FEDERAL UNIVERSITY OF TECHNOLOGY

P.M.B.1526 OWERRI
A PRESENTATION ON

NUMERICAL CONTROL VS TRADITIONAL MACHINING

DONE BY
ATUOMA ALOZIE ALEXANDER - 20191161073
Atubu Miracle Chibueze - 20191171973
Anyanwu Israel chibuike - 2019119443
Anyanwu Ifeanyichukwu Michael - 20191162873
Aruka Fortune Arinzechukwu - 20191145013
Aniemezie Emmanuel Kosisochi - 20191161273
ARINZE CHIZULUMOKE FAVOUR - 20191147683
IN IPE 509(NC MACHINE TOOLS)

SUBMITTED TO
ENGR. DANIEL
OF
DEPARTMENT OF MECHANICAL ENGINEERING
IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR
THE AWARD OF THE BACHELOR DEGREE (B. Tech) IN SCHOOL OF BIOLOGICAL
SCIENCES

MAY, 2024
NUMERICAL CONTROL VS TRADITIONAL MACHINING

AIMS

 COMPARE AND CONTRAST NUMERICAL CONTROL MACHINING

WITH TRADITIONAL MACHINING SYSTEMS

# Difference Between Numerical Control (NC) and Traditional Machining Systems

 Introduction

Manufacturing has undergone significant transformations over the past few decades,
with advancements in technology driving these changes. Two primary methods of
machining in modern manufacturing are Numerical Control (NC) and traditional
machining systems. Understanding the differences between these two approaches is
essential for making informed decisions about manufacturing processes. This report
provides an in-depth comparison of Numerical Control and traditional machining
systems, focusing on their principles, capabilities, advantages, limitations, and
applications.

Traditional Machining: A Legacy of Craftsmanship

Traditional machining is a time-tested practice that relies on the expertise of skilled

machinists. These artisans operate machine tools manually, manipulating cutting tools
and workpieces to achieve the desired shapes and features. It encompasses a wide
range of techniques, including:

 Turning: The workpiece rotates on a lathe while a cutting tool removes

material to create cylindrical shapes. Factors like cutting tool geometry, feed
rate, and spindle speed significantly impact the resulting form and surface
finish.
 Milling: A multi-tooth rotary cutting tool removes material from a stationary
workpiece. Milling machines offer versatility for creating flat surfaces,
pockets, slots, and complex geometries depending on the toolpath and setup.
 Drilling: Rotary cutting tools with various diameters create holes of precise
depths and sizes. Drilling machines can be simple drill presses or sophisticated
computer-aided drilling (CAD) systems for high-precision applications.
 Grinding: An abrasive wheel removes minute amounts of material for
achieving high-precision finishes and tight tolerances. Grinding machines are
used for applications like sharpening tools, smoothing surfaces, and creating
intricate shapes.
 Sawing: Toothed blades cut through material to separate workpieces or create
specific shapes. Band saws, circular saws, and hacksaws are common
examples of sawing equipment used in traditional machining.

The Art of the Machinist:

The success of traditional machining hinges on the skill and experience of the
machinist. They possess a deep understanding of:

 Machining principles: Cutting forces, chip formation, surface finish, and

material properties all play a crucial role in selecting appropriate machining
parameters.
 Cutting tool selection: Choosing the right tool material, geometry, and
coating is essential for efficient material removal and optimal part quality.
 Setup and fixturing: Securing the workpiece precisely on the machine tool is
critical for achieving accurate dimensions and geometries.
  Measurement and inspection: Traditional machinists rely on various
measuring instruments (calipers, micrometers, gauges) to ensure parts meet
dimensional specifications.

The Rise of Automation: Numerical Control Machining

NC machining introduces computer automation into the traditional machining

process. A digital program, often written in G-code, dictates the precise movements of
the machine's axes, cutting tool paths, speeds, and feeds. This program controls the
entire machining process, resulting in high precision and repeatability.

Essential Components of an NC System:

 CNC Machine: A computer-controlled machine tool with motors for precise

movement of cutting tools and workpieces. These machines come in various
configurations (mills, lathes, machining centers) with advanced features like
automatic tool changers and tool path optimization.
 CNC Controller: A computer that interprets the program instructions and
transmits them to the machine's actuators. It acts as the brain of the system,
ensuring accurate execution of the machining process.
 Programming Software: CAD/CAM software allows for the design of the
desired part in a 3D modeling environment. From the digital model, the
software generates the NC program containing the instructions for the CNC
machine.

CHAPTER 1. Principles of Operation

1.1 Numerical Control (NC)

Numerical Control (NC) machining involves the use of computers to control machine
tools. The main components of an NC system include:

- Controller: The brain of the NC system, responsible for interpreting the coded
instructions and converting them into machine movements.
- Machine Tool: The physical device that performs the cutting or shaping of materials.
- Program: A set of coded instructions (G-code or M-code) that specifies the
movements and operations of the machine tool.

In NC machining, the controller receives instructions from a computer program and

sends precise commands to the machine tool, resulting in highly accurate and
repeatable operations. The program can be created using Computer-Aided Design
(CAD) and Computer-Aided Manufacturing (CAM) software, which allows for the
design and simulation of machining processes before they are executed on the
machine.

1.2 Traditional Machining Systems

Traditional machining systems rely on manual control, where an operator directly

controls the machine tool's movements and operations. Key components include:

- Operator: A skilled machinist who manually adjusts the machine tool's settings and
controls.
- Machine Tool: Similar to NC systems, the tool performs the actual cutting or
shaping.
- Manual Controls: Levers, wheels, and buttons that the operator manipulates to
control the machine tool.

Traditional machining is heavily dependent on the operator's skill and experience,

with each operation requiring direct human intervention. The operator must have a
deep understanding of the machine's mechanics and the material being machined to
produce accurate and high-quality parts.

CHAPTER 2. Capabilities and Precision

2.1 Numerical Control (NC)

NC machines are known for their high precision and repeatability. They can perform
complex operations with tight tolerances and intricate geometries, making them ideal
for high-precision industries such as aerospace, automotive, and electronics. Key
capabilities include:

- Complex Contours: Ability to machine intricate shapes and profiles. This is

achieved through multi-axis movements, allowing the tool to approach the workpiece
from various angles.
- High Repeatability: Consistency in producing identical parts. Once a program is
optimized, it can be reused to produce large batches of parts with minimal variation.
- Multi-Axis Machining: Advanced NC machines can operate on multiple axes,
allowing for more complex part geometries. For example, 5-axis machining centers
can move the tool along the X, Y, and Z axes and rotate it around two additional axes.

2.2 Traditional Machining Systems

Traditional machining systems, while versatile, are limited in precision and

complexity compared to NC systems. The capabilities of traditional machining
include:

- Simple Geometries: Best suited for parts with straightforward shapes. Operators can
manually adjust the machine settings to achieve the desired shape.
- Lower Precision: Precision depends on the operator's skill, leading to potential
variability. Human error and fatigue can affect the accuracy of the machined parts.
- Manual Adjustments: Changes in part dimensions or operations require manual
reconfiguration by the operator. This process can be time-consuming and may
introduce inconsistencies.

CHAPTER 3. Advantages and Limitations

3.1 Numerical Control (NC)

Advantages

- High Precision: Consistent and precise machining with minimal human error. NC
machines can achieve tolerances within micrometers, making them suitable for high-
precision applications.
- Efficiency: Faster production times due to automated operations. NC machines can
run continuously, increasing productivity and reducing lead times.
- Flexibility: Easy to reprogram for different parts or modifications. Changes in
design can be quickly implemented by updating the program.
- Complex Machining: Capable of handling intricate designs and tight tolerances.
Multi-axis NC machines can produce complex shapes that would be challenging or
impossible with traditional methods.
- Reduced Waste: Optimized tool paths and precise control reduce material waste,
contributing to cost savings and environmental sustainability.

Limitations

- High Initial Cost: Significant investment required for NC machines and software.
The cost includes not only the machines but also the CAD/CAM software and training
for operators and programmers.
- Technical Expertise: Requires skilled personnel for programming and maintenance.
Advanced knowledge of machining processes, computer programming, and machine
maintenance is essential.
- Dependency on Power: Susceptible to power failures and electronic malfunctions.
Interruptions in power supply can halt production and potentially damage the machine
or workpiece.

3.2 Traditional Machining Systems

Advantages

- Lower Initial Cost: More affordable upfront investment compared to NC systems.

Traditional machines are less expensive to purchase and maintain.
- Versatility: Can handle a wide range of machining operations with manual
adjustments. Operators can adapt to various tasks without the need for
reprogramming.
- Independence from Electronics: Less affected by power outages or electronic issues.
Traditional machines can be operated manually, ensuring continuity in production
during power interruptions.

Limitations

- Operator Dependency: Quality and precision heavily depend on the operator’s skill.
Variability in operator performance can lead to inconsistencies in the final product.
- Lower Efficiency: Slower production times due to manual operations. The need for
constant human intervention reduces overall productivity.

CHAPTER 4. Applications
4.1 Numerical Control (NC)

NC machining is widely used in industries requiring high precision and complex part
geometries. Common applications include:

- Aerospace: Manufacturing of intricate components for aircraft and spacecraft. Parts

such as turbine blades, airframes, and complex structural components are produced
using NC machines.
- Automotive: Production of precision engine parts and other critical components. NC
machines are used to manufacture engine blocks, transmission parts, and intricate
components for electric vehicles.
- Electronics: Fabrication of detailed parts for electronic devices and circuit boards.
High-precision NC machines produce components for smartphones, computers, and
medical devices.
- Medical Devices: Creating precise and intricate medical implants and instruments.
NC machines ensure the high accuracy required for surgical tools and prosthetics.

4.2 Traditional Machining Systems

Traditional machining is suitable for applications where high precision is not critical,
or production volumes are low. Typical applications include:

- Prototyping: Initial development of prototypes where flexibility is essential.

Traditional machining allows for quick adjustments and modifications during the
development phase.
- Repair and Maintenance: Machining parts for repairs or maintenance tasks.
Operators can manually adjust the machines to produce replacement parts or perform
custom repairs.
- Custom Parts: Low-volume production of custom or one-off parts. Traditional
machining is ideal for producing unique parts that do not justify the cost of NC
programming.

CHAPTER 5. Future Trends

5.1 Advances in NC Technology

The future of NC machining includes advancements such as:

- Automation: Increased integration of robotics for loading/unloading parts and

performing auxiliary tasks. Automation reduces human intervention, increases
efficiency, and ensures consistent quality.
- AI and Machine Learning: Enhancements in predictive maintenance, process
optimization, and adaptive control. AI can analyze machine performance data to
predict failures, optimize tool paths, and adjust machining parameters in real-time.
- Internet of Things (IoT): Real-time monitoring and data analysis for improved
efficiency and quality control. IoT enables machines to communicate with each other
and with central systems, providing insights into production processes and enabling
remote monitoring and control.

5.2 Hybrid Systems

Hybrid systems combining NC and traditional machining capabilities are emerging.

These systems offer the flexibility of manual control with the precision and efficiency
of NC machining, providing a versatile solution for various manufacturing needs.
Hybrid machines can switch between manual and automated modes, allowing
operators to take advantage of both methods depending on the complexity and
precision required.

Conclusion

Numerical Control (NC) and traditional machining systems each have their unique
strengths and limitations. NC machining excels in precision, efficiency, and handling
complex geometries, making it ideal for high-demand industries. In contrast,
traditional machining offers flexibility and lower initial costs, suitable for low-volume
and custom applications. Understanding these differences is crucial for selecting the
appropriate machining method based on specific manufacturing requirements and
goals.

Advancements in technology continue to blur the lines between these two approaches,
with hybrid systems and innovations enhancing the capabilities and applications of
both. As manufacturing evolves, the integration of advanced technologies will further
drive efficiency, precision, and versatility in machining processes. The future of
machining lies in the seamless combination of NC and traditional methods, leveraging
the strengths of each to meet the diverse needs of modern manufacturing.