There is another article included in this web site called The Basics of CNC that explains how to program, setup, and operate CNC machines in greater detail. Additionally, we offer a series of products aimed at helping you learn how to use CNC machines. Here we're relating how CNC works in very general terms.

As you might already have guessed, everything that an operator would be required to do with conventional machine tools is programmable with CNC machines. Once the machine is setup and running, a CNC machine is quite simple to keep running. In fact CNC operators tend to get quite bored during lengthy production runs because there is so little to do. With some CNC machines, even the workpiece loading process has been automated. (We don't mean to over-simplify here. CNC operators are commonly required to do other things related to the CNC operation like measuring workpieces and making adjustments to keep the CNC machine running good workpieces.)

Let's look at some of the specific programmable functions.

Motion control

All CNC machine types share this commonality: They all have two or more programmable directions of motion called axes. An axis of motion can be linear (along a straight line) or rotary (along a circular path). One of the first specifications that implies a CNC machine's complexity is how many axes it has. Generally speaking, the more axes, the more complex the machine.

The axes of any CNC machine are required for the purpose of causing the motions needed for the manufacturing process. In the drilling example, these (3) axis would position the tool over the hole to be machined (in two axes) and machine the hole (with the third axis). Axes are named with letters. Common linear axis names are X, Y, and Z. Common rotary axis names are A, B, and C.

Programmable accessories

A CNC machine wouldn't be very helpful if all it could only move the workpiece in two or more axes. Almost all CNC machines are programmable in several other ways. The specific CNC machine type has a lot to do with its appropriate programmable accessories. Again, any required function will be programmable on full-blown CNC machine tools. Here are some examples for one machine type.

Machining centers

Automatic tool changer

Most machining centers can hold many tools in a tool magazine. When required, the required tool can be automatically placed in the spindle for machining.

Spindle speed and activation

The spindle speed (in revolutions per minute) can be easily specified and the spindle can be turned on in a forward or reverse direction. It can also, of course, be turned off.

Coolant

Many machining operations require coolant for lubrication and cooling purposes. Coolant can be turned on and off from within the machine cycle.

The CNC program

Think of giving any series of step-by-step instructions. A CNC program is nothing more than another kind of instruction set. It's written in sentence-like format and the control will execute it in sequential order, step by step.

A special series of CNC words are used to communicate what the machine is intended to do. CNC words begin with letter addresses (like F for feedrate, S for spindle speed, and X, Y & Z for axis motion). When placed together in a logical method, a group of CNC words make up a command that resemble a sentence.

For any given CNC machine type, there will only be about 40-50 words used on a regular basis. So if you compare learning to write CNC programs to learning a foreign language having only 50 words, it shouldn't seem overly difficult to learn CNC programming.

The CNC control

The CNC control will interpret a CNC program and activate the series of commands in sequential order. As it reads the program, the CNC control will activate the appropriate machine functions, cause axis motion, and in general, follow the instructions given in the program.

Along with interpreting the CNC program, the CNC control has several other purposes. All current model CNC controls allow programs to be modified (edited) if mistakes are found. The CNC control allows special verification functions (like dry run) to confirm the correctness of the CNC program. The CNC control allows certain important operator inputs to be specified separate from the program, like tool length values. In general, the CNC control allows all functions of the machine to be manipulated.

What is a CAM system?

For simple applications (like drilling holes), the CNC program can be developed manually. That is, a programmer will sit down to write the program armed only with pencil, paper, and calculator. Again, for simple applications, this may be the very best way to develop CNC programs.

As applications get more complicated, and especially when new programs are required on a regular basis, writing programs manually becomes much more difficult. To simplify the programming process, a computer aided manufacturing (CAM) system can be used. A CAM system is a software program that runs on a computer (commonly a PC) that helps the CNC programmer with the programming process. Generally speaking, a CAM system will take the tediousness and drudgery out of programming.

In many companies the CAM system will work with the computer aided design (CAD) drawing developed by the company's design engineering department. This eliminates the need for redefining the workpiece configuration to the CAM system. The CNC programmer will simply specify the machining operations to be performed and the CAM system will create the CNC program (much like the manual programmer would have written) automatically.

What is a DNC system?

Once the program is developed (either manually or with a CAM system), it must be loaded into the CNC control. Though the setup person could type the program right into the control, this would be like using the CNC machine as a very expensive typewriter. If the CNC program is developed with the help of a CAM system, then it is already in the form of a text file . If the program is written manually, it can be typed into any computer using a common word processor (though most companies use a special CNC text editor for this purpose). Either way, the program is in the form of a text file that can be transferred right into the CNC machine. A distributive numerical control (DNC) system is used for this purpose.

A DNC system is nothing more than a computer that is networked with one or more CNC machines. Until only recently, rather crude serial communications protocol (RS-232c) had to be used for transferring programs. Newer controls have more current communications capabilities and can be networked in more conventional ways (Ethernet, etc.). Regardless of methods, the CNC program must of course be loaded into the CNC machine before it can be run.