CNC Machining

Operations
Submitted By : Waqar Ahmad (22)
Sibghat ullah (20)

Submitted to : Engr. Umer Farooq

CNC Machines

1. CNC lathe Machine

2. CNC Milling Machine
3. CNC EDM wire cutting ( Electric Discharge Machine )
4. CNC Gear Hobbing Machine
5. CNC Grinding
6. CNC Drilling Machine
CNC lathe Machine

▪ A CNC lathe is typically designed to utilize modern versions of carbide

tooling and processes. A part can be designed for customization, and
the machine’s tool paths are often programmed using the CAD or CAM
processes. However, a programmer can manually design a part or tool
path as well. The resulting coded computer file is then uploaded to the
CNC machine, and the machine will then automatically produce the
desired parts for which it was programmed to design.
CNC lathe Machine
Types of Lathe Operation

▪ The working of the CNC lathe

machine changes with every
operation and cut desired.
There are a lot of operations
used for using the CNC lathe
machine. Some of the common
lathe operations are:
Facing
This is usually the first step of any lathe operation on the lathe machine. The metal is cut from the
end to make it fit in the right angle of the axis and remove the marks.

Tapering
Tapering is to cut the metal to nearly a cone shape with the help of the compound slide. This is
something in between the parallel turning and facing off. If one is willing to change the angle then
they can adjust the compound slide as they like.

Parallel Turning
This operation is adopted in order to cut the metal parallel to the axis. Parallel turning is done to
decrease the diameter of the metal.
Parting
The part is removed so that it faces the ends. For this the parting tool is involved in slowly to make
perform the operation. For to make the cut deeper the parting tool is pulled out and transferred to
the side for the cut and to prevent the tool from breaking.  

Lathe Cutting Tools

There are several lathe cutting tools that help in cutting with the lathe machine. The commonly
used tools are mentioned below:
Lathe Cutting Tools
There are several lathe cutting tools that help in cutting with the lathe machine. The commonly
used tools are mentioned below:

1. Carbide tip tools

2. Grooving tool

3. Cut-Off blade

4. Parting blades

5. Boring bar

6. Side tool
CNC Milling Machine

CNC milling, or computer numerical control

milling, is a machining process which employs
computerized controls and rotating multi-point
cutting tools to progressively remove material
from the workpiece and produce a custom-
designed part or product. This process is
suitable for machining a wide range of materials,
such as metal , plastic , glass, and wood, and
producing a variety of custom-designed parts
and products.
Types of CNC Milling Machines
CNC Milling Operations

CNC milling is a machining process suitable for producing high accuracy, high tolerance and
parts are typically produced with tolerances ranging between +/- 0.001 in. to +/- 0.005 in., some
milling machines can achieve tolerances of up to and greater than +/- 0.0005 in. The versatility
of the milling process allows it to be used in a wide range of industries and for a variety of part
features and designs, including slots, chamfers, threads, and pockets. The most common CNC
milling operations include:

1. Face milling
2. Plain milling
3. Angular milling
4. Form milling
CNC Milling Operations

Face Milling

Face milling refers to milling operations in which the cutting tool’s axis of rotation is
perpendicular to the surface of the workpiece. The process employs face milling cutters which
have teeth both on the periphery and tool face, with the peripheral teeth primarily being used for
cutting and the face teeth being used for finishing applications. Generally, face milling is used to
create flat surfaces and contours on the finished piece and is capable of producing higher
quality finishes than other milling processes. Both vertical and horizontal milling machines
support this process.
Types of face milling include end milling and side milling, which use end milling cutters and side
milling cutters , respectively
Face Milling
Plain Milling

Plain milling, also known as surface or slab milling, refers to milling operations in which the
cutting tool’s axis of rotation is parallel to the surface of the workpiece. The process
employs plain milling cutters which have teeth on the periphery that perform the cutting
operation. Depending on the specifications of the milling application, such as the depth of the
cut and the size of the workpiece, both narrow and wide cutters are used. Narrow cutters allow
for deeper cuts, while wider cutters are used for cutting larger surface areas
Plain Milling
Angular Milling

Angular milling, also known as angle milling, refers

to milling operations in which the cutting tool’s axis
of rotation is at an angle relative to the surface of
the workpiece. The process employs single-angle
milling cutters—angled based on the particular
design being machined—to produce angular
features, such as chamfers, serrations, and
grooves. One common application of angular milling
is the production of dovetails, which employs 45°,
50°, 55°, or 60° dovetail cutters based on the design
of the dovetail.
Form Milling

Form Milling

Form milling refers to milling operations involving irregular

surfaces, contours, and outlines, such as parts with
curved and flat surfaces, or completely curved surfaces.
The process employs formed milling cutters or fly cutters
specialized for the particular application, such as convex,
concave, and corner rounding cutters. Some of the
common applications of form milling include producing
hemispherical and semi-circular cavities, beads, and
contours
Gang Milling

Gang milling refers to milling operations which

employ two or more cutters—typically of
varying size, shape, or width—on the same
machine arbor. Each cutter can perform the
same cutting operation, or a different one,
simultaneously, which produces more complex
parts in shorter production times.
Gear cutting

Gear cutting is a milling operation which

employs involute gear cutters to produce
gear teeth. These cutters, a type of formed
milling cutters, are available in various
shapes and pitch sizes depending on the
number of teeth necessary for the particular
gear design
Other Machining Processes

Since milling machines support the use of other machine tools besides
milling tools, they can be used for machining processes other than milling,
such as drilling, boring, reaming, and tapping
WHAT IS EDM?

 Electrical Discharge Machining

 Used on hard metals
 works with electrically conductive materials
BASIC DEFINITIONS

 Workpiece
 Sparks
 Electrodes

 Dielectric liquid Deionized water Dielectric oil

 Cutting speed
 Accuracy
Types of EDM

 Wire Machining ¢ Ram Machining

WHEN TO USE EDM

 Where deep cutting is required

 In unattended cutting
 For high-expertise parts
 Where EDM finish is specified

 For hard materials

 For sharp inside corners
 For the most complex geometry
HOW EDM WORKS?

 Uses very powerful sparks

 Series of rapidly recurring charge

 Electroerosion

 Remove excess by fluid flow

SPARKS

The phenomena “Breakdown”

occurs
A path for the current through
dielectric
Locally 10-15.000 ºC
Ionize the fluid
Metal melts or vaporizes
 MOVING THE TOOL

CNC control (computer numerical controlled)

Enable 3D movement
Not neccessary in all types
Very important in wire EDM
Wire EDM for detailed shapes
Sinkr EDM for dies (mold) industry
WIRE EDM

Needs wire feed

Can work overnight
Impossible to have
narrower gap than the
wire
Can be close to wire
diameter
 Voltage changes with
distance
 Distance must be
controlled
 Manufacturer programs
do all the work
 Promising method with
oscilloscope
EDM is a machining method typically used for hard
metals which are electrically conductive.

It Makes possible to work with metals for which traditional machining techniques are ineffective
APPLICATIONS

EDM can be used to make fixtures, collets

and jet engine blade slots, mold cooling ribs
and reinforcing ribs. This fact makes wire
and ram EDMs ideal for making magnetic
reader heads for missiles, artificial joints,
turbine blades and car engine prototypes
(bgpeck)
Engine Turbine Blades
 GEAR HOBBING

Gear hobbing is a multipoint machining process in

which gear teeth are progressively generated by a
series of cuts with a cutting tool known as hob. Both
the hob and the workpiece revolve constantly as the
hob is fed across the face width of the gear blank.
GEAR HOBBING

 Gear hobbing is a multipoint machining process in which gear

teeth are progressively generated by a series of cuts with a
cutting tool known as hob. Both the hob and the workpiece
revolve constantly as the hob is fed across the face width of
the gear blank.
Process Characteristics

 Is a gear generating process that uses a hob cutter

 Cutters and blanks rotate in a timed relationship

 Maintains a proportional feed rate between the gear blank and the hob

 Cuts several teeth on a progressive basis used for high production runs
Gear Production Parameters

 Feed rate

 Indexing head

Index and feed change gears establish the definite relationship for a
specific gear.
Indexing

The relationship between the rotation of the hob, the

rotation of the work , and the amount and direction of
feed that enables the gear to be cut.

 Speed change gears can be changed without affecting the

relationship between hob, work and feed.
Indexing Head

 The cutter spindle mounted on swirling head is connected

through toothed gearing of different combinations to the
table upon which the blank is carried

 For each revolution of the table and blank, the cutter makes a
definite number of revolution in the same period of time.
Indexing Movements

The movements of indexing head is controlled by

following to main components

 Indexing Gearing

 Feed Gearing
 Indexing Gearing

▪ The driving shaft and the table upon which the blank is mounted
both fixed and change gear wheels are usually employed.
▪ Generally for spur gears

No.of teeth in driving wheels No.of theads in cutter x Constant quantity.

=
No.of teeth in drivenwheels No.of teeth to be cut in blank
 Feed Gearing

▪ Controls the feed of the cutter relatively to the blank,it is defined as

the movement of the cutter with respect to the blank per revolution
ot the blank and table,in direction parallel to axis of latter.
▪ For spur gears

No.of teeth in driving wheels Feed per rev. of blank x No.of threads
in cutter
=
No.of teeth in driven wheels No of teeth to be cut in blank x Const.
Relationship between index & feed

To maintain desired relationship between index and feed there are two
constant, to decide correct change gears

 Machine index constant

 Machine feed constant
Machine Index Constant

 The machine index constant is the number of revolutions of

the hob spindle during one revolution of the work spindle
For spur gears
Index gear ratio = KT
N
K= machine index constant
T= number of threads on hob
N= number of teeth on gear
Machine Feed Constant

The machine feed constant is the distance in inches which the hob
slide will advance during one revolution of the work spindle when the
ratio of the feed change gear is 1:1

Feed gear ratio = F

M
 F= feed in per revolution of the work
 M= machine feed constant
INDEXING FIXTURE

 The index fixture consists of an index head, also called a

dividing head

 Footstock which is similar to the tailstock of a lathe.

 The index head and footstock attach to the worktable of the

milling machine by T-slot bolts
 Index Plate

 The indexing plate is a round plate with a series of six or more circles
of equally spaced holes.
 The index pin on the crank can be inserted in any hole in any circle.
 The interchangeable plates regularly furnished with most index
heads, the spacing necessary for most gears, boltheads, milling
cutters, splines, and so forth can be obtained.
Types of indexing

 Direct indexing

 Indirect indexing

 Differential indexing
 Application

▪ Application in Gear Hobbing Machine

▪ The two shafts (Hob spindle and work piece spindle) are rotated at a
proportional ratio
▪ This determines the number of teeth on the blank; for example, if the
gear ratio is 40:1 the hob rotates 40 times to each turn of the blank,
which produces 40 teeth in the blank.
 Thank You
Any Questions….??