Chapter 2 :- Literature Review

2.1. THEORETICAL BACKGROUND

CNC is the acronym for Computer Numerical Control. It is an outgrowth of the older
term "NC", which stands for just "Numerical Control". It refers to the idea of controlling
machine tools programmatically via computer. With the older "NC" term, a computer
need not be involved. The machine might be controlled using, for example, punched tape.
NC, and later CNC, allowed for tremendous increases in productivity for machine tools
because the machines could be run automatically without requiring constant attention
from their operator. Before the advent of such automation, there was a lesser automation
opportunity in the form of hydraulic tracer systems. Such systems used hydraulics to
cause the cutting tools of a lathe or mill to follow a template. The taper attachments
available for many manual lathes are not unlike the hydraulic tracer capability, it's just
that the tracer is capable of more elaborate templates than simple tapers.
But the advent of first NC and then later CNC radically increased the amount of
automation that was possible.

SHORT HISTORY:-

The first commercial NC machines were built in the 1950's, and ran from punched tape.
While the concept immediately proved it could save costs, it was so different that it was
very slow to catch on with manufacturers. In order to promote more rapid adoption, the
US Army bought 120 NC machines and loaned them to various manufacturers so they
could become more familiar with the idea. By the end of the 50's, NC was starting to
catch on, though there were still a number of issues. For example, g-code, the nearly
universal language of CNC we have today, did not exist. Each manufacturer was pushing
its own language for defining part programs (the programs the machine tools would
execute to create a part).

1959 CNC Machine: Milwaukee-Matic-II was first machine with a tool changer...

The concept for modern numerical control (NC)- the forerunner to today's computerized
numerical control (CNC)- was originally conceived c.1947 by John T. Parsons (19132007) and Frank L. Stulen (1921-2010) at the Rotary Wing Branch of the Propeller Lab at
Wright-Patterson Air Force Base, in Dayton, Ohio as a result of the US Air Force's
(USAF's) search for a system to design and manufacture more accurate and complex
airplane parts (Source: History of CNC Machining: How the CNC Concept Was Born,"
CMS North America, Inc.). Early on, Parsons and Stulen developed a helicopter-blade
template fabrication system using an IBM 602A multiplier to calculate airfoil coordinates
and feed data points directly into a Swiss jig-borer, which impressed their USAF research
colleagues. Shortly thereafter, Parsons and Stulen developed a unique, computerized,
punch-card program to render complex 3-D shapes, leading Parsons to start his own
company, Parson Corp., operating out of Traverse City, Michigan.
In 1948, representatives of the US Air Force (USAF) visited the Parsons Corp.
headquarters and Parsons was awarded a contract to make new and innovative wing
designs for military applications. This, in turn, led to a series of USAF research projects
at the Massachusetts Institute of Technology (MIT) Servomechanisms Laboratory,

culminating in the construction of the very first numerically-controlled, albeit awkward,

machine prototype. To accomplish this, Parsons purchased a Cincinnati DK Series, 28inch Hydro-tel verticle-spindle contour milling machine consisting of a table and spindle
that moved along X, Y and Z-axes. Over the next two years, the Cincinnati was
disassembled, significantly modified, retrofitted, and reassembled. As application studies
proceeded, the prototype was augmented to produce a motion of the head, table, or crossslide to within 0.0005" for each electrical impulse fed by the director. To ensure the
prototype was functioning as instructed, a feedback system was added. In response to
movement, synchronous motors geared to each motion produced voltage. This voltage
was sent back to the detector for comparison to the original command voltage.
By 1953, enough data had been culled to suggest practical, aeronautic applications, and
the Cincinnati prototype, which employed a Friden Flexowriter with its 8-column paper
tape, tape reader, and vacuum-tube control system, became the de facto prototype for all
successive developments. To this day all CNC controlled machines, even the most
sophisticated still require three basic systems to operate: a command function system, a
drive/motion system, and a feedback system.
Although CNC gained slow acceptance throughout the '50s, in 1958 MIT
Servomechanisms Laboratory developed g-code, which has become the most universally
used operating language for CNC devices.
In the early '60's the Electronic Industry Alliance (EIA) standardized g-code and
computer-aided design (CAD) became a nascent technology providing a firmer
technology foundation. As a result, CNC soared and began steadily supplanting older
technologies.
By the '70s, minicomputers such as the DEC PDP-8 and the Data General Nova made
CNC machines more powerful and cost-effective. US companies responsible for the CNC
revolution, focused on high-end equipment. German and Japanese companies sensing the
need, began producing smaller, less expensive CNCs, and since 1979 they have been
outselling the United States.
More recently, microprocessors have made CNC controls even cheaper, culminating with
the availability of CNC for the hobby and personal CNC market. The Enhanced Machine
Controller project, or EMC2, was a project to implement an Open Source CNC controller
that was started by NIST, the National Institute of Standards and Technology as a
demonstration. Sometime in 2000, the project was taken into the public domain and Open
Source, and EMC2 appeared a short time later in 2003.
Mach3 was developed by Artsoft founder Art Fenerty as an offshoot of early EMC
versions to run on Windows instead of Linux, making it even more accessible to the
personal CNC market. Art's company, ArtSoft, was founded in 2001.

Both the EMC2 and Mach3 CNC software programs are alive and thriving today, as are
many other CNC technologies.

2.2. RECENT WORK

Machining goes digital

Like all computerized applications, CNC has developed over time. Programs that
once ran on paper tape are now digital, and the job of the machinist has, to a large
extent, changed from that of machine operator to programmer. Machining cells
combine multiple tools, further reducing the need for human intervention. As a
result, traditional CNC machining has evolved from being a heavily front-endloaded process to todays labor-saving, digital process. Tool path creation was once
a complex process, taking many man-hours of programming before the first part
could be produced. Cost-per-part dropped sharply as the computer and machining
cells churned out unlimited quantities of identical parts. Production volume was
large enough, the high setup cost could be amortized over a large number of parts,
making machining a cost-competitive production method. However, machining
small numbers of prototypes or small numbers of production parts quickly and costeffectively remained a challenge.

Bridging the CAD/CAM gap

Recent developments have made CNC machining a competitive method for making
metal or plastic parts in prototype quantities. In the past the challenge was the time
and labor cost of creating first-part tool paths. Fortunately, sophisticated software is
now replacing the human programmer, cutting costs and delays.For example,
software used by Proto Labs can convert a complex 3D CAD model to tool paths in
only hours. This automation of tool path development not only slashes the cost of
that first part, making CNC machined parts cost-competitive with layered parts, it
also eliminates the possibility of error being introduced by the human involvement
between computerized-aided design (CAD) and computer-aided manufacturing
(CAM).

CNC Cutting tool material new products

In recent years , the CNC cutting tool material applications is on the basis of
scientific research and the results of the new products focus on in high-speed , hard
(including heat-resistant, difficult to machine), dry fine (super fine) CNC machining
technology field. CNC cutting tool material research and development of new

products gets rapid development and progress in the super hard materials ( diamond
surface modified coating material, TiC base class cermet , CBN , Al203 , Si3N4 base
class ceramic) , W , Co-like coating and fine particles ( Ultrafine particles ) cemented
carbide substrate and Go-class containing powder metallurgy fields.

2.3. SUMMARY OF PAST WORK

18 Research Papers were analyzed with emphasis on: Workpiece Material
Input Parameters
Output Parameters
Most Significant Parameters
The following table elucidates the effect of above mentioned parameters.

Table 1: Summary of Research Papers

Ref.
No.

1.

2.

3.

Year

Authors
Name

2002

C. X. Feng, X.
Wang

2007

Hasan
Gkkaya,
Muammer
Nalbant

2012

H.K. Dave,
L.S. Patel, H.
K. Raval

Material

Input Parameter

Output
Paramete
r

Work piece hardness (Steel

(8620) HRB 86, AL (6061T)
HRB 52),
Steel 8620 Feed (0.051, 0.203 mm/rev.),
Surface
Al 6061T
Tool point angle (35, 80), Roughness
Depth of cut (0.51, 1.02 mm),
Speed (1200, 1800 rpm),
Cutting time
Insert Radius (0.4, 0.8, 1.2
mm),
AISI 1030
Surface
DOC (0.5, 1, 1.5, 2, 2.5 mm),
Steel
Roughness
Feed (0.15, 0.2, 0.25, 0.30,
0.35 mm/rev.)
Tool (CN1500, CC8020),
Work Material (EN-8, ENSurface
31),
Roughness
EN-8,
Cutting Speed (100, 150
EN-31
m/min.),
DOC (1, 1.5 mm),
MRR
Feed (0.25, 0.30 mm/rev.)

Most
Significant

Workpi
ece
Hardne
ss

Tool
point
angle

Feed

Insert
Radiu
s

Tool

DOC

DOC

Tool

5.

2013

Harish Kumar
Mohd. Abbas
Dr.
AasMohmmad
etc.

6.

2011

IlhanAsilturk,
HarunAkkus

7.

8.

10.

12.

13.

14.

2013

MS 1010

AISI 4140
(51 HRC)

JakhalePrashan High alloy

t, Jadhav B. R.
steel

Speed (1600, 1300, 1000

rpm),
Feed (0.04, 0.03, 0.02
mm/rev.),
DOC (0.35, 0.30, 0.25 mm)
Cutting Speed (90, 120, 150
m/min.),
Feed (0.18, 0.27, 0.36
mm/rev.),
DOC (0.2, 0.4, 0.6 mm)
Cutting Speed (100, 125, 150
m/min.),
Feed (0.24, 0.26, 0.28
mm/rev.),
DOC (1, 2, 3 mm)

Surface
Roughness

Speed

Feed

Surface
Roughness

Feed

DOC

Surface
Roughness

DOC

Speed

Speed

Nose
Radiu
s

DOC

Feed

Feed

Nose
Radiu
s

DOC

Speed

Feed

Nose
Radiu
s

Cutting Speed (150, 170, 190,

210 m/min.),
Surface
Feed (0.15, 0.20, 0.25, 0.30 Roughness
mm/rev.),
DOC (0.5, 1.0, 1.5, 2.0 mm),
MRR
Nose Radius (0.4, 0.8 mm)
Cutting Speed (111, 200
Surface
m/min.),
Roughness
Feed (0.15, 0.25 mm/rev.),
DOC (0.25, 0.75 mm),
MRR
Nose Radius (0.4, 0.8 mm)
Cutting Speed (150, 170, 190,
210 m/min.),
Feed (0.15, 0.20, 0.25, 0.30
Surface
mm/rev.),
Roughness
DOC (0.5, 1.0, 1.5, 2.0 mm),
Nose Radius (0.4, 0.8 mm)

M. Kaladhar,
K. Venkata,
Ch. Srinivasa
Rao

AISI 304
Austenitic
Stainless
Steel

M. Kaladhar,
K. V.
Subbaiah, Ch.
Srinivasa, K.
Narayana,

AISI 202
Austenitic
Stainless
Steel

2012

M. Kaladhar,
K. Venkata ,
Ch. Srinivasa
Rao

AISI 304
Austenitic
Stainless
Steel

2010

M. Kaladhar,
K. Venkata ,
Ch. Srinivasa
Rao, K.
Narayana Rao

AISI 202
Austenitic
Stainless
Steel 300
series 200
Series

Cutting Speed (111, 200

m/min.),
Feed (0.15, 0.25 mm/rev.),
DOC (0.25, 0.75 mm),
Nose Radius (0.4, 0.8 mm)

Surface
Roughness

Feed

Nose
Radiu
s

AISI 1030
Steel bar

Nose Radius (0.4, 0.8, 1.2

mm),
DOC (0.5, 1.5, 2.5 mm),
Feed (0.15, 0.25, 0.35
mm/rev.)

Surface
Roughness

Nose
Radius

Feed

2012

2011

2007

M. Nalbant, H.
Gokkaya, G.
Sur

15.

16.

17.

2013

N.E. Edwin
Paul, P.
Marimuthu,
R.Venkatesh

EN8 Steel

2005

zel T., Hsu

T.K., Zeren E.

AISI H13
Steel

2014

Ranganath M.
S., Vipin, R. S.
Mishra

Aluminiu
m (6061)

Aluminiu
m
KS1275

19.

2014

Ranganath M.
S., Vipin, Nand
Kumar, R.
Srivastava

20.

2014

Ranganath M.
S., Vipin

Aluminiu
m (6061)

2014

Ranganath M.
S., Vipin

Aluminiu
m (6061)

2012

Upinder
Medium
Kumar Yadav,
Carbon
Deepak
steel
Narang, Pankaj
AISI 1045
Sharma

21.

22.

Cutting Speed (200, 240, 280

m/min.),
Feed (0.15, 0.20, 0.25
mm/rev.),
DOC (0.8, 1.0, 1.2 mm)
Cutting Edge Geometry
(Honed, Chamfer),
Workpiece Hardness (51.3,
54.7),
Feed (0.05, 0.10, 0.20
mm/rev.),
Cutting Speed (100, 200
m/min.)
Speed (180, 450, 710 rpm),
Feed (0.2, 0.315, 0.4
mm/rev.),
DOC (0.2, 0.4, 0.6 mm)
Depth of Cut (0.25, 0.50, 0.75
mm),
Speed (1600, 1900, 2200
RPM),
Feed (0.1, 0.2, 0.3 mm/rev.)
Tool Rake Angle (16, 18,
20)
Tool Nose Radius (0.4, 0.8,
1.2 mm),
Cutting Speed (175, 225, 275
m/min.),
Feed Rate (0.05, 0.1, 0.15
mm/rev.),
Depth of Cut (0.1, 0.2, 0.3
mm)
Rake angle (16, 18, 20)
Nose Radius (0.4, 0.6, 0.8
mm)
Cutting Speed (175, 220, 264
m/min.),
Feed (0.1, 0.2, 0.3 mm/rev.),
DOC (0.5, 1.0, 1.5 mm)

Surface
Roughness

Speed

Feed

Surface
Roughness

Feed

Cuttin
g
Edge
Geom
etry

Surface
Roughness

Speed

DOC

MRR

DOC

Speed

Surface
Roughness

Feed

Depth
of Cut

Surface
Roughness

Feed

Depth
of Cut

Surface
Roughness

Rake
Angle

Nose
Radiu
s

Surface
Roughness

Feed

Speed

The following conclusions have been made on the basis of analysis performed by previous
researchers:

 CNC Turning gives better results, as speed and feed can be set at any value within a
specified range, according to the requirement, compared to a conventional machine in
which only some fixed values can be selected.
Among the input parameters, most researchers analyzed the effect of Speed, Feed and
Depth of Cut, while only a few considered Cutting environment, cutting tool and
work piece material.
Among output parameters, all of the researchers have taken Surface Roughness and
MRR.
Better results have been obtained in terms of DOE techniques such as Taguchi and

RSM using MINITAB software.