MODULE-5

Computer Numerical Control (CNC)

Introduction:

CNC (Computer Numerical Control) is a manufacturing process where machines are

controlled by computers to cut, shape, and produce parts with high precision. Instead of
manually operating tools, operators program the machine using coded instructions.

What is CNC?

CNC refers to automated control of machining tools like drills, lathes, mills, and grinders using a
computer. These machines follow pre-programmed sequences of commands (called G-code) to
perform tasks accurately and repeatedly.

Definition of NC (Numerical Control)

Numerical Control (NC) is a method of controlling machine tools using a set of coded
numerical instructions. These instructions direct the machine's movements and operations, such
as cutting, drilling, milling, or turning, without requiring continuous manual control by an
operator.

Definition of CNC (Computer Numerical Control)

Computer Numerical Control (CNC) is a manufacturing technology in which machine tools

are controlled by a computer that executes programmed numerical instructions to perform
operations such as cutting, drilling, milling, turning, and grinding automatically.

Components of a CNC System

A CNC (Computer Numerical Control) system consists of several major components that
work together to automate machining operations.
1. Input Device

The input device is used to enter the part program into the CNC machine.

Examples:

• Keyboard
• USB drive
• Network connection
• Manual Data Input (MDI)

Function: Transfers machining instructions (G-code) to the CNC controller.

2. Machine Control Unit (MCU)

The MCU is the brain of the CNC system.

Functions:

• Reads and interprets the program.

• Processes commands.
• Controls machine movements.
• Coordinates spindle speed, feed rate, and tool changes.

3. Drive System

The drive system converts control signals from the MCU into mechanical motion.

Components:

• Servo motors
• Stepper motors
• Amplifiers

Function: Moves the machine axes accurately according to the program.

4. Machine Tool

This is the actual machine that performs the machining operation.

Examples:

• CNC Lathe
• CNC Milling Machine
• CNC Drilling Machine
• CNC Grinding Machine

Function: Removes material from the workpiece to create the desired shape.

5. Feedback System

The feedback system monitors the machine's actual position and performance.

Components:

• Encoders
• Linear scales
• Sensors

Function: Sends information back to the controller to ensure accuracy and correct errors.

6. Display and Control Panel

The operator interacts with the CNC machine through the control panel.

Functions:

• Program entry and editing

• Machine monitoring
• Displaying alarms and status information
• Manual machine control
Definition of CAD, CAM, CAE and CIM

CAD (Computer-Aided Design): CAD is the use of computer software to create, modify,
analyze, and optimize engineering designs and drawings. It helps designers develop accurate 2D
and 3D models of products before manufacturing.

CAM (Computer-Aided Manufacturing): CAM is the use of computer systems and software
to plan, manage, and control manufacturing operations. It converts CAD designs into machine
instructions that can be used by CNC machines to manufacture products efficiently and
accurately.

CAE (Computer-Aided Engineering): CAE is the use of computer software to analyze,

simulate, test, and optimize product designs before they are manufactured. It helps engineers
evaluate the performance, strength, durability, and behavior of a product under different
conditions, reducing the need for physical prototypes.

CIM (Computer-Integrated Manufacturing): CIM is a manufacturing approach that integrates

CAD, CAM, production planning, inventory control, quality control, and other business
functions through a computer-based system. It enables the automation and coordination of the
entire manufacturing process, improving productivity, quality, and efficiency.
Automation:

Automation is a technology concerned with the applications of Mechanical, Electronics and

Computer system to operate and control the entire production in a manufacturing plant.

Types of Automation
1. Fixed automation
2. Programmable automation
3. Flexible automation

Fixed Automation:

As the name suggests in case of fixed automation the sequence of processing operations can be
fixed and cannot be changed.

Typical features of fixed automation are;

1. Initial investment is high

2. High production rates
3. Overall investment is less
4. The sequence of operations are clearly defined and simple

Examples of fixed automation are;

▪ Machining transfer lines

▪ Automated assembly machines
Programmable Automation:

Programmable automation is one in which the sequence of processing operations can be changed
based on different product configuration. The operation is controlled by a program, a program
contain set of instructions, the automation reads the program codes based on that it can be
operate.

Typical features of programmable automation are;

1. The sequence of processing operations can be changed

2. Lower production rates than fixed automation
3. Overall investment is high
4. Suitable for batch production

Examples of programmable automation are;

▪ Numerical controlled machine tools

▪ Industrial robots
▪ Programmable logic controllers

Flexible Automation:

Flexible automation is an extension of programmable automation but more beneficial than this.
Flexible automation produces a variety of products with no change over time involved from one
batch to the next batch. Since all the required programs and physical settings incorporated in the
main system itself, hence there is no loss of production.

Typical features of flexible automation are;

1. High initial investment

2. Medium production rates
3. Sequence operations are complex than other type of automations
4. No loss of production because no change over time involved from batch to batch

Examples of flexible automation are;

▪ Flexible manufacturing system

 ▪ Industrial robots

Reasons for Automation:

Some of the reasons used to justify automation are following;

1. To increase productivity
2. To reduce labour cost
3. To mitigate the effects of labour shortage
4. To reduce manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish processes that cannot be done manually
9. To avoid the high cost of not automating
10. To improve the accuracy

Additive Manufacturing:
Additive Manufacturing (AM) is a process of fabricating three-dimensional objects directly
from digital CAD models by adding material layer by layer, rather than removing material as in
conventional manufacturing methods. This layer-wise approach enables the production of
complex and intricate geometries, customized components, and lightweight structures with
minimal material waste. The process involves slicing the digital model into thin layers and
sequentially depositing or fusing materials such as plastics, metals, or ceramics until the final
object is formed. Additive Manufacturing significantly reduces lead time and is widely used for
rapid prototyping, tooling, and functional part production.
Definition: “Additive Manufacturing is a modern manufacturing process in which a three-
dimensional object is created by adding material layer by layer based on a digital 3D model”.
Unlike traditional (subtractive) manufacturing, material is added only where needed, resulting in
minimal waste. It is commonly known as 3D printing or Rapid Prototyping.
Basic Principles of Additive Manufacturing (AM) Systems:
The basic principles of additive manufacturing are;
1. Digital Design (CAD Model)
• The process starts with a 3D model created using CAD software or obtained from
3D scanning.
• The model defines the exact geometry of the part.
2. Conversion to STL/AM File Format
• The CAD model is converted into a standard format (e.g., STL, AMF, or 3MF).
• The surface of the model is approximated using small triangles.
3. Slicing into Layers
• Specialized software slices the 3D model into thin horizontal layers.
• Each slice represents a cross-section of the part to be built.
4. Layer-by-Layer Fabrication
• Material is added only where required, following the sliced data.
• Each new layer is bonded to the previous one (by melting, curing, or sintering).
5. Material Deposition or Solidification
• Depending on the process, material may be:
▪ Melted and deposited (FDM)
▪ Selectively fused or sintered (SLS, DMLS)
▪ Cured using light (SLA, DLP)
• Common materials include polymers, metals, ceramics, and composites.
6. Support Structures (if required)
• Temporary supports may be built to hold overhangs or complex features.
• These are removed after printing.
7. Post-Processing
• Printed parts may require:
▪ Support removal
▪ Heat treatment
▪ Surface finishing or machining
• Improves strength, accuracy, and surface quality.
8. Direct Manufacturing from Digital Data
 • No molds or tooling are required.
• Enables rapid prototyping, customization, and complex geometries.

Additive Manufacturing Processes

Photo polymerization

Photo polymerization, also known as Stereolithography (SLA), is widely recognized as the first
commercialized 3D printing process. It works on the principle that liquid photopolymer resins
undergo polymerization when exposed to ultraviolet (UV) light, causing the resin to cure and
solidify layer by layer to form a solid part. Fig.5.2 clearly demonstrates the photo polymerization
process.

Processing Steps of Photo polymerization

1. The photopolymer resin is contained in a vat (large container) with a movable build
platform.
2. A UV laser/light source is directed across the surface of the resin. The light source moves
in the X and Y directions according to the 3D CAD data supplied to the machine.
3. When the UV light interacts with the resin, the resin cures and hardens precisely at the
locations where the laser strikes the surface.
4. After completion of one layer, the build platform moves downward along the Z-axis by a
distance equal to the layer thickness, and the next layer is traced by the laser.
5. This process is repeated layer by layer until the entire object is formed.
 6. Finally, the build platform is raised, and the completed object is removed from the vat for
post-processing such as washing, curing, and support removal.

Advantages Photo polymerization

1. High dimensional accuracy

2. Smooth surface finish
3. Complex geometry possible
4. Rapid curing
5. Low material wastage
Disadvantages of Photo polymerization
1. Limited material properties
2. Material cost is high
3. Post-curing required Shrinkage and distortion
4. Limited long-term durability
5. Extra time and care needed for support removal and finishing.
Material Extrusion Process

In the material extrusion process, a thermoplastic filament is passed through a heated nozzle
where it melts and is deposited layer by layer on the build platform. After each layer is
deposited, the material cools and solidifies. The nozzle moves in the horizontal directions, while
the build platform moves downward for the next layer.

This process is commonly known as Fused Deposition Modelling (FDM). It uses materials such
as ABS (Acrylonitrile Butadiene Styrene) plastic to produce parts with good structural strength.
The process is suitable for low-volume production and prototyping and is more economical than
injection moulding. Fig.5.5 clearly demonstrates the Material Extrusion process.

Processing steps of Material Extrusion Process

1. The filament, supplied in the form of a spool, is fed into a heated nozzle where it is
melted.
2. Under constant pressure, the nozzle extrudes and deposits the molten material onto the
build platform to form the initial layer.
3. After completion of each layer, the build platform is lowered by a distance equal to one
layer thickness, allowing subsequent layers to be deposited on top of the previous layers.
4. The deposited layers fuse together as the material is in a molten or semi-molten state
during deposition.
5. After completion of the build, the part is carefully removed from the build platform for
further post-processing operations.
Advantages of Material Extrusion Process

1. Simple and low-cost process

2. Easy operation and maintenance
3. Wide range of thermoplastic materials (PLA, ABS, etc.)
4. Minimal material wastage
5. Suitable for rapid prototyping

Disadvantages of Material Extrusion Process

1. Poor surface finish due to visible layer lines

2. Lower strength compared to conventional manufacturing
3. Limited dimensional accuracy
4. Anisotropic mechanical properties
5. Post-processing often required

Powder Bed Sintering Process

Powder Bed Fusion (PBF), also called powder bed sintering, hardens powders using heat. It
has three main components: a heat source (laser, electron beam, or thermal print head), a
control system, and a mechanism to add layers. Powder is spread over the build platform
with a roller or blade. No extra support is needed as unfused powder supports the part. The
process occurs in a temperature-controlled chamber, usually slightly below the material’s
melting point. Selective Laser Sintering (SLS) process which uses the principle of Powder
Bed Sintering is demonstrated in Fig.5.6
Processing steps of Powder Bed Sintering Process

1. The build material, in the form of fine powders, is loaded into a hopper positioned
adjacent to the build platform.
2. A thin layer of powder, typically around 0.1 mm thick, is spread evenly over the build
platform using a roller or blade.
3. A heat source such as a thermal print head, laser, or electron beam selectively fuses the
powder particles in the first layer according to the design geometry.
4. A new layer of powder is spread over the previously fused layer using a roller or blade.
5. Steps 3 and 4 are repeated sequentially, fusing and building up successive layers to form
the complete 3D model.
6. The process continues until the entire part is fully built.
7. Loose, unfused powder remains around the model and is removed during post-processing
for finishing and cleanup.

Advantages of Powder Bed Sintering Process

1. Capable of producing complex geometries

2. Material-efficient; unfused powder can be reused
3. No tooling required
4. Ideal for rapid prototyping and customization
5. Good mechanical properties with post-processing
6. Can produce lightweight structures
7. Highly automated

Disadvantages of Powder Bed Sintering Process

1. Rough surface finish

2. Relatively slow build speed
3. Limited material options
4. Requires careful powder handling
5. May need support structures
6. Dimensional accuracy issues (shrinkage/warping)
Automotive and Aerospace Applications of Additive Manufacturing

Automotive Applications:

In the automotive industry, additive manufacturing is used for rapid prototyping, allowing
manufacturers to quickly develop and test new vehicle designs. It is also used to produce
customized parts, tooling, molds, jigs, and fixtures. AM enables the manufacture of lightweight
components that reduce vehicle weight and improve fuel efficiency. Additionally, it is used for
producing spare parts on demand, reducing inventory costs and lead times.

Examples:

• Prototype engine components

• Customized interior parts
• Lightweight brackets and housings
• Production tooling and fixtures
• Spare parts manufacturing

Aerospace Applications:

In the aerospace industry, additive manufacturing is used to produce lightweight and complex
components that are difficult or impossible to manufacture using conventional methods.
Reducing component weight helps improve fuel efficiency and aircraft performance. AM is also
used for manufacturing engine parts, turbine blades, fuel nozzles, structural components, and
satellite parts. The technology reduces material waste and allows the integration of multiple parts
into a single component.

Examples:

• Aircraft engine components

• Fuel nozzles
• Turbine blades
• Lightweight structural brackets
• Spacecraft and satellite components
Applications of AI in the Automobile Industry

1. Autonomous Vehicles

AI enables self-driving and advanced driver-assistance systems (ADAS) by processing data from
cameras, sensors, radar, and LiDAR.

Examples:

• Lane-keeping assistance
• Automatic braking
• Adaptive cruise control
• Self-parking systems

Companies such as Tesla and Waymo use AI extensively for autonomous driving.

2. Predictive Maintenance

AI analyzes vehicle sensor data to predict component failures before they occur.

Benefits:

• Reduced downtime
• Lower maintenance costs
• Improved vehicle reliability

3. Quality Inspection

Computer vision systems inspect vehicle parts and assemblies for defects.

Applications:

• Paint quality inspection

• Weld inspection
• Surface defect detection

4. Supply Chain Optimization

AI forecasts demand, manages inventory, and optimizes logistics.

Benefits:
 • Reduced inventory costs
• Faster delivery
• Better production planning

5. Smart Manufacturing in Automotive Plants

Robots powered by AI perform:

• Assembly operations
• Material handling
• Welding
• Painting

Applications of AI in Manufacturing

1. Predictive Maintenance of Machines

AI monitors machine parameters such as:

• Temperature
• Vibration
• Pressure
• Power consumption

This helps prevent unexpected breakdowns.

2. Process Optimization

Machine learning algorithms optimize manufacturing parameters to improve:

• Productivity
• Energy efficiency
• Product quality

Examples:

• CNC machining optimization

• Injection molding control
• Casting process improvement

3. Industrial Robotics

AI-powered robots can:

• Adapt to changing environments

• Handle complex assembly tasks
 • Collaborate with human workers (cobots)

4. Automated Quality Control

Computer vision systems detect:

• Dimensional errors
• Surface defects
• Assembly mistakes

Advantages:

• Faster inspection
• Higher accuracy
• Reduced human error

5. Production Scheduling

AI helps determine:

• Optimal production sequences

• Workforce allocation
• Resource utilization

6. Digital Twins

A digital twin is a virtual model of a machine, product, or manufacturing process.

Benefits:

• Performance monitoring
• Process simulation
• Failure prediction
• Design optimization

Applications of AI in Mechanical Design

1. Generative Design

AI generates multiple design alternatives based on specified requirements such as:

• Weight
• Strength
• Material constraints
• Manufacturing methods
Engineers can select the most efficient design.

Used in software such as Autodesk Fusion.

2. Design Optimization

AI helps optimize:

• Shape
• Material selection
• Structural performance
• Cost

Applications:

• Automotive components
• Aerospace structures
• Industrial equipment

3. Finite Element Analysis (FEA) Enhancement

AI accelerates simulation processes by predicting stress, deformation, and failure patterns.

Benefits:

• Reduced simulation time

• Faster product development

4. CAD Automation

AI assists engineers by:

• Automatically generating models

• Recognizing design patterns
• Suggesting design improvements

5. Material Selection

Machine learning evaluates large material databases and recommends materials based on:

• Strength
• Weight
• Cost
• Corrosion resistance

6. Failure Analysis
AI analyzes historical failure data to identify:

• Root causes
• Failure trends
• Reliability improvements

7. Intelligent Product Development

AI supports:

• Requirement analysis
• Concept generation
• Design validation
• Lifecycle management