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{1. CNC MACHINE INTRODUCTION}

 CNC machine is introduced by JOHN-T-PARSON in 1949. CNC,

or Computer Numerical Control, refers to the automated control of
machining tools by means of a computer. A CNC machine is a
high-precision electromechanical device that can create complex
parts and components by removing material from a work piece,
based on programmed instructions.

Key components of a CNC machine include:

 Controller/Computer – Executes the program and controls the

machine movements.
 Drive system – Provides motion via motors and actuators.
 Machine tool – Performs the actual machining operations.
 Feedback system – Monitors and ensures accuracy of movements.
 Interface – Allows the operator to interact with the machine.

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Difference between Conventional & Non-Conventional

machines?

Conventional machine Non-Conventional machine

1. It is manually operated 1. It is computerized control machines

machines such as Lathe, Milling, like CNC, VMC, and HMC etc.
and Shaper etc.
2. These machines are not directly
2. These machine are directly connect of tool and work piece.
connect of tool and work piece.
3. Tool life is More.
3. Finishing accuracy is less.
4. Finishing accuracy is more.
4. More noise is produced.
5. Tool may not be harder.
5. There are suitable for all
material. 6. Chips removes at microscopic level.

6. Cutting tool is always harder 7. More Skilled person require.

than work piece.

7. Tool life is less.

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{2. AXIS AND CO-ORDINATE SYSTEM.}

Axis:
An axis is a direction along which the CNC machine or tool can move.
Most CNC machines are based on the Cartesian coordinate system,
using the following axes:
 X-axis – Left ↔ Right (horizontal)
 Y-axis – Front ↔ Back (depth)
 Z-axis – Up ↕ Down (vertical)
Example: A 3-axis CNC machine can move the tool in X, Y, and Z
directions.

Coordinate System:
A coordinate system defines the position and movement of the CNC
tool relative to a specific point, usually called the origin (0, 0, and 0).
There are two main coordinate systems:
1. Machine Coordinate System (MCS):
 Set by the machine itself.
 Cannot be changed by the operator.
 The origin is usually at the machine's home position.
2. Work Coordinate System (WCS):
 Set by the operator.
 Allows the origin to be placed anywhere on the work piece.
 Common in G-code using commands like G54, G55, etc.

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{3. UNIT CONVERSION.}

Unit Conversion is the process of changing a measurement from one unit

to another without changing its actual value.
In CNC Programming:
You can specify units in G-code using:

 G20 – Set units to inches

 G21 – Set units to millimeters

For example: Inch into cm

Cm into mm
Mm into ft. etc.

 Unit conversion Que:

 2.5ft in mm = 762mm.
 4ft into microns = 1219200microns.
 1ft in cm = 30.48cm
 2.54cm into mm = 25.4mm.
 3 inch into cm = 7.62cm.
 4 miles into km = 6.437km.
 22.526mm into microns = 22526microns.
 0.02mm into microns = 20microns.
 256 cm into mm, microns = 2560mm, 2560000microns.
 12.56ft into inch, cm, mm, microns =150.72inch, 382.829cm,
3828.288mm, 3828288microns.

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{4.G-CODES & M-CODES}

G-CODES (GEOMATRY CODES)

 G00- Rapid interpolation
 G01- Linear interpolation
 G02- Circular interpolation (CW)
 G03- Circular interpolation (CCW)
 G04- Dwell time
 G17- X, Y plane
 G18- X, Z plane
 G19- Z, Y plane
 G20- Inch system
 G21- Matric system
 G28- Reference
 G32- Oil groove cycle
 G40- Tool nose radius compensation OFF
 G41- Tool nose radius compensation LHS
 G42- Tool nose radius compensation RHS
 G50- Max. spindle speed
 G54- Work offset
 G70- Stock removal finishing cycle
 G71- Stock removal turning cycle

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 G72- Stock removal facing cycle

 G73- Stock removal pattern cycle
 G74- Face grooving cycle
 G75- Grooving cycle
 G76- threading cycle/ Taper threading cycle
 G83- Peck drilling cycle
 G90- Turning cycle
 G92- Threading cycle
 G94- Facing cycle
 G96- Constant surface speed
 G97- Constant spindle speed
 G98- Return to R plane (VMC)
 G99- Feed per revolution

M-CODES (MACHINE CODES)

 M00- Compulsory stop M09- Coolant off
 M01- Optional stop M19- Spindle lock
 M02- Program end M30- Program end & reset
 M03- Spindle (rotate clock wise)
 M04- Spindle rotate (counter clock wise)
 M05- Spindle stop
 M08- Coolant On

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{5.MODES IN CNC}

There are some modes in CNC machine:

1. EDIT MODE: Function: Allows the operator to create, modify, or
delete CNC programs.
 Use: Writing new G-code or editing existing programs.
 Common Actions:
Renaming or saving programs

2. JOG MODE: Allows to movement the axis through manually.

 Use: Manually movement of axis, spindle rotate (CW),
(CCW), Clamp, De-clamp, Tool change, Coolant ON/OFF.

3. MEMORY MODE/ AUTO MODE:

 Function: Executes a saved CNC program from the machine’s
memory.
 Use: Running actual machining operations.
 Common Actions:
Pressing Cycle Start to begin program execution
Tool changes, spindle operations, feed movements happen
automatically

4. MDI (MANUAL DATA INPUT):

 To input and execute short G- codes command manually.
 Run one line of code without a full program.
 E.g. Spindle rotate, tool change etc.

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5. Handle mode:

Purpose: Like Jog mode but controlled by a physical hand wheel.

What you do here:
 Precise manual axis movement using the MPG (Manual Pulse
Generator).
 Helpful for fine-tuning positions.

6. ZERO RETURN / REFERENCE Mode:

Purpose: Send machine to its home or reference position.

What you do here:
 Initialize machine position.
 Often done after power-up.

7. Dry run mode:

Purpose: To test the CNC program without actual cutting

Key feature:
 Simulate the machining process.
 Verifies program logic and tool paths.
 Helps avoid crashes or programming error.

8. DND mode (Direct numerical control):

Purpose: To run program directly to the computer or external
devices.
Key Features:
 Useful for large programs that exceed the CNC memory.
 Often used in older machines with limited memory.

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{6.GAUGES, INSTRUMENT, SYMBOLS,

FULLFORMS}

GAUGES:
1. SNAP GAUGE: A Snap Gauge is a
precision inspection tool used to quickly check
the external dimensions (such as diameter,
thickness, or width) of a part. It gives a GO/NO-
GO judgment based on whether the part falls
within specified tolerance limits.
How It Works:
 It typically has two fixed jaws (one for the maximum limit –
NO-GO, and one for the minimum limit – GO) and a spring-
loaded or adjustable jaw in between.
The part is "snapped" into the gauge:
 If it passes through the GO side and stops at the NO-GO side,
it is within tolerance.
 If it does not pass the GO or passes through the NO-GO, it is
out of tolerance.

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2. RING GAUGE: A Ring Gauge is a cylindrical precision tool used to

check the external diameter of cylindrical parts such as shafts. It
works on a GO/NO-GO principle, similar to plug
and snap gauges, but is designed specifically to
inspect outer dimensions

How It Works:
 The part (shaft) is inserted into the ring.

There are usually two types of ring gauges:

1. GO Ring Gauge: Should fit smoothly over the part – confirms

minimum size limit.
2. NO-GO Ring Gauge: Should not fit over the part – confirms
maximum size limit.

3. PLUG GAUGE: A Plug Gauge (also known as Go/No-Go Gauge) is

typically a cylindrical tool made from hardened
steel or carbide. It comes in two ends:
 Go End: This end should fit easily into the
hole if the part is within the specified tolerance.
 No-Go End: This end should not fit if the hole
is within tolerance. If it does, the part is rejected.

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Types of Plug Gauges:

1. Go/No-Go Plug Gauge – Most common.
2. Plain Plug Gauge – For standard hole checks.
3. Taper Plug Gauge – Used for checking taper holes.
4. Thread Plug Gauge – For checking internal threads.

4. RADIUS GAUGE: A Radius Gauge is a handheld tool consisting of a

set of curved blades or leaves, each marked with
a specific radius. These are used to compare and
measure the radius of a curved surface.
USE:
 To measure internal and external radii of machined parts.
 To ensure components meet design specifications.
 Useful in quality control and tool & die making.

5. THREAD GAUGE: A Thread Gauge is a tool used to measure the

pitch or lead of a screw thread. It helps in
identifying the type and size of threads—
both internal and external—on fasteners,
screws, or threaded holes.

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USE:
 To determine the thread pitch (the distance between threads).
 To identify thread type (e.g., metric, imperial, unified, BSP,
etc.).
 Commonly used in machining, quality control, and
maintenance.

INSTRUMENTS:

1. VERNIER CALLIPER:

A Vernier Caliper was introduced by PIERRE VERNIER in 1631.

It is a precision measuring instrument used to measure the length,
internal and external diameters, and depths of objects with high
accuracy. It is widely used in engineering, manufacturing, and quality
control.

USE:
 To measure:
External dimensions (e.g., width, thickness)
Internal dimensions (e.g., hole diameters)
Depths (e.g., of slots, steps)

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 More accurate than a regular ruler.

 Common in workshops, labs, and industrial training environments.

PARTS OF VERNIER CALLIPER:

 Main scale
Function: Fixed scale marked in mm or inches; gives the base
measurement.
 Vernier scale
Function: Sliding scale for reading smaller increments (usually 0.02 mm
or 0.001 in)

 Fixed jaws
Function: Stays attached to the main scale; one contact point for
measurement.

 Moveable jaws
Function: Slides to grip the object; attached to Vernier scale.

 External measuring jaws

Function: For measuring outside dimensions like diameter, thickness,
etc.

 Internal measuring jaws

Function: For measuring internal diameters of holes or slots.

 Depth bar
Function: For measuring the depth of holes or recesses.

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2. MICRO METER:

Micrometer was introduced by William Gascoigne

A micrometer (also known as a micrometer screw gauge) is a precision
measuring instrument used to measure very small dimensions with high
accuracy, typically in the range of 0.01 mm or 0.001 inches.

USE:
Measuring the diameter, thickness, or length of small parts like bolts,
shafts, and metal sheets.

Parts:
 Frame
Function: The C-shaped body that holds all parts together.

 Anvil
Function: The fixed measuring surface against which the object is
held.

 Spindle
Function: Movable measuring surface that advances or retracts using the
thimble.

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 Sleeve
Function: Fixed scale marked with mm and inches graduation.

 Trimble
Function: Rotating part with scale moves the spindle. Each rotation
equals a set distance.

 Ratchet stop
Function: Controls the pressure applied for consistent measurements.

 Lock Nut
Function: Locks the spindle in place to hold a measurement.

 Measuring faces
Function: Contact points of the spindle and anvil where the object is
held.

SYMBOLS:
1. = Diameter
2. R = Radius
3. = Perpendicular
4. = Depth
5. = Countersink
6. = Counter bore
7. = Parallel
8. = Flatness
9. = Runout
10. = Total Runout
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11. ○ = Roundness
12. = Positional Tolerance
13. = Conical Taper
14. = Taper
15. ⌭ = Cylindricity

16. ⌯ = Symmetry
17. = Arc Length
18. = Concentric

FULL FORMS:

1. HND: Handle mode.

2. ZRN/REF: Zero return/ Reference position.

3. MEM/AUTO: Memory mode/Auto mode

4. EDIT: Program edit

5. JOG: Jogged mode

6. MDI: Manual data input

7. SBK: Single block mode

8. PCD: Pitch circle dia

9. ATC: Arm tool change

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10. R: Radius/ Retraction value

11. BDT: Block skip/ Block delete

12. OSP: Option stop/ Optional block skip

13. EOB: End of block

14. DRY: Dry Mode

15. POS: Position

16. PROG: Program

17. T: Tool

18. S: Spindle

19. F: Feed

20. H: Tool height

21. P: Rest time

22. Q: Peck depth

23. CW: Clock wise

24. CCW: Counter clock wise

25. RPM: Revolution per minute

26. EXTC: External clamping

27. INTC: Internal clamping

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{7.TOLERANCE, FITS, OFFSET}

TOLERANCE:

It is the permissible limit or limit of variation is known as tolerance. It is

also known as upper limit and lower limit.

It has two types:

 Unilateral tolerance.
 Bilateral tolerance.

Unilateral tolerance:
The unilateral tolerance have only one limit positive or negative .
For example:
Nominal size = 50 mm
Tolerance = +0.00 / -0.05 mm

Bilateral tolerance:
In bilateral tolerance, variation is allowed in both directions (positive
and negative) from the nominal size.
For example:
Nominal size = 50 mm
Tolerance = ±0.05 mm

FITS:
The degree of looseness and typness is called fits.

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There are having two types of fits:

1. Clearance fit: There is always a space (clearance) between the

shaft and the hole, even at the tightest tolerance limits.
Purpose: Allows easy assembly and movement.
Example: A bolt freely passing through a hole.

2. Interference Fit: The shaft is larger than the hole, causing a tight,
non-movable joint. It requires force or heat to assemble.
Purpose: Provides a strong, permanent connection.
Example: Gears or bearings pressed onto shafts.

3. Transitional Fit:

 Definition: Depending on tolerance variation, the fit may have

either slight clearance or slight interference.
 Purpose: Ensures precise location with some holding power.
 Example: Locating dowels, precise assemblies

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{8.TOOL NOSE RADIUS COMPENSATION.}

Tool Nose Radius Compensation is a function in CNC (Computer

Numerical Control) machining that adjusts the programmed tool path to
account for the radius at the tip of a turning tool (or lathe insert).
Without compensation, the toolpath would be inaccurate, especially in
contouring or angled cuts, because the CNC program assumes a sharp
point, but the actual tool has a rounded tip.

Why It's Important:

 Turning tools are not perfectly sharp — they have a nose radius
(e.g., 0.4 mm or 0.8 mm) to increase strength and reduce wear.

 If the CNC machine does not compensate for this radius, the part
dimensions and surface finish will be incorrect.

 TNRC ensures the cutting edge (not the center of the tool tip)
follows the intended part geometry.
How It Works:

 The programmer defines the geometry of the part.

 The CNC controller shifts the toolpath based on the tool nose
radius and the tool direction.

 The compensation is applied using CNC codes (e.g., G41 and

G42).

G-Codes Used for TNRC:

Code Function
G41 Tool nose radius compensation left
G42 Tool nose radius compensation right
G40 Cancel tool nose radius compensation

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{9.INSERTS AND TOOL NOMANCLATURE.}

INSERT NOMANCLATURE:
In CNC machining, insert nomenclature refers to a standardized
code that identifies the geometry and properties of a cutting insert.
This code helps machinists and engineers quickly select the correct
insert for specific materials, operations, and cutting conditions.

Typical Insert Code Format: Example

C N M G 12 06 02

(Insert nose radius)

Width of insert

Length of insert

Clamping type/ Chips breaking system

Tolerance angle

Clearance angle/ Relief angle

Insert shape

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INSERT SHAPES:

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Normal clearance:

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