Center Machine by Programming Based On Labels: Designing and Manufacturing of Profile by Using CNC Turning

DESIGNING AND MANUFACTURING OF PROFILE BY USING CNC TURNING
CENTER MACHINE BY PROGRAMMING BASED ON LABELS
A Project report submitted in partial fulfillment of the requirements
For the award of degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Of
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPURAM
By
M.ARUNA PRATAP REDDY (17G31A0316)
BADINEHAL SANDEEP (17G31A0301)
U.MOHAMMAD SOHAIL (17G31A0329)
S.MUSTAQHAHAMMMAD (17G31A0326)
M.SURENDRA (17G31A0314)
Under the Esteemed Guidance of

Mr.N. FRANCIS M.Tech,
Assistant Professor
Mechanical Engineering Dept.
Department of Mechanical Engineering

ST. JOHNS COLLEGE OF ENGINEERING & TECHNOLOGY
(Permanently Affiliated to JNTU Anantapuram, Accredited by NAAC, Approved

by AICTE, New Delhi) Yerrakota, Yemmiganur, Kurnool – 518 360 (A.P)
2017-2021
St. JOHNS COLLEGE OF ENGINEERING & TECHNOLOGY
(Permanently Affiliated to JNTU Anantapuram, Accredited by NAAC Approved by
AICTE, New Delhi)
Yerrakota, Yemmiganur - 518360, Kurnool (Dist). A.P.
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the project report entitled “DESIGNING ANDMANUFACTURING

OF PROFILE BY USING CNC TURNING CENTER MACHINE BY PROGRAMMING
BASED ON LABELS” is being submitted by M.ARUNA
PRATAPREDDY (17G31A0316), BADINEHAL SANDEEP (17G31A0301),
U.MOHAMMAD SOHAIL (17G31A0329), S.MUSTAQHAHAMMMAD (17G31A0326),
M.SURENDRA (17G31A0314) in partial fulfillment of the requirement for the award of
theDegree inBachelor of Technology in “MECHANICAL ENGINEERING”inSt. JOHN’S
COLLEGEOF ENGINEERING & TECHNOLOGY is a record of bonafide work carried out
under theguidance and supervision.
Project Guide HOD

Mr.N.FRANCISM.Tech, Mr.M.RAVISHANKAR, M.Tech,(Ph.D.)
Assistant Professor Associate Professor
Dept. of Mechanical Engineering, SJCET Dept. of Mechanical Engineering, SJCET
Place:
Date:
Certified that the candidate was examined by me in the viva-voce Examination held on
________________ at St. Johns College of Engineering & Technology, Yemmiganur.
INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT
We sincerely express our gratitude thanks to Mr.N.FRANCIS,M.Tech. Assistant
professor for his guidance and encouragement that led to the completion of this project work.
We extend our sincere and heartful thanks to Mr. M.RAVISHANKAR,M.Tech,(Ph.D).

Head of the Mechanical Engineering Department for giving this opportunity to do the project
work.
We extend our sincere and heartful thanks to Dr. VEERANNA, Ph.D Principal for
giving this opportunity to do the project work.
We take this occasion to express our acknowledgement to all the faculty members and
Non-teaching staff of Mechanical Engineering Department for their co-operation
andencouragement throughout our post-graduation and to all our friends who have helped in
one way or the other.
Finally, we are greatly thankful to our beloved parents for their motivation and
encouragement during the project work and made a part in our success.
CONTENTS
CHAPTER NO TITLE PAGE NO
ABSTACT
CHAPTER 1
INTRODUCTION 1-11
1.1 Machine 1
1.2Conventional Machines 1
1.3 Numerical Control Machine 4
1.4 Introduction of CNC Machine 6
1.5 Working of CNC Machine 7
1.6Various Types Of CNC Machines 8
1.7 Advantages 8
1.8 Limitations 9
1.9 Applications of CNC Machine 9
CHAPTER 2
CNC PROGRAMMING BASICS 12-23
2.1 Coordinating System 12
2.2 Programming System 15
2.3 Incremental and Absolute systems 17
2.4 Part Programming in CNC 19
2.5 Preparatory Codes 20
2.6 List of G-Codes & M-Codes 21
CHAPTER 3
CNC SOFTWARES 24-35
3.1 CNC Software’s Introduction 24
3.2 SINUMERIK 828D 26
3.3 Versions of the SINUMERIK 828D 28
3.4 Tool Management 31
3.5 CNC Stimulation 32
3.6 Optimum View Guaranteed 33
CHAPTER 4
HISTORY AND DEVELOPMENT OF CNC MACHINE 36-44
4.1History of N.C Machine 36
4.2 Changes from NC to CNC System 37
4.3 Common CNC Machine 39
4.4 Development Between Conventional and Non convectional machine 42
4.5 Difference Between Conventional and Non convectional machine 44
CHAPTER 5:
ACTUAL PROJECT PROGRAM 45-53
5.1 Aim 45
5.2 Description 45
5.3 Designing of Profile 45
5.4 Profile Programming 46
5.5 Manufacturing of The Profile By Using CNC Smart run Lathe Machine 53
CHAPTER 6:
RESULT &CONCLUSIONS 57-59
6.1Results 57
6.2 Conclusion 58
REFERENCES 59
PHOTO GRAPHS 60-61
FIGURES
FIGURE NO TITLE PAGE NO
Fig. 1.1 Conventional Lathe Machine 3
Fig. 1.2 Conventional Grinding Machine 4
Fig. 1.3 NC Milling Machine 6
Fig. 1.4 NC Lathe Machine 6
Fig. 1.5 CNC Lathe Machine 10
Fig. 1.6 CNC Milling Machine 11
Fig. 2.1 Intersecting Lines from Right Angles 13
Fig. 2.2 The Three Dimensional Coordinate System 13
Fig. 2.3 Three Finger Rule 13
Fig. 2.4 Three Hand Rule 14
Fig. 2.5 Quadrant system 15
Fig. 2.6 Programming System 16
Fig. 2.7 A Work Piece Dimensioned in the Absolute System Mode 17
Fig. 2.8 Difference between Absolute And Incremental Positioning 18
Fig. 3.1 SINUMERIK 828D 25
Fig. 3.2 Keyboard 25
Fig. 3.3 SINUMERIK 828D 27
Fig. 3.4 Milling Machining Setting up and Getting Started 29
Fig. 3.5 Turning Machining Guaranteed to Turnout Well 30
Fig. 3.6 Tool Management 31
Fig. 3.7 CNC Stimulation 32
Fig. 3.8 Optimum View 33
Fig. 3.9 SINUMERIK 828D Alignment 34
Fig. 4.1 Numerical Control Machining Began in Aircraft Industry 35
Fig. 4.2 NC Machine 36
Fig. 4.3 New CNC Machines 36
Fig. 4.4 Tape Reader 37
Fig. 4.5 CNC Machine Key 37
Fig. 4.6 CNC Machines May Contain Many Tools 37
Fig. 4.7 CNC Milling Machine 38
Fig. 4.8 CNC Lathe Machine 39
Fig. 4.9 CNC Grinding 39
Fig.4.10 CNC Punch Press Use One Tool 39
Fig. 5.1 Profile Design 45
Fig. 5.2 Profile Program 49
Fig. 5.3 Work Piece Dimensions 50
Fig. 5.4 Stock Removal 51
Fig. 5.5 Grooving 51
Fig. 5.6 2-D Simulation 52
Fig. 5.7 3-D Simulation 52
Fig. 5.8 Half cut Simulation 53
Fig. 5.9 Aluminium Work Piece 54
Fig. 5.10 Tools Used 55
Fig. 5.11 Profile Manufacturing 55
Fig. 5.12 Machining Process 56
Fig. 6.1 The profile Output 57
ABSTRACT
The aim of the project is to manufacture the designed profile by using CNC machine.
The profile designed is needed to write a CNC program based on labels, the label mode of
program is selected because the programming is too easy even for complicated shapes.
CNC’s had made revolutionary changes with in the manufacturing sector in before days
achieving productivity up to the desired level was not possibilities due to lots of drawbacks
like complication of shapes and sizes, lack of skilled labours, lots of wastages and scraps due
to unexpected mistakes and low quality levels and accuracy. By using CNC this all draw
backs can be overcome and this was our small contribution to show the performance of CNC.
Initially we got trained about the CNC programming and operations for the period of one
month during the training decided to carry our project on CNC , we designed a profile to be
manufactured which would be tough to achieve it by conventional machining process and we
designed to make use of aluminium material as a work piece of dimension, after the basic
selections and decisions the preparation of an program (based on labels) was done and we went
for simulation and verified it thoroughly weather the profile achieved by simulation is matching
to the designed after lots of observation we went for manufacturing the profile in CNC machine
available at the source place and the results we got was smooth finished surface with high rate of
accuracy with less machining time which directly increases the productivity and the process
would be economical when compared to the normal conventional machining process.
DESIGNING AND MANUFACTURING OF PROFILE BY USING CNC TURNING CENTER
MACHINE BY PROGRAMMING BASED ON LABELS
CHAPTER: 1 INTRODUCTION
MACHINE:
Machine is an apparatus using mechanical power and having several parts,

each with a definite function and together performing a particular task.
Machines are usually powered by
• Mechanical
• Chemical
• Thermal
• Electrical
In olden days Conventional Machines were used for performing operations .It
takes lots of time to do operations and by the improvement of technology the NC
Machines came into existence. By this NC machines, the conventional machine
drawbacks were overcome. But the problem with the NC machines was that it has no
storage facility and functions achieved by this were limited. By technology development
the CNC Machines came into existence. The machine was equipped with the computer
and supportive software's with help of this it was been made too easy to operate with the
complicated operations and has lots of space to store the data.
The concepts of Conventional, NC, and CNC machines are been discussed below.
CONVENTIONAL MACHINES:
1.2.1ConventionalMachines:-
Machines that are driven or operated with the help of human resource are termed as
Conventional Machines. Example: -Small scale welding. - Small scale moulding. - Lathing.
Conventional machines require direct contact of tool with work piece material for
metal removing in form of chip. Conventional machining process involves tool wearing as
there is a physical contact between the tool and the work piece. Turning, drilling,
grinding, broaching, are example of conventional machining process. Conventional
machining process have many
DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 1

DESIGNING AND MANUFACTURING OF PROFILE BY USING CNC
TURNING CENTER MACHINE BY PROGRAMMING BASED ON LABELS
advantages over non-conventional machining process as they are more precise, no wear of
tool, no heat generation etc.
Manufacturing processes can be broadly divided into two groups and they are Primary
manufacturing process and Secondary manufacturing process. The former ones provide basic
shape and size to the material as per designer's requirement. Casting, forming, powder
metallurgy are such processes to name. Few secondary manufacturing processes provide the
final shape and size with tighter control on dimension, surface characteristics etc.; Material
removal processes are mainly secondary manufacturing processes.
Material removal processes are once again divided into mainly two groups on there
are "Conventional machining processes" and "Non Traditional Manufacturing processes".
Examples of conventional machining processes are

• Turning
• Boring
• Milling
• Shaping
• Broaching
• Slotting
• Grinding etc.
Conventional machining usually involves changing the shape of work piece using
an implement made of a harder material. Using conventional methods to machine hard
metals and alloys means increased demand of time and energy and therefore increase in
cost in some cases conventional machining may not be feasible.
Conventional machining also cost in terms of tool ware and in loss of quality in
the product owing to induced residual stresses during manufacture with ever increasing
demand for manufactured goods of hard alloys and metals such as inconel718 or
Titanium. Bore interest as gravitated to Non-conventional machining methods.
Conventional machining can be defined as a processes using mechanical (motion)

energy conventional manufacturing processes:

Generally macroscopic chip formation is by shear deformation.

There may be a physical tool present. For example a cutting tool in a lathe machine.
• Cutting tool is harder than work piece at room temperature as well as

under machining conditions.
• Material removal takes place due to the application of cutting forces-energy
domain can be classified as mechanical.
• Conventional machining involves the direct contact of tool and work piece.
• Lower accuracy and surface finish
• Suitable for every type of material economically.
• Tool life is less due to high surface contact and wear.
• Higher waste of material due to higher wear.
• Nice operation mostly causes sound pollution.
• Lower capital cost
• Easy setup of equipment.
• Skilled or unskilled operator may be required.
• Generally they manual to operate.
• They can't be used to produce proto type parts very efficiently and economically.
Some of the Conventional Machines are shown in figures

below:
Fig.1.1. Conventional Lathe Machine

Fig.1.2. Conventional Grinding Machine
NUMERICAL CONTROL MACHINE:
Numerical Control Machine tools may be defined as a method of automation in which

various functions of machine tools are controlled by letters, numbers and symbols. Basically a
NC Machine runs on a program fed to it. The program consists of precise instructions about
the methodology of manufacture as well as movements. For example, what tool is to be used,
at what speed, at what feed and to move from which point to which point in what path. Since
the program is the controlling point for product manufacture, the machine becomes versatile
and can be used for any part. All the functions of a NC machine tool are therefore controlled
electronically, hydraulically or pneumatically. In NC Machine tools, one or more of the
following functions may be automatic.
• Starting and stopping of machine tool spindle.
• Controlling the spindle speed.
• Positioning the tool tip at desired locations and guiding it along desired paths by
automatic control of motion of slides.
• Controlling the rate of movement of tool tip (feed rate).
• Changing of tools in the spindle.

An operational numerical control system consists of the following three basic components:
• Program of instructions.
• Controller unit also called as machine tool unit.
• Machine tool or other controlled process.
The program of instructions serves as input to the controller unit, which in

turn commands the machine tool or other process to be controlled.
PROGRAM OF INSTRUCTIONS:
The program of instructions is the detailed step by step set of instructions which
tell the machine what to do. It is coded in numerical or symbolic form on some type of
input medium that can be interpreted by the controller unit. The most common one is the
1-inch-wide punched tape. Over the years, other forms of input media have been used,
including punched cards, magnetic tape, and even 35mm motion picture film.
There are two other methods of input to the NC system which should be
mentioned. The first is by manual entry of instructional data to the controller unit. This is
time consuming and is rarely used except as an auxiliary means of control or when one or
a very limited number of parts to be made. The second method of input is by means of a
direct link with the computer. This is called Direct Numerical Control, or DNC.
CONTOLLER UNIT:
The second basic component of NC system is the controller unit. This consists of
electronics and hardware that read and interpret the program of instructions and convert it
to mechanical actions of the machine tool. The typical elements of the controller unit
include the tape reader, a data buffer, signal output channels to the machine tool, and the
sequence controls to coordinate the overall operation of the foregoing elements.
The tape reader is an electrical-mechanical device for the winding and reading the
punched tape containing the program of instructions. The signal output channels are
connected to the servomotor and other controls in machine tools. Most N.C. tools today are
provided with positive feedback controls for this purpose and are referred as closed loop
systems. However there has been growth in the open loop systems which do not make

use of feedback signals to the controller unit.
The advocates of the open loop concept claim that the reliability of the system is great
enough that the feedback controls are not needed.
MACHINE TOOL:
The third basic component of an NC system is the machine tool or other controlled
process. It is part of the NC system which performs useful work. In the most common
example of an NC system, one designed to perform machining operations, It also includes
the cutting tools, work fixtures and other auxiliary equipment‟s .
Some of the NC Machines are shown in figures below:
Fig.1.3. NC Milling Machine Fig.1.4. NC Lathe Machine
INTRODUCTION OF CNC MACHINES:
CNC is the short form for COMPUTER NUMERICAL CONTROL. As we all know
that NC (NUMERICAL CONTROL) Machine works as per the program of instructions fed
into the controller unit of the machine. The CNC Machine comprises of the mini computer or
the microcomputer that acts as the controller unit of the machine. While in the NC machine
the program is fed into punch cards, in CNC Machines the program of instructions is fed
directly into the computer via a small board similar to the traditional keyboard.

In CNC Machine the program is stored in the memory of the computer. The
programmer can easily write the codes and edit the programs as per the requirements.
These programs can be stored in the memory of the computer. These programs can be
used for different parts, and they don’t have to be repeated again and again.
Compare to the NC machine, the CNC machine offers greater additional flexibility
and computer capability. New systems can be incorporated into the CNC controller
simply by reprogramming the unit. Because of its capacity and the flexibility the CNC
machines are called as “soft-wired” NC. The numerical data required to produce a part is
provided to a CNC machine in the form of program, called “Part Program”. The program
is translated into the appropriate electrical signals for input to motors that run the
machine. A CNC Machine is a Numerical Control Machine with the added feature of an
on board computer which is referred to as the machine control unit (MCU).
CNC Computer Numerical Machines are widely used in manufacturing industries.

Traditional machines such as vertical millers, center lathes, shaping machines, routers etc.
operated by a trained engineer have, in many cases, been replaced by “COMPUTER
CONTROL MACHINES.”
1.4.1 NECESSARY OF CNC MACHINES:
CNC Machine Operators work in a wide variety of fields. People from all different
pursuits, such as hobbyists and even military group, take advantage of the cost saving
accrued by using CNC machines to turn raw materials into final products. The machines
are faster, more efficient and safer, too.
WORKING OF CNC MACHINES:
The CNC machine comprises of the computer in which the program is fed for
cutting of the metal of the job as per the requirements. All the cutting processes that are to
be carried out and all the final dimensions are fed into the computer via the program. The
computer thus knows what exactly is to be done and carries out all the cutting processes.
CNC machine works like the Robot, which has to be fed with the program and it follows
all your instructions.
Some of the common machine tools that can run on the CNC are: Lathe, Milling
machines, Drilling Machine etc. The main purpose of these machines is to remove some

of the metal so as to give it proper shape such as round, rectangular, etc. In the traditional
methods these machines are operated by the operators who are experts in the operation of
these machines. Most of the jobs need to be machined accurately, and the operator should
be expert enough to make the precision jobs. In the CNC machines the role of the
operators is minimized. The operator has to merely feed the program of instructions in the
computer, load the required tools in the machine, and rest of the work is done by the
computer automatically. The computer directs the machine tool to perform various
machining operations as per the program of instructions fed by the operator.
VARIOUS TYPES OF CNC MACHINES:
There are many different types of CNC Machines used industry, such as
• Mills and machining centers

• Lathes and turning centers
• Drilling machines
• EDM (Electron Discharge Machine) sinker
• Wire cut machines
• Flame and Laser Cutting Machines
• Water Jet profilers
ADVANTAGES OF A CNC MACHINES:

CNC machines offer the following advantages in manufacturing,
• Higher flexibility: This is essentially because of programmability, programmed
control and facilities for multiple operations in one machining center.
• Increased productivity: Due to low cycle time achieved through higher material
removal rates and low set up times achieved by faster tool positioning, changing,
automated material handling etc.
• Improved quality: Due to accurate part dimensions and excellent surface finish
that can be achieved due to precision motion control and improved thermal control
by automatic control of coolant flow.
• Reduced scrap rate: Use of Part programs that are developed using
optimization procedures
• Reliable and Safe operation: Advanced engineering practices for design and
manufacturing, automated monitoring, improved maintenance and low human

interaction
• Smaller footprint: Due to the fact that several machines are fused into one.
LIMITATIONS OF CNC MACHINES:
• CNC Machines are more expensive than manually operated
machines, although cost is slowly coming down.
• The CNC Machine operator only needs basic training and skills, enough
to supervise several machines.
• Fewer workers are required to operate the CNC machines compared to manual
operated machines. Investment in CNC Machine can leads to unemployment.
APPLICATIONS OF CNC MACHINES:

• Milling: Milling is the most common form of machining, a material removal
processes, which can create a variety of features on an apart by cutting away
the unwanted material.
• Drilling: Drilling is a cutting process that uses a drill bit to cut or enlarge a hole
of circular cross-section in solid materials.
• Welding: joining of two similar, dissimilar metals with or without use of filler metal.
• Boring: In machining, boring is the processes of enlarging a hole that

has already been drilled, by means of a single-point cutting tool.
• Bending: Bending is the ability to manipulate an element and is significant
to many aspects life in the world of avatar.
APPLICATIONS OF CNC IN SOME INDUSTRIES:

• Automotive Industry: The automotive industry employs various technique of
machining to manufacture a variety of automobile components such as wind
screens, outer body, sheets, door panels and integral components.
• Aerospace Industry: CNC cutting machines for aerospace have been instrumental
in increasing productivity by utilizing coded instructions to do complicated work
quickly have been efficiently. Retro systems water jet cutting machines ability to
cut a broad array of materials make them well suited for aerospace applications.
• Metal Removal Industry: The metal removing industries remove the metal from
the raw materials to give it the desired as per the requirements. All these metal
removal works are performed by different machine tools like lathe, milling,

drilling machines etc.

• Electrical Discharge Machining: The EDM Machines remove the metal by creating
the spark that burns the metal. They are two types of EDM with the CNC auto
machine, Vertical EDM and Wire EDM. The EDM needs an electrode of the shape
and size of the cavity that is be made in the job. Wire EDM is used to makethe punch and die
combinations for the dies set that are used in the industries where fabrication is done..
• Medical Industry: In Medical Industries these CNC‟s are going to user for
preparing operational instruments.
• Industries For Fabricating Materials: In many industries thin plates like steel plates
are required for various purpose inn fabrication industry the machining operations
are performed on such plates.
• Other Industries Where CNC Machines Are Used: CNC Machines are also used
extensively in the wood working industries to perform various operations like
routing and drilling. CNC technology is also used in number of lettering and
engraving systems.
Some of the CNC Machines are shown in the figures below:
Fig.1.5. CNC Lathe Machine

Fig.1.6. CNC Milling Machine

CHAPTER: 2
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.
An “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.
Some of the Important Things to Know:

• Coordinate System
• Machine Coordinate System -Three Finger Rule
• Coordinates: X,Y,Z, RX,RY,RZ
• Quadrant System
• Units, incremental or absolute positioning
• G - Codes And M-Codes
• Part Programming
• Preparatory Codes in Programming
COORDINATE SYSTEM:
Cartesian coordinate system:
Almost everything that can be produced on a conventional machine tool can be
produced on a computer numerical control machine tool, with its many advantages. The
machine tool movements used in producing a product are of two basic types: point to-
point (straight-line movements) and continuous path (contouring movements).
The Cartesian, or rectangular, coordinate system was devised by the French
mathematician and philosopher Rene‟ Descartes. With this system, any specific point can
be described in mathematical terms from any other point along three perpendicular axes.
This concept fits machine tools perfectly since their construction is generally based on
three axes of motion (X, Y, and Z) plus an axis of rotation. On a plain vertical milling
machine, the X axis is the horizontal movement (right or left) of the table, the Y axis is
the table cross movement (toward or away from the column), and the Z axis is the vertical
movement of the knee or the spindle. CNC systems rely heavily on the use of rectangular
coordinates because the programmer can locate every point on a job precisely.

When points are located on a work piece, two straight intersecting lines, one vertical and
one horizontal, are used. These lines must be at right angles to each other, and the point
where they cross is called the origin, or zero point .
Fig.2.1. Intersecting lines from right angles and Fig.2.2. The three dimensional
coordinate planes establish the zero point (Allen-Bradley)(axes) used in
CNC. (The Superior
Electric Company)
Machine Coordinate System (MCS):
The machine coordinate system comprises all the physically existing machine
axes. Reference points and tool and pallet changing points (fixed machine points) are
defined in the machine coordinate system.
Fig.2.3. Three Finger Rule

Three Finger Rule:

The Orientation the coordinates system relative to the machine depends on the
machine type. The axis directions follow the so-called "Three Finger Rule" of the right
(according to DIN66217).
When seen from the front of machine, the middle finger of the right hand machines
is in the opposite direction to the in feed of the main spindle. Therefore,
• The thumb points in the +X direction
• The index finger points in the +Y direction
• The middle finger points in the +Z direction
Fig.2.4 Three Hand Rule
Positions of the coordinate system in milling machine the positions of the

coordinate system resulting from the three figure rule can have a different orientation for
different machine type, as mentioned below
Quadrant System:
The three-dimensional coordinate planes are shown in Fig. 2. The X and Y planes
(axes) are horizontal and represent horizontal machine table motions. The Z plane or axis
represents the vertical tool motion. The plus (+) and minus (-) signs indicate the direction
from the zero point (origin) along the axis of movement. The four quadrants formed when
the XY axes cross are numbered in a counter clockwise direction (Fig. 3). All positions
located in quadrant1 would be positive (X+) and positive (Y+). In the second quadrant, all
positions would be negative X (X-) and positive (Y+).In the third quadrant, all locations
would be negative X (X-) and negative (Y-). In the fourth quadrant, all locations would be
positive

X (X+) and negative Y (Y-).
Fig.2.5.Quadrant System
The quadrants formed when the X and Y axes cross are used to accurately locate
points from the XY zero, or origin, point (Allen-Bradley).
In Fig, point A would be 2 units to the right of the Y axis and 2units above the X
axis. Assume that each unit equals 1.000. The location of point A would be X + 2.000
and Y + 2.000. For point B, the location would be X + 1.000 and Y - 2.000. In CNC
programming it is not necessary to indicate plus (+) values since these are assumed.
However, the minus (-) values must be indicated. For example, the locations of both A
and B would be indicated as follows:
A
X2.000
Y2.000
B
X1.000
Y-2.000

PROGRAMMING SYSTEM
Two types of programming modes, the incremental system and the absolute system,
are used for CNC. Both systems have applications in CNC programming, and no system
is either right or wrong all the time. Most controls on machine tools today are capable of
handling either incremental or absolute programming.
Incremental programs locations are always given as the distance and direction
from the immediately preceding point (Fig. 6). Command codes which tell the machine to
move the table, spindle, and knee are explained here using a vertical milling machine as
an example:
Fig.2.6.Programming System
Work piece being dimensioned in the Incremental system mode (Icon Corporation).
• A “X plus” (X+) command will cause the cutting tool to be located to the
right of the last point.
• An “X minus” (X-) command will cause the cutting tool to be located to the left

of the last point.

• A “Y plus” (Y+) command will cause the cutting tool to be located
toward the column.
• A “Y minus” (Y-) will cause the cutting tool to be located away from the column.
• A “Z plus” (Z+) command will cause the cutting tool or spindle to move up
or away from the work piece.
• A “Z minus” (Z-) moves the cutting tool down or into the work piece.
In incremental programming, the G91 command indicates to the computer and
MCU (Machine Control Unit) that programming is in the incremental mode.
Absolute program locations are always given from a single fixed zero or origin
point (Fig. 7). The zero or origin point may be a position on the machine table, such as the
corner of the worktable or at any specific point on the work piece. In absolute
dimensioning and programming, each point or location
Fig.2.7.A work piece dimensioned in the Absolute system mode.
Note: All dimensions are given from a known point of reference (Icon Corporation)onthe
work piece is givens a certain distance from the zero or reference point.
• A “X plus” (X+) command will cause the cutting tool to be located to the
right of the zero or origin point.
• A “X minus” (X-) command will cause the cutting tool to be located to the left
of the zero or origin point.

• A “Y plus” (Y+) command will cause the cutting tool to be located

toward the column.
• A “Y minus” (Y-) command will cause the cutting tool to be located away
from the column.
In absolute programming, the G90 command indicates to the computer and
MCU that the programming is in the absolute mode.
Incremental and Absolute systems:
CNC systems are further divided into incremental and absolute systems. In
incremental mode, the distance is measured from one point to the next. For example, if
you want to drill five holes at different locations, the x-position commands are
x + 500, + 200, +600, - 300, -700, -300.
An absolute system is one in which all the moving commands are referred from a
reference point (zero point or origin). For the above case, the x-position commands are,
x 500,700, 1300, 1000, 300, 0.
Both systems are incorporated in most CNC systems. For an inexperienced
operator, it is wise to use incremental mode.
Fig.2.8.Difference between absolute and incremental positioning

(a) Absolute versus incremental; in absolute positioning, the move is specified by x = 6,
y = 8 ; in incremental, the move is specified by x=4, y=5 for the toolto be moved from
(2,3) to (6,8)
(b) Drilling 5-holes at different locations

The absolute system has two significant advantages over the incremental system:
Interruptions caused by, for example, tool breakage (or tool change, or checking
the parts), and would not affect the position at the interruption. If a tool is to be replaced
at some stage, the operator manually moves the table, exchanges the tool, and has to
return the table to the beginning of the segment in which the interruption has occurred. In
the absolute mode, the tool is automatically returned to the position. In incremental mode,
it is almost impossible to bring it precisely to that location unless you repeat the part
program2. Easy change of dimensional data
The incremental mode has two advantages over the absolute mode.
• Inspection of the program is easier because the sum of position commands for
each axis must be zero. A nonzero sum indicates an error. Such an inspection
is impossible with the absolute system.
• Mirror image programming (for example, symmetrical geometry of the parts) is
simple bychanging the signs of the position commands.
SNo. Absolute System Incremental System

1. The entered values are related to the The entered values are related to the current
work piece zero position. position(Last Position)
2. Point zero is fixed Every stop becomes zero position

3. If any dimensions it wrong it only affect If any dimension is wrong their after entire
for the particular step or operation only, dimensions are accepted
other dimensions will remain as same as
given.
4. Indicated with code G90 Indicated with code G91

Table: 1 Difference between Absolute and Incremental Systems
PART PROGRAMMING IN CNC
The transfer of an engineering blueprint of a product to a part program can be

performed manually using a calculator or with the assistance of a computer language. A
part programmer must have an extensive knowledge of the machining processes and the
capabilities of the machine tools. In this section, we describe how the part programmers
execute manually the part programs.
First, the machining parameters are determined. Second, the optimal sequence of

operations is evaluated. Third, the tool path is calculated. Fourth, a program is written.
Each line of the program, referred to as a block, contains the required data for transfer
from one point to the next.
A typical line for a program is given below.

N100 G91 X -5.0 Y7 .0 F100 S200 T01 M03 (EOB)
The significance of each term is explained below.

Sequence Number, N
Consisting of typically three digits, its purpose is to identify the specific machining
operation through the block number particularly when testing a part program.
Preparatory Function, G
It prepares the MCU circuits to perform a specific operation. The G-codes (some) are
shown in Table 1. G91 implies incremental mode of operation.
Dimension Words
1. Distance dimension words, X, Y, Z
2. Circular dimension words, I, J, K for distances to the arc center
3. Angular dimensions, A, B.C
While (1) and (3) are expressed either by incremental or absolute mode, (2) is
always in given in incremental mode. All angular dimensions are specified in revolutions
or degrees.
In the above block, X moves a distance of 5 in. in the negative direction while Y
moves distance of 7 in. in the positive direction. Other axes remain stationary. In some
systems, actual distances are used. In others, the dimension words are programmed in
BLUs.
Feed rate, F
It is expressed in in/min or mm/min and, is used in contouring or point-to-point or
straight- cut systems. For example, a feed rate of F100 implies 100 in/min or 100
mm/min. Feed rates are independent of spindle speed.
In linear motions, the federate of the cutting tool is not corrected for the cutter radius.
But in circular motions, the feed rate should be corrected for the tool radius as follows:
F= [(part contour radius ± tool radius)/part contour radius] (required feed rate)
For cutting around the outside of a circle, the plus sign in the above equation is

used, and the feed rate is increased. For cutting around the inside of a circle, the
minus sign is used, and the feed rate is decreased.
Spindle speed, S
Programmed in rev/min, it is expressed as RPM or by a three-digit code
number that is related to the RPM.
Tool word, T Consisting of a maximum of five digits, each cutting tool has a
differentcode number. The tool is automatically selected by the automatic tool
changer when the code number is programmed in a block.
Miscellaneous Function, M
Consisting of two digits, this word relates to the movement of the machine
in terms of spindle on/off, coolant on/off etc.
EOB
The EOB character is used at the end of each block to complete a line
PREPARATORY CODES:
Programming consists of a series of instructions in form of letter 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
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 thepath that is followed in arriving at the final destination.
G01 –Tool is required to move in a straight line connecting current position and
finalposition. 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)
List of M Codes/Miscellaneous in SIEMENS CONTROL
M Miscellaneous function, Max 5 M-codes in single block

M00 Program Stop
M01 Optional Stop
M02 End of program
M03 Spindle Rotation Clock Wise

M04 Spindle Rotation Counter Clock Wise

M05 Spindle Stop
M06 Tool Change
M17 Sub Program End
M30 End OF Main Program
Table: 2 M Codes
2.5.4 List of G Codes/Preparatory function in SIEMENS CONTROL:
G00 Rapid Movement

G01 Linear Movement
G02 Circular Interpolation Clock Wise
G03 Circular Interpolation Counter Clock Wise
G04- S Dwell Time To Stop Spindle
G04-F Dwell Time To Stop Feed Rate
G17 Selection Of X and Y Plane (In Milling)
G18 Selection Of X and Y Plane (IN Turning)
G25 X, Z, Minimum working Area Limitation-WALIM ON/OFF
G26 X, Z, Maximum Working Area Limitation-WALIM ON/OFF
G33 Thread Cutting With Constant Pitch
G40 Tool Nose Radius Compensation OFF
G41 Tool Nose Radius Compensation Active –Left Side Of The Geometry
G42 Tool Nose Radius Compensation Active –Right Side Of The Geometry
G53 Suppression Of Current Frames-Zero Offset Deactivate –Non Modal
G54 TO G57 Settable Zero Offset ON
G60 Exact Stop In Whole Program-Model
G64 Continuous Path Movement
G70 Inch Dimensioning
G71 Metric Dimensioning
G74 Reference Point Approach
G75 Fixed Reference Point
G90 Absolute Dimensioning
G91 Incremental Dimensioning

G94 Feed rate in mm/min
G95 Feed rate in rev/mm
G96 Constant Cutting Speed ON
G97 Constant Cutting Speed OFF
G450 Transition Circle
G451 Point Of Intersection
G500 Deactivate All Settable Zero Offset
Table: 3 G Codes

CHAPTER:3
CNC SOFTWARES
There are many software used in CNC Machine, some of them are listed as below.
• SIEMENS
• FANUC
• HANS
• MITSUBHUSHI
• HADEN HAND
In this machine we have Siemens software, and the Siemens have following software’s.
They are:
• Siemens 802D
• Siemens 802DCL
• Siemens 810 D
• Siemens 810 DI
• Siemens 810DISL
• Siemens 840 D
• Siemens 840 DI
• Siemens 840 DISL
As per consumer requirement they had simplified their software between

from Siemen802D to Siemen840D for their use similar work they had created
new software called SIEMENS 828D.
• Siemens 828D maintenance cost is low.

• It works without air conditioner.
• It has better utilization of machine.
• It makes the operator to work easy.
• It works under dust condition. Etc.,

The specifications and details about Siemen828D are given below:
Enabled for Heavy Duty Optimal View Scalable

study CNC Communication operator
panel
Fig.3.1.SINUMERIC 828D
(1) (2) (3) (3)

Fig.3.2.Keyboard

1. Low-maintenance
• No battery (non-volatile data buffer thanks to NV-RAM technology)
• No hard disk
• No fan
2. User-Friendly
• Full QWERTY keyboard
• Hard keys with protective foil
• IP65 degree of protection
3. Clever
th
• 3/8 thread for additional components
4. Optimally
connected
Rear side
parts
• USB 2.0
• RJ45 Ethernet
• DRIVE-CLiQ
• PLC I/O Interface
• RS 232 C
• NC Inputs/Outputs
By devising the SINUMERIK 828D, we have managed to develop a panel-based

CNC that is tailor-made for use in milling and turning machines. The product combines
CNC, PLC, operating and axis control functions for six CNC measuring circuits into one
Compact units, which is designed to fit any operator panel housing. Despite its compact
Dimensions, the SINUMERIK 828D is a real powerhouse. Equipped with premium CNC
functions such as the ability to execute kinematic transformations or powerful Tool
management, the product leaves nothing to be desired…and all without being
unnecessarily complicated. The SINUMERIK 828D is ideal for the shop floor thanks to
its unique graphical user interface. Users can quickly commission, operate, program,
Service and maintain machines and tasks without the need for extensive training.

SINUMERIK 828D: One system, two versions, many advantages.

The SINUMERIK 828D is available in two versions that offer different
performance levels, which means it can be perfectly adapted to suit the power
requirements of the machine. There are separate software versions for milling and turning
applications. These provide the maximum possible number of machine presets, thereby
helping to keep commissioning times to a minimum.
Heavy duty:
The operator panel front of the SINUMERIK 828D is made from heavy duty die-
cast magnesium. This ensures that the SINUMERIK 828D remains in good condition
even if subjected to harsh operating conditions. The hard keys on the CNC keyboard are
covered In embossed foil to provide perfect protection against moisture.
Compact and user-friendly:

Thanks to its mounting dimensions, the SINUMERIK 828D can even be built into
highly compact operator panel housing. Despite its small dimensions, the SINUMERIK
828D features a 10.4” colour display along with a full QWERTY keyboard and offers
maximum user friendliness.
Enabled for communications:
The SINUMERIK 828D is equipped with all the latest communications ports. The
Compact Flash (CF) Card, USB and service ports are located behind the flap on the
operator panel front, from where they can be directly accessed. The flap can even be
closed once a CF Card has been inserted.

Fig.3.3. SINUMERIK 828D

Low-maintenance:
The SINUMERIK 828D has no hard disk and no fan. Thanks to the removal of
these parts, which are subject to wear, the SINUMERIK 828D is relatively easy to
maintain and easy to service. In addition, no battery is required and the use of NV-RAM
does away with the need for backup.
Scalable:
The SINUMERIK 828D is available with both a horizontal and a vertical operator
panel layout. Both operator panel orientations are available in conjunction with two
different performance ratings. As a result, the SINUMERIK 828D can be perfectly
matched to the installation locations well as the power requirements
VERSIONS OF THE SINUMERIK 828D:
• Standard version
PPU 260 (vertical operator panel
layout) PPU 261 (horizontal
operator panel layout)
• Performance version
PPU 280 (vertical operator panel
layout) PPU 281 (horizontal

operator panel layout)

Milling machines: Setting up and getting started.
The SINUMERIK 828D is perfect for equipping vertical and straight forward
horizontal milling centers featuring up to six CNC measuring circuits. And thanks to the
new Advanced Surface motion control function it can also be used in tool- and mould
making applications. Straightforward operation across the board.
As well as being suitable for use with milling spindles and geometry axes (X-, Y-,
and Z- axes), the CNC can be used to operate other machine units as an alternative. These
include:
• CNC rotary table (C-axis) for machining on two stations

• CNC reversible clamping device (A-axis) for milling and hole machining
on cylindrical work pieces
• CNC gantry axes (gantry operation)
• Inclinable heads or swivel tables for milling and hole machining in
statically rotated machining planes
• CNC-controlled tool change.
Fig.3.4.Milling machines: Setting up and getting started.

The SINUMERIK 828D is perfect for equipping vertical and straightforward

horizontal milling centers featuring up to six CNC measuring circuits. And thanks to the
new Advanced Surface motion control function it can also be used in tool- and mould
making applications. Straight forward operation, across the board.
As well as being suitable for use with milling spindles and geometry axes (X-, Y-,
and Z- axes), the CNC can be used to operate other machine units as an alternative.
These include:
• CNC rotary table (C-axis) for machining on two stations
• CNC reversible clamping device (A-axis) for milling and hole machining
on cylindrical work pieces
• CNC gantry axes (gantry operation)
• Inclinable heads or swivel tables for milling and hole machining in statically
rotated machining planes
• CNC-controlled tool changer
Turning Machine is shown in the figure below:
Fig.3.5.Turning machines guaranteed to turn out well.

Another application for the SINUMERIK 828D is the control of turning machines.
The functional scope has been tailored for horizontal and vertical turning centers equipped
with one machining channel and up to eight CNC measuring circuits.
Flexible Use:
Besides being suitable for use with lathe spindles and geometry axes (X- and
Z-axes), as an alternative the product can be used to operate other machine units:
• Power tools, peripheral C-axis mode, and Y-axis (orthogonal or diagonal)
for end face and surface machining
• Counter spindle with synchronous spindle function for two-sided work
piece machining
• Tailstock axis (with travel to fixed stop function)
• CNC-controlled turret
TOOL MANAGEMENT:
Fig.3.6.Tool Management

Tool management made easy. The SINUMERIK 828D features a command center
for all tool and magazine tasks so that the machining process is never interrupted. If the
tool is at the end of its service life, the SINUMERIK 828D will send a text message
(SMS) as necessary – thanks to the Easy Message technology.
Everything at a Glance:
The SINUMERIK 828D„s tool management system presents tool data and
position information on one screen so there is no need to keep switching screens. The tool
type is presented in the form of a pictogram. Both primary and secondary cutting edges
are indicated for turning tools.
Therefore, process stability can be guaranteed simply by looking at the tool table.
Simply Brilliant:
The SINUMERIK 828D does not just recognize tools in the tool magazine. Simply
create a tool in the tool list and it is ready to be programmed and simulated. At the touch of a
button, the tool management function will search for a suitable magazine location. Assign
relevant names for the tools, then call the tool name in the CNC part program and the
SINUMERIK 828D will automatically take care of everything else for you.
CNC SIMULATION: Maximum process stability guaranteed.
Fig.3.7.CNC Simulation
3.5.1 Maximum Process Stability:

The SINUMERIK 828D‟s simulation feature guarantees maximum process
stability because it uses the actual geometrical data of the tools installed on the machine.
Therefore, the SINUMERIK 828D doesn’t just look good; it shows an exact image of the

desired machining process.

Ensuring machine productivity is partly a question of preparing well for the
machining process. The SINUMERIK 828D‟s powerful CNC simulation feature helps in this
regard. And not just by a brilliant simulation display. The calculation of the machining time
provides the ideal basis for determining work piece costs. In all circumstances
Any CNC that is available on the market today is capable of generating
simulations in top and side view. But what about simulations involving kinematic
transformations? Even here, the SINUMERIK 828D shows what it is made of. Whether it
is being used for front and peripheral surfaces in the case of turning machines or rotated
machining planes in the case of milling machines, the SINUMERIK 828D can simulate
machining whatever the circumstances.
Optimum View Guaranteed:

Worried about detailed machining? Not a problem for the SINUMERIK 828D.
The user can zoom in to the smallest corners of the CNC simulation without having to
restart it. In addition, the simulation can be interrupted at any time and controlled in terms
of speed. As a result, even the smallest detail is not overlooked. Machine setup made easy.
Fig.3.8.Optimum view
Everything as it should be:

Blanks often need to be shaped prior to machining. The SINUMERIK 828D does
not require any additional CNC part program for this purpose. A work piece can be

face milled or face turned simply by setting the relevant parameters in setup mode. Simply
select NC Start and off you go. Want to bore clamping jaws? The SINUMERIK 828D can
also do this at the touch of a button.
Perfectly Aligned:
All you need to do is trace the edge, corner or boreholes and the system will
determine the clamping position including the work piece’s basic rotation. The
SINUMERIK 828D offers a variety of measurement variants – even for sloping Work
piece surfaces.
Particularly within the context of job shop manufacturing (small batch
production), machines frequently need to be reset. Tracer processes for work piece setup
or process measurement for the establishment of tool geometries are provided in a format
tailored to the user’s requirements. Perfectly equipped.
The SINUMERIK 828D makes it really easy to quickly determine the tool length.
Whether you are determining the tool geometry by “scratching” or using a tool
measurement system, all you need to do is press a button and the geometry will be stored
in the CNC‟s tool offset memory.
User memory and data transfer: All data under control.
Fig.3.9.SINUMERIK 828D Alignments

Unlimited user memory:
The SINUMERIK 828D is already equipped with a basic 3 or 5 MB user memory.
If this memory capacity is not sufficient, then memory can be expanded by inserting a
Compact Flash (CF) Card into the front port.

Perfect Diagnostics:
Need quick and easy service? The SINUMERIK 828D is available to you from
anywhere. The remote diagnostics function enables remote operation as well as
supporting file transfer. The contents of the CNC screen are displayed directly on the
workstation where the remote diagnostics are being carried out. Simply connect a modem
that supports the required
Data transfer method (analogue, ISDN, etc.)
Text message (SMS), USB and Ethernet – the SINUMERIK 828D uses the latest
methods of communication to guarantee data transfer at all times. To the front Ethernet
port of the SINUMERIK 828D and you’re online. The CNC also offers a user-friendly PC
tool in the form of the RCS Commander.

CHAPTER:4
HISTORY AND DEVELOPEMENT OF CNC MACHINES
History of NC Machines:
Numerical control machining began in the aircraft industry. Engineers wanted to

make complex aircraft parts quickly and accurately. In 1947, two aircraft component
contractors for the
U.S. Air Force, John Parsons and Frank Stolen, perfected the use of three-axis curvature
data to control machine tool motion. In 1951, the government funded the
Servomechanisms Lab of the Massachusetts Institute of Technology to design and build
the first NC Machine. The first prototype of a three-axis vertical milling machine debuted
in 1952. Parsons was able to end mill and face mill an aluminium plate.
Fig.4.1. Numerical control machining began in

aircraft industry
Increase in NC Use:
Though the first NC machine was a success, private businesses lacked the funding
to make it practical. So from 1955-1956, the Air Force sponsored NC development at
several companies across nation, and NC machining gained popularity.

As the benefits to NC machining became more apparent between 1958 and 1960,
aerospace company managers started to place their orders for the new equipment, and some
even began to build their own machines. NC machines soon after began competing with
manual machines like the manual mill in Figure.4.1. In many shops, manual machines have
been retrofitted with CNC, like the mill in Figure.4.2.NC machines quickly displayed their
worth. They were more accurate, held better tolerances, and produced more uniform
dimensions than the manual machining methods of the day. In addition to increasing
accuracy, NC machines reduced the amount of non-productive time in the machining cycle.
Fig.4.2. NC machines began competing Fig4.3.Instead of buying new

machines some With manual machines such as this companies retrofit
with CNC machine manual mill
Changes from NC to CNC Systems:

The first CNC machines were actually called NC machines. They existed before
small computers were common. NC Machines were controlled by complex electrical
circuitry.NC machines read and executed one line of code at a time from a part program
punched into a paper tapper Mylar tape. When the entire program was executed, the tape

reader, like the one in would rewind back to the beginning of the program. With further
development of small computers, machine tool builders began using computers to control
machine tools. The term CNC was born. CNC machines can now hold hundreds of
programs in memory. Any one of these programs can be instantly called up for execution
through a control panel like the one in figure.4.4. Many CNC machines also contain
multiple tools, as shown in figure.4.5.This greatly boosts productivity.
Fig.4.4.Tape Reader Fig.4.5.CNC Machine
NC machines read and executed one line of The machine operator calls and
executes Code at a time from a part program punched a part program from the control
panel. Into paper are Mylar tapes.
Fig.4.6. CNC machines may contain many tools
DEPARTMENTOF MECHANICAL ENGINEERING -SJCET Page 39

COMMON CNC MACHINES:

There are many types of CNC machines. The two most common CNC machines
in the metalworking industry are:
Mills or machining centers (Figure 4.7): Generally, the work piece is held on the table
whilecutting tools perform their work.
Lathes or turning centers (Figure 4.8): A work piece spins as the cutting
tools arebrought in contact with it. Lathes create symmetrical pieces.
In every CNC use, a programmer plans the best way to cut the work piece and then
codes the movement of the tool. These instructions are interpreted by the computer
controller. The controller then ensures that every part is handled in exactly the same
manner for both small and large production runs. This process eliminates guesswork and
the downtime involved while a human operator decides the best method for machining a
part in the middle of production
Fig.4.7.Milling Machine Fig.4.8.Lathe Machine

A CNC mill often called a machining center, A CNC lathe often called a turning
Centre, holds a part while a rotating tool cuts metal. Rotate a work piece while a tool cuts
metal.

Other CNC Machines:

Besides mills and lathes, you will find CNC systems in these machines as well:
• Grinders: There are many different types of grinders, one of which is shownin
fig.4.9 grinding is a finishing operation that creates a smoother surface.
• Punch presses: Punching, or stamping, can apply large forces to sheet metal to
create holes or bends. Some punch presses have one tool, as shown in fig.4.10.
• Welders: There are several types of welding. The welder applies heat and a filler
to fasten the pieces together.
You will also find CNC systems in operations that involve robotics, laser cutting,
automatic testing machines, drafting systems, electronic assembly systems, and more.
As you can see, computers have proven very useful in many aspects of manufacturing.
Fig.4.9. A CNC grinder creates a smoother Fig.4.10. A CNC punch press uses one
tool. Surface on a work piece.
CNC (Computer Numerical Control) is the combination of Numerical Control (NC,

the controlling of machinery using numbers either to manipulate discrete controls, or more
directly via punch cards or tapes or other electrical signals) and computers.
The history starts with early efforts to automate industrial machinery such as looms.
1801-Jacquard Loom
The Jacquard loom is a mechanical loom, invented by Joseph Marie Jacquard, first
demonstrated in 1801, that simplifies the process of manufacturing textiles with complex
patterns using punch cards.

1810-Milling Machine
Machines which make use of rotary filing are developed for metalworking.
1820-Cams
Used in gun-stock copying and turret lathes. Development continued through

World War I.
1822-Difference Engine
Charles Babbage conceives of the Difference Engine, an early mechanical

computer for calculating polynomials.
1915-Electric Wood Router
The first electrical power tool, the wood router inaugurated the idea of bringing
the tool to the piece being worked, a concept central to CNC.
1931-Servos and Selwyn’s
Adding power to Cams didn't address the matter of controlling the position
accurately under all possible circumstances. Servomechanisms and seasons allowed the
machine to provide measurement information as it worked, increasing accuracy.
1940-Tracer Control
Adding hydraulics to Cams allowed for the use of a stylus to trace a template
controlling a machine which would cut a part to match.
1946-Numerical Control
John T. Parsons developed Numerical Control (NC) so as to be able to fabricate

parts for helicopter rotors for the Sikorsky Helicopter Company using funding from the
United States Air Force.
1949-Numerical Control using Punch Cards
Parsons turned to M.I.T. to make use of servomechanisms or to otherwise improve

the accuracy of NC under an Air Force contract for the construction of two "Card-a-matic
Milling Machines", a prototype and a production system.

1952-A Working machine
M.I.T. instead attempted to develop a machine on their own, but Parsons filed for
a patent on "Motor Controlled Apparatus for Positioning Machine Tool" on 5 May 1952,
sparking a filing by MIT for a "Numerical Control Servo-System" on 14 August 1952.
Parsons received US Patent 2,820,187 on 14 January 1958, and the company sold an
exclusive license to Bendix. IBM, Fujitsuand General Electric all took sub-licenses after
having already started development of their own devices.
M.I.T. continued with their development, using roller chains to manipulate the
machine along three axes (X, Y, and Z) and used standard 7-track punch tape for input.
1953-Proliferation of NC
The Air Force Numeric Control and Milling Machine projects formally concluded
in 1953, but development continued at the Giddings and Lewis Machine Tool Co. and
other locations.
1955-G-Code/Magnetic Tape
Electronic control was added with the use of magnetic tapes to record and play
back calculated machine paths, which are described using the nascent G-code.
1958-Computer Aided Design (CAD)
The Automatically Programmed Tool project and the report, then later project,
Computer- Aided Design: A Statement of Objectives 1960 of Douglas T. Ross were the first
CAD systems.
1959-First Computer Numerical Control system
On 25 February 1959, Aircraft Industries Association (AIA) and Air Material

Command at Wright-Patterson Air Force Base produce a fully computer-controlled NC
system and demonstrate it to the press, including an ashtray made of machined aluminum
in the press kits.
1960-Proliferation of CNC in Industry
The falling price of computers and the rising costs of labour resulted in a
proliferation of CNC machines using PDP-8s and the Data General Nova.

1984-Stereolithography (3D printing) and STL File Format
Chuck Hull of 3D Systems Corp invented a process known as stereo lithography

employing UV lasers to cure photopolymers.
DEVELOPEMENT OF CNC MACHINES
First concept developed for the manufacture of helicopter blades Alongside Frank
L. Stulen, John T. Parsons‟ first utilized computer methods to overcome machining
setbacks, especially the accurate interpolation of the curves found in helicopter blades. In
the process of developing smoother rotors, Parsons and Stuller generated an early version
of a Numerical Control (NC) machine.
Developed with assistance of MIT:
To further develop this machine, in 1949, Parsons turned to Gordon S. Brown’s

Servomechanism Laboratory at the Massachusetts Institute of Technology (MIT). At MIT, a
feedback system designed to gauge how far the controls had turned was developed.
While the US Air Force halted its funding in 1953 due to expense, the project was
resumed by Giddings and Lewis Machine Tool Co. who reduced expense but improved
quality and efficiency.
Reduced production time from 8 hours down to 15 minutes:
The first CNC machine was developed when John Runyon managed to produce
punch tapes under computer control. By doing this, he managed to reduce the normal
production time of 8 hours down to 15 minutes. By 1956, the US Air Force had accepted
the proposal to produce a generalized programming language for NC.
The invention of CNC machines paved the way for automated tools that enabled
efficient production for manufacturers. Today’s CNC machines bear little difference with
the original machines in terms of concept. Both produce outputs in three dimensional
directions: X and Y axes and depth.

The types of CNC machine:
The types of CNC machine that exist today include the following:
CNC turning lathes–CNC turning lathes produce parts by turning rod materials
andfeeding a cutting tool into the turning material.
CNC milling machines –Using a rotating cylindrical cutting tool, CNC Milling utilizes
amachining process similar to both drilling and cutting. The cutter in a milling machine has
the ability to move along multiple axes and can create a variety of shapes, slots and holes
CNC routers - CNC routers are similar to handheld routers but the tool paths are
insteadcontrolled via computer numerical control. CNC routers can be used for cutting
various hard materials including wood, composites, aluminium, steel, plastics and foams.
Difference between Conventional and Non-Conventional Machines
In conventional lathe, all the operations are manual. Changing tool, moving the
tool post, adjusting feed, depth of cut etc. must be done manually.
In CNC lathe, all these operations can be programmed and saved it in the machine.
You can machine as many parts as you want. You need to load the work piece and press
CYCLE START. The machining work is performed based on your program automatically.
CNC lathes - High precision CNC lathes even for the most complicated parts.
Various modern options for perfect efficiency.
Conventional lathes - Efficient machining of work pieces, in both serial and

unit production.
Highly accurate finishing and roughing of various types of metals and plastics.
Conventional Lathes are the pioneer of manufacturing. The operations like knurling,
drilling, facing, cut-off, boring etc. are done .In all the above mentioned operations ,gear
shifting for speed(Belt changing in case of Belt lathes which are out of date),tool changing,
feeding the work piece etc. are done by the machine operator manually. Also the high
accuracy of microns cannot be achieved in conventional machines.
CNC standing for computer numerical control is the present market trend. CNC
turning centers are those machines where the operations of tool changing, Speed etc. are

controlled automatically through the programmers. In case of turning centers, only the
work piece had to be fed to the machine and the operations are carried automatically.

CHAPTER: 5
ACTUAL PROJECT WORK
AIM
Designing of a profile and Manufacturing the desired profile by using CNC Smart run Lathe
machine.
DESCRIPTION
The profile is designed by using SINUMERIK 828D software. In this software we gave
the required dimensions of the profile that we want to produce by using CNC Lathe machine. The
design of this profile is given by the manual or cycle program in the software. After giving the
program, the program is been simulated before executing in the CNC machine.
DESIGNING OF THE PROFILE
Basic profile design of the profile using AUTOCAD is shown in the figure below:
All dimensions are in ‘mm’
Fig.5.1. Profile design

PROGRAM FOR DESIGNED PROFILE:
N1 MSG ("PROJECT5")
N2 WORKPIECE ("CYLINDER",192,0,-200,-150,60’’) N3 G18 G54 G95 G71
N4 T="FINISHING TOOL 3 A D1
N5 M06 D1
N6 G96 M03 S1000
N7 M08
N8 G00 X0 Z5
N9G41 G01 X34Z0 F0.5
N10 Z-10
N11G03X44
N12 Z-15CR=2.5
N13 G01 Z-30
N14 G03X54Z-35CR=5
N15 G01 Z-50
N16 G01 X60
N17G01 Z-95
N18 G75 X0 Z0
N19 M05
N20 M09
N21 M30

Fig;5.2 Program Excution
Fig.5.3 work piece dimension

The SINUMERIC 828Dsoftware is shown in the figure below with the profile program:
Fig.5.4. 2D simulation
Fig.5.5. 3D simulation

Fig5.6 Stock removal
Fig5.7 Face View

HALF-CUT SIMULATION
Fig.5.8. Half cut simulation
MANUFACTURING OF THE PROFILE BY USING CNC

SMARTRUN LATHE MACHINE
After designing the profile using the SINUERIK 828D Software it is simulated in the
different views as shown in the above figures. The program for this profile design is copied
and pasted in the actual CNC Lathe machine for execution.
Before manufacturing the given profile the following points should be followed:
• Measure the diameter and length of the given work piece that is to be manufactured.
• Clamp the work piece within the chucks tightly.
• Start the spindle by giving command in MDI mode to check
whether the work piece clamped properly or not.
• Clamp the tools in the tool holder that are used for manufacturing the given profile.
• Measure the tool offset manually through JOG mode and fixes the X and Z axis.
• Give the command to move the X axis and Z axis to the work piece with
less federate. If the tool doesn’t make any error and reaches the work piece
zero point then the tool offset given is correct. Now bring the X axis and Z axis
to the reference point by using REFERENCE mode.
• Now the machine is ready to design the given profile.

The work piece used is aluminium for profile manufacturing is shown in the below figure:
The work piece dimensions before manufacturing the profile is as follows,
80mm diameter 200mm Length
All dimensions are in mm.
Fig.5.9 Aluminium work piece

The tools used for manufacturing the given profile design are shown in the below figure:
Fig.5.10 Tools used

The machining process is shown in below figures:
Fig.5.11. Profile manufacturing
Fig.5.12. Machining process

CHAPTER: 6
RESULT & CONCLUSION
Thus we achieved desired profile, by using CNC machines we can complete

the work with less time and with great accuracy compare to conventional machines.
The profile produced by this Smart run CNC lathe machine has good finishing
surface and with accurate dimensions in 30 minutes cycle time.
.Fig.6.1 The profile output

CONCLUSION:
The Indian CNC systems though have made a beginning with both imported
technologies and indigenous development, the technologies adopted in this field are
comparatively outdated and do not incorporate recent development and, also, are found to
be wanting in terms of meantime between failures. There is a high degree of obsolescence
in this area. It is an acknowledged fact that latest developments inthese fields are not
effectively transferred by advanced countries, under the normal technology transfer.
Under these circumstances, a long term strategy for keeping abreast in this important
sphere, by self-reliant efforts, needs to be speedily evolved.
Compare to conventional machine, CNC machines provide many advantages than

traditional machines.
CNC Machines are very accurate. The CNC machines produce high production
compare to conventional machines.
These CNC Machines doesn’t require a skilled operator to perform specified
operations, whereas in conventional machining the operator should have good skill and well
trained.
In CNC Machines we can produce complicated profiles easily with less
time rather than conventional machine.
Now-a-days large numbers of industries are coming forward to plant CNC
Machines in their respective industries which increase the demand of CNC Machines and
their developments.
CNC machines are applicable to perform any type of processing easily within
short time required.
Many industries would like to prefer using CNC machines for
productivity as well as quality of the products.
CNC machine have high storage capacity which store lot of programs and
these will be used for mass production.

REFERENCES
http://www.ehow.com/about_5415088_types-cnc-machines.html
http://www.cncci.com/resources/articles/what%20is%20cnc.htm
http://www.bracingsystemsinc.com/basic-motion-types-in-a-cnc-machine
http://www.madehow.com/Volume-2/CNC-Machine-Tool.html
http://dget.nic.in/lisdapp/Trade/syllabus/pdf/TTCNC.pdf
http://users.isr.ist.utl.pt/~pjcro/courses/api0910/API_I_C5.pdf
http://www.tradekorea.com/products/cnc_machine.html
http://www.nd.edu/~manufact/MET%20pdf_files/MET_Ch37.pdf
http://huayucnc.win.mofcom.gov.cn/en/plate01/product.asp?id=24916
http://www.automation-drive.com/cnc-lathe-machine http://www.cnc-
machining-center-yida.com/cnc-turning-center-bml-420.html
http://cnc-machine-center.blogspot.com/2008/09/cnc-surface-
grinding-machine.html
http://cadcamcnccenter.com/cadcamthai/cnc/machine/108-what-is-cnc
http://news.thomasnet.com/news/machinery-machining-
tools/electro-discharge- machines
http://zaipul.wikispaces.com/file/view/01+Introduction+to+CNC+Technology.pdf
http://www.metalshopsolutions.com/
http://www.efunda.com/eds/company_details.cfm/id2/4846/pv/NO/cp/Zhejiang%
2020Co m
http://boeingcockpit.com/html
http://www.westone.wa.gov.au/toolbox8/furniture/toolbox/shared/resources_m
w/ask_expert/tony/advantages.html

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DESIGNING AND MANUFACTURING OF PROFILE BY USING CNC TURNING

CENTER MACHINE BY PROGRAMMING BASED ON LABELS

A Project report submitted in partial fulfillment of the requirements

For the award of degree of

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPURAM

U.MOHAMMAD SOHAIL (17G31A0329)

Under the Esteemed Guidance of

Mechanical Engineering Dept.

Department of Mechanical Engineering

(Permanently Affiliated to JNTU Anantapuram, Accredited by NAAC, Approved

DEPARTMENT OF MECHANICAL ENGINEERING

This is to certify that the project report entitled “DESIGNING ANDMANUFACTURING

Project Guide HOD

________________ at St. Johns College of Engineering & Technology, Yemmiganur.

INTERNAL EXAMINER EXTERNAL EXAMINER

We extend our sincere and heartful thanks to Mr. M.RAVISHANKAR,M.Tech,(Ph.D).

Machine is an apparatus using mechanical power and having several parts,

Machines are usually powered by

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 1

Examples of conventional machining processes are

Conventional machining can be defined as a processes using mechanical (motion)

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 2

Generally macroscopic chip formation is by shear deformation.

• Cutting tool is harder than work piece at room temperature as well as

Some of the Conventional Machines are shown in figures

Fig.1.1. Conventional Lathe Machine

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 3

Fig.1.2. Conventional Grinding Machine

NUMERICAL CONTROL MACHINE:

Numerical Control Machine tools may be defined as a method of automation in which

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 4

The program of instructions serves as input to the controller unit, which in

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 5

use of feedback signals to the controller unit.

Some of the NC Machines are shown in figures below:

Fig.1.3. NC Milling Machine Fig.1.4. NC Lathe Machine

INTRODUCTION OF CNC MACHINES:

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 6

CNC Computer Numerical Machines are widely used in manufacturing industries.

1.4.1 NECESSARY OF CNC MACHINES:

WORKING OF CNC MACHINES:

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 7

VARIOUS TYPES OF CNC MACHINES:

• Mills and machining centers

ADVANTAGES OF A CNC MACHINES:

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 8

APPLICATIONS OF CNC MACHINES:

• Boring: In machining, boring is the processes of enlarging a hole that

APPLICATIONS OF CNC IN SOME INDUSTRIES:

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 9

drilling machines etc.

Fig.1.5. CNC Lathe Machine

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 10

Fig.1.6. CNC Milling Machine

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 11

Some of the Important Things to Know:

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 12

Fig.2.3. Three Finger Rule

DEPARTMENT OF MECHANICAL ENGINEERING -SJCET Page 13

Three Finger Rule:

Fig.2.4 Three Hand Rule

Positions of the coordinate system in milling machine the positions of the