DIPLOMA ENGINEERING 11th- 12th

All Branch All Branch Science

MHT-CET | JEE | NEET
All Subjects All Subjects
For Online Classes, Download the App. “Vineet Tutorials” From Playstore
ic Science Contact For Enquiry:- 7721920707, 7507378196

Sub :- Production Processes

UNIT : 1
Fundamentals Of CNC Machine

CNC Machine
 Definition :- "A Computer Numerical Control (CNC) machine is a computer-
controlled machine tool that uses programmed instructions to automate manufacturing
processes, such as cutting, drilling, and shaping, with high precision and accuracy."

Elements Of CNC Machine :

 Input / Output Device
 Machine Control Unit
 Machine Tool
 Driving System
 Feedback Devices
 Display Unit
 Advantages Of CNC Machine :-
1. High Accuracy : CNC machines provide precise and accurate results.
2. Increased Productivity : Automated processes enable faster production rates.
3. Improved Quality : Consistent results and reduced human error.
4. Reduced Labor Costs : Automated processes minimize manual labor.
5. Flexibility : CNC machines can perform multiple tasks with ease..
6. Scalability : Easily scalable for large production runs.
7. Reduced Material Waste : Precise cutting and shaping minimize waste.
8. Improved Safety : Reduced risk of human injury.
9. Easy Maintenance : Automated diagnostics and maintenance alerts.
10. Cost-Effective : Long-term cost savings due to increased efficiency.

Disadvantages Of CNC Machine

1. High investment cost
2. Complicated maintenance so higher maintenance cost
3. it required Skilled operator For programming
4. High tooling cost

 Application Of CNC Machine

1. Aerospace
2. Automotive
3. Medical
4. Electronics
5. Metalwork
6. Education
7. Art
8. Defense.
 Classification Of CNC Machine
(1) According To Positioning Control System :
(A) Point To Point
(B) Straight Path
(C) Continuous Path
(2) According To Programming Method :
(A) Absolute
(B) Incremental
(3) According To Feedback System :
(A) Open Loop
(B) Closed Loop
(4) According To Axis :
(A) Horizontal CNC machining
(B) Vertical CNC machine
(1) According To Positioning Control System
A) POINT TO POINT CNC MACHINE :
• Point to point control system in a CNC machine is a numerical control system that
moves a tool from one specific point to another.
• The PTP system is also known as positioning system.
• In point-to-point control system both workpiece & tool are kept in constant position
while tool performs it required duty and move from one point to another point so that
machining take place.
Example : 1) CNC drilling 2) Punching 3) Spot Welding machine
 B) STRAIGHT LINE CONTROL CNC MACHINE :
• Straight line control system is an extension of point-to-point control system with the
provision of machining along a straight line as in case of milling and turning
operations.
• Straight line control system is also known as linear interpolation.
• Straight line cut is obtained by controlling movement of tool with controlled feed rate
in one of the axis direction at time
• Example : 1) Face Milling
2) Stepped turning operations

C) CONTINOUS PATH CONTROL CNC MACHINE :

• This type of CNC machine operates continuously &
perform a specific task or operation without
stopping.
• The machine receives continuous commands from
the CNC controller, allowing it to perform complex
operations without interruption.
• Continue path controlling machine is a high
technology & most versatile control system.
EXAMPLE :- 1. CNC Lathes
2. CNC Grinder
3. CNC Milling Machines
(2) According To Programming Method
A) ABSOLUTE CO-ORDINATE TYPE CNC MACHINE :-
• An Absolute Coordinate CNC Machine is a type
of CNC machine that uses a fixed reference point
(origin) to determine the position of the cutting
tool or workpiece.
• All movements are referenced from this fixed
point, allowing for precise and accurate
machining.

B) INCREMENTAL CO-ORDINATE TYPE CNC MACHINE :-

• Incremental Coordinates do not use the point
of origin. In this method each point is
specified using the reference of previous point
position.
• These coordinates reset to (0, 0) after every
point.
• The next position is calculated starting at (0,0).

(3) According To Feedback System

A) OPEN LOOP TYPE CNC MACHINE :-
• The Open-loop control system do not have a feedback mechanism.
• Open loop CNC machine is less accurate as compare to close loop system because of
no monitoring of actual displacement of machine slide
Example : CNC drilling machine
B) CLOSE LOOP TYPE CNC MACHINE :-
• The closed loop system has a feedback system to monitor the output of the motors.
• The close loop controls machine is very accurate because it control the drive system
by comparing it with input information.
Example : CNC Lathe Machine

 Constructional Element Of CNC

1. Structure
2. Spindle and Feed Drives
3. Actuator Support Bearings
4. Feedback (Devices) Systems
5. Automatic tool changer
6. Automatic pallet changer
 Structure:
The CNC machine tool structure consists of following parts:
1. Bed 2. Column
[Link] or slide-ways 4. Table

1. Bed : -
• The machine bed supports the entire machine and other machine components.
• The machine bed made from high-quality cast iron.
• Provides stiffness, low weight, and damping to reduce the vibration.
2. Saddle (slide-ways) :-
• Slideways are flat surface in CNC machine that machine components move along X
axis.
• The saddle or slide way normally mounted on the bed ways.

3. Column :
• The column is mounted on the saddle. It is designed with high torsional strength in
prevent distortion and deflection during machining.
• The column provides the machining center with the Y-axis linear movement.
4. Table :
• The table is mounted on the bed.
• It provides the machining center with the Z-axis linear movement.

 Spindle and Feed Drives :

In most of the machine tools, the drives are used to drive spindle and feed motion
devices, both of which as either holding workpiece or cutting tool.
Most commonly used drives:
1. Stepper motors
2. DC servo motors
3. AC servo motors
4. Fluid motors
1. Stepper motors :
• Stepper motor convert electricity into rotation.
• The stepper motors Is very easy to control and usually used in open loop control
systems where feedback is not required.
• Stepper motor have excellent speed control and better positioning and repeatability of
movement
• The common application of stepper motors is in machine tool slides or feed drives.

2. DC servo motors :
• A servomotor that uses DC electrical input to produce mechanical output like position,
velocity, or acceleration is called a DC servomotor.
• DC drives are widely used in NC/CNC machines with closed loop control system.
• Advantage of DC motor : Ease of control of speed of rotation.
• Limitations of DC motors : Costly, large dimensions and large weight.
3. AC servo motors :
• A servomotor that uses AC electrical input in order to produce mechanical output in
the form of precise angular velocity is known as AC servo motor.
• AC servo motors are designed for precise control of position, speed, and acceleration,
with a feedback system for accuracy.
• Advantages of AC servo motors : high power to weight ratio, low rotor inertia,
constant continuous torque, constant overload capacity over the full speed range, and
no requirement of additional cooling of motor.

4. Fluid motors :
• Hydraulic motors are mechanical devices that convert force of pressurized hydraulic
fluids into both torque and angular movement.
• The fluid motors are also used for driving the spindle. Usually, high pressure oil or air
is used for running the motor.
  Actuator Support Bearings :-
1. Re-circulating Ball Screw :
 A recirculated ball screw is a mechanical device that converts rotary motion into linear
motion using ball bearing mechanism. The ball roll between the screw and nut in
helical grooves which eliminate the friction and nut is move smoothly along the screw
length.
 The re-circulating types of ball screws are widely used in NC/CNC machines.
 In such systems, the balls are in continuous circulation between nut & screw during
complete motion of slide. These balls provides rolling friction, and hence, have a low
coefficient of friction.

2. Linear motion guideways :

• Linear motion guideways are mechanical components that allow for the precise and
smooth movement of heavy objects in a straight line.
• It is also known as LM Guides
• In CNC machines, there are support structures which moves on either bed ways or
slide ways. To minimize friction and wear in such sliding elements, rolling elements
are used. The systems used for such purpose are called as linear motion systems.
  According To Feedback (Devices) Systems:-
 Feedback system is a measuring device which compare the actual position with
input programme value.
 Types of incremental Encoders as Feedback Devices :
1) Rotary encoders
2) Linear encoders
1. Rotary Encoders as Feedback Devices :
• A rotary encoder acts as a "feedback device" by providing precise information about
the angular position of a rotating shaft.
• A rotary encoder consists of a glass disc with etched lines that rotate between a light
source and photodiode. The lines break the beam, generating pulses that are magnified
into a square wave output. A 360-line encoder produces 360 pulses per revolution.
• This disc is connected to the lead screw or timer belt.

2. Linear Encoders Feedback Devices :A linear encoder works by moving a glass scale
with lines along a stationary guide. As the scale moves, a sensor detects the movement
and sends out light pulses. These pulses are then converted into an electric signal, which
shows the exact linear movement.
 Automatic Tool Changers :
 An Automatic Tool Changer (ATC) is a device that stores multiple preset tools and
automatically selects the required tool for a specific machining operation, by part
programming (Without manual operator).
 ATC change tool automatically by sending command to the control unit.
 ATC change tools rapidly, reducing non-productive time.
 They are generally used to improve the capacity of the machines to work with a
number of tools.
 Types of Tool Changers Used in CNC Machine Tools :
1. Magazine tуре
2. Turret head

1. Tool Magazine :
• A tool magazine is a storage device in a CNC (Computer Numerical Control) machine
that holds number of cutting tools.
• The CNC machine can automatically select and change tools from the magazine
during the machining process according to command given to it.
• Tool automatically selected by tool control function (T word) used in Part
programming By using M06 code.
• e.g. T06 – Tool number 6 is selected.

2. Turret head :
• A "turret head" in CNC machine is a rotating component on a CNC lathe that holds
multiple cutting tools, allowing for quick and efficient changing different tools during
the machining process.
• The turret head can handle items with a wider diameter. More cutting tools can be
fitted onto a turret head.

 Pallet Changer Systems :

• A "pallet changer system" in CNC machining is a mechanism that automatically move
out (Change) one pallet with new pallet on a CNC machine, during machining on the
current part.
• The system automatically moves a loaded pallet out of the machining area & replaces
it with a new, pre-loaded pallet, during machine continues to operate.
• It reducing downtime and increasing overall production efficiency.
• it enables continuous machining by eliminating the manually loading and unloading
parts directly into the machine every time.
• Pallet changer systems are of two types :
1) Linear pallet changer system.
2) Rotary pallet changer system
1) Linear Pallet Changer System :
• In a CNC machine, the Linear Pallet Changer System enables efficient and automated
exchange of pallets holding workpieces linearly.
• The system's linear motion enables smooth and precise pallet exchange, making it an
essential component in modern CNC machining.
• Advantages: streamlines production, reduces setup time, and increases machine
utilization.
 2) Rotary pallet changer system :
• The pallet with the finished part is lifted up together with the pallet with the raw
(unfinished) part. It is then rotated 180 degrees and placed onto the CNC index or
rotary table. At the same time, the first pallet is placed on the loading and unloading
stations.
• In rotary pallet changer system pallets are indexed one by one for machining operation
to perform on workpiece mounted on each pallet in clockwise or anticlockwise
rotation in front of machine spindle.

 CNC Machine Tooling :-

• CNC machine tooling is a set of tools used in CNC machines to perform cutting,
milling, drilling, and shaping.
• CNC machine tooling include :-
1. Tools
2. Tool holders

1. Tools :
 There are number of tools are used in CNC machine to perform the various operations.
 Each tool having its unique features and specification.
 Tools are used according to operations, Sizes & condition of work piece.
 Example : End mills, fly cutter, knurling tool, boring tool, carbide lathe cutter.

2. Tool holders :
 The main function of tool holder is to hold the tool in it and perform the operation on
workpiece.
 A tool holder is a device that attaches cutting tools to machine tools. It's an essential
component of machining operations, as it ensures the tool is securely held and properly.
 Need of Indexable Inserts :
• Metal turning is very critical operation in manufacturing industry because of it involve
removing of material from the work piece to get required shapes and sizes, and for that
purpose selection of right tool is very important, So that we use indexable insert, In
which we replace the cutting edges very easily without replacing the entire tool.

 What are Indexable Inserts ?

• Indexable inserts are removable cutting tips that can be exchanged when they become
worn or damaged. They are used in machining operations like turning, milling,
drilling, and threading.
• Indexable inserts are cutting tool inserts made from various materials, such as tungsten
carbide, cermet, ceramic, cubic boron nitride (CBN) and also High Speed Steel (HSS).
• They are designed to be easily mounted onto compatible tool holders, making them
replaceable when the cutting edge becomes worn or damaged.
• The primary function of an indexable insert is to provide a sharp, durable cutting edge
that can efficiently remove material from a workpiece.
• The inserts are held in place by tool holders designed with precise clamping
mechanisms to ensure stability and accuracy during cutting.

Working principle of Indexable Inserts :-

• An indexable insert has multiple edges generally three to eight depending on its shape
and design. When one edge become worn or damaged then change it.
• First we remove the screw then remove the insert from insert seat on the tool holder
then rotate or change the insert as per requirement after that screw it back and ensure
that it fit correctly or not.
• The clamping mechanism can vary but the common methods include screw, clamps
and wedges. these mechanisms allow for quick and easy replacement of insert and
minimising the time required for tool changes and increase the overall productivity.

 Types of Indexable Inserts

1. Tungsten carbide insert :-
• A tungsten carbide insert is Most commonly used which is made from a mixture of
cemented carbides, primarily composed of tungsten carbide, used in cutting tools for
machining metal.
• It has excellent properties like hardness, Toughness, wear resistance, and ability to
withstand high temperatures, making it ideal for cutting applications across various
industries like manufacturing, aerospace, and oil drilling.

2. Ceramic insert :-
• Ceramic inserts are tool materials used for machining heat-resistant alloys, high speed
machining of cast iron, and hardened steel.
• They are made from silicon nitride or aluminium oxide, and are harder than cemented
carbide tools.
It is more brittle so proper handling is required.

3. Diamond insert :-
• Diamond inserts are cutting tools with diamond grains attached to them. They are used
in many industries for precision cutting operations.
• Diamond inserts are very hard and used for machining non-ferrous material like
aluminium, copper and other non-metallic substances.
• It is used to achieve superior surface finishing and mostly use in high precision
application like jewellery making, optics manufacturing.
4. Cermet insert :-
• Cermet inserts are cutting tools made from a composite of ceramic and metal, and are
used for finishing steel, cast iron, and stainless steel.
• They are an alternative to carbide inserts and are known for their dimensional
accuracy, heat resistance, and tool life.
• They can withstand high temperature and provide superior wear resistance.

5. CBN insert :-
• CBN inserts are cutting tools made from cubic boron nitride (CBN), a synthetic
material that's almost as hard as diamond.
• They're used to machine hard materials like hardened steel, cast iron, and super alloys.

 Advantages of Indexable Inserts:-

1. Cost-effective: The ability to replace only the worn insert, instead of entire tool body,
so lowering overall machining costs.
2. Versatility: Indexable inserts come in a wide variety of shapes, sizes, and cutting
materials
3. High machining efficiency: By quickly changing worn inserts, downtime for tool
resharpening is minimized, so improved production rates.
4. Suitable for a wide range of applications: Indexable inserts can be used for various
operations like turning, milling, drilling, and threading across diverse industries.
5. Consistency and Precision: Indexable inserts are manufactured to high tolerances,
ensuring consistent performance and precision.

 ISO Code & Nomenclature :-

 ISO 1832:2017 is an international technical standard for indexable insert and
turning tool holder.
 The system is designed so that each important features and dimensions of the insert
is shown by using code system.
 ISO code contain various letters and numbers and each one has specific meaning
such as shape, relief angle, tolerance, cross section type, thickness & radius etc.
Designation Meaning
C Insert shape
N Relief angle
M Tolerance
G Cross section type
12 Cutting edge length / diameter
04 Thickness
08 Nose radius
MP Chip breaker