Subject: Introduction to Mechanical Engineering Subject code: BESCK104D

Module 2 (Part B)

Advanced Manufacturing Systems

CNC

Introduction to CNC

 Numerical control (also computer numerical control, commonly called CNC) is the automated
control of machining tools (such as drills, lathes, mills, grinders, routers, and 3D printers)
utilising a computer.
 A CNC machine processes a piece of material (metal, plastic, wood, ceramic, or composite) to
meet specifications by following coded programmed instructions and without a manual
operator directly controlling the machining operation.
 A CNC machine is a manoeuvrable motorised tool and often a manoeuvrable motorised
platform, both controlled by a computer, according to specific input instructions. Instructions
are delivered to a CNC machine in a sequential program of machine control instructions such
as G-code and M-code and then executed. The program can be written by a person or, far more
often, generated by graphical computer-aided design (CAD) or computer-aided manufacturing
(CAM) software. In the case of 3D printers, the printed part is sliced before the instructions (or
the program) are generated. 3D printers also use G-Code.

 In modern CNC systems, the design of a mechanical part and its manufacturing program are
highly automated. The part's mechanical dimensions are defined using CAD software and then
translated into manufacturing directives by computer-aided manufacturing (CAM) software.
 After the advent of computer numerical control (CNC) in the 1960s, milling machines evolved
into machining centres: machines augmented by automatic tool changers, tool magazines or
carousels, CNC capability, coolant systems, and enclosures. Milling centres are generally
classified as vertical machining centres (VMCs) or horizontal machining centres (HMCs).

Components of CNC

 Input – input devices used to input the part program in the CNC machine.
 MCU – The memory/Main Control Unit is the heart of the CNC machine. It performs all the
controlling actions of the CNC machine.
 Machine Tool – A CNC machine tool always has a sliding table and a spindle to control the
position and speed.
 Feedback – This system consists of transducers that act like sensors. It is also called a measuring
system. It contains position and speed transducers that continuously monitor the position and
speed of the cutting tool located at any instant.
 Display Unit – A monitor is used to display the programs, commands, and other valuable data
of the CNC machine.

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 Subject: Introduction to Mechanical Engineering Subject code: BESCK104D

Advantages of CNC

 CNC machines can be used continuously 24 hours a day, 365 days a year.
 CNC machines are programmed with a design which can then be manufactured hundreds or
even thousands of times.
 Each manufactured product will be the same.
 Modern design software allows the designer to simulate the manufacturing, as there is no need
to make a prototype or a model. This saves time and money.
 A person can control many CNC machines as once programmed, they can do the tasks
efficiently without human intervention.

Disadvantages of CNC

 Expensive
 Requires programming skills
 Requires skills for setting up the machines
 Leads to unemployment
 Software compatibility issues can cause some programs to run in one machine, which
can/cannot run in another

Applications of CNC

 Embroidery machines
 Woodcutters
 Wire-bending machines
 Foam cutters
 Laser cutters
 Cylindrical grinders
 3D printers
 Glass cutters

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 Subject: Introduction to Mechanical Engineering Subject code: BESCK104D

3D Printing

Definition

 3D printing or additive manufacturing is the construction of a three-dimensional object from

a CAD model or a digital 3D model. It can be done in a variety of processes in which material
is deposited, joined, or solidified under computer control, with material being added together
(such as plastics, liquids or powder grains being fused), typically layer by layer.
 In the 1980s, 3D printing techniques were considered suitable only to produce functional or
aesthetic prototypes, and a more appropriate term for it at the time was rapid prototyping.
 As of 2019, the precision, repeatability, and material range of 3D printing have increased to the
point that some 3D printing processes are considered viable as an industrial-production
technology, whereby the term additive manufacturing can be used synonymously with 3D
printing. One of the key advantages of 3D printing is the ability to produce very complex shapes
or geometries that would be otherwise infeasible to construct by hand, including hollow parts
or parts with internal truss structures to reduce weight.
 Fused deposition modelling (FDM), which uses a continuous filament of a thermoplastic
material, is the most common 3D printing process in use as of 2023.

3D printing Process

Basic 3D Printer Layout

 Print Bed: The print bed is the surface that your objects are printed on to. Typically, it will
consist of a sheet of glass, a heating element, and some kind of surface on top to help the plastic
stick.
 Filament: This is the plastic that's consumed by the printer. It comes on a spool. Printers use
two different sizes of filament, 1.75 mm, and 3 mm. There are a variety of different materials.
 Extruder: The extruder is the core of the printer. It is where the plastic gets drawn in, melted,
and pushed out. It is essentially a fancy hot glue gun. It is small, but it is where most of the
printer’s technology is located. The extruder consists of two parts: the hot end and the cold end.
The cold end has a motor that draws the filament in and pushes it through. The hot end is where
the filament gets melted and squirted out.
 Heater Cartridge: The heater cartridge is self-explanatory. It heats the plastic. It is simply a
high-power resistor. Almost all modern printers use cartridge heaters, but many older printers

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 Subject: Introduction to Mechanical Engineering Subject code: BESCK104D

used coils of nichrome wire (like the kind in a toaster). If you are replacing your heater
cartridge, of even your entire hot end, make sure you know if the system is running 12v or 24v.
 Thermistor/Thermocouple/RTD: These are all various types of sensors for determining the
temperature of the hot end. They are essentially electronic thermometers. Thermistors are the
most common type of sensor, but some printers will use thermocouples for extremely high
temperature printing.
 Nozzle: The nozzle is simply a piece with a small hole for the melted filament to come out of.
Nozzles are interchangeable and come in various sizes; 0.4 mm is normal, while you might use
a smaller nozzle for finer detail or a larger nozzle to print faster. Nozzles can also sometimes
get clogged. This is one of the most common issues with 3D printers.
 Stepper Motors: Unlike regular DC motors, which rotate continuously when given power,
stepper motors rotate in increments. This gives them precise control over their position.
 Power Supply: This takes the 120V AC electricity from the wall and converts it to low voltage
DC power for your printer to use.
 Motherboard/Controller Board: The motherboard is the brain of the printer. It takes the
commands given to it by your computer (in the form of G-Code) and orchestrates their
execution. The motherboard contains a microcontroller (essentially a tiny, self-contained
computer) and all the circuitry needed for running the motors, reading the sensors, and talking
to your computer.

Materials used in 3D Printing Process

 Metallic Materials – Plain Carbon Steel, Tool Steel, Stainless steel, Aluminium, Copper,
Titanium, Bronze.
 Polymers and Polymeric Composites – ABS, Nylon (Polyamide), Polycarbonate, PP, Epoxies,
Glass filled polyamide, Polystyrene, Polyester
 Others – Sand, Ceramics, Elastomers, Tungsten, Wax, Starch, Plaster
 Bio Compatible Materials – Poly Capro Lactone (PCL), Polymethyl Methacrylate (PMMA)

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 Subject: Introduction to Mechanical Engineering Subject code: BESCK104D

Challenges of 3D Printing

 Speed
 Cost
 Accuracy
 Surface finish
 Strength
 Material options

Applications of 3D Printing

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