Chapter-1

INTRODUCTION
1.1 Numerical control
Numerical control for machines .tools were introduced in 1950s by Prof.John T
Parsons. The first NC machine was built at the Massachusetts institute of Technology in 1953
by joint efforts of US Air Force, the MIT and parsons cooperation. NC is control by numbers
.NC is control recorded information called part program, which is set of coded instructions
given as numbers for automatic control of am machine in a pre-determined sequence.
Numerical control can be defined as a technique of controlling a machine tool by the
direct insertion of numerical data at some point of the system .The functions that are
controlled on the machine tool are displacement of the slide members, spindle speeds ,tool
selection etc.At first ,the numerical control was used to produce geocentrically complex parts
,but later used for added efficiency in medium batch production of turned and milled parts
presently, Numerical control is employed in all sectors of production .
Rapid development in the field of electronics such as integrated circuit, large scale
integrated circuits and development of minicomputer lead to the development of
minicomputers based CNC systems. Further development and the electronic chip
revolution have ushered in the current generation compact and powerful Microprocessor
based CNC systems.
Development of computer numerically controlled (CNC) machines is an outstanding
contribution to the manufacturing industries. It has made possible the automation of the
machining process with flexibility to handle small to medium batch of quantities in part
production.
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
extremely large.

Fig. 1.1 CNC Machine

Initially, the CNC technology was applied on basic metal cutting machine like lathes,
milling machines, etc. Later, to increase the flexibility of the machines in handling a variety
of components and to finish them in a single setup on the same machine, CNC machines
capable of performing multiple operations were developed. To start with, this concept was
applied to develop a CNC machining centre for machining prismatic components combining
operations like milling, drilling, boring and taping. Further, the concept of multi-operations
was also extended for machining cylindrical components, which led to the development of
turning centers.
Computer Numerical Control (CNC) is a specialized and versatile form of Soft
Automation and its applications cover many kinds, although it was initially developed
to control the motion and operation of machine tools.
Computer Numerical Control may be considered to be a means of operating a
machine through the use of discrete numerical values fed into the machine, where the
required 'input' technical information is stored on a kind of input media such as floppy disk,
hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The machine follows a
predetermined sequence of machining operations at the predetermined speeds necessary
to produce a workpiece of the right shape and size and thus according to completely
predictable results. A different product can be produced through reprogramming and a
low-quantity production run of different products is justified.

1.2 CNC Systems

1.2.1 Introduction
Numerical control (NC) is a method employed for controlling the motions of a
machine tool slide and its auxiliary functions with input in the form of numerical data. A
computer numerical control (CNC) is a microprocessor-based system to store and process the
data for the control of slide motions and auxiliary functions of the machine tools. The CNC
system is the heart and brain of a CNC machine which enables the operation of various
machine members such as slides, spindles, etc. as per the sequence programmed into it,
depending on the machining operations.
The main advantage of a CNC system lies in the fact that the skills of the operator
hitherto required in the operation of a conventional machine is removed and the part
production is made automatic.
The CNC systems are constructed with a NC unit integrated with a programmable
logic controller (PLC) and some times with an additional external PLC (non-integrated). The
NC controls the spindle movement and the speeds and feeds in machining. It calculates the
traversing path of the axes as defined by the inputs. The PLC controls the peripheral actuating
elements of the machine such as solenoids, relay coils, etc. Working together, the NC and
PLC enable the machine tool to operate automatically. Positioning and part accuracy depend
on the CNC system's computer control algorithms, the system resolution and the basic
mechanical machine accuracy. Control algorithm may cause errors while computing, which
will reflect during contouring, but they are very negligible. Though this does not cause point
to point positioning error, but when mechanical machine inaccuracy is present, it will result in
poorer part accuracy.
Computer Numerical Control (CNC) is a specialized and versatile form of Soft
Automation and its applications cover many kinds, although it was initially developed
to control the motion and operation of machine tools.
Computer Numerical Control may be considered to be a means of operating a
machine through the use of discrete numerical values fed into the machine, where the
required 'input' technical information is stored on a kind of input media such as floppy disk,
hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The machine follows a
predetermined sequence of machining operations at the predetermined speeds necessary
to produce a work piece of the right shape and size and thus according to completely
3

predictable results. A different product can be produced through reprogramming and a lowquantity production run of different products is justified.
1.2.2 Control Systems

Open Loop Systems :

Open loop systems have no access to the real time data about the performance of the

system and therefore no immediate corrective action can be taken in case of system
disturbance. This system is normally applied only to the case where the output is almost
constant and predictable. Therefore, an open loop system is unlikely to be used to control
machine tools since the cutting force and loading of a machine tool is never a constant. The
only exception is the wirecut machine for which some machine tool builders still prefer to use
an open loop system because there is virtually no cutting force in wirecut machining.

Fig. 1.2 Block Diagram of an Open Loop System

Close Loop Systems:

In a close loop system, feedback devices closely monitor the output and any disturbance will
be corrected in the first instance. Therefore high system accuracy is achievable. This system
is more powerful than the open loop system and can be applied to the case where the output is
subjected to frequent change. Nowadays, almost all CNC machines use this control system.

Fig. 1.3 Block Diagram of a Close Loop System

Chapter-2
OVERVIEW OF CNC MACHINE
2.1 Introduction
CNC machines, DNC machines, Advantages and disadvantages of CNC machines,
Parts suitable for CNC machines and Environmental control for CNC machines are described
in this Unit. 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 extremely large.

2.2 Meaning of CNC

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.

Fig. 2.1 Computer Numerical Control (CNC) Machine

The information stored in the computer can be read by automatic means and
converted into electrical signals, which operate the electrically controlled servo systems.
Electrically controlled servo systems permits the slides of a machine tool to be driven
simultaneously and at the appropriate feeds and direction so that complex shapes can be cut,
often with a single operation and without the need to reorient the work piece.
Computer Numerically Control can be applied to milling machines, Lathe machines,
Grinding machines, Boring machines, Flame cutters, Drilling machines etc.
5

A CNC system basically consists of the following :

1. Central processing unit (CPU)
2. Servo control unit
3. Operator control panel
4. Machine control panel
5. Programmable logic controller
6. Other peripheral devices.

2.3 Evolution of the CNC Machines

The first CNC Machine was built in 1949 at MIT,USA for manufacturing of the Air
Craft components having intricate profiles using electron tubes & core memory.
The technology advancement from the Tube technology to the open architecture system has
enabled to revolutionize the manufacturing processes.

CNC MACHINES DEVELOPMENTS

VERTICAL MACHINING CENTRE (VMC)

TURRET MACHINING CENTRE (TMC)

HORIZONTAL MACHINING CENTRE (HMC)

UNIVERSAL MACHINING CENTRE (UMC)

CNC TURRET PUNCH PRESS

CNC BENDING MACHINE

CNC UNIVERSAL GRINDING MACHINE

CNC GEAR CUTTING MACHINE

2.4 Elements of CNC Machine

A CNC machine consist of following 6 major elements:

Input Device

Machine Control Unit

Machine Tool

Driving System

Feedback Devices
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Display Unit

2.5 Benefits of CNC Machines

INCREASED FLEXIBILITY.

IMPROVED QUALITY.

REDUCED LEAD-TIME.

HIGHER PRODUCTIVITY.

ECONOMICAL BATCH PRODUCTION.

REDUCED CYCLE-TIME.

REDUCED SCRAP GENERATION.

2.6 Use of Typical CNC Machine

1. 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.
2. 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.
3. 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. When the machine starts working, the vice moves up, down, right and left according
to the design
4. 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.
5. The CNC is turned on and the shape is cut from the material. When the cutter has
stopped the shaped material can be removed from the vice.

2.7 Parts of CNC Machine

Fig. 2.2 Parts of CNC Machine

VICE: This holds the material to be cut or shaped. Material 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. When 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.
LATHE BED: The base of the machine. Usually a CNC is bolted down so that it cannot
move through the vibration of the machine when it is working.
CUTTING TOOL: This is usually made from high quality steel and it is the part that
actually cuts the material to be shaped.
8

2.8 Machine Tool Requirement

In a NC machine certain design features are desirable on machine tool.
Simultaneous movement of 2 or more axes and high removal capability of NC machines
demand high dynamic stiffness in drives and also stiff structural elements. The structure
of NC machines should be very rigid to withstand heavy cuts and it must be maintained
for long time to obtain high accuracies.
High positioning accuracy needed in NC machine make it essential to have
backlash free screw and nut and slides with a very low friction of co-efficient. This is
achieved by ground re circulating ball screw and nut, tachoway bearings, hardened
and ground guideways and friction reducing linears such as Turcite and PTFE.
Electronic spindle drives on NC machines facilitate step less speed over a wide range of
RPMs.
All axes are driven by powerful DC Servo drives controlled by PWM or SCR
controllers through preloaded ball screw and nuts.
Automatic tool changer, centralized lubrication system, index table or fourth axis is
common features on NC machines.
Accuracies
CNC machines ensure better and consistent accuracies on job compared to
conventional machines. Positioning accuracies to be extent of +10 or -10 microns and
repeatability of +5 or-5 microns can be achieved in NC machines depending on the
elements used.
Parts Suitable For CNC Machines:To utilize the CNC machine effectively and economically the suitable pats selection
is very important, the following guidelines should be observed:

High number of operation per component.

Complexity of operation.

Size of batches medium.

Repetitions of batches are often.

Labor cost of component is high.

9

Requires substantial tooling.

Requires 100% inspection.

Setup and inspection time is high.

Ration of cutting time to non-cutting time is high.

Varieties of components produced are more.

Skilled required by operator is high.

10

Chapter-3
CONFIGURATION OF THE CNC SYSTEM
Fig. shows a schematic diagram of the working principle of a NC axis of a CNC
machine and the interface of a CNC control.

Fig. 3.1 Schematic diagram of a CNC machine tool

3.1 Block Diagram of CNC Machine

Fig. 3.2 Block Diagram of CNC Machine

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3.2 Machine Control Unit (MCU)

The machine control unit is the heart of the CNC system. There are two sub-units in
the machine control unit: the Data Processing Unit (DPU) and the Control Loop Unit (CLU).
a. Data Processing Unit
On receiving a part programme, the DPU firstly interprets and encodes the part
programme into internal machine codes. The interpolator of the DPU then calculate the
intermediate positions of the motion in terms of BLU (basic length unit) which is the smallest
unit length that can be handled by the controller. The calculated data are passed to CLU for
further action.
b. Control Loop Unit
The data from the DPU are converted into electrical signals in the CLU to control the
driving system to perform the required motions. Other functions such as machine
spindle ON/OFF, coolant ON/OFF, tool clamp ON/OFF are also controlled by this unit
according to the internal machine codes.
Machine Tool
This can be any type of machine tool or equipment. In order to obtain high accuracy
and repeatability, the design and make of the machine slide and the driving lead screw of a
CNC machine is of vital importance. The slides are usually machined to high accuracy and
coated with anti-friction material such as PTFE and Turcite in order to reduce the stick and
slip phenomenon. Large diameter recirculating ball screws are employed to eliminate the
backlash and lost motion. Other design features such as rigid and heavy machine structure;
short machine table overhang, quick change tooling system, etc also contribute to the
high accuracy and high repeatability of CNC machines.

12

Fig. 3.3 Ball Screw in a CNC machine & Ball screw structure
Driving System
The driving system is an important component of a CNC machine as the accuracy and
repeatability depend very much on the characteristics and performance of the driving system.
The requirement is that the driving system has to response accurately according to the
programmed instructions. This system usually uses electric motors although hydraulic motors
are sometimes used for large machine tools. The motor is coupled either directly or through a
gear box to the machine lead screw to moves the machine slide or the spindle. Three types of
electrical motors are commonly used.
a. DC Servo Motor

Fig. 3.4 DC Servo Motor

This is the most common type of feed motors used in CNC machines. The principle
of operation is based on the rotation of an armature winding in a permanently energized
magnetic field. The armature winding is connected to a commutator, which is a cylinder of
13

insulated copper segments mounted on the shaft. DC current is passed to the commutator
through carbon brushes, which are connected to the machine terminals. The change of the
motor speed is by varying the armature voltage and the control of motor torque is
achieved by controlling the motor's armature current. In order to achieve the necessary
dynamic behaviour it is operated in a closed loop system equipped with sensors to obtain the
velocity and position feedback signals.

Fig. 3.5 DC Servo Motor

b. AC Servo Motor
In an AC servomotor, the rotor is a permanent magnet while the stator is
equipped with 3-phase windings. The speed of the rotor is equal to the rotational frequency of
the magnetic field of the stator, which is regulated by the frequency converter. AC motors are
gradually replacing DC servomotors. The main reason is that there is no commutator or
brushes in AC servomotor so that maintenance is virtually not required. Furthermore, AC
servos have a smaller power-to-weight ratio and faster response.

Fig. 3.6 AC Servo Motor

14

c. Stepping Motor
A stepping motor is a device that converts the electrical pulses into discrete
mechanical rotational motions of the motor shaft. This is the simplest device that can be
applied to CNC machines since it can convert digital data into actual mechanical
displacement. It is not necessary to have any analog-to-digital converter nor feedback
device for the control system. They are ideally suited to open loop systems.
However, stepping motors are not commonly used in machine tools due to the following
drawbacks: slow speed, low torque, low resolution and easy to slip in case of overload.
Examples of stepping motor application are the magnetic head of floppy-disc drive and hard
disc drive of computer, daisy-wheel type printer, X-Y tape control, and CNC EDM Wire-cut
machine.

Fig. 3.7 Stepping Motor

Feedback Device
In order to have a CNC machine operating accurately, the positional values and speed
of the axes need to be constantly updated. Two types of feedback devices are normally used
positional feedback device and velocity feedback device.
a. Positional Feed Back Devices
There are two types of positional feedback devices: linear transducer for direct
positional measurement and rotary encoder for angular or indirect linear measurement.
Linear Transducers
A linear transducer is a device mounted on the machine table to measure the actual
displacement of the slide in such a way that backlash of screws; motors, etc would not cause
any error in the feedback data. This device is considered to be of the highest accuracy and
15

also more expensive in comparison with other measuring devices mounted on screws or
motors.

Fig. 3.8 Linear Transducer

Rotary Encoders
A rotary encoder is a device mounted at the end of the motor shaft or screw to
measure the angular displacement. This device cannot measure linear displacement directly
so that error may occur due to the backlash of screw and motor etc. Generally, this
error can be compensated for by the machine builder in the machine calibration
process.

Fig. 3.9 Incremental and Absolute Rotary Encoder

b. Velocity Feedback Device
The actual speed of the motor can be measured in terms of voltage generated from a
tachometer mounted at the end of the motor shaft.DC tachometer is essentially a small
generator that produces an output voltage proportional to the speed. The voltage generated is
16

compared with the command voltage corresponding to the desired speed. The difference of
the voltages can is then used to actuate the motor to eliminate the error.

Fig. 3.10 Tachogenerator

Display Unit
The Display Unit serves as an interactive device between the machine and the
operator. When the machine is running, the Display Unit displays the present status
such as the position of the machine slide, the spindle RPM, the feed rate, the part
programmes, etc. In an advanced CNC machine, the Display Unit can show the graphics
simulation of the tool path so that part programmes can be verified before the actually
machining. Much other important information about the CNC system can also displayed for
maintenance and installation work such as machine parameters, logic diagram of the
programmer controller, error massages and diagnostic data.

17

3.3 Objectives of CNC Maintenance

The main objectives of CNC equipment maintenance are to:

Attempt to maximise dependable uptime.

Minimise repair time (downtime)

Maintain positional accuracy and repetitive tolerances.

To increase equipments service life.

Fig. 3.11 CNC equipment maintenance

3.4 CNC Machine - Input, Process, Output

A CNC production facility needs three pieces of equipment:
A Computer:
The computer is used to draw the design. However, 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 Interface:
A 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.

18

CNC (Computer Numerical Control) 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 X, Y and Z.
(Horizontally, vertically and depth). The signals also control the speed of the cutting tool.

Fig. 3.12 CNC Input-Output Process

3.5 CNC Machine Tool Elements

Fig. 3.13 CNC Machine Tool Elements

19

CNC machines tool elements can be grouped into these categories. Vis.,
1. Machine elements
2. Hydraulic elements, and
3. Electrical and Electronic elements.
The general items under machine elements are:
a) Ball lead screws.
b) Ball bushings
c) Re-circulating roller packs and hardened, ground replaceable steel
strips.
d) Lubrication elements.
e) Curvic couplings
f) Headstock, table assembly, rotary table, pallet changers etc.
The items under hydraulic elements are:
a) Servo valves
b) Servo drives
c) Power packs
d) Solenoid valves, relief valves, pressure switches etc.
e) Accumulators
f) Fittings, seals and packings etc.
g) Filters.
h) Hydraulic cylinders, motors etc.
The items under electrical and electronic elements:
a) Limit switches
b) Servo motors
c) Measuring system such as inductosyns, encoders, resolvers etc.
d) Relays, contactors, etc.
e) Tape reader, tape punching unit etc.

20

3.6 Control Panel of CNC

A CNC machine is normally controlled by a computer and software. However, 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 cheap/basic/manual machines.
When a CNC machine is used manually it is been used well below its capability and
specification.

Fig. 3.14 CNC Control Panel

RESET BUTTON: The must important control button is usually the reset button.
When the CNC machine is turned on, the reset button is pressed by the machine operator.
This zeros the cutter, moving the cutter to coordinates 0, 0, 0 on the X, And Z axis. 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.

21

MANUAL CONTROL: The cutter can be controlled manually although this is

rarely needed. The X and Y buttons control the movement of the cutter along the
horizontal surfaces. The Z buttons control depth and up / down movement.
STOP BUTTON: Most control panels have stop buttons. When pressed these stop
the machine very quickly.
SPEED AND FEED: On some CNC machines it is possible to manually vary the
speed and feed of the cutter.

3.7 CNC Router - The Important Parts

Fig. 3.15 CNC Router

22

Chapter-4
SETTING UP THE CUTTING TOOL TO THE CORRECT
LENGTH
4.1 Introduction
One of the few operations that the machine operator carries out is to change the
cutting tool. Each CNC machine has a range of cutting tools. Straight cutters chamfer Vgroove and radius cutters are some examples. 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 exactly to the same length in the cullet. If
this is not done the material being machined will be machined at incorrect depths. A special
depth gauge is used to accurately set up the cutting tools. (See diagram below). This rule
applies to all CNC machines although different techniques may be used depending on the
type of the CNC machine.

23

Fig. 4.1 CNC Set up Cutting Tool

A 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.

4.2 Industrial Production Flowchart

24

Fig. 4.2 Industrial Production Flow Chart with CNC

Chapter-5
25

CNC MACHINES AND SAFETY

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.

Fig. 5.1 Safety Issue of CNC Machine

1. Most modern CNC machines are designed so that the cutting tool will not start
unless the guard is in position. Also, 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.
2. It is essential that pupils / students / machine operators receive quality instruction
before attempting to use any CNC equipment.
3. CNC routers, used for shaping materials such as woods and plastics, have built in
extraction. Dust can be very dangerous if inhaled and can also cause eye irritation. The CNC
Router shown above has an outlet for an extraction unit. As the router is fully enclosed, dust
26

cannot escape into the atmosphere. If an extraction unit is attached the dust is removed
automatically. Most manually operated machine routers have very limited extraction systems
which leave some dust in the air.
4. 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. A single
phase electrical supply can be plugged into any available socket. The electrical supply for
the machine comes through a residual circuit breaker (RCB). If an electrical fault develops
the RCB will cut off electrical power immediately.
5. Single 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.
6. Most 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 sharp/hot material.
7. Commonsense applies to the use of all machines including CNC machines. Basic
safety training regarding working in a workshop and with other machines applies to CNC
machines as well.

27

Chapter-6
TESTING AND MAINTENANCE OF CNC MACHINE
6.1 Barball Testing
What Is A Barball?
A barball moniters machine tool spindle movements as it follows a
programmed circular path and compares the test path to that of a circle.

Fig. 6.1 Barball Testing

Barball Testing can analyze:

Machine Geometry

Circularity

Stick/Slip

Vibration

Backlash

Repeatability

Barball Testing allow your company to:

Product parts to Six Sigma

28

Make better products by greatly reducing downtime

Keep a history of your machines

Sharpen your machines' accuracy and improve performance on tight

tolerance jobs

Schedule maintenance and repairs due to early detection

6.2 Spindle & Ballscrew Repair/Rebuild

Fig. 6.2 Spindle & Ball Screww Repair

Draw Bar Testing and Certification

Pull Force Testing and Certification

Dedicated Clean Room

Spindle Repair and Balancing

Spindle Break-in

Spindle Testing

Tolerance to .00005"

Vibration Analysis

Evaluation and Final Reading Documentation

Climate Controlled Environment

Thermal Testing

29

Bearing Break-in Seating

Extended Warranty Options

6.3 Coolant Maintenance

Fig. 6.3 Coolant Maintenance

Coolant Maintenance Solutions From CNC :

Vortex Filter

Oil Skimmers

Oil Separators

High Pressure Coolant Systems

Coolant Filtration Systems

30

6.4 Preventative Maintenance

Fig. 6.4 Preventative maintenance of CNC Machine

Machine Condition Monitoring (MCM)

Standard or tailored maintenance service contracts

Machine Repairs

Machine Rebuilds

Machine Tool Installation

Control/Drive System Troubleshooting/Repair

Hydraulic, Pneumatic, Electronic, and Mechanical Troubleshooting/Repair

CNC Machine Maintenance/Operator Training

Machine Surveys/Appraisal
31

Insurance Assessments

Factory Relocation

Way Cover Repair

Ballbar Testing, Documentation, and Repair

Chapter-7
APPLICATIONS, ADVANTAGES AND
DISADVANTAGES OF CNC MACHINE
7.1 Application
CNC machines are widely used in the metal cutting industry and are best used to produce the
following types of product:

Parts with complicated contours

Parts requiring close tolerance and/or good repeatability

Parts requiring expensive jigs and fixtures if produced on conventional

machines

Parts that may have several engineering changes, such as during

the development stage of a prototype

In cases where human errors could be extremely costly

Parts that are needed in a hurry

Small batch lots or short production runs

Some common types of CNC and instruments used in industry are as following:

Drilling Machine

Lathe / Turning Centre

Milling / Machining Centre

Turret Press and Punching Machine

Wirecut Electro Discharge Machine (EDM)

32

Grinding Machine

Laser Cutting Machine

Water Jet Cutting Machine

Electro Discharge Machine

Coordinate Measuring Machine

Industrial Robot

7.2 Advantages of CNC Machines

Productivity
Since cutting tool is brought to its machining position much more efficiently than

it was done manually by the machine operator, NC machine is spending much more time
per shift cutting than in past. Conventional machines very seldom remove metal for more
than 15% of total available time under normal batch production conditions. Whereas
CNC machine tools should be capable of removing metal for between 50% and 75% of
available time. When working on medium batch production, CNC machining has around
4 to 1 productivity advantage over conventional machine. The actual productivity
advantage may vary from batch to batch depending upon the complexity of components
to be produced and is normally proportional to the number of conventional operation
required to produce the components.

Flexibility in design and production

Machine can switch over to different job as set up times are low and sudden changes
in sales requirement are much more easily catered for. This enables the formulation of
more aggressive marketing plans. The use of CNC machines also give designers freedom
to design components which, by conventional means, are often impossible to produce.
Change of design can also be easily incorporated as it means change of tape.

Inspection

High position accuracies and repeatability are inherent features of CNC machines
and reduce inspection time considerably.
Normally a 100% inspection of the first component produced by a new tape is all that is
necessary to prove the tape and tooling. Subsequently it is required to have only sample
inspection. In process gauging and inspection is also provided on modern CNC
33

machines.

Floor space

One CNC machine can replace five to six conventional machines. Thus
manufacturing activities of a company can be expanded without increasing the floor area
proportionately.

Inventory

By using CNC machine, procurement sizes and batch sizes can be reduced because
of shorter lead times .This results in substantial saving. Lead time is time taken to
progress a batch of component through a batch of production shop and is proportional to
number of operation required by conventional methods. For example a component which
requires 112 set ups by conventional methods may requires only 1 or 2 set ups in CNC
machining center reducing total product flow times.

Material Handling

Handling of component from machine to machine which is necessary on

conventional machine is significantly reduced on CNC machine, as all the operations are
performed on one machine. This obviously reduces labor cost.

Tooling

This ability to complete machine part in a single setup means that fewer and simpler
fixtures are required, which in turns requires less storage space and maintenance. The
simpler a fixture is, the less expensive is to manufacture it.

Operators Skill

Dependence on skilled labor can be dispensed with. The accuracy of part

produced with CNC machines machine depend upon accuracy and ability of
machine and tape and not on individual operator.

Scrap and Rework

Drastic reduction in scrap is achieved because of the inherent accuracy and

repeatability of CNC machine.

Costing
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Time required to produce a component is a function of machining cycle of CNC

machines and is not influenced by operators efficiency or variation in labors rate, a
great stability of prices can often be achieved throughout the life cycle of the respective
product. Also cost accounting becomes very precise.

Better Management Information and Control

With various advantages of CNC machines, decisions effecting unit cost, delivery
and quality are firmly placed in the hands of management and not of the machine
operator.

High Repeatability and Precision, e.g. Aircraft parts.

Volume of production is very high.

Complex contours/surfaces need to be machined, e.g. Turbines.

Flexibility in job change, automatic tool settings, less scrap.

Safer, higher productivity, better quality.

Less paper work, faster prototype production, reduction in lead times.

Easier to program.

Easy storage of existing programs.

Avoids human errors.

Usually generates closer tolerances than manual machines.

Program editing at the machine tool.

Control systems upgrades possible.

Option -resident CAM system at machine tool.

Tool path verification.

7.3 Disadvantages of CNC MACHINES

Costly setup, skilled operators.

Computers, programming knowledge required.

Maintenance is difficult.
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Machines have to be installed in air conditioned places.

CONCLUSIONS
It is true that CNC machine costs more to install initially. But higher initial cost is
set off by the direct and indirect gains resulting from various advantages of CNC
machines. In most cases, careful techno- economic evaluation of a given manufacturing
situation will clearly bring out that unit cost of production is definitely less tools with
that of so called conventional machines. Latest CNC machines are very sophisticated and
costly equipment. Their accuracy and production capability will be greatly reduced it they are
not properly maintained. Use of diagnostic tasks and pinpoint troubled areas. Remote
diagnostic features of CNC system greatly reduce the diagnostic communication systems for
computer controlled machine tools further simplifies the task of maintenance personnel. To
conclude numeric control is the most sophisticated form of automatic control of machine
tool. It has high degree of precision and reliability. The control system has undergone
several stage of development.
The programs written for CNC are easy to write and understand. These programs use
either G-cod or M-code that runs the program. The codes are simple to understand. No
wonder CNC machines tools are becoming more and more popular day by day in
modern industries. In longer run CNC machine pays for itself with such outstanding
qualities.

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11) http://en.wikipedia.org/wiki/computer_numerical_control
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