Aim of the experiment:

To study turning operation CNC Lathe machine.

Apparatus Required:

 CNC Lathe
 Vernier Calliper
 Single point cutting tool

Theory:

What is a CNC machine?

CNC: Computerised Numerical Control (Computer + Numeric control).

Numeric control is programmable automation in which рrосеss is controlled by

Numbers, Letters, and symbols. CNC Machining a process used in the manufacturing sector
that involves the use of computer to control machine tools like lathes, mills and grinders.

Why CNC Machining necessary?

 To manufacture complex curved geometries in 2D or 3D is extremely expensive by

mechanical means (which usually would require complex jigs to control the cutter
motions).
 Machining components with high repeatability and precision.
 Unmanned machining operations.
 To improve production planning and to increase productivity.
 To survive in global market CNC machining are must to achieve close tolerance.

Major Components Related to CNC machine Tools:

Any CNC machine tool essentially consists the following parts.

Part program

 A series of coded instructions required to produce a part.

 Controls the movement of the machine took and on/offs.
 Control of auxiliary functions such as spindle rotation and coolant supply.
 The coded instructions are composed of letters, numbers and symbols.

Program input device:

The program input device in the means for part program to be entered into the CNC control.

Three commonly used program input devices are punch tape reader, magnetic tape reader and
computer via RS-232 - Communication.

Machine Control Unit:

The machine control unit is the heart of a cnc system. It is used to perform the following
functions.

 To read the coded instructions.

 To decode the coded instructions.
 To implement interpolations (linear, circular and helical) to generate axis motion
commands.
 To feed the axis motion commands to the amplifier circuits for driving the axis
mechanisms.
 To receive the feedback signals of position and speed for each drive axis.
 To implement auxiliary control functions such as coolant or spindle on/ off and tool
change.

Machine Tool:

CNC controls are used to control various types of machine tools. Regardless of which type of
machine tool is controlled, it always has a slide table and spindle to control position and speed.

The machine table is controlled in the x and y axes, while the spindle suns. along the z-axis.

Drive Systems:

Drives are used to provide controlled motion to CNC elements.

A drive system consists of amplifier circuits, drive motors, the ball lead-screws.

The MCU feeds the control signals (position and speed) of each axis to the amplifier circuits.

The control signals are augmented to actuate drive motors which in turn rotate the ball lead-
screws to position the machine table.

Power Drives:

In machine took power is generally required for driving the main spindle, saddle and carriges
and to some auxiliary units.
The motors used for CNC system are of two kinds.

 Electrical - AC, DC or Stepper motors.

 Fluid- Hydraulic or Pneumatic

In CNC, usually stepper and servo electrical drives are used. They exhibit favourable torque-
speed characteristics and are relatively inexpensive.

Stepper motor:

A stepper motor is a pulse driver motor that changes the angular position of the motor in steps.
Due to this type of nature of a stepper motor, it is widely used in low cost, open weep position
control systems.

Types of Stepper motor:

 Permanent magnet- Employs permanent magnet, low speed and relatively high torque
 Variable Reluctance- Does not have permanent magnet, Low torque

CNC Program Structure:

Character is the smallest unit of CNC program. It can have Digit / Letter / Symbol.
Word is a combination of alpha- numerical characteristics. This creates a single instruction to
the CNC machine. Each word begins with a capital letter followed by a numeric. There are
used to represent axes positions, feedrate, speed, preparatory commands, and miscellaneous
functions. A program block may contain multiple words sequenced in a logical order of
processing.

The program comprises of multiple lines of instructions, blocks which will be executed
by the machine control unit (MCU). There are 4 basic terms used in CNC programming.

Character →Word →Block → Program

Commonly Used addresses:

N CODE: Sequence number. It is used to identify each block with in an NC program and
provides a mean by which NC commands may be rapidly located. It is a program line number.
It is a good practice to increment each block number by 5 to 10 to allow additional blocks to
be inserted if future changes are required.
G-CODE: Preparatory Word, used as a communication device to prepare the MCU. The G-
CODE indicates that a given control function such as G01, linear interpolation is obtained.

X, Y & Z - CODES: Coordinates. These give the co-ordinate positions of the tool.

F-CODE: Feed rate. The F-CODE specifies the feed in the machining operation.

S-CODE Spindle speed. The s-code specifies the cutting speed of machining process.

T CODE: Tool selection. The T-code specifies which tool is to be used in a specific operation

M-CODE: Miscellaneous function. The M-code in used to designate a particular mode of

operation for an NC machine tool.

I, J & K CODES: They specify the centre of arc coordinates from starting.

Classification of NC systems:
There are three types of motion control of tools in NC systems. They are listed here under in
increasing level of sophistication
(1) Point to point
(2) Straight cut
(3) Contouring

(1) Point-to-Point (PTP) system:

PTP system or positioning system refers to operations that require fast movement to a point
followed by a manufacturing operation at that paint. NC drill machine is an example of
PTP system.

(2) Straight cut NC:

In straight cut NC, the tool moves parallel to one of the major axes at a desired rate suitable
for machining. It is quite appropriate for milling workpieces of rectangular configurations.
Any NC machine tool capable of straight cut movement can perform point to-point
operation also.

(3) Contouring systems:

 In contouring or continuous path system the tool follows the desired shape since the
commands are far more descriptive than for the point-to-point system. The movement of
the tool is precisely controlled at all times, in all planes. All axes of motion might move
simultaneously, each one at a different speed, while this speed may be changed even within
the path between two given paints. This system is commonly used in milling machines.

Types of NC machines:

(1) Single Spindle drilling machine:

It is the simplest numerically controlled machine. Most drilling machines are programmed
on three axes.

X - controls table movement to the right or left of column

Y - controls table movement toward or away from the column

Z - controls up and down movement of spindle

(2) Lathe :

Lathe in the most productive machine tool to manufacture round parts. Lathes are
programmed on two axes

X: controls the cross motion of the cutting tool.

Z: controls the carriage travel towards and away from the head stock.

(3) Milling machine:

Milling machine has been accepted as one of the most versatile machine tools used in
manufacturing industry.

X: controls table movement left or right.

Y: controls the table movement towards and away from column.

Z: controls vertical movement of the Knee or spindle.

 Turning centres, machining centres, Grinding machines, Wire cutting EDM machine are
some more types of NC machines.

Procedure:

In CNC lathes materials is clamped of rotated by the main spindle, while the cutting tool that
work on the material, is mounted and moved in various axes.

(1) The workpiece is fixed on spindle in 3 Jaw self-centred chuck.

(2) Facing is done without running the program. The single point cutting tool that work on the
material is mounted and moved in various axes.

(3)The single point cutting tool was touched from the bottom right end to the workpiece and
taken as reference (0,0) in the software.

(4) Turning operation to ensure smooth and curved surface

(5) The written program was fed into the system and was executed.

(6) The job was unmounted after performing the required operations & was checked for the
dimensions by using Vernier calliper.

Program:

G 21
G7
G0 X10.0 Z15.0
G0 Z0.0
G0 X9.80 Z2
G1 Z19.0 Y0.0
G0 X10.0 Z0.2
G1 X9.6
G1 Z19.5
G0 X10.0 Z0.2
G1 X9.4
G0 X10.0 Z0.2
G1 X9.4
G1 Z19.0
G0 X10.0 Z0.2
G1 X9.2
G0 X10.0 Z0.2
G1 X9.0
G1 Z9.0
G0 X10.0 Z0.2
G1 X8.8
G1 Z4.0 f100
G0 X10.0 Z0.2
G1 X8.6
G1 Z4.0 f100
G0 X10.0 Z0.2
G1 X8.4
G1 Z4.0 f100
G0 X10.0 Z0.2
G1 X8.2
G1 Z4.0 f100
G0 X10.0 Z0.2
G1 X8.0
G1 Z4.0 f100
G0 X10.0 Z15.0
G0 Z50.0
M02

Conclusion:
The Operations of CNC lathe machines was successfully performed using the above code.