BAEEE101 – BASIC
ENGINEERING
Module – IV – Manufacturing Processes,
Energy conversions and Mechanical
Automation
Lecture – 3 – CNC Machining and Additive
Manufacturing
Course Faculty:
Dr. Saravanakumar D, SMEC
VIT Chennai.
CNC (Computer Numerical Control) Machining
❑ CNC machining is a manufacturing process in which pre-programmed
computer software controls the movement of machine tools such as lathes,
mills, routers, and grinders. The process follows coded instructions (G-code
and M-code) to precisely cut, shape, or remove material from a workpiece.
Key Difference from Manual Machining
Aspect Manual Machining CNC Machining
Operated by hand using
Controlled by computer
Control dials, levers, and manual
programs (G-code)
measurements
Dependent on operator High repeatability and
Precision
skill accuracy
Faster, automated
Speed Slower, more setup time
operation
Complex geometries
Complex Shapes Limited
possible
Operator Involvement Constant monitoring Minimal during operation
CNC (Computer Numerical Control) Machining
Role in Modern Manufacturing
High Precision Production – Essential for aerospace, medical, and automotive
industries.
Mass Production Efficiency – Produces thousands of identical parts with minimal
variation.
Complex Geometry Capability – Enables shapes impossible or costly with manual
machining.
Reduced Human Error – Automation ensures consistent quality.
Integration with CAD/CAM – Streamlines design-to-production workflow.
CNC (Computer Numerical Control) Machining
Advantages of CNC Machining
• High accuracy and repeatability
• Complex shapes and contours possible
• Reduced labor requirement
• Consistent quality
• Shorter production times
Limitations of CNC Machining
• High initial cost
• Skilled operators required for setup/programming
• Less economical for small-scale production
Applications of CNC Machining
• Aerospace components
• Automotive parts
• Medical implants and tools
• Industrial machinery components
Principle of CNC Machining
❑ CNC = Computer Numerical Control → Automation of machine tools using
computers.
❑ Numerical commands (G-code & M-code) control tool movement, speed,
feed rate, and other parameters.
❑ Operates on a CAD → CAM → CNC workflow:
1. CAD (Computer-Aided Design): Part design is created digitally.
2. CAM (Computer-Aided Manufacturing): Converts CAD model into
machining instructions (toolpaths).
3. CNC Execution: Machine controller reads and executes the G-code to
perform the operation.
❑ Example:
• A 3D part is designed in CAD software.
• CAM software generates G-code.
• CNC milling machine executes commands to cut the part with precision.
CNC System Components
Operation of CNC Machine
[Link]
CNC Machining Processes
CNC Turning (Lathe) CNC Milling
CNC Drilling CNC Grinding
Additive Manufacturing
❑ A manufacturing process that builds objects layer-by-layer directly from a
digital 3D model.
❑ Also called 3D Printing.
❑ Uses materials such as plastics, metals, ceramics, or composites.
Difference from Subtractive Manufacturing (CNC)
Subtractive
Aspect Additive Manufacturing
Manufacturing (CNC)
Adds material layer-by- Removes material from a
Process
layer solid block
Material Usage Minimal waste Higher waste
Easily produces complex
Complexity Limited by tooling
shapes
Speed for Prototyping Faster Slower
Best for small-
Production Scale Best for mass production
batch/custom
Additive Manufacturing
Advantages of 3D Printing
❑ Design freedom and complex geometries
❑ Rapid prototyping
❑ Customization without added cost
❑ Reduced material waste
Limitations of 3D Printing
❑ Slower production for large batches
❑ Limited material strength compared to conventional methods
❑ Surface finish may require post-processing
Applications of 3D Printing
❑ Prototyping and product development
❑ Aerospace lightweight structures
❑ Medical implants and prosthetics
❑ Automotive design and spare parts
❑ Consumer products and fashion
Principle of Additive Manufacturing
Layer-by-Layer Material Deposition
•Object is built progressively by adding material in thin layers.
3D CAD Model Creation
•Design created using CAD software.
•Model is exported as an STL (Standard Tessellation Language) file.
Slicing Process
•Slicing software divides the 3D model into horizontal layers.
•Generates G-code containing instructions for the printer.
Printing Process
•Material is deposited or solidified according to the G-code.
•Methods include extrusion, laser curing, or powder sintering.
Common 3D Printing Processes
Fused Deposition Modeling (FDM)
❑ Melts and extrudes thermoplastic filament (e.g., PLA, ABS).
❑ Builds parts layer by layer.
❑ Common in low-cost desktop 3D printers.
Stereolithography (SLA)
❑ Uses a UV laser to cure liquid resin into solid layers.
❑ Produces high-resolution, smooth-surface parts.
Selective Laser Sintering (SLS)
❑ Laser fuses powdered material (e.g., nylon, metal).
❑ No need for support structures; unused powder supports the part.
Binder Jetting
❑ Liquid binder selectively applied to a powder bed to join particles.
❑ Post-processing (e.g., sintering or infiltration) often required.
Components of a FDM 3D Printer
Working of a FDM 3D Printer
[Link]