TWO MARKS QUESTIONS

1.Define Numerical Control (NC)?

NC stands for Numerical Control, which refers to the use of programmed instructions to
control the movements of machines in manufacturing. The earliest NC machines used
punched cards to input the instructions, but today’s NC machines typically use computer
software to generate and execute the instructions.

2. State two differences between NC and CNC?

NC: NC machines used punched cards to input the instructions.
No Edit and Delete the Program.
CNC: Is a more advanced form of NC that uses a computer to control the movements of
machines.
CNC programs can be use ‘N’ number of time.

3. What is Direct Numerical Control (DNC)?

DNC stands for Direct Numerical Control, which is a method of controlling multiple CNC
machines from a central computer. DNC systems allow the central computer to send
instructions directly to individual machines, eliminating the need for manual programming
of each machine.

4. What are the characteristics of the CNC Machine?

• Greater Precision.
• Increased Efficiency.
• Flexibility.
• Improved Safety.
• Cost-Effective

5.Write few advantages of CNC?

➢CNC machines can be used continuously and only need to be switched off for
occasional maintenance.
➢These machines require less skilled people to operate unlike manual lathes / milling
machines etc.
➢CNC machines can be updated by improving the software used to drive the machines.
➢Training for the use of CNC machines can be done through the use of ‘virtual software’.

6. Write few disadvantages of CNC?

➢CNC machines are generally more expensive than manually operated machines.
➢The CNC machine operator only needs basic training and skills, enough to supervise
several machines.
➢Increase in electrical maintenance, high initial investment and high per hour operating
costs than the traditional systems.
➢Fewer workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.

7. Mention different parts of CNC machine tools?

• Input Device
• Machine Control Unit (MCU).
• Motion Control Unit.
• Axes of Motion.
• Machine Tool
• Feedback Devices.
• Display Unit.

8. Mention two industries where CNC machines are widely used?

CNC machines are widely used in the aerospace and medical industries.

9. What is part program?

A part program is a sequence of instructions that describe the work that needs to be done
on a part in a format that can be understood by a computer for CNC machining. It defines
the motion of the tool or workpiece within a coordinate system.

10. What is a program input device?

A program input device is any device that allows a user to input instructions or data into a
program or system.

11. What is a machine control unit (MCU)?

A Machine Control Unit (MCU) is a specialized computer system that controls the operations
of automated machinery, particularly CNC machines. It’s the “brain” of the machine.

12. What is the role of a spindle drive in a CNC machine?

The spindle drive is responsible for rotating the main spindle of the CNC machine, which
holds the cutting tool.
It allows for precise control of the cutting tool’s speed and rotational direction.

13. What is the use of guideways in CNC machines?

The Guideway is one of the important elements of machine tool. The main function of the
guideway is to make sure that the cutting tool or machine tool operative element moves
along predetermined path. The machine tool operative element carries workpiece along
with it.

14. What is the use of spindle in CNC machines?

The spindle is the rotating component of a CNC machine that holds the cutting tool.
It allows the cutting tool to rotate at high speeds and provides the power required for
machining.

15. What is the purpose of a ball lead screw in a CNC machine?

A ball lead screw is a mechanical linear actuator that translates rotational motion to linear
motion with little friction.
They are used in CNC machines to move the various axes, such as the X, Y, and Z axes, as
well as for tool changing and other linear movements.

16. What is the purpose of an automatic tool changer (ATC)?

Tooling used with an automatic tool changer should be easy to center in the spindle, for the
tool changer to grab the tool holder.
The tool changer grips the tool at a point and places it in a position aligned with the spindle.

17. What is the purpose of an automatic pallet changer?

It helps to reduce non-productive time in CNC machines by enabling the operator to load
the workpiece on one pallet while machining of the workpiece on the second pallet is going
on.
This rapid change of workpiece reduces the idle time of the machine.

18. Mention two advantages of hydraulic spindle drives?

Higher torque: Hydraulic spindle drives can generate significantly higher torque compared
to other types of spindle drives.
Lower operating speeds: Hydraulic spindle drives can operate at lower speeds, which can be
beneficial in applications where a slower and smoother cutting action is required.

19. Name two feedback devices used in CNC systems?

Open Loop and Closed Loop Control system.
Velocity feedback: To measure and monitor the speed of the drive motor.
Positional feedback: To measure and monitor the position or displacement of the machine
slides.

20. Give important causes of accidents in CNC machine?

➢Machines are not built and tested with proper safety systems, interlocks and alarms
➢Safety features are too cumbersome and are removed by end users
➢End users are not properly trained
➢Plant production needs take precedence over safety.

21. List two safety precautions to be followed when operating a CNC machine?
➢Do not attempt to measure work piece while the machine is running.
➢Do not approach movable parts of the machine during operation.
➢Do not try to operate the machine and engage fellow workers in conversation at thesame
time.
➢Keep your mind on your work and let the other fellow do the same.

22. Define Part programming?

Definition: Part programming is the process of creating a set of instructions for a CNC
machine to produce a desired part.

23. State two differences between absolute programming and incremental programming?
Absolute programming uses a fixed reference point, typically the machine’s home position,
for all tool movements.
Incremental programming defines movements relative to the current tool position, meaning
the machine moves a certain distance from its current location.

24. What are the types of cuts used in CNC turning centre machine?
 Facing
  Turning (Rough)
 Turning (Finish)
 Drilling
 Threading
 Parting
 Threading

25. What are the axes used in CNC turning centre machine?
X-Axis: Controls the radial movement of the cutting tool.
Z-Axis: Controls the longitudinal movement of the cutting tool.

26. Name the different types of coordinate system used in CNC turning centre?
Machine Coordinate System:
Origin: Fixed, typically at a specific point on the machine bed.
Work Coordinate System:
Origin: Set at a specific point on the workpiece, usually a corner or the center.

27. Write short notes on tool function used in CNC turning centre.?
The choice of cutting tool is essential in CNC turning centres as it influences the efficiency,
accuracy, and overall quality of the final part.
Many factors influence the choice of a cutting tool, including:
 The operations required.
 The material being machined.
 The accuracy and surface finish requirements.
 The machine’s capabilities.
 Availability of tools.
 Cost.

28. Write short notes on speed function used in CNC turning centre?
Most CNC machines that are currently available come equipped with a stepless variation of
spindle speeds.
Therefore, spindle speeds are programmed using spindle speed word S.
The S word address sets the spindle speed in revolutions per minute (RPM) or
meters/minute (m/min).

29. Write short notes on CNC milling?

A CNC milling machine is programmed with a series of instructions that define the toolpath,
cutting parameters, and other machining operations.
The cutting tool is mounted on a spindle, which rotates at a high speed.
The workpiece is clamped to a table that can move in multiple axes (X, Y, and Z).

30. Name all part programming fundamentals of CNC milling?

 Relative Movement.
 Tool or Workpiece Motion.
 Reference Directions.
 Machine Tool.
  Tool or Workpiece.
 Part Program.
 Sequence of Instructions.
 G-code.
 Process Planning.
 Objective.

31. How the CNC controls are classified in a machining centre (Milling)?
Basic CNC Controls: These are the simplest form of controls, with limited functionality and
primarily used for basic operations like drilling, milling, and tapping.
Advanced CNC Controls: These controls offer greater flexibility and programmability. They
include features like:
 Multi-axis Control.
 Programmable Cycle.
 Adaptive Control.
 Tool Management.
 Motion Control.
 Interface.
High-End CNC Controls: These are highly specialized and sophisticated, offering:
 Multi-tasking Control.
 Advanced Programming.
 Real-time Monitoring.
 Closed-Loop Feedback.

32. How the axis nomenclature was calculated in CNC milling?

X-axis: This controls the movement of the cutting tool horizontally along the machine table.
Y-axis: This controls the movement of the cutting tool horizontally along the machine table,
but perpendicular to the X-axis.
Z-axis: This controls the movement of the cutting tool vertically, moving it up and down
relative to the machine table.
It’s important to note that these axes are relative to the machine’s coordinate system. The
actual direction of movement will depend on how the machine is set up and the specific
application.
33. Write short notes on coordinate system used in CNC milling?
Right-Hand Rule: The standard convention in CNC milling uses the right-hand rule to define
the orientation of axes:
X-Axis: Horizontal and perpendicular to the spindle.
Y-Axis: Horizontal and parallel to the spindle.
Z-Axis: Vertical and along the spindle.

34. Name different types of words used in CNC program.

G-Codes:
Preparatory Codes: These codes define the geometry of the CNC program, such as the path
of motion, speed, and cutting tools.
M-Codes:
Miscellaneous Codes: These codes control the auxiliary functions of the CNC machine, such
as spindle speed, coolant flow, and tool change.

35. Write short notes on Tool function used in CNC machining centre?
The tool function in a CNC machining centre refers to the selection of the appropriate
cutting tool based on the machining operation required, the material being machined, and
the desired accuracy.
It depends on the accuracy requirements, the machine capability and availability, cutting
tool availability, and shop practices.

36. Write short notes on Speed function used in CNC machining centre?
The speed function in CNC machining, represented by the letter “S,” is used to program the
spindle speed of the machine tool.
Spindle speed is a critical factor in machining, as it determines the cutting speed, cutting
force, surface finish, and tool life.

THREE MARKS QUESTIONS

1.List three major applications of CNC machines in the manufacturing industry.
➢CNC mills and machining centres.
➢CNC lathes and turning centers
➢CNC EDM
➢CNC grinding machines
➢CNC cutting machines (laser, plasma, electron, or flame)
➢CNC fabrication machines (sheet metal punch press, bending machine, or press brake)
➢CNC welding machines
➢CNC coordinate measuring machines.

2. Write few notes on recirculating ball screw mechanism used in CNC machines?
Recirculating Ball Screw Mechanism
Mechanism: Recirculating ball screws utilize a threaded shaft and a nut with a recirculating
ball system.
Function: Converts rotary motion from the drive motor to linear motion for moving machine
axes.
Advantages:
 Low Friction.
 High Accuracy.
 Long Life.
 High Load Capacity.
Components:
 Screw.
 Nut.
 Balls.
 Ball Return System.
Applications: Used in a wide range of CNC machines, including lathes, mills, and machining
centers.

3. Write the characteristics of metallic and non-metallic bearings used in CNC machines?
General Characteristics of Metallic and Non-Metallic Bearings:
Low wear rates: Both types exhibit a high resistance to wear, ensuring longer lifespan.
Relatively high performance rating (PV): Indicates their ability to withstand high pressures
and speeds.
Bearing O.D.’s compatible with standard sizes: Allows for easy upgrades in existing
equipment.
Kinetic and static coefficient of friction virtually the same: Ensures consistent performance
under various loads.
Extremely low coefficient of friction: Enables smooth and efficient operation.
Light weight: Contributes to reduced overall machine weight and energy consumption.
Ability to conform under load: Allows for proper load distribution and reduced stress on the
bearing surfaces.

4. Write the characteristics of guide ways used in a CNC machine?

Guideways ensure smooth and accurate movement of the cutting tool and workpiece along
a predetermined path.
Requirements:
High rigidity: Prevents bending and deflection under load.
High accuracy: Ensures precise positioning of the cutting tool.
Durability: Withstands the wear and tear of repeated movements.
Low friction: Minimizes energy consumption and ensures smooth operation.
Good damping properties: Minimizes vibrations and oscillations.

5. What is a stepper motor, and why is it used in CNC machines?

A stepper motor is a type of electric motor that rotates in steps.It converts electrical pulses
into discrete mechanical movements.The rotation is dependent on the rate and pattern of
the electrical pulses applied.
Uses in CNC machines
Precise positioning: Stepper motors allow for accurate, controlled movements in small
increments.
Open loop control: They don’t require feedback sensors, making them simpler to implement
and control.
High torque at low speeds: They provide ample torque for holding positions, even under
load.
Digital control: They are easily controlled with digital signals, making them ideal for use in
computer-controlled systems.

6. What is a servo motor, and why is it used in CNC machines?

What is a servo motor?
A servomotor (or servo motor) is a simple electric motor, controlled with the help of a
servomechanism.
If the motor is a controlled device, associated with servomechanism is a DC motor, then it is
commonly known as a DC Servo Motor.
If AC operates the controlled motor, it is known as an AC Servo Motor.
Why are servo motors used in CNC machines?
Servo motors are commonly used in CNC machines because they can provide precise control
over the position and speed of the machine’s axes.
They are also relatively robust and reliable, making them well-suited for the demanding
environments of CNC machining.

7. Write short notes on automatic swarf removal mechanism used in CNC machines?
The automatic swarf removal mechanism is a key feature in CNC machines to address the
problem of chips accumulating during metal cutting operations.
It is used to automatically remove swarf from the machining area, preventing the workspace
from getting clogged.
These systems are essential for maintaining efficient machining processes and reducing
downtime.
This mechanism is crucial for ensuring the accuracy and quality of finished components.
In the case of turning centers, the slanted bed design allows chips to accumulate at the
bottom of the machine, away from the machining zone.

8. Write short notes on CNC Turning.

CNC turning is a subtractive manufacturing process that uses a computer numerical control
(CNC) machine to remove material from a workpiece to create a desired shape. The CNC
turning machine is equipped with a cutting tool and a rotating workpiece, and a computer
program controls the movement of the tool and workpiece.
Process:
 Workpiece Setup.
 Toolpath Programming.
 Tool Selection.
 Cutting Process.
 Part Inspection.

9. What are the safety precautions that must be taken to avoid electrical hazards in CNC
machines?
Electrical Hazards:
Always ensure that the electrical system of the CNC machine is properly grounded.
Use caution when working near electrical components.
Never touch exposed wires or energized parts.
Do not use damaged or faulty electrical equipment.
Report any electrical hazards to a qualified technician immediately.

10. What are the basic steps in CNC machine followed for planning and programming?
Objective: To convert raw material into a finished product on a lathe.
Steps:
Understanding the Workpiece:
 Material.
 Geometry.
 Tolerance and Surface Finish.
 Sequence of Operations.
 Tool Selection and Setup.
 Machining Parameters.
 Fixture Design and Work Holding.
 Quality Control.
  Safety Considerations.
 Documentation and Record-Keeping.
Part Programming:
Objective: Create instructions for the CNC machine to produce a desired part.
 Process Planning.
 Understanding the Workpiece.
 Define Reference Directions.
 Create a Part Program.
 Verify the Program.
 Transfer the Program.

11. Write few notes on offsets used in CNC turning centre machine?
Tool Length Offsets (TLO): Compensate for the difference between the actual length of the
tool and the length the CNC machine assumes. This ensures the tool reaches the correct
cutting depth.
Tool Diameter Offsets (TDO): Compensate for the difference between the actual diameter of
the tool and the diameter the CNC machine assumes. This ensures accurate cutting of the
desired diameter.
Workpiece Offsets (WPO): Define the position of the workpiece relative to the machine
coordinate system. This helps the CNC machine understand where the workpiece is located.

12. Write short notes on preparatory function used in CNC turning centre?
G-Codes: These are preparatory functions that define the geometrical part of the CNC
program. They control the machine tool’s movements in terms of:
Linear interpolation (G01)
Circular interpolation (clockwise, G02, or counter-clockwise, G03)
Dwell (G04): pausing the tool for a specified time.
Rapid positioning (G00): moving the tool quickly to a new position.
Other functions like G20, G21, G28, G32, and G33 control units, tool radius compensation,
and threading.
M-Codes: These are miscellaneous functions that control the machine tool’s auxiliary
operations:
Tool changes (M06)
Spindle operations (M03, M04, M05)
Coolant control (M07, M08, M09)
Program stops (M00, M01, M02, M30)
Preparatory functions (G-Codes and M-Codes) are essential for creating a CNC program that
will accurately and efficiently machine a workpiece.

13. Write short notes on miscellaneous function used in CNC turning centre.
M00 - Program Stop: This code instructs the CNC to halt execution of the program.
M01 - Optional Stop: This code allows for a program to pause at a specified point. It is
typically used for manual inspection or adjustment of the work piece.
M02 - Spindle On Program End Request: This code instructs the spindle to turn on at the end
of the program.
M03 - Spindle On Clockwise: This code rotates the spindle in a clockwise direction.
M04 - Spindle On Counter Clockwise: This code rotates the spindle in a counterclockwise
direction.
M05 - Spindle Stop: This code stops the spindle rotation.
M07 - Mist Coolant On: This code turns on a mist coolant system, which provides a fine
spray of coolant to the work piece.
M08 - Flood Coolant On: This code turns on a flood coolant system, which provides a
continuous flow of coolant to the work piece.
M09 - Coolant Off: This code turns off the coolant system.
M30 - Program Stop and Rewind: This code stops the program execution and rewinds the
program to the beginning.

14. What is cut planning in CNC programming, and why is it important?

Cut planning is the process of determining the best cutting tools and parameters for a
specific machining operation.
Why is Cut Planning Important?
Efficiency: Minimizing tool changes and repositioning to save time.
Accuracy: Ensuring precise setups and operations to meet specifications.
Consistency: Maintaining consistent machining practices to produce uniform parts.
Tool Life: Optimizing cutting parameters to extend the life of cutting tools and minimize tool
wear.
Surface Finish: Selecting the right tools and parameters to achieve the desired surface finish.
Machining Time: Minimizing machining time while maintaining part quality.
Cost Reduction: Using the right tools and parameters to reduce material waste and machine
wear.
Safety: Following safety procedures to prevent accidents.

15. How the cutting parameters planned for a program in CNC milling?
Process Planning: The act of developing detailed instructions to convert raw material into a
finished product on a lathe.
Objective: Optimize the sequence of operations to ensure efficiency, accuracy, and safety.
 Understanding the Workpiece.
 Sequence of Operations.
 Tool Selection and Setup.
 Machining Parameters.
 Fixture Design and Work Holding.
 Quality Control.
 Safety Considerations.
 Documentation and Record-Keeping.

16. Write short notes on programming structure used in CNC milling?

Part Programming:
A set of instructions that define the tool path and machining operations for a CNC milling
machine.
Coordinate System:
CNC milling machines use a three-dimensional Cartesian coordinate system (X, Y, Z) to
define the position of the tool and the workpiece.
Preparatory (G) Codes:
G-codes specify the type of motion, interpolation, and other preparatory functions.
Auxiliary (M) Codes:
M-codes control machine functions such as spindle speed, coolant flow, tool change, and
program flow.
Data Input:
Part program data is typically entered using a programming language (e.g., G-code) or
through a graphical interface (CAD/CAM software)..
Control System:
The CNC control system interprets the part program instructions and converts them into
electrical signals to control the machine’s movements.
Verification and Simulation:
It’s essential to verify the accuracy of the part program and simulate the machining process
before actual cutting.

17. Write short notes on preparatory function used in CNC machining centre?
Preparatory function is an essential part of CNC programming that provides instructions for
the machine tool to prepare for the machining process.
These functions are represented by “G” codes.
Some common preparatory functions are as follows:
G00 - Rapid Positioning: Moves the tool rapidly to the desired position without any
interpolation.
G01 - Linear Interpolation: Moves the tool in a straight line with a constant feed rate.
G02 - Circular Interpolation Clockwise: Moves the tool in a circular path in a clockwise
direction.
G03 - Circular Interpolation Counterclockwise: Moves the tool in a circular path in a
counterclockwise direction.
G20 - Inch Units: Sets the units for the program to inches.
G21 - Metric Units: Sets the units for the program to millimeters.
M00 - Program Stop: Stops the program.
M06 - Tool Change: Instructs the machine to change tools.
M30 - Program End: Indicates the end of the program.

18. Write short notes on miscellaneous function used in CNC machining centre?
M-Codes: M-codes are used to control auxiliary functions, such as spindle operations (start,
stop, direction, speed), coolant flow, tool changes, and program control.
M00: Program Stop: Brings the program to a halt.
M01: Optional Stop: A programmable stop point for pausing execution.
M02: Spindle On, Program End: Turns the spindle on and stops the program.
M03: Spindle On, Clockwise: Starts spindle rotation in a clockwise direction.
M04: Spindle On, Counter-Clockwise: Starts spindle rotation in a counter-clockwise
direction.
M05: Spindle Stop: Stops spindle rotation.
M06: Tool Change: Instructs the machine to switch to a different tool.
M07: Mist Coolant On: Activates a mist coolant system.
M08: Flood Coolant On: Activates a flood coolant system.
M09: Coolant Off: Deactivates the coolant system.
M30: Program End, Rewind: Stops the program and returns the machine to its starting
position.

FIVE MARKS QUESTIONS

1.Explain the basic working principle of a CNC system using a block diagram and how
itdiffers from conventional machining?
A CNC system works by using a computer to control the movements of a machine tool. Here
is a basic block diagram:

Program Input: The operator creates a program that contains instructions for the machine
tool. This program is inputted into the system using a computer.
Control Unit: The control unit reads the program and converts it into a series of electrical
signals that control the machine tool’s movements.
Machine Tool: The machine tool receives the electrical signals and uses them to perform the
machining operations.
Feedback: Sensors monitor the machine tool’s movements and provide feedback to the
control unit. This feedback is used to ensure that the machine tool is operating accurately.
The main difference between CNC and conventional machining is that CNC uses a computer
to control the machine tool, while conventional machining relies on human operators. This
allows for a greater degree of flexibility, accuracy, and speed with CNC, making it ideal for
producing high-volume, complex, and precise parts.

2. Briefly explain stepper motors and servo motors in terms of their working principle and
applications in CNC axis drives?
Stepper Motors
Working Principle: Stepper motors convert electrical pulses into discrete mechanical
movements. The rotor rotates in steps, controlled by the rate and direction of the electrical
pulses applied.
Applications in CNC Axis Drives: Stepper motors are used in CNC machines, especially in the
control of axes with high positioning
accuracy and low speeds.
Servo Motors
Working Principle: Servo motors are
controlled using a feedback system called
a servomechanism. They use a
combination of a DC or AC motor and a
control circuit, which adjusts the motor’s
rotation based on the feedback signal.
Applications in CNC Axis Drives: Servo
motors are preferred for high-precision
and high-speed control in CNC systems.

3. Explain the any three friction reducing

elements and its advantages used in CNC
machines?
Lead Screws:
Description: Lead screws are threaded shafts that convert rotational motion into linear
motion. They are used to move the axes of a CNC machine.
Advantages:
 High Precision.
 High Efficiency.
 Durability.
 High Load Capacity.
Recirculating Ball Screws:
Description: Recirculating ball screws are similar to lead screws but incorporate a system of
rolling balls to reduce friction. The balls circulate within grooves machined into the screw
and nut, minimizing sliding contact.
Advantages:
 Ultra-Low Friction.
 High Accuracy.
 Long Service Life.
 High Load Capacity.
Linear Guides:
Description: Linear guides are precision-machined components that support and guide the
movement of linear axes. They use rolling elements (balls or rollers) to minimize friction.
Advantages:
 Minimal Friction.
 Smooth and Accurate Movement.
 High Load Capacity.
 High Stiffness.

4. Write a brief note on the general safety precautions to be followed during CNC machine
operations?
Read and understand the manual: Always familiarize yourself with the machine’s operation
manual and safety guidelines before operating it.
Proper training: Always receive appropriate training from qualified personnel on how to
operate the CNC machine and its specific functions.
Maintain a safe work environment: Keep the work area clean, organized, and free of clutter.
Use personal protective equipment (PPE): Wear appropriate PPE, such as safety glasses,
hearing protection, and gloves, to protect yourself from potential hazards.
Never operate the machine when under the influence of drugs or alcohol: Maintain a clear
and alert mind when operating machinery.
Do not attempt to measure workpieces while the machine is running: This can lead to
serious injuries.
Do not approach movable parts of the machine during operation: Be aware of moving parts
and keep a safe distance.
Do not attempt to operate the machine and engage in conversations with other workers at
the same time: Focus solely on the task at hand.
Report any safety concerns or equipment malfunctions immediately: Do not hesitate to
alert supervisors or maintenance personnel.
Always prioritize safety over production needs: Never compromise safety for production
deadlines or goals.
Understand and follow all safety procedures and protocols: Adhere to all established safety
guidelines and procedures.

5. Explain the fundamental steps followed in process planning for programming in CNC
lathe?
Process Planning: Developing detailed instructions to transform raw material into a finished
product on a lathe.
Objective: Optimize the sequence of operations to ensure efficiency, accuracy, and safety.
Understanding the Workpiece:
Material: Type and properties of the material (e.g., steel, aluminum).
Geometry: Initial dimensions and required final dimensions.
Tolerance and Surface Finish: Specifications for accuracy and surface quality.
Sequence of Operations:
Facing: Create a flat reference surface on one end of the workpiece.
Turning: Reduce the diameter of the workpiece to the desired size.
Drilling/Boring: Create internal holes or enlarge existing ones.
Parting/Cut-off: Separate the finished part from the remaining stock.
Threading: Cut threads on the workpiece if required.
Tool Selection and Setup:
Tool Types: Select appropriate cutting tools (e.g., turning tools, boring bars, parting tools).
Tool Material: Choose based on workpiece material (e.g., carbide, HSS).
Tool Holders: Secure tools in the turret or tool post.
Tool Offsets: Set tool length and diameter offsets in the CNC machine.
Machining Parameters:
Spindle Speed (RPM): Set based on material and tool specifications.
Feed Rate: Determine based on desired surface finish and tool life.
Depth of Cut: Set for each pass to balance material removal rate and tool wear.
Fixture Design and Work holding:
Chuck/Collet Selection: Choose the appropriate work holding device.
Alignment and Clamping: Ensure the workpiece is properly aligned and securely clamped to
avoid movement during machining.
Quality Control:
In-Process Inspection: Check dimensions during machining using callipers, micrometers, and
other gauges.
Final Inspection: Verify all dimensions and surface finish meet the specifications before
removing the part from the machine.
Safety Considerations:
Machine Safety: Ensure all guards and safety devices are in place and functioning.
Operator Safety: Wear appropriate personal protective equipment (PPE) and follow safe
operating procedures.

6. What are basic preparatory functions in CNC milling? Provide examples and explain their
uses.
G00 - Rapid Positioning: Used to move the cutting tool quickly to a new location without
cutting.
Example: G00 X10 Y20 Z5
Use: For positioning the tool at the beginning of a cut or moving it to a new starting point.
G01 - Linear Interpolation: Used to move the cutting tool in a straight line at a constant feed
rate.
Example: G01 X10 Y20 F100
Use: For cutting straight lines or creating linear features.
G02 - Circular Interpolation Clockwise: Used to move the cutting tool in a circular path
clockwise.
Example: G02 X10 Y20 I5 J5 F100
Use: For cutting arcs or creating circular features.
G03 - Circular Interpolation Counter-Clockwise: Used to move the cutting tool in a circular
path counterclockwise.
Example: G03 X10 Y20 I5 J5 F100
Use: For cutting arcs or creating circular features.
G20 - Inch Input: Sets the units of measurement to inches.
Example: G20
Use: For programs written in inches.
G21 - Metric Input: Sets the units of measurement to millimeters.
Example: G21
Use: For programs written in millimeters.
G28 - Return to Home Position: Returns the cutting tool to its home position.
Example: G28 X0 Y0 Z0
Use: For resetting the tool to a known starting point.
G32 - Thread Cutting Single Pass: Used for single-pass thread cutting.
Example: G32 X20 Z10 F200
Use: For creating threads in a single pass.
G33 - Thread Cutting Variable: Used for thread cutting with variable parameters.
Example: G33 X20.

8. Briefly explain the purpose of each step in this CNC milling program, from the initial
setupto returning to the home position.
Initial Setup:
G21: Sets the units to millimeters.
G17: Selects the X-Y plane for milling operations.
G40: Ensures tool radius compensation is off.
G49: Cancels any tool length offsets.
G80: Cancels any active canned cycles.
G90: Sets absolute positioning mode.
G54: Selects the work coordinate system.
G00 Z5: Moves the tool rapidly to 5 mm above the part.
Tool Selection and Spindle Start:
T1 M06: Selects tool 1 and changes the tool.
S1500 M03: Starts the spindle at 1500 RPM in the clockwise direction.
G43 H1 Z5: Applies tool length offset 1 and moves to 5 mm above the part.
Straight Cut:
G00 X0 Y0: Moves the tool rapidly to the starting position (X0, Y0).
G01 Z-5 F100: Moves the tool down to the cutting depth at a feed rate of 100 mm/min.
G01 X50 F200: Performs a linear move to X50 at a feed rate of 200 mm/min.
Angular Cut:
G91: Switches to incremental positioning mode.
G01 X20 Y-20 F200: Moves 20 mm in X and -20 mm in Y from the current position, creating
an angled cut.
Circular Arc:
G90: Switches back to absolute positioning mode.
G02 X70 Y-40 I10 J0 F200: Creates a clockwise arc from the current position to (X70, Y-40)
with the arc center offset 10 mm in X from the start point.
Return to Home Position:
G00 Z5: Moves the tool rapidly up to 5 mm above the part.

7. Write a CNC part program for step turning using G90 code.