INTRODUCTION

CNC programming (Computer Numerical Control Programming) is utilized by manufacturers to

create program instructions for computers to control a machine tool. CNC is highly involved in the
manufacturing process and improves automation as well as flexibility. In this project we are required
to do CNC programming based on the CNC programming we have learn which is lathe and milling.
We are required to do one design for both lathe and milling. There are two types of CNC
programming, lathe and milling.

CNC machining is a manufacturing process suitable for a wide variety of industries, including
automotive, aerospace, construction, and agriculture, and able to produce a range of products, such
as automobile frames, surgical equipment, airplane engines, gears and hand and garden tools. The
process encompasses several different computer-controlled machining operations—including
mechanical, chemical, electrical, and thermal processes designed part or product. While chemical,
electrical, and thermal machining processes are covered in a later section, this section explores some
of the most common mechanical CNC machining operations including:

 Drilling
 Milling
 Turning

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 work piece and produce a custom-designed part or product. This process is suitable for
machining a wide range of materials, such as metal, plastics, glass, and wood, and producing a
variety of custom-designed parts and products. CNC milling is a mechanical machining process along
with drilling, turning, and a variety of other machining processes, meaning that material is removed
from the work piece by the mechanical means, such as the actions of the milling machine’s cutting
tools. CNC milling is a type of machining that uses cutters to shape a work piece, often on a
moveable table, although some milling machines also feature movable cutters. Milling started out as
a manual task performed by humans but most milling these days is done by a CNC milling, which
utilizes a computer to oversee the milling process. CNC milling offers higher precision, accuracy, and
production rates, but there are still some situations when manual milling comes in useful. Manual
milling, which requires a lot of technical skill and experience, offers shorter turnaround times. It also
has the added benefit that manual mills are cheaper and the user doesn’t need to worry about
programming the machine. The CNC milling process utilizes computerized controls to operate and
manipulate machine tools which cut and shape stock material. In addition, the process follows the
same basic production stages which all CNC machining processes do, including:

 Designing a CAD model

 Converting the CAD model into a CNC program
 Setting up the CNC milling machine
 Executing the milling operation
The CNC milling process begins with the creation of a 2D or 3D CAD design. Then the completed
design is exported to a CNC-compatible file format and converted by CAM software into a CNC
machine program which dictates the actions of the machine and the movements of the tooling
across the work piece. Before the operator runs the CNC program, they prepare the CNC milling
machine by affixing the work piece to the machine’s work surface or work holding device and
attaching the milling tools to the machine spindle.

Once the CNC milling process is initiated, the machine begins rotating the cutting tool at speeds
reaching up to thousands of RPM. Depending on the type of milling machine employed and the
requirements of the milling application, as the tool cuts into the work piece, the machine will
perform one of the following actions to produce the necessary cuts on the work piece:

1. Slowly feed the work piece into the stationary, rotating tool
2. Move the tool across the stationary work piece
3. Move both the tool and work piece in relation to each other

As opposed to manual milling processes, in CNC milling, typically the machine feeds moveable work
pieces with the rotation of the cutting tool rather than against it. Milling operations which abide by
this convention are known as climb milling processes, while contrary operations are known as
conventional milling processes. Generally, milling is best suited as a secondary or finishing process
for an already machined work piece, providing definition to or producing the part’s features, such as
holes, slots, and threads. However, the process is also used to shape a stock piece of material from
start to finish. In both cases, the milling process gradually removes material to form the desired
shape and form of the part. First, the tool cuts small pieces off the work piece to form the
approximate shape and form. Then, the work piece undergoes the milling process at much higher
accuracy and with greater precision to finish the part with its exact features and specifications.
Typically, a completed part requires several machining passes to achieve the desired precision and
tolerances. For more geometrically complex parts, multiple machine setups may be required to
complete the fabrication process. Once the milling operation is completed, and the part is produced
to the custom-designed specifications, the milled part passes to the finishing and post-processing
stages of production.

The most common CNC milling operations include:

 Face milling
 Plain milling
 Angular milling
 Form milling

There are several different types of milling machines available which are suitable for a variety of
machining applications. Beyond classification based solely on either machine configuration or the
number of axes of motion, milling machines are further classified based on the combination of their
specific characteristics. Some of the most common types of milling machines include:

 Knee-type
 Ram-type
 Bed-type (or manufacturing-type)
 Planer-type
Milling cutters come in several shapes and many sizes. There is also a choice of coatings, as well
as rake angle and number of cutting surfaces.
 End mill
 Roughing end mill
 Ball cutter
 Slab mill
CNC Lathe are machine tools where the material or part is clamped and rotated by the main spindle,
while the cutting tool that work on the material, is mounted and moved in various axis.
CNC Lathes are normally used for machining parts, where the material / part is clamped and rotated
whereas the cutting tool is stationery mounted for OD (Outer Diameter) and ID (Inner Diameter)
operations, e.g. shafts and pipes. They are ideal for parts that have same symmetry around an axis
that could be chucked up in the spindle. A simple CNC Lathe operates on 2-axis and the tool is
located in a fixed position at 8 to 24 station turret. The rotating action of the part is called “turning”,
hence certain types of CNC Lathes are called CNC Turning Machines. Milling (cutting tool moves
around stationery work piece), boring and tapping (a tool that cuts threads inside hole) tools are
normally driven by a separate drive system inside the turret. Depending on the application, the life
tools are mounted for axial or radial operational directions. These could be found in 3-axis CNC
Lathes or CNC Turning Machines. Lathe machines with additional options such as Y-axis, sub-
spindles, or specific selected options for automation are commonly called Turning Centres.

CNC lathes are classified into types by how many axes they have. They are available with different
axes, allowing more complex parts to be produced without manually switching machines or tools.
The different axes affect how the machined part or the tool can be positioned, rotated, and
approached during the machining process.

 2-axis CNC lathe

 3-axis CNC lathe
 4-axis CNC lathe
 5-axis CNC lathe
 6 or more-axis CNC lathe

A CNC lathe must be used with care. Although the process is automated, an operator must
understand computer programming parameters, safety standards, and other vital information. With
the lathe's focus on detail, a qualified professional must run the machine. Manufacturing processes
are made easier due to the automation, which consists of complex commands and speed rate
instructed by an internal computer, but a human operator must still oversee the overall process. This
means that special training to develop the necessary skills is essential.

When choosing the right CNC lathe machine, there are many factors to consider, such as the quality
of clamps that hold the work piece steady and the CNC lathe machine's tolerance level.  Weight is a
significant factor in choosing a CNC machine. A heaver machine will survive the rigorous vibrations
and other operations that impact a CNC lathe's effectiveness. A lightweight CNC lathe can get out of
balance more quickly, thus impacting the output result.

The swing measurement is another consideration. It is the maximum amount of diameter of any
material which can be cut or machined on a lathe. This measurement is taken from the bed of the
lathe to the center of the spindle. If the desired output size is known, this measurement will help
when choosing a CNC lathe.
A CNC lathe machine is normally used to perform or produce precise round shapes with both an
Outer Diameter (OD), and an Inner Diameter (ID). Practically all kinds of structures could be
machined with this machine tool, depending on their needs in different industries.

In general, CNC Lathe machines comes in the following main configurations:

 Horizontal
 Vertical
 Slant Bed
 Flat Bed
 Standard
 Multi-axis

There is a wide range of lathe tools can be classified according to materials, structures and
purposes or uses.

1. Turning Tool
Turning tools are designed for removing the materials from the stock, a rough turning tool is
used to remove the maximum amount of material and the finishing turning tool is serve for
good surface quality, just remove a small amount, to make the piece more accurate.
 
2. Boring Bar
A boring bar is required when you want to make an existed hole bigger, a boring bar can
easily bore into the hole that is already drilled, and widen its diameter. It can enlarge the
hole quickly and process it in the proper size to fit other components correctly.
 
3. Chamfering Tool
Chamfer is a transitional edge between two faces of an object, also defined as a form of the
bevel. The chamfering tool is used to create a bevel or furrow on the part. A chamfer can be
used to smooth sharp or hazardous edges on a work piece. 
 
4. Knurling Tool
Knurling tools are used to produce knurled lathe parts, through creating or pressing a
pattern onto a round section, used as a grip for a handle, also usually created on fasteners
like nuts. A knurling tool is designed with a specific pattern. 
 
5. Parting Tool
A parting tool refers to a narrow-bladed tool used in turning or planning or for cutti ng a
piece in two, or defined as a tool used for cutting off pieces from the main body of stock
being machined, it is manufactured in many forms.
 
6. Thread Cutti ng Tool
Thread cutting tools are used to cut a thread on the lathe part. In external thread cutti ng,
the piece can be held in a chuck or mounted between two centers, in internal thread cutti ng,
the part is held in a chuck, the tool moves across the part linearly, taking chips off the work
piece with each pass. 
 
7. Facing Tool
A facing tool is used for facing operation on the lathe to cut flat surface perpendicular to the
piece’s rotational axis, the tool is mounted into a tool holder that rests on the carriage of
the lathe, during the process, the facing tool will feed perpendicularly across the rotational
axis of the part.
 
8. Grooving Tool
A grooving tool is usually a carbide insert mounted in a special tool holder, it’s designed to
an insert with multiple tips, often ground to the dimensions and shape required for a
particular job, including cutti ng a slot and complete other work.
 
9. Forming Tool
Forming tools are made flat or circular in shape when used in the lathe. Simple forming tools
have cutting edges ground to the shape of the groove, undercut, or thread to be cut.