DEFINITION

• In CNC (Computer Numerical Control), the

instructions are stored as a program in a
micro-computer attached to the machine.
The computer will also handle much of the
control logic of the machine, making it
more adaptable than earlier hard-wired
controllers.
Utilization of computers in
manufacturing applications has
proved to be one of the most
significant developments over the
last couple of decades in helping to
improve the productivity and
efficiency of manufacturing
systems.
CNC SYSTEM
ELEMENTS
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
NC SYSTEM ELEMENTS

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OPERATIONAL FEATURES of
CNC MACHINES
 CNC MACHINE TOOL

Part drawing Input Part Programming

& By Tape / MDI / Computer
Part Programming
How CNC Works

• Controlled by G and M codes.

• These are number values and co-
ordinates.
• Each number or code is assigned to a
particular operation.
• Typed in manually to CAD by machine
operators.
• G&M codes are automatically generated
by the computer software.
Features of CNC Machinery

• The tool or material moves.

• Tools can operate in 1-5 axes.
• Larger machines have a machine control
unit (MCU) which manages operations.
• Movement is controlled by a motors
(actuators).
• Feedback is provided by sensors
(transducers)
• Tool magazines are used to change tools
Tools

• Most are made from

high speed steel (HSS),
tungsten carbide or ceramics.
• Tools are designed to direct waste away
from the material.
• Some tools need coolant such as oil to
protect the tool and work.
Tool Paths, Cutting
and Plotting Motions
• Tool paths describes the route the cutting tool takes.
• Motion can be described as point to point, straight
cutting or contouring.
• Speeds are the rate at which the tool operates e.g. rpm.
• Feeds are the rate at which the cutting tool and work
piece move in relation to each other.
• Feeds and speeds are determined by cutting depth,
material and quality of finish needed. e.g. harder
materials need slower feeds and speeds.
• Rouging cuts remove larger amounts of material than
finishing cuts.
• Rapid traversing allows the tool or work piece to move
rapidly when no machining is taking place.
CNC Programming Basics

• CNC instructions are called part program commands.

• When running, a part program is interpreted one

command line at a time until all lines are completed.

• Commands, which are also referred to as blocks, are

made up of words which each begin with a letter address
and end with a numerical value.
Programming Key Letters
• O - Program number (Used for program identification)
• N - Sequence number (Used for line identification)
• G - Preparatory function
• X - X axis designation
• Y - Y axis designation
• Z - Z axis designation
• R - Radius designation
• F – Feed rate designation
• S - Spindle speed designation
• H - Tool length offset designation
• D - Tool radius offset designation
• T - Tool Designation
• M - Miscellaneous function
Explanation of commonly used
G codes
• G00 – Preparatory code to control final position of the
tool and not concerned with the path that is followed in
arriving at the final destination.

• G01 – Tool is required to move in a straight line

connecting current position and final position. Used for
tool movement without any machining- point to point
control. (linear interpolation)

• G02 – Tool path followed is along an arc specified by I, J

and K codes.( circular interpolation)
 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
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning
Table of Important M codes
• M00 Program stop
• M01 Optional program stop
• M02 Program end
• M03 Spindle on clockwise
• M04 Spindle on counterclockwise
• M05 Spindle stop
• M06 Tool change
• M08 Coolant on
• M09 Coolant off
• M10 Clamps on
• M11 Clamps off
• M30 Program stop, reset to start
 Program Command Parameters

Optimum machine programming requires consideration of certain machine

operating parameters including:
• Positioning control
• Compensations
• Special machine features

Positioning control is the ability to program tool and machine slide movement
simultaneously along two or more axes. Positioning may be for point-to-point
movement or for contouring movement along a continuous path. Contouring
requires tool movement along multiple axes simultaneously. This movement is
referred to as “Interpolation” which is the process of calculating intermediate
values between specific points along a programmed path and outputting those
values as a precise motion. Interpolation may be linear having just a start and end
point along a straight line, or circular which requires an end point, a center and a
direction around the arc.
CNC Programming Basics
• Each letter address relates to a specific machine
function. “G” and “M” letter addresses are two of the
most common. A “G” letter specifies certain machine
preparations such as inch or metric modes, or absolutes
versus incremental modes.

• A “M” letter specifies miscellaneous machine functions

and work like on/off switches for coolant flow, tool
changing, or spindle rotation. Other letter addresses are
used to direct a wide variety of other machine
commands.
 CNC programming
• Programming consists of a series of instructions in form of letter
codes

• Preparatory Codes:
• G codes- Initial machining setup and establishing operating
conditions

• N codes- specify program line number to executed by the MCU

• Axis Codes: X,Y,Z - Used to specify motion of the slide along X, Y,

Z direction

• Feed and Speed Codes: F and S- Specify feed and spindle speed

• Tool codes: T – specify tool number

CNC programming
Important things to know:

• Coordinate System

• Units, incremental or absolute positioning

• Coordinates: X,Y,Z, RX,RY,RZ

• Feed rate and spindle speed

• Coolant Control: On/Off, Flood, Mist

• Tool Control: Tool and tool parameters

Rules for programming
Block Format

N135 G01 X1.0 Y1.0 Z0.125 F5

Sample Block
• Restrictions on CNC blocks
• Each may contain only one tool move
• Each may contain any number of non-tool move G-codes
• Each may contain only one feed rate
• Each may contain only one specified tool or spindle speed
• The block numbers should be sequential
• Both the program start flag and the program number must be
independent of all other commands (on separate lines)
• The data within a block should follow the sequence shown
in the above sample block
Hardware Configuration of NC
Machine
Machine Control Unit (MCU)
the brain of the NC machine.
The Data Processing Unit (DPU)
reads the part program.
The Control Loop Unit (CLU)
controls the machine tool operation.

26
Point to Point and Tool Paths
Point-to-Point Tool Movements
Point-to-point control systems cause the tool to move to a point on
the part and execute an operation at that point only. The tool is not in
continuous contact with the part while it is moving.
Drilling, reaming, punching, boring and tapping are examples of point-to-
point operations.

28
 Continuous-Path Tool Movements
Continuous-path controllers cause the tool to maintain continuous contact
with the part as the tool cuts a contour shape. These operations include milling
along any lines at any angle, milling arcs and lathe turning.

29
Loop Systems for Controlling Tool
Movement
Open Loop
System
Uses stepping motor to create movement. Motors rotate a fixed
amount for each pulse received from the MCU. The motor
sends a signal back indicating that the movement is
completed. No feedback to check how close the actual
machine movement comes to the exact movement
programmed.

30
Loop Systems for Controlling Tool
Movement
Closed Loop System
AC, DC, and hydraulic servo-motors are used. The speed of
these motors are variable and controlled by the amount of
current or fluid. The motors are connect to the spindle and the
table. A position sensor continuously monitors the movement
and sends back a single to Comparator to make adjustments.

31
 CNC Machine Axes of Motion
The coordinate system used for the tool path must be identical to the
coordinate system used by the CNC machine. The standards for
machine axes are established according to the industry standard
report EIA RS-267A.
Right hand rule

Horizonta
l milling
machine

CNC machines milling machines can

perform simultaneous linear motion along
the three axis and are called three-axes
machines. 32
CNC Machine Axes of Motion

Coordinate system for a Lathe

33
CNC Machine Axes of Motion
More complex CNC machines have the capability of executing additional
rotary motions (4th and 5th axes).

34
CNC Machine Axes of Motion

Five-axis
machine
configurations

35
DEFINING THE AXIS OF CNC MACHINING CENTRE

Z+

Y+
X+

X0.Y0.Z0

X-
Y-
Z-
 AXIS DEFINITION OF CNC LATHE

X+
Z- Z+
X-
X0,Z0
 Coordinate System
Machine Vs Work piece

X Machine
Reference Point
Y X0,Y0,Z0
Z

Work piece
Work piece Machine Table
Reference Point
X0,Y0,Z0
Z AXIS MACHINE REFERENCE POINT SETTING

MACHINE Z 200+25 mm
SPINDLE
STANDARD
Z 25 mm TOOL BAR
LENGTH 200 mm

MACHINE TABLE
SLIP GAUGE(25 mm)
 SHIFTING MACHINE REFERENCE POINT
TO
WORK PIECE REFERENCE POINT IN CNC LATHE

Z1
MACHINE
REFERENCE
POINT
X0,Z0 X1

MEASURED VALUE
CODE FOR SHIFTING MACHINE REFERENCE POINT
TO WORK PIECE REFERENCE POINT
OR ZERO OFFSET

ZERO OFFSET are G54,G55, G56,G57,G59,G60

CANCELLATION OF ZERO OFFSET IS G53

EXAMPLE G54 X,Y,Z

The Values of X,Y,Z are

Note: difference between machine reference point
to work piece reference point
Manual Part Programming Vs Computer Programming

R1>R2
R1

End mill

R2

Work Piece
 Coordinate Values in Absolute / Incremental

Absolute Incremental
60

Y B Y B

30
A A
30

X 30 X

20 20 20
40
 Commonly used Geometry
X1.Y1
Starting point Starting point
& or
Ending point are same Ending point
X1.Y1
Part of Circle I.J
X2,y2
I.J Ending point
or
Starting point
Centre of
Circle circle

Starting point Ending point

or or
Ending point Straight Line Start point
G00 OR G01
 CIRCULAR MOTION
End point
CIRCULAR MOTION
GO3
COUNTERCLOCKWISE
Start point
DIRECTION

Start point
CIRCULAR MOTION
GO2 CLOCKWISE
End point
DIRECTION
Circular Interpolation With Respect to plane selection

G02 G18 G03

G0
3
02
G
G17 G19

G02
3
G0

Z
 Basic Concept of Part
Programming
Part programming contains geometric data about the part and motion
information to move the cutting tool with respect to the work piece.
Basically, the machine receives instructions as a sequence of blocks
containing commands to set machine parameters; speed, feed and
other relevant information.
A block is equivalent to a line of codes in a part program.
N135 G01 X1.0 Y1.0 Z0.125 T01 F5.0

Coordinates Special function

Block number
G-code Tool number

47
 Basic Concept of Part
Programming
Preparatory command (G code)

The G codes prepare the MCU for a given operation, typically involving a cutter
motion.
G00 rapid motion, point-to-point positioning
G01 linear interpolation (generating a sloped or straight cut)
G06 parabolic interpolation (produces a segment of a parabola)
G17 XY plane selection
G20 circular interpolation
G28 automatic return to reference point
G33 thread cutting

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Basic Concept of Part
Programming
Miscellaneous commands (M code)

M00 program stop

M03 start spindle rotation (cw)
M06 tool change
M07 turn coolant on

Feed commands (F code)

Used to specify the cutter feed rates in inch per minute.

Speed commands (S code)

Used to specify the spindle speed in rpm.

Tool commands (T code)

Specifies which tool to be used, machines with automatic tool
changer.
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CNC Machine Tool Positioning
Modes
Within a given machine axes coordinate system, CNC can be
programmed to locate tool positions in the following modes; incremental,
absolute, or mixed.

Mechanical Engineering
Department 50
Manual Part Programming
Example:

51
 Example of a part program
N001 G91 (incremental)
N002 G71 (metric)

Rapid
Loading tool motion Tool change
N003 G00 X0.0 Y0.0 Z40.0 T01 M06
Start spindle
Positioning tool at P 1
Start coolant
N004 G01 X75.0 Y0.0 Z-40.0 F350 M03 M08

Linear interpolation

Mechanical Engineering
Department 52
Manual Part Programming
Answer:
N001 G91
N002 G71
N003 G00 X0.0 Y0.0 Z40.0 T0.1 M06
N004 G01 X65.0 Y0.0 Z-40.0 F950 S717 M03
N005 G01 X10.0 F350 M08
N006 G01 X110.0
N007 G01 Y70.0
N008 G01 X-40.86
N009 G02 X-28.28 Y0.0 I14.14 J5.0
N010 G01 X-40.86
N011 G01 Y-70.0
N012 G01 X-75.0 Y0.0 Z40.0 F950 M30

53
 Computer-Assisted Part
Programming
Automatically Programmed Tools (ATP) language is the most comprehensive
and widely used program. The language is based on common words and easy
to use mathematical notations

• Identify the part geometry, cutter motions, speeds,

feeds, and cutter parameter.
• Code the above information using ATP.
• Compile to produce the list of cutter movements and
machine control information (Cutter Location data
file, CL).
• Use post-processor to generate machine control
data for a particular machine. This is the same as
NC blocks.

54
 CRC CUTTER RADIUS COMPENSATION G41& G42

Nomenclatur Tool Radius Lengt

e No X h
Z
ENDMILL T01 20.00 150.0 Actual tool path
0
DRILL T02 0 100.0
0
BORING Tool T03 125.0
0
G41

Starting point
Ending point

Required tool path Starting point

G42
 Radius Compensation Execution
Programmed path

X2,Y2
G42
Arc ending point
Cutter moving path

Centre of arc
I, J
LEAD

Arc starting point X1,Y1 Cutter compensation executed

Tool Starting point

X1,(Y1+LEAD)
 CIRCULAR INTERPOLATION PROGREMME
Point1
Greater than
Cutter
Radius
Point2
%N9001
R1 N10 G00 G90
N20 G54 X (point1 value) Y(point1 value) Z500
N30 T0101 M06
N35 M03
N40 G01 G42 X (point2 value) Y(point2 value)
N50 G91
N55 G01 Z-500 F500
R2 N60 G02X-(R1value) Y-(R1value) I0 J-(R1value)
N70 G03 X0 Y0 I0J-(R2value)
N80 G02X-(R1value) Y+(R1value) I0 J+(R1value)
N90 G53 G00 G40 X(point1 value) Y(point1 value)
N95 M05
 CIRCULAR INTERPOLATION PROGREMME
Point1
Greater than
Cutter
Radius
Point2

R1 %N9001
N10 G00 G90
N20 G54 X (point1 value) Y(point1 value) Z500
N30 T0101 M06
N40 G01 G42 X (point2 value) Y(point2 value)
N60 G02X-(R1value) Y-(R1value) I0 J-(R1value)
N50 G91
R2 N55 G01 Z-500 F500
N70 G03 X0 Y0 I0J-(R2value)
N65 E0205
N85 G01 G90 Z500
N80 G02X-(R1value) Y+(R1value) I0 J+(R1value)
N90 G53 G00 G40 X(point1 value) Y(point1 value)
 THREAD CUTTING PROGRAMME
Point 1
Point2 Greater than Cutter Radius
R1

R1 Greater than Cutter Radius

R2 R2 Circular Interpolation
G90
G00 X (Point1 value) Y (Point1 value) Z0
D01
G41 G01 X (Point 2value) Y (Point2 value)
G91 G03 X-(R1value) Y+(R1value) I-(R1value) J 0
G03 X0 Y0 I0 J-(R2value) Z -(Pitch value)
G03 X-(R1value) Y-(R1value) I0 J-(R1value)
G90 G00 Z500
G40
Threading tool
 DRILLING PROGRAMME
M10, 4Nos 10mm depth
Tapped as shown % N9005 Sub Programme Points X Y
N10 G80 G00 X50000 Y50000 1 10.00 30.00

2 20.00 30.00
%N9001 3 10.00 60.00
N10 G54
4 20.00 60.00
N20 G22 X9005
Centre N30 T0101 M06
drilling N40 G81 M03 X10.00 Y30.00 R200S500 F300 Z-300
N50 G22 X9008
N60 G22 X9005
60
30

Core N30 T0102 M06

drilling N40 G81 M03 X10.00 Y30.00 R200 S500 F300 Z-1500
N50 G22 X9008
M10 N60 G22 X9005
10 20
Tapping N40 G84 M03 X10.00 Y30.00 R200 S40 F100 Z-1500

% N9008 Sub Programme N50 G22 X9008

N10 X2000 Y3000 N60 G22 X9005
N20 X1000 Y6000 N70 G53 M05
N30 X2000 Y6000
Programme using Mathematical Function

#102 = 12
#103 = 90
#110 = 1
#104 = #103 + #102
N10 #105= 270 *COS(#104)
#106=270*SIN(#104)
IF( #110 EQ 8) GOTO30
IF (#110 EQ 15) GOTO30
IF (#110 EQ 22) GOTO30
G81 x#105 Y#106 Z-8 R10 F150
N30 IF(#110GT30) GOTO20
#110=#110+1
#104 = #104 +#102
GOTO10
N20 G80
 ROUGH TURNING CYCLE AT CNC LATHE

X4.Z4

X1.Z1
X3.Z3
X2.Z2 X0.Z0

G00 X4+500 Z+200

G71 P10 Q60 U200 W200 D300 e100
N10 G00 X0
G42 G01 Z0
X1 Z1
G03 X2 Z2 R400
G01X3Z3
N60 X4 Z4
G40
Direct numerical control

63
CNC Machines-
Advantages/Disadvantages
Advantages:
• 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
• More safe, higher productivity, better quality
• Less paper work, faster prototype production, reduction in lead
times

Disadvantages:
• Costly setup, skilled operators
• Computers, programming knowledge required
• Maintenance is difficult
CNC Lathe

• Automated version of a manual lathe.

• Programmed to change tools
automatically.
• Used for turning and boring wood, metal
and plastic.
CNC Milling Machine

• Has 3 to 5 axes.
• Used for wood, metal and plastic.
• Used to make 3D prototypes, moulds,
cutting dies, printing plates and signs.
ADVANTAGES of CNC

• Productivity
Machine utilisation is increased because
more time is spent cutting and less time is
taken by positioning.
Reduced setup time increases utilisation
too.

2004 67
ADVANTAGES of CNC

• Quality
Parts are more accurate.
Parts are more repeatable.
Less waste due to scrap.

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ADVANTAGES of CNC

• Reduced inventory
Reduced setup time permits smaller
economic batch quantities.
Lower lead time allows lower stock levels.
Lower stock levels reduce interest charges
and working capital requirements.

2004 69
ADVANTAGES of CNC

• Machining Complex shapes

Slide movements under computer control.
Computer controller can calculate steps.
First NC machine built 1951 at MIT for
aircraft skin milling.

2004 70
ADVANTAGES of CNC

• Management Control
CNC leads to CAD
Process planning
Production planning

2004 71
DRAWBACKS of CNC
• High capital cost
Machine tools cost $30,000 - $1,500,000
• Retraining and recruitment of staff
• New support facilities
• High maintenance requirements
• Not cost-effective for low-level production on
simple parts
• As geometric complexity or volume increases
CNC becomes more economical
• Maintenance personnel must have both
mechanical and electronics expertise

2004 72
INDUSTRIES MOST AFFECTED
by CNC
• Aerospace
• Machinery
• Electrical
• Fabrication
• Automotive
• Instrumentation
• Mold making
2004 73