CNC Machine

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PT
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Prof. Janakarajan Ramkumar
Professor
Department of Mechanical
IIT Kanpur, India.
 Index
• CNC machining centres
• CNC turning centres

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• CNC milling centres
• Vertical machining centre

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• 5-axis machining centre
• CNC travelling column
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• Horizontal machining centre
 CNC Machining centres
• The term “machining centres” describes almost any CNC milling and
drilling machine that includes an automatic tool changer and a table

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that clamps the workpiece in place.

• CNC machine centre is a advance manufacturing machine tool which

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performs wide range of machining operation with accuracy and good
quality surface finish.
N
• The orientation of the spindle is the most fundamental defining
characteristic of a CNC machining centres.
 CNC Machining centres
Various mechanisms used in CNC machining centers, there main aim is to
reduce the production time and gives the best quality results.

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1. ATC (Automatic tool changer)

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2. APC (Automatic Pallet changer)

3. Feedback systems
N
4. Servo motors systems

5. Re-circulating Ball screw and Nut

 CNC Machining centres

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CNC machining centers can further be classified based on the rotation of
either the work piece Or the rotation of the tool as:

1. CNC turning machines

2. CNC Milling machines

PT
N
 CNC Turning

• The primary function of a CNC Turning Center is that it rotates (or “turns”)

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your workpiece.

• CNC Turning Machines are one of the oldest and simplest forms of

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machining parts, called “lathes,” .

• Can be either horizontal or vertical depending on the weight and

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tolerance of the workpiece.

• Workpeices for this process are usually round, but can be other shapes —
like squares or hexagons.
 CNC Turning
• The workpiece is held in place by an instrument known as the “chuck.”
The chuck then spins at various RPMs (depending on the capability of
your machine).

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• When this occurs, the machine’s tool moves into the rotating workpiece
and begins to shave away material to create the desired shape.

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N
CNC Turning

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https://giphy.com/explore/cnc
 CNC Milling machines
• The primary function of a CNC Milling Machine is that your tool will be
doing the rotating and moving while your workpiece stays in one spot

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(generally).

• Milling is a more specific process that is similar to drilling and cutting.

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• These machines can also be either horizontal or vertical, again
depending on the tolerance and weight of your workpiece.
N
• This process has many axes that allow for a variety of shapes, holes,
and slots to be cut into the workpiece at many angles.

• These axes provide many different maneuvers, either by the spindle or

the bed, to cut the part desired to the exact specifications.
CNC Milling machines

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https://gfycat.com/gifs/search/milling+machine
 CNC Turning centre
Schematic of a concrete bed of a CNC Turning centre

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Rao, CAD/CAM Principles and Applications, 2010, TMH

CNC Turning centre

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Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning centre
Spindle design for a CNC turning centre

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Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning centre
Spindle design with an integral spindle motor and cooling
system for CNC Machining centre

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https://www.pinterest.com/pin/715368722039972918/
 CNC Turning centre
Bifurcated column structure for CNC Machining centre to improve torsional
rigidity

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PT
N

Rao, CAD/CAM Principles and Applications, 2010, TMH

 v
CNC Machining centres

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According to the orientation of spindle, CNC machining centre can be classified
as :

• Vertical machining centres (VMCs): generally favour precision while

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• Horizontal machining centres (HMCs) generally favour production
N
• Universal Machining centres (UMC) 5 axis machining centre, which is able to
pivot the tool and/or the part in order to mill and drill at various orientations
 CNC vertical
machining centre
• In CNC vertical machining center, the workpiece is held on the table
base and the spindle which contains the cutting tool is fixed on vertical

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spindle Z axis. The table moves in X and Y axis and spindle with cutting
tool moves in Z axis.

PT
N
 CNC vertical
machining centre
• Travelling column

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• Gantry structure

• Multiple spindle
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N
 CNC vertical
machining centre
• Present day production vertical axis CNC machining centre Bridgeport
VMC 500

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PT
N

https://auctions.charterauctions.co.uk
5-Axis machine

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https://i.ytimg.com
CNC travelling column

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PT
N

Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC travelling column
• The possible rotary motions of the tool head of a CNC travelling column

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PT
N

Rao, CAD/CAM Principles and Applications, 2010, TMH

 5-Axis CNC
travelling column

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PT
N

http://www.asquithbutler.com
 Gantry cnc machining centre
• A gantry type CNC machining centre DMC 65V for high speed machining

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N

https://5.imimg.com
 4-axis CNC machine
• A 4-spindle CNC machining centre 4CUT for high speed machining

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N

https://5.imimg.com
 Horizontal Machine centre
• Rotary table used in HMC for machining all four faces.

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PT
N

Rao, CAD/CAM Principles and Applications, 2010, TMH

 Horizontal Machine centre
• Spindle swivelling facility in HMC for machining in two different planes
(XY as well as XZ)

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PT
N

Rao, CAD/CAM Principles and Applications, 2010, TMH

 Horizontal Machine centre
• Horizontal axis machining centre provided with a 2-axis rotary table

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https://encrypted-tbn0.gstatic.com
 Horizontal Machine centre
• Various planes possible by the 2-axis rotary table with a HMC

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Rao, CAD/CAM Principles and Applications, 2010, TMH

 Horizontal Machine centre
• A typical horizontal machining centre with an automatic pallet changer.

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N

Rao, CAD/CAM Principles and Applications, 2010, TMH

 Pallet in HMC
• Typical pallet designs used with HMC, a) Pallet with holes; b) pallet with
T-slots

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Rao, CAD/CAM Principles and Applications, 2010, TMH

.
Pallet in HMC
• A typical pallet changer with a rotary style pallet changer

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PT
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Rao, CAD/CAM Principles and Applications, 2010, TMH

 Pallet in HMC
• A typical pallet changer with a shuttle pallet changer combined with a 6
pallet carousal.

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N

Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning Centres
• Turn mill centres (X, Z, C)

• Multiple axis turning centres (X, Z, C, Y)

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• Vertical turning centres

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• Twin turret turning centres

• Multiple spindle turning centres

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• Integrated material handling
 CNC Turning Centres
• The slant bed of a CNC turning centre

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PT
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https://automatecnc.com
 CNC Turning Centres
• Machining of a key way or drill a hole away from the centre of the
workpiece.

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PT
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Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning Centres
• The drive for tooling in the turret of a CNC turn mill centre

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Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning Centres
• A tool turret with driven tooling to be used in CNC turn mill centre.

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https://www.ctemag.com
 CNC Turning Centres
• Typical shapes of component that can be machined by the combination
of X, Z and C-axis movements.

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Rao, CAD/CAM Principles and Applications, 2010, TMH

.
CNC Turning Centres
• CNC Turning centre with twin turrets

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Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning Centres
• Twin spindle CNC Turning centre

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https://i.ytimg.com
 CNC Turning Centres
• Twin spindle CNC Turning centre Mazak Dual Turn 20

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PT
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Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning Centres
• CNC turn Mill centre with Y-axis, Yamazaki Integrex 30

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https://5.imimg.com
 CNC Turning Centres
• The types of machining that can be done using a CNC turn Mill centre
with Y-axis

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Rao, CAD/CAM Principles and Applications, 2010, TMH

 CNC Turning Centres
• CNC Vertical turning centre, Yamazaki

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https://5.imimg.com
 CNC Turning Centres
• CNC Vertical turning centre with inverted arrangement EMAG VSC
250HDS,

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Rao, CAD/CAM Principles and Applications, 2010, TMH

Chip conveyors in CNC
machine tools

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Rao, CAD/CAM Principles and Applications, 2010, TMH

 Summary

• What is CNC machining centres?

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• What is CNC turning centres?
• What is CNC milling centres?
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• Various Vertical machining centre
• 5-axis machining centre
N
• Various Horizontal machining centre
• Various pallet changer used in the CNC
Thank You

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CNC Tooling

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Prof. Janakarajan Ramkumar
Professor
Department of Mechanical
IIT Kanpur, India.
 Index

• CNC tools

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• Cutting tools materials
• High speed steel tool
• Cement carbide tools
•
•
•
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Ceramics tools
ISO coding system of tools
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Tools magazines
• Automatic tool changer (ATC)
• Modular accessories in CNC
 CNC Tools

• The concept of computer numerical control (CNC) incorporates a wide

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range of machines that perform various functions. These CNC machines
are designed with precisely crafted tools to aid in the production
process

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• If CNC machine is the brain, machine tools are the limbs- converting
instructions into actual action.
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• These tools perform precise cuts on metal, wood, steel, aluminum, and
a variety of other materials.

• Multi-axis cutting tools can move in many directions, enabling the most
precise cuts possible on the materials at-hand.
 CNC Tools

Although all cutting tools serve one purpose, to cut through a material,

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there is a huge difference in their purpose.

Normally, for a cutting tool to be effective, it has to:

•
•
•
be easily fabricated.
PT
be 30% to 50% harder than the material it will work on.
N
have high thermal conductivity.
• have low coefficient of friction.
• be very resistance to wear.
• be chemically inert and stable.
 Cutting tool materials
• High Speed Steel

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• Cemented Carbides
• Coated Carbides
• Ceramics
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N
 High Speed Steel

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• It‘s composed of high carbon steel with a reasonable amount of
element alloys like chromium, tungsten, and molybdenum.

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• With this combination, it improves hardness, wear resistance, and
toughness. It also offers higher removal rate for metals and other
materials.
• To improve its property, you’ve got to apply certain surface treatment.
N
• This property allows HSS to cut faster than high carbon steel, hence the
name high-speed steel.
 High Speed Steel

• The main use of high-speed steels continues to be in the

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manufacture of various cutting tools: drills, taps, milling cutters, tool
bits, gear cutters Hobbing, saw blades, planer and jointer blades,
router bits, etc.

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https://www.banggood.in/Drillpro-8pcs-2-12mm-4-Flute-End-Mill-Cutter-HSS-Straight-Shank-Milling-Cutter-CNC-Tool-p-1376890.html
 Cemented carbide
• Cemented carbide is a hard material used extensively as cutting tool
material, as well as other industrial applications.

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• It consists of fine particles of carbide cemented into a composite by a
binder metal. Cemented carbides commonly use tungsten carbide (WC),

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titanium carbide (TiC), or tantalum carbide (TaC) as the aggregate.

• Most of the time, carbide cutters will leave a better surface finish on the
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part, and allow faster machining than high-speed steel or other tool
steels.

• Carbide tools can withstand higher temperatures at the cutter-

workpiece interface than standard high-speed steel tools (which is a
principal reason for the faster machining).
 Cemented carbide

• Choose a grade with the lowest cobalt content and the finest grain size

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consistent with adequate strength to eliminate chipping.

• Use straight WC grades if cratering, seizure or galling are not

experienced in case of work materials other than steels.

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• To reduce cratering and abrasive wear when machining steel, use grades
containing TiC.
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• For heavy cuts in steel where high temperature and high pressure
deform the cutting edge plastically, use a multi carbide grade containing
W-Ti-Ta and/or lower binder content.
Cemented carbide

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PT
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https://www.indiamart.com/proddetail/dagalloy-cemented-carbide-tools-8865787888.html
 Ceramic cutting tools

• Ceramic cutting tools are constructed mainly from alumina (Al2O3) and silicon

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nitride (SiN).

• Recent advances have also introduced the use of silicon carbide (SiC) and

the cutting tool. PT

ceramic matrix composites (CMCs) in order to enhance the performance of

• They all exhibit excellent hardness, toughness and thermal conductivity.

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• The advantages of using ceramic materials in manufacturing revolve around
ceramic’s greater ability to withstand much higher temperatures than tools
made from carbide or high-speed steel.
 Usability of Ceramic
cutting tools
• Use the highest cutting speed recommended and preferably select

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square or round inserts with large nose radius.

• Use rigid machine with high spindle speeds and safe clamping angle.

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• Machine rigid work pieces.

• Ensure adequate and uninterrupted power supply.

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• Use negative rake angles so that less force is applied directly to the
ceramic tip.

• The overhang of the tool holder should be kept to a minimum; not more
than 1.5 times the shank thickness.
 Usability of Ceramic
cutting tools
• Large nose radius and side cutting edge angle on the ceramic insert to

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reduce the tendency of chipping.

• Always take a deeper cut with a light feed rather than a light cut with

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heavy feed; ceramic tips are capable of cuts as deep as one-half the
width of the cutting surface on the insert.

• Avoid coolants with aluminium oxide based ceramics.

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• Review machining sequence while converting to ceramics and if possible
introduce chamfer or reduce feed rate at entry.
Ceramic cutting tools

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PT
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https://www.ctemag.com/news/articles/ceramic-composite-cutting-tools-are-they-tough-Enough
https://www.ceramtec.com/spk-cutting-materials/
 ISO coding
• The ISO coding system for tungsten carbide inserts used in turning.

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PT
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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

 ISO coding
• The ISO coding system for tungsten carbide turning tool holders used in
external turning (SCEA - side cutting edge angle, ECEA - end cutting edge
angle).

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PT
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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

 Contour capability
• The typical contour capability of external turning tools

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PT
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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

 Contour capability
• The typical contour capability of internal turning tools

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PT
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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

Tooling used in turning centers

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PT
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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

Modular tooling

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PT
N

TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

Clamping system

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PT
N
The complete tool assembly

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TMH, New Delhi, CAD/CAM Principles and Applications by P N Rao, 3rd Ed

 Retention knob
• Retention knob as used in the top of tool assembly for clamping and
releasing purpose as used in a CNC machining centre.

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PT
N
 Digital tool setting system

• Typical digital tool setting system, which is essentially a digital height

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gauge useful for machining centre tooling

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N
 Tool setter integrated
• Typical tool setter integrated with a CNC turning centre helps in correct
positioning of tool

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N
 Automatic tool changers

• An Automatic tool changer or ATC is used in computerized numerical control

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(CNC) machine tools to improve the production and tool carrying capacity of
the machine.

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• ATC changes the tool very quickly, reducing the non-productive time.

• Generally, it is used to improve the capacity of the machine to work with a

number of tools.
N
• It is one more step towards complete automation.

• A tool magazine where sufficient number of tools can be stored.

• The tool adopter that has a provision for pick-up by the tool change arm
Automatic tool changers

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PT
N

https://www.decispindle.com/atc-spindle-motor-deci/
 Tool turret
• Typical tool turret used in CNC drilling/ milling machines.

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PT
N
CNC drill using a tool turret

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PT
N
 Chain type tool magazine 1

• A chain type tool magazine for holding larger number of spindle tooling

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used in CNC machining centres.

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N
Chain type tool magazine 2

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N
Chain type tool magazine 3

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N
Chain type tool magazine

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N
 Tool changing

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• Stopping the spindle at the correct orientation for the tool change arm to pick
the tool from the spindle.

• Tool change arm to move to the spindle.

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• Tool change arm to pick the tool from the spindle.

• Tool change arm to index to reach the tool magazine.

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• Tool magazine to index into the correct position where the tool from the
spindle is to be placed.
 Tool changing

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• Place the tool in the tool magazine.

• Indexing the tool magazine to bring the required tool to the tool change
position.

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• Tool change arm to pick the tool from the tool magazine.
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• Tool change arm to index to reach the spindle.

• New tool is placed in the spindle.

• Tool change arm moves into its parking position.

 Tool changing arm
• One common type of tool change arm used for tool changing with a double
gripper.

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PT
N
Tool changing Procedure

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PT
N
Disc type tool magazine

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PT
N
 Drum type tool magazine
• Drum type tool magazine used in CNC turning centres with modular
tooling for storing large number of tools.

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PT
N
 Grid plate
• A grid plate with holes which can be used as a machine table.

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PT
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https://www.ame.com/grid-plates
 Tombstone

• A tombstone for mounting multiple components on different faces.

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PT
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https://www.ame.com/tombstones-fixtures
 Modular fixture
• Modular fixture elements used for supporting complex workpieces.

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https://www.ctemag.com/news/articles/modular-fixturing-pros-and-cons
 Summary

• What are CNC tools?

EL
• High speed steel tool
• Cement carbide tools
• Ceramics tools
•
•
•
PT
What is ISO coding system of tools?
Various tools magazines
N
What is Automatic tool changer and its working?
• Various accessories used in CNC machines?
Thank You

EL
PT
N