CHAPTER 3 : COMPUTERISED

NUMERICAL CONTROL (CNC)

DMA1112: MACHINING TECHNOLOGY
 CONTENT
3.1 Numerical Control 3.5 CNC EDM

3.1.1 Definition of Numerical Control 3.5.1 Types of CNC EDM

3.1.2 NC and CNC Technology 3.5.2 CNC Die Sinker (Vertical EDM)

3.1.3 Numerical Control Advantages 3.5.2.1 Die Sinker Process

3.2 CNC Machine Tools 3.5.2.2 Electrode and Material

Selection
3.2.1 Types of CNC Machine Tools
3.5.2.3 Electrode Wear
3.2.2 Advantages of CNC Machine Tools
3.5.2.4 Die Sinker Flushing
3.3 CNC Turning
3.5.3 CNC Wire Cut (Wire EDM)
3.3.1 Types of CNC Lathes
3.5.3.1 Wire Cut Process
3.4 CNC Milling
3.5.3.2 Wire Types and Selection
3.4.1 Types of CNC Milling
3.5.3.3 Wire Flushing
 3.1 NUMERICAL CONTROL
3.1.1 Definition of Numerical Control
• Numerical Control (NC) technology has caused something of revolution in
manufacturing field and metal working. Before the days that computer became
standard fixtures in every company and homes, NC were specially equipped in
machine tool in many machine shop.
• “NC can be defined as an operation of machine tools by means of specifically
coded instruction to the machine control system.”
• The specifically coded instruction are the combinations of letters of alphabet, digits,
symbols (decimal, percent) and parenthesis symbols. The instruction are written in a
logical order and predetermined form.
• The collection of instruction are called an NC Program, CNC Program or Part
Program. This can be stored and used repeatedly any time to achieve identical
machining.
 3.1 NUMERICAL CONTROL
3.1.2 NC and CNC Technology
• The NC stands for the older and original NC technology while CNC stands for the
newer CNC technology (a modern successor to its older relatives).
• Both systems perform the same task, namely manipulated of data for the sole
purpose of machining a part. Both, the control system internal design contains all
logical instructions that process the input data. At this point, the similarity ends.
• The NC system used a fixed logical functions, those that are built in and permanently
wired within the control input and cannot be changed or “hardwired”.
• All required program changes must be made away from the control. NC system
typically requires the compulsory use of punched tapes for input of the program
information.
 3.1 NUMERICAL CONTROL
3.1.2 NC and CNC Technology
• The modern CNC system (not the old NC system), uses an internal micro processor
(i.e., a computer). This computer contains memory registers storing a variety of
routines that are capable of manipulating logical functions.
• This allows the changed in any program at the control unit (at the machine). This
flexibilities is the greatest advantage of CNC systems.
• CNC program and the logical functions are stored on special computer chips, as
software instructions. In contras to the NC system, CNC systems is synonymous with
the term “softwired”.
• As a conclusion, NC can also mean CNC but, CNC can never refer to the older
technology.
 3.1 NUMERICAL CONTROL
3.1.2 Numerical Control Advantages
There are some advantages of CNC users can and would expect improvement;
1. Setup time reduction
2. Lead time reduction
3. Accuracy and repeatability
4. Contouring of complex shapes
5. Simplified tooling and work holding
6. Consistent cutting time
7. General productivity increase
 3.2 CNC MACHINE TOOLS
3.2.1 Types of CNC Machine Tools
• Different types of CNC machines cover rather large variety. Due to rapid pace of
advanced technology; it is impossible to identify all possible applications, it would
make a long list.
• The CNC machine tools that can be listed here are:
1. Mills and Machining centres
2. Lathes and turning centres
3. Drilling machines
4. Boring mills and profilers
5. EDM
6. Punch presses and shears
7. Flame cutting machines
8. Routers
9. Cylindrical grinders
10. Welding machines
 3.2 CNC MACHINE TOOLS
3.2.2 Advantages of CNC Machine Tools

1. CNC machines can be used continuously 24 hours a day, 365 days a year and only need to
be switched off for occasional maintenance.

2. CNC machines are programmed with a design which can then be manufactured hundreds or
even thousands of times. Each manufactured product will be exactly the same.

3. Less skilled or trained people can operate CNCs unlike manual lathes or milling machines
etc.. which need skilled engineers. One person can supervise many CNC machines as once
they are programmed they can usually be left to work by themselves.

4. CNC machines can be updated by improving the software used to drive the machine.

5. Training in the use of CNCs is available through the use of ‘virtual software’. 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.
 3.2 CNC MACHINE TOOLS
Disadvantages of CNC Machine Tools
1. CNC machines are more expensive than manually operated machines, although
costs are slowly coming down.
2. 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.
3. Less workers are required to operate CNC machines compared to manually
operated machines. Investment in CNC machines can lead to unemployment.
4. Many countries no longer teach students how to use manually operated lathes or
milling machines.
 3.3 CNC Turning
• A turning machine is used to produce round or cylindrical parts by rotating the
workpiece as a securely held cutting tool removes material.
• The term ‘turning centre’ is rather unpopular, but an accurate overall description of a
computerised lathe, CNC.
• Most CNC turning machines does not have a Y-axis. Z-axis is the longitudinal motion of
the machine slide. The direction of motion that is perpendicular to the Z-axis is the X-
axis, and this axis has motion during a facing cut.
• The addition of an automatic tool changer (ATC) in combination with an automated
means of loading/unloading material and part allows these machines to be run virtually
unattended.
 3.3 CNC Turning
• When a CNC Lathe is equipped with ATC, it is called a turning centre. In a simple word,
turning centres are CNC lathe with addition ATC.
• Basic workframe of a CNC lathe is similar to manual lathe. Turning centres are also
designed for production work and aggressive material removal rates and does not have
provisions to used manually.
• Mostly, the turning machines also have angled bed on which the X-axis rides and called
“slant-bed”. Slant bed machines put the tool and the machine mechanicals behind the
workpiece, which make the operator visibility of the work much better.
 3.3 CNC Turning

• The chips do not accumulate and easily slide down the bed due to gravity.
• The turning centres also features low friction linear guide-way which greatly minimises
wear, reduces friction (enabling high rapid traverse feeds) and allows for very high
accuracies due to a zero clearance preloaded ball bearing design.
• In addition to the standard lathe operations such as turning and boring, CNC lathe can be
used for drilling, grooving, threading, knurling and burnishing.
 3.3 CNC Turning

3.3.1 Types of CNC Lathes

• A CNC lathe has no ATC.
• Basically, CNC lathe can be categorised by the type of design and the number of axes.
Two basic types of CNC lathe are Vertical CNC Lathe and Horizontal CNC Lathe.
• Vertical CNC lathe is somehow less common compared to horizontal CNC lathe,
however, irreplaceable for a large diameter work. There is no significant differences in
programming approach between the two lathe types for CNC programmer.
• Turning machines types are Turret Type Machine and Gang Tool Type Machine.
 3.3 CNC Turning
• Most Turret Type Machine are fitted with circular turret where all of the tooling is mounted.
Turret Type Machines are popular due to their ability to fit a high quality of tolls in a small
amount of space. Some turret machine are even fitted with more than one turret.
• Gang Tool Type Machine are flat bed design and fitted with carriage where tools are
installed.
• Most machines align the tools in a row next to each other on a top plate.
• Gang tools : great rigidity, high accuracy and extremely simple design with few moving
parts.
 3.3 CNC Turning
TOOL MOUNTING
• Each styles of turning machine accepts tools differently.
• A Turret Type Machine will usually either have bolt-on machine tool-mounting adapter or a
style known as VDI (Verein Duestche Ingenieure). It is mounted directly to either the turret
face or turret periphery with bolts.
• Cutting toolholders: usually, same type of cutting tooling will be used no matter what
machine style. Common types of cutting tools include OD (outside diameter) turning, OD
grooving, ID grooving, threading, cut-off, boring, drilling, reaming and tapping. With CNC
turning centre, however, the means of holding them may be a bit different.
• Hole-working toolholders: CNC collet chucks are very versatile and often used for holding
many different types of hole working tools.
 3.3 CNC Turning
• OD working toolholders: OD turning and threading toolholders come in right-hand, left-hand
and neutral orientation. Neutral is not oriebted left or right but aimed straight.

• Grooving and cutoff toolholder: this tools can plunge into a part, create a groove and then
feed sideway, creating a turned diameter or contour. Cutoff designed for cutting off spinning
parts in the machine by inserting the sharp corner so the minimal burr will be produced.
 3.3 CNC Turning
• ID toolholders: the inserted mounted in these bar type holder are usually identical to those
used for OD working.
• Bar pullers and bar feeders: a bar puller is a tool that is mounted to the turret and when
programmed can approach the remaining bar material after a part that has been cutoff, grip
the bar and after the workholding device is released, pull the bar to the desired length. Bar
puller are available in many form such as gripping ring type, spring jaws type and coolant
powered hydraulic.
• Bar pullers and bar feeders: Bar feeder mount outside the machine headstock, in line with
the spindle centerline and accept entire lengths of bar stock. The bar rotates in the feeder
tube and the feeder controls the bar from whipping out of balance.
 3.3 CNC Turning
Workholding
• Workholding devices for CNC turning are selected based on size, shape and work style. The
common are three-jaw chuck, four-jaw chuck, collet chuck and lathe centre.
 Question

1. What are Slant bed machines advantages?

2. Name the two primary machine axes on most CNC turning machines.
3. Explain the difference between a turning centre and a CNC lathe.
4. Name three types of work-holding devices for turning centre.
 3.4 CNC Milling
• Operations performed on manual milling primarily
produce flat surfaces, straight slots and steps, and
accurately locate hole position.
• This can also produce by CNC but with greater
speed and accuracy.
• The X-, Y- and Z-axes can be programmed to move
simultaneously, this CNC also create an endless
variety or arcs, contours and three dimensional
surfaces.
• CNC Milling is a machining centre with ATC. Since
this type are intended for heavy duty production
and aggressive material removal rate, they typically
will not be used manually. There are some
distinctive features of their design that make them
well suited for these applications.
3.4 CNC Milling
3.4.1 Types of CNC Milling
• Machining centres are separated into two major class; vertical spindle
and horizontal spindle.
• Vertical machining centre (VMC) can be compared to standard vertical
knee type mill.
• Horizontal machining centre (HMC) is the most popular due partly to the
versatility ofworkholding, the inherit rigidity of the machine’s column and
the ability to allow gravity to help remove chips out of the machining
area.
• Machining centre construction uses low friction guideways for sliding
machine surfaces.
• ATC types: there two basic types of ATC which are Carousel Type Tool
Changer and Swing Arm Type Tool Changer.
 3.4 CNC Milling
TOOLHOLDING
• A machining requires a toolholder for spindle to hold the cutting tool. Two major
characteristics when determining the appropriate toolholder for an application are; the
spindle mounting type and holder to tool attachment style.
• Tool attachment styles: there are several types of holders available for mounting different
types of cutting tools for CNC milling. Some just like the manual machine some are
specially designed for CNC machines.
1. CNC Endmill holder: the holder contain a bore to receive a specific tool shank diameter
just like those used for manual mills. They also have tapped hole with a setscrew at 90
degrees to the bore. This setscrew is tightened onto a Weldon flat on the shank of the
tool. Only tools with flats on their shanks should be mounted in this type of holder.
Endmill are inexpensive, rigged, simple and capable of transmitting torque. But,
different size is needed for each shank diameter.
2. CNC collet chuck toolholders: they are very versatile and commonly used for holding
many different types of straight-shank milling tools. An advantage of collet chuck is that
they run truer than endmill holders because there is no setscrew to unbalance the
holder.it can be used for holding nearly type of straight shank tool, including endmill,
drills and reamer.
 3.4 CNC Milling
3. Shrink-fit toolholder: is designed and machined so that there is an
interference fit between its bore and tool’s. The holder’s nose must be
heated to insert and secure a tool in this type of holder.
4. CNC drill chuck toolholder: this are three-jaw drill chuck with adapters
suited to fit the machine’s spindle taper. This intended to hold low
torque.
5. CNC shell mill and face mill toolholders: simple arbors used for
mounting shell mills and face mills.
6. CNC tapping toolholders: some hold taps rigidly in the holder. Others
hold taps in specialised spring-loaded devices that allow extension and
compression. This called as floating holder.
3.4 CNC Milling
Workholding: these are the workholding in cnc milling
1. Clamps
2. Machine vises
3. Chuck or collet closer
4. Pallet systems
5. Tombstones
6. Vacuum plates, magnetic and adhesive based workholding
7. Custom fixtures
 Questions
1. Explain the different between a machining centre and a CNC Mill.
2. Name two major types of ATCs.
3. What is VMC and HMC?
4. What are two major characteristics when determining the appropriate toolholder
for an application?
3.5 CNC EDM
3.5.1 Types of CNC EDM
CNC EDM can be divided into two which are;
1. Die sinking: use electrode and submerged in dielectric
2. Wire cut: a long wire needed to cut metal by current flow in dielectric
 3.5.2 CNC Die Sinker (Vertical EDM)
3.5.2.1 Die Sinker Process

• Die sinker is also called as vertical EDM. Die sinker is using electrode to fabricate. The selection of
electrode is quite challenging. To operate EDM Die sinker, the operator need to choose the best way to
fabricate.

3.5.2.2 Electrode and Material Selection

• Before the fabrication, the electrode must be identified. To identify, we need to know the types and
characteristic of the electrode.

• The electrode must be;

1) Good conductor and heat transfer.
2) Easy to be machined and reasonable.
3) Doest not change to any other shape during fabrication.
4) Low electrode wear compared to workpiece.
5) Efficiently surface finish.
 3.5.2 CNC Die Sinker (Vertical EDM)
3.5.2.2 Electrode and Material Selection

• After knowing the electrode characteristic, the types of electrodes should be considered. The most popular
electrodes are copper and graphite.

Type of electrode

1. Graphite:
2. Metallic:
Evaluation of graphite materials

•Advantages: high strength, good machinability, high speed, excellent wear

resistance, can be abraded or ultrasonic machined.

•Disadvantages: cost. Low degree of safety, wire cuts slowly

Evaluation of Metallic materials

•Advantages: low cost, high strength, machining safety, good entry level, mirrored
finish, discharge dressing, wire cut readily and clean.

•Disadvantages: cost. Low grindability index, burrs, slower machining speeds,

higher wear
 3.5.2.3 Electrode Wear

•When predicting electrode war, several combined parameters will determined the
part finish and consequently the amount of wear realised in any given “burn”.
•Primarily, it is the ability of the electrode material itself to resist thermal damage, but
the electrode’s density, polarity and the frequencies used are also a major part of the
“wear equation”.
•Graphite have higher resistance to heat and wear at lower frequencies, but will wear
significantly more during high frequency.
•The use of high frequencies with graphite is usually reserved for finishing operation
with very little material to be removed. This might be quickly generating clearance
holes or for roughing simple shapes that can be easily fabricated or redressed.
 3.5.2.3 Electrode Wear

•Surface finish: power setting is reduced in conjunction with high frequencies. These
parameters will always produce more wear to the electrode, regardless of the
electrode material.
•The degree of wear will depend upon the type and grade of material and the finish
desired.
•Wear can be incurred with every single sparks that leaves the electrode.
•Small spark = small craters, but the trade off is: more sparks = more wear.
3.5.2.4 Die Sinker Flushing

• Flushing is the key of successful EDM operation.

• Flushing is the process of introducing clean dielectric fluid into and through the spark gap. This
are for several purpose;

1) Introduces “fresh” dielectric to the cut

2) Flushes away the “chips” and debris from the spark gap

3) Cools the electrode and workpiece

• Types of flushing:

a) Pressure: the most common type of flushing or referred as injection flushing. The oil is force
through the spark gap.

b) Suction: opposite from pressure. It is pulled through by vacuum.

c) Jet or side: the least efficient method. This is the strategic placement of hoses or flushing
“wands” to direct the stream of oil to flush the gap during pulsed electrode movement.
3.5.3 CNC Wire Cut (Wire EDM)
3.5.3.1 Wire Cut Process

• EDM wire cut is a thermal mass reducing process that uses a continuously moving wire to
removal material.

• A thin wire of brass, Tungsten or copper is used as an electrode.

• EDM wire cut can cut any design to detail design.

• In this process, a thin metallic wire is submerged in a tank of dielectric fluid. The wire is
constantly fed from a spool, is held between upper and lower diamond guides. The guides
are usually CNC controlled.

• The area where in discharge take place gets heated to very high temperature such that the
surface gets melted and removed.

• The wire and workpiece must be electrically conductive.

• The sparks will produces and get flushed away by the continuously flowing dielectric.
 3.5.3 CNC Wire Cut (Wire EDM)
3.5.3.2 Wire Types and Selection
3.5.3 CNC Wire Cut (Wire EDM)
3.5.3.3 Wire Flushing
• Flushing is the key of successful EDM operation.
• Flushing is the process of introducing clean dielectric fluid into and
through the spark gap. This are for several purpose;
1) Introduces “fresh” dielectric to the cut

2) Flushes away the “chips” and debris from the spark gap

3) Cools the electrode and workpiece

• Types of flushing:
a) Flush cups and nozzles: is a plastic or ceramic devices that is
positioned over the wire guide and through which water is forced to
flush chips and debris from the spark gap.
References
• E.Bud Guitrau (1997), “The EDM Handbook”, Hanser Gardner Publication,
Cincinnati.