Report 2

Ain Shams University.
Computerized Numerical Controlled Machines

Faculty of Engineering. MDP 483s
Design and Production Eng. Dept. Spring 2024
Assignment 2
CNC Milling & Turning report
Student Name: ‫أحمد محمد الشين‬
Student ID: 1901192
Remarks: Degree:
10
Ain Shams University. Computerized Numerical Controlled Machines
Abstract:
CNC (Computer Numerical Control) machines have revolutionized the manufacturing
industry by offering unprecedented precision, automation, and efficiency in machining
operations. While CNC machines share fundamental systems with traditional machines, they
incorporate advanced technologies and design modifications, eliminating the need for constant
human intervention. This report provides an in-depth analysis of the integration of engineering
systems in CNC machines.
Introduction
Evolution of CNC Machines: The advent of computer technology in the mid-20th century
paved the way for a paradigm shift in machining with the introduction of CNC machines. Unlike
traditional machines, CNC machines feature embedded computers and software algorithms that
govern their operation, allowing for precise and repeatable machining tasks with minimal human
intervention. While CNC machines retain the same mechanical, hydraulic, and electrical systems
found in traditional counterparts, they have been extensively modified and optimized to interface
seamlessly with computer control systems.
The CNC follows the same steps many other machining types do, including making a
computer-aided design (CAD) model, getting the CNC machine set up, and operating the
machine to create the desired part.
step-by-step process:
▪ First, the fitter prepares the machine by setting up the worktable and the work holding
device and attaching the cutting tools and machine spindle.
▪ Create a 2D or 3D CAD part design and export it to a CNC file format (part program), which
is converted to a CNC machine program utilizing CAM software (ex, fusion 360)
▪ The CNC program diagnoses and analyzes the process sheet done by the operator.
▪ Using the machine interface, the machine adjusts its feed rate and the zeros to begin the
work.
Objective
• Explain the function of various components and the function of each key of the
operation panel in milling machine.
• Explain the function of various components and the function of each key of the
operation panel in lathe machine.
Mechanical components
1. Machine structure
The load carrying and supporting members for all the other mechanical parts. It should
keep them well aligned.
• Column and Base:
The column and base are designed to support all other components in a CNC machine. They also
provide rigidity and resist vibrations generated during the machining process. These components
are often made of cast iron. The base supports the weight of the whole machine. The column is
a vertical component that is connected to the base, and it travels along an axis. It holds the tool
turret and houses the oil and coolant system.
• Knee:
A knee is a component that is fixed to the column through a dovetail. It can be moved up and
down by a vertical positioning screw. This allows for vertical adjustment of the worktable. CNC
mills are equipped with an automated system that adjusts the position of the knee based on the
G-code supplied to the CNC controller. You can also move the knee manually through a hand
crank. The knee also provides extra support to the saddle and milling table.
• Saddle:
The saddle is positioned between the knee and the worktable. It is typically made of cast iron and
serves to support the worktable.
• Worktable:
Most of machine operations are conducted on the worktable. The table is a flat platform
used to hold the workpiece during machining. It is mounted on top of the saddle. In most CNC
machines, the worktable is equipped with T-slots. These T-slots allow for the workpiece to be
secured onto the table through different fastening devices such as clamps or vices. Worktables
are adjustable, and the power feed mechanism is responsible for their movement.
• Ram:
The ram is an adjustable, arm-shaped component that is specific to a vertical milling machine.
It’s positioned on top of the column, and it serves to hold the milling head.
• Overhanging Arm:
Just as the ram is specific to vertical milling machines, the overhanging arm is a feature of
horizontal milling machines. This cast iron beam is mounted on top of the column, and it holds
the milling head which supports the milling tool assembly.
• Arbor Support:
The arbor support is a cast iron part that is specific to a horizontal milling machine. It is linked
to the spindle via bearings and is responsible for supporting the cutting tool. The arbor
support also plays an important role in dampening vibrations generated during machining
activities.
• Spindle:
A spindle is one of the key components of a CNC system. It consists of a taper that holds the
milling tool. The spindle is linked to the main motor of the CNC machine. The CNC controller
reads and translates the G-code, rotating the spindle at the specified speed. Spindle rotation
is very important as it drives the cutting tool. This component also houses the milling chuck.
• Tool Changer:
A CNC machine will often utilize an automatic tool changer especially if a workpiece requires
different milling operations. This component allows the machine to perform a range of
machining operations in a single run, without stopping to engage another cutting tool. There
are two types of ATC:
Drum ATC: They are suitable for milling requiring less than 30 tools.
Chain ATC: They are suitable for milling requiring more than 30 tools. These are either
mounted at the column or separately mounted to the machine.
• Milling tools:
The milling tool is the component responsible for the actual cutting operations. This cutting
tool is connected to the column, and it performs milling operations based on the G-code
supplied by the operator. There are different cutting tools, each designed for different types of
milling operations. Therefore, your choice of milling tool depends on the type of operation. Further,
different materials will require varying cutting tools. For example, while titanium is machined using
rigid tools, copper requires tools with less flute.
• Tool Holders: The tool holder holds the cutting tools to the CNC machine. There are
different designs and sizes, with the three major types of tool holders being: BT, BBT, CAT,
and HSK.
BT toolholders: They are the standard size for tool holders. BT toolholders have a robust design
and a retention knob made with metric threading.
BBT toolholders: These are upgraded BT toolholders with double contact points with the
spindle which improves their stability and rigidity. Consequently, BBT toolholders are highly
recommended in the CNC milling space.
The used tool holder:

HSK toolholders (Hollow Taper Shank): They are European-designed toolholders with the same
angle as the BT toolholders. However, they have an additional orientation groove at the flanges.
They are suitable for high-speed machines with low tolerance.
• Guideways:
Guideways are used in machine tools to Control the direction of travel and absorb all the static
and dynamic forces.
The used Guideway: Antifriction Linear Motion (LM) Guideways It is characterized by: Reducing
the amount of wear, Improving the smoothness of the movement, reducing friction, Reducing
heat generation, No stick-slip, Ease of assembly, Commercially available in ready-to-fit condition,
High load carrying capacity, Heavier preloading possibility and High traverse speeds
▪ Linear motion transmission element

The used transmission element: Ball and Screws Ball and screws are used in CNC machines
replacing the screw and nut system.
The main criterion in designing the ball and screw is: High natural frequency, High stiffness,
Sufficient damping, Low friction, Backlash free operation, Low drive power requirement, little
temperature rise, Less wear and hence longer life, No stick-slip effect, High traverse speed and
High efficiency.
• Torque Transmission Elements: Various elements are used on CNC machines to transmit
the torque, viz., gears, timing belts, flexible couplings, etc.
Gear Box: It is required to reduce the high motor speed to the desired speed.
They are more frequently used where the reduction is required between the shafts
which are not coaxial or parallel.
Timing Belts: These are endless toothed belts. The teeth engage with a timing pulley
having teeth on its periphery. They are becoming more popular due to their inherent
advantages of low cost, less noise, elimination of lubrication, less maintenance, and
higher efficiency. Timing belt has a steel wire reinforcement.
Flexible Couplings: These couplings are used when the driver and driven shafts are
coaxial, but, since it is difficult to align the driver and driven shafts perfectly on the
same axis, heat and elastic deformation cause additional misalignments between the
two coaxial shafts, a certain amount of flexibility is built into the couplings to
compensate for these errors.
• Guards (cast-iron chassis): As CNC machines are working with heavy cutting conditions
with higher metal removal rates, and for the safety of the operators, guards are used to
shield the working area of the machines from the surroundings. So, all the electrical
cabinets and panels have been guarded. The cutting area has been guarded by front and
side guards. These guards are permitted to be opened only while setting the machine or
manually operating some functions in the machine. In most CNC machines these guards
must be closed to allow the main motor to run when executing the part program.
• Lubricating System: The main function is to lubricate the slides of the machine, ball nuts
and ball screws supporting bearings, spindle bearings, table components, indexing turret
components and tool Changer components.
• Hydraulic System: The main hydraulic applications include work piece clamping, tool
changer, weight compensation, axis and turret head clamping, and indexing of spindle.
• Coolant System: Some CNC machines must be equipped with a coolant system. Some CNC
machines are equipped with two types of coolant systems; one is continuous flooding of
coolant, and the other is a spraying system. Coolant is delivered to the cutting area and
helps control heat created by tool friction. Coolant helps to minimize the heat and provides
lubrication between the tool and workpiece.
There are four main units in the coolant system:
➢ Tank capacity indicates the amount of coolant required. In some applications, a
larger tank is required to dissipate excessive heat. The coolant in a small tank
may become hot over time because the same fluid is recycled too quickly and is
unable to cool off.
➢ Coolant pump motor which provides both the amount of coolant and the
pressure.
➢ Filter which cleans the coolant from the chip.
➢ Hoses, connections and stop valves in heavy cutting machines with power over
50 hp.
2. Electrical Systems
The main function of the electrical panel is to provide the different systems by regulated
stepped down voltages. It houses the transformers, relays, circuit breakers, push
buttons, contactors, and overload protectors.
3. CNC control Systems

o Central Processing Unit (CPU):
It is the brain of the system. Its main function is to retrieve the stored input data from the
Memory in the form of the part program, works with the Speed Control Unit to decode the
data, transform the decoded data into position and velocity signal. It receives, also, the actual
position and produces a corrective action. Again, it calculates errors in the system such as lead
screw pitch error, tool wear, backlash, etc. it develops a compensating signal to correct the
situation. It carries out several safety checks and energizes the shutting down of the system
when necessary.
o Servo Control Unit (SCU): The Servo control unit receives the decoded position and velocity
signals from the CPU and generates command values which are fed to the Servo Drive
Units. The later are coupled with the axes and spindle motors.
o Operator control panel (OCP): It is the user interface with the different systems.
o Machine control panel (MCP): It is the user interface to operate the hardware of the
machine manually.
o Programmable logic controller (PLC): It is the controller which replaced the old, wired
relays in the early NC machines. It is responsible for the implementation of all the logic to
the system.
o Other peripheral devices (OPD): Those are the external devices that are linked with the
CNC machines such as communicating equipment, external computer unit, tape reader, ….
etc.
CNC Controller: The CNC controller serves as the brain of the machine. It is responsible for
controlling the movements and functions of the CNC milling machine. CNC controllers eliminate
the need for manual machining. They read the CNC program or G-code supplied by the input
device and convert these codes into the respective machine movements. The CNC controller
then executes the commands by sending the proper signals to the stepper and servo motors.
This facilitates efficient and precise machining processes.
Components of the operation panel in Milling machine.

Before we dig into the operating panel and describe it ... the interface of the operating panels
for every CNC machine can be considered the same IN EVERY buttons and indicators , with
just some changes in the design or the layout but all in all do the same fumctions.
1. Control panel
Display screen: It’s often an LCD or touchscreen, providing operator

with visual feedback on machine status, program code, tooling
information, program path, and diagnostic messages. It serves as a
primary interface for information presentation and interaction.
Text editing keys: These keys are used to input information first to the
input buffer, an editing line at the bottom of the screen. The [INPUT]
key is used to copy the text from the input buffer into the control. The
most used letters are available, with the less common ones available by
first pressing the [SHIFT] key. You do not need to hold down shift, a ^
will be displayed in the input buffer meaning shift is active. [SHIFT] [Z]
would put a W in the buffer. [CAN] or cancel is backspace, and [DELETE]
will clear the input buffer. [EOB] is a semicolon. [ALTER] will overwrite
whatever is selected and [INSERT] will put the code after the word
selected by the curser.
Navigation: This functions as a regular old “d-pad” up down left right

used to navigate fields on the control. [PAGE UP] / [PAGE DOWN]
buttons to jump to the bottom or the top page.
Display Modes: [POS] Stands for position, pressing this will display on
the screen the current position with the soft keys offering different
coordinate systems. Relative, Absolute, Machine, or Distance to Go.
[PROG] stands for program. This will display the active program. We
always run from the (CHECK) screen within the program which also
displays all coordinate systems as well as the active G and M codes.
[OFS/SET] This key is referred to as offsets. It is where you can store
work offsets and tool length offsets. [MESSAGE] is the key which will
display the alarm screen or the operator message screen. To return
the screen to display the program you are running you would need to
hit the program key. [System] Used to change the computer
parameters and maintain it
2. Machine panel
Emergency Button: It tells the control to immediately stop Spring
Design and Production Eng. Dept. 2024
all motion,
including the spindle and all axes. Always depress this switch prior to turning
the main power switch on or off as a safety measure
Spindle Speed Override: allows the operator to adjust the spindle speed during
operation. Speed override functions as a percentage of the programmed value.
Ranging from 0.5 to 1.2 times the programed speed.
Feed-rate override: An override that allows the operator to adjust the feed rate
of the tool during operation. Feed rate override functions as a percentage of the
programmed value. Ranging from 0 to 1.2 times the programmed feed
Operation Modes: change which input will control machine motion. Only one
switch can be active at a time and they must be chosen correctly for the desired
function to be performed. [MDI] Manual Data Input allows for G-Code to be
input using the Text Editing Keys to write simple programs on the fly. This is
used extensively in setup to load tools, check offsets, or drive to a specific
location, it’s faster than jogging the machine. [REMOTE] mode tells the control
that you want to run a file from the server. This is the mode that allows you to
run a large. [DNC] or direct numerical control in which Files are stored centrally
and are drip fed and buffered in local memory. [JOG] mode allows you to press
and hold the marked keys below to continuously jog in those axes. [Edit]
enables operators to modify or edit the existing CNC program directly from the
machine's control panel. It allows for alterations in the program, such as adding,
deleting, or editing specific commands or parameters. [AUTO] used to run
selected program with CNC memory mode the press cycle start button the
program will be executed. [Reference] used to establish and set reference
points or. It enables the machine to determine its home position accurately.
[Handle] or Manual Pulse Generator (MPG) mode, permits manual control
using a handwheel or handle. Operators can manually move axes or adjust

positions using the handwheel for precise adjustments or setups. [Incremental]
in which movements or coordinates are specified relative to the machine's
current position. It allows operators to specify incremental distances or angles
for tool movements rather than absolute positions.
[JOG] mode allows you to press and hold the marked keys below to
continuously jog in those axes. You will jog at 100ipm by pressing the key alone,
and 600ipm by holding down the directional axis key then also depressing the
[RAPID] key. When you are closer than 3 inches from the part in any direction
it’s time to use the Manual Pulse Generator (MPG) also called the Hand Wheel.
This will give you much more control. Not pictured here, there are two selector
knobs at the top, one for axis and one for step speed with a large wheel labeled
+ in one direction and – in the other. Axes are X, Y, Z and 4. Use 4 to lock off the
hand wheel when passing it off or hanging it up, that axis it is not connected.
The other selector knob chooses step amount.
Spindle Control Switches: [SPDL CW] turns the spindle clockwise on at the last
programmed speed, can only be used in JOG mode. Must be used to re-start
the spindle if you stopped the spindle during regular operation. [SPDL STOP]
stops the spindle, will stop the spindle while a program is running hit [CYCLE
STOP] first or you will break a tool. [SPDL CCW] rotates the spindle counter
clockwise.
Indicator Lights: they provide visual cues regarding the machine's status,
indicating power on/off, program execution, error conditions.
INC jog: This key used to run axis in micron
[DRN] In this mode, the program executes the commands given rapidly to check
it. [Coolant off/on] This key used to turn the coolant on or off.
Conditional Switches: [SINGLE BLOCK] stops the control after executing each
line of code [BLOCK SKIP] skips any line of code that starts with a / character
[OPT STOP] stops the control wherever an M01 is present in the code. Pressing
[CYCLE START] is needed to continue.
Motion Control Switches: [CYCLE STOP] also called Feed Hold, this will pause
motion immediately without completing the current block. [PROG STOP] this
will not stop motion but will light up if the program has been stopped by an
M00 command.
Feed Hold: it temporarily pauses the execution of the CNC program, holding the
machine in its current position. It allows operators to make adjustments or
perform inspections before resuming the program.
Cycle start: this starts the operation, or re-starts motion after M01,so the
machine checks systems and determine if it is safe to start the program or not
if not the warning message or the alarm displayed
Components of the operation panel in Lathe machine.

Operating & control Panels
• It provides the user interface.

• It facilitates a two-way communication between the user, the CNC system and the machine
tool. It must include certain minimum functions as included in the following slides.
• They may be separate panels or integrated ones.
The function of operating control panel

Power On/Off Button:

This button is used to turn the CNC
machine on or off, allowing operators
to start or shut down the machine
safely.
Emergency Stop Button:

The emergency stop button is a
prominent red button that immediately
halts all machine operations in case of
an emergency or unsafe conditions.
CNC control panel keys explain.

• Program automatic operation refers
to the automatic operation of the
program in the processing sequence.
It is a commonly used machining
process. In this state, the operator
only needs to fix the product, and
then press the program start key.
• The second is the program editing
button. It is mainly used for editing
programs.
• The third is the MDI mode, which is
mainly used for manual input of short
code such as S600M3.
• DNC mode is mainly used for
connection processing.
CNC Operating Panel Explanation

• Program return to ZERO button, for
return to zero operation.
• Fast feed mode. Press this button to
match the corresponding axis to move
quickly.
• Handwheel keys, press this key to
operate the handwheel.
CNC Programming for Machining Center

• Single section execution, press this
key program to execute a section will
stop.
• Program segment skips instructions. If
there is a symbol in front of a program
segment, press this key and the
program will not execute.
• Choose to stop. When there is M01 in
the program, press this key and the
code will work.
• Manual Demonstration Instructions
CNC Machining Center Operating Panel

Explain
• Program restart button.
• Machine latching command, press
this key machine will lock, do not
move. Used for debugging.
• Empty operation, usually with latch
command of machine tool, for
debugging program
Tail stock and quill button

The tailstock's position is adjusted
along the bed ways to fit pieces of
different lengths. Once it is locked in
place, the tool is mounted and moved
into the exact position using a
leadscrew.
To move the quill in the tail stock
CNC Programming Panel Explanation

The loop start button, Program pause,
Program MOO stop.
the manual & automatic button

To operate the machine from manual to
automatic and reverse
CNC machine spindle direction control

The spindle turns forward, the spindle stops
and the spindle reverses
Display unit
Shows:
• Information on the block being

executed (sequence number,
programmed position, feed rate,
rotational speed, active G and M)
• Actual position values, errors, current
feed rate, spindle speed
• Alarm messages
The pulley
Pulley to move the X-axis and Z-axis

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Ain Shams University.

Computerized Numerical Controlled Machines

Student Name: ‫أحمد محمد الشين‬

Student ID: 1901192

• Column and Base:

The used tool holder:

▪ Linear motion transmission element

3. CNC control Systems

Components of the operation panel in Milling machine.

Display screen: It’s often an LCD or touchscreen, providing operator

Navigation: This functions as a regular old “d-pad” up down left right

using a handwheel or handle. Operators can manually move axes or adjust

INC jog: This key used to run axis in micron

Components of the operation panel in Lathe machine.

• It provides the user interface.

• They may be separate panels or integrated ones.

The function of operating control panel

Power On/Off Button:

Emergency Stop Button:

CNC control panel keys explain.

CNC Operating Panel Explanation

CNC Programming for Machining Center

CNC Machining Center Operating Panel

Tail stock and quill button

To move the quill in the tail stock

CNC Programming Panel Explanation

the manual & automatic button

CNC machine spindle direction control

• Information on the block being

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