL )51 :oring cycle ! )51 BL ,L CL "L )53 :oring cycle % )53 BL ,L CL "L )55 :oring cycle * )55 BL ,L CL "L )56 :oring cycle 0 )56 BL ,L CL "L )67 (bsolute mode )6! Incremental mode )6% /ome coordinate reset )6% BL ,L CL )60 I-& mode >.athe? default )61 I-" mode >.athe? )63 Constant +urface Feed On >.athe?

)64 Constant +urface Feed Off >.athe? )!!7 .athe )roove Face )!!! .athe )roove O# )!!% .athe )roove I# )!!* .athe Thread O# )!!0 .athe Thread I# )!!1 .athe Face "ough )!!3 .athe Turn "ough )!%7 &ill Outside +=uare )!%! &ill Outside Circle or Island )!%% &ill Out Counter :ore )!%* &ill Outside 'llipse pocket )!%0 &ill Inside 'llipse pocket )!%1 &ill Outside +lot )!%3 &ill Inside +lot pocket )!*7 *# tool compensation with gouge protection )!*! *# offset parallel to *# profile )!*% *# tool compensation with gouge protection in the C a is only )!*1 1 a is tool compensation with gouge protection )!*3 Included angle limit for gouge protection. )!*3 .L )!07 *# part rotation and plane tilting )!07 $L 8L 9L "L )!0! +cale factor for the B a is only. )!0! .L )!0% +cale factor for the , a is only. )!0% .L )!0* +cale factor for the C a is only. )!0* .L )!37 &ill *# Cylinder )!3% &ill *# +phere )!3* &ill *# "amped -lane )!47 +et soft limits and crash fi tureDchuck barriers to defaults )!4! +et backward crash fi tureDchuck barriers )!4! $L 8L 9L

)!4% +et forward crash fi tureDchuck barriers )!4% $L 8L 9L )!5! :olt /ole #rill )!5% :olt /ole #well )!5* :olt /ole -eck )!50 :olt /ole Tap )!51 :olt /ole :ore

M C$/es #efault & codes used on most machines types. $ser customi<able & codes will change based on application and user definition. &7! -rogram +top &7% 'nd of -rogram &7* +pindle On Clockwise, .aser, Flame, -ower ON &70 +pindle On Counter Clockwise &71 +pindle +top, .aser, Flame, -ower OFF &73 Tool Change &75 Coolant On &76 Coolant Off &!7 "eserved for tool height offset &!* +pindle On, Coolant On &*7 'nd of -rogram when macros are used &6! "eadout #isplay Incremental &6% "eadout #isplay (bsolute &64 )o to or Mump to line number &65 Nump to macro or subroutine &66 "eturn from macro or subroutine &!77 &achine Cero "eset &!66 &id program start

CONTRO! S+STEMS IN CNC

There are two main systems of control, O-'N and C.O+'# loop.

Open !$$p
This form of control is relatively cheap, but does not have good repeatability of position. The a is motor is a stepper motor and this is not only the motive power, but also the method of achieving accuracy.

Cl$se/ !$$p C$n'($l

In closed loop there is a feedback loop that informs the controller whether or not the slide has reached the desired position. +ervo motors are used and the system has very good repeatability. The drawback is the e tra cost of such a system. On the ne t page the methods of reading positions using transducers will be e plained.

REFERANCE BOOKS

+r (uthor No. ! &r. +anMay "aut

Title CNC machine I -rograming CNC &achine (dvance CNC &achine I -rogramming

-ublisher -une 8idyarthi )ruh, -une +tandard -ublishers

% *

&r. Nitendra ;ulkarni (ntech Technology