1 Experiment No.

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1.1 Objective
To perform multiple machining operations on CNC machine
1.2 Difference between Conventional and Non-conventional Machining
 Conventional Machining
Conventional machining process usually involves changing the shape of a 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 increases in costs. In some cases,
conventional machining may not be feasible.
Conventional machining also costs in terms of tool wear and in loss of quality in the product because of
induced residual stresses during the manufacturing process. With the ever-increasing demand for
manufactured goods made of hard alloys and metals, more interest has gravitated to non-conventional
machining methods.
It can be defined as a process using mechanical energy.
Examples:
 Turning
 Boring
 Milling
 Shaping
 Broaching
 Slotting
 Rinding

Figure 1 Conventional Machining Process

 Non-Conventional Machining
The process of non-conventional machining, on the other hand, employs modern and latest technology
in processing. This process involves no contact between the machine tools and material.

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Non-conventional method uses tools that are less noisy thus preventing noise pollution. In conventional
machining processes, there is a risk of tool wearing since physical contact is required to perform the job.
This is not true when it comes to non-conventional machining processes. Non-conventional process
promoted longer tool life because no direct contact is made between the tool and the materials. Tools
used in non-conventional processes are more accurate and with higher precision compared to
conventional tools that create conventional parts. When it comes to costs, non-conventional tools are
more expensive compared to conventional ones. It is easier to find spare parts for conventional machines
but harder for non-conventional ones. Non-conventional tools require skilled operators who are experts
in machining because it has a complicated set up while conventional tools are easier to set-up and
operate without the assistance of professionals. 
Examples:
Examples of non-conventional machining are:
 Abrasive Jet Machining
 Ultrasonic Machining
 Water Jet Machining
 Electro-discharge Machining

Figure 2 Non-Conventional Machining

1.3 CNC Machines
CNC machines are making parts around the world for almost every industry. They create things out of
plastics, metals, aluminum, wood and many other hard materials. The word “CNC” stands for Computer
Numerical Control, but today everyone calls it CNC. So, how do you define a CNC machine? All
automated motion control machines have three primary components –a command function, a
drive/motion system, and feedback system. CNC machining is the process of using a computer-driven
machine tool to produce a part out of solid material in a different shape.
1.3.1 Types of CNC Machines
 CNC Milling Machine.
 CNC Lathe Machine.
 CNC Drilling Machine.

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  CNC Laser Cutting Machine.
 CNC Grinding Machine.
 CNC Waterjet Cutting Machine.
 CNC Plasma Cutting Machine.
 CNC Electrical Discharge Machine

Figure 3 Types of CNC Machines

1.3.2 Working Principle of CNC Machines

The working of a CNC machine is quite interesting due to the fact that it is a computer base. The
machine works based on CAD and CAM programs as well as computer control. just as earlier
mentioned, the CAD (Computer-Aided Diagram) is a drawing software of the item to be produced,
which serves as a carbon-copy of the product. That is, the computer automatically produces what the
CAD displays. It is also used to improve the productivity of the designer, improve communication
through documentation, improve quality of design and create a backup file for the next production.
Whereas, CAM (Computer-Aided Manufacturing) features two different code such as G-codes and M-
codes on which all programs are written and feed to the machine to perform various operations i.e. the
turning and grooving operation on a lathe. The first to do when working on a CNC machine is to write
and insert the part program which is G-code and M-code. This will be done in the Machine control unit
of the CNC machine, which allows all data process to takes place. It will then send it to the driving
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system, which helps to controls the motion and velocity of the machine tool. There is a feedback system
that records the position and velocity measurement of the machine tool and sends a feedback signal to
the MCU. This MCU then compares the feedback signals with the reference signal to check for errors
and if there is, it corrects it and sends a new signal to the machine tool. CNC machines also feature a
display unit which is used to see commands, programs and other important data

1.3.3 Codes in CNC Machines

G-code is the simple programming language for CNC machines. It consists of lines of code that are
organized in blocks. Each block controls one CNC machining operation, such as a cutting operation with
a specific tool. Each line in a block is labeled with the letter N and a number.
1.3.3.1 Critical G Commands
Every G-code command is a letter/number combo, and there are 5 main letters used in the language.
Each letter corresponds to a different type of action for the machine to execute.  These are the letters you
need to know:
 M: machine action codes
 G: motion codes
 F: feed control
 S: spindle speed
 T: tool operations
1.3.3.2 M Commands
M commands control the machine, doing things such as starting or stopping the spindle or
initiating a tool change.
 M00: program stop
 M02: end of program
 M03: spindle on, clockwise rotation
 M04: spindle on, counter clockwise rotation
 M05: spindle stop
 M06: tool change
 M08: flood coolant on

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  M09: flood coolant off
 M30: end of program, rewind and reset modes
1.3.3.3 G Commands
 G0: rapid motion
 G01: controlled motion
 G02: clockwise motion
 G03: counterclockwise motion

1.3.4 Advantages of CNC Machines

 They can run for 24 hours a day.
 They can produce jobs with higher accuracy and precision than other manual machines.
 Operators can make changes easily, which reduces the delay time.
 Fewer workers are needed to operate these machines, which saves labor costs.
 CNC machines have the capability to create complex designs with high accuracy in a short
amount of time.
 The modern design software for CNC machines removes the need of producing a prototype or
model before executing a project, which saves money and time in the long run.

1.3.5 Disadvantages of CNC Machines

 They are costly
 Trained operator is required to operate the machine
 In case of breakdown a highly skilled professional is required to solve the problem
 Reduction in manual labour can lead to unemployment
 Its installation cost is high