What Is CNC Machines – Complete guide – history and how it work

What Is CNC Machines?

Machining is a process that transforms raw materials into desired shapes and precise dimensions through various methods such as turning, milling, planing, grinding, boring, drilling, electrical discharge machining, shearing, bending, and laser cutting. The equipment used for these processes is referred to as machine tools.

Traditional machining involves manual operation of conventional machine tools. Operators manually manipulate mechanical tools to cut metal and use tools like calipers to measure product accuracy.

Building upon conventional machine tools, computer numerical control (CNC) technology has been introduced, giving rise to CNC machine tools. CNC machine tools can automatically carry out machining operations based on pre-programmed instructions, a process known as CNC machining.

CNC, short for Computer Numerical Control, relies on computerized numerical control to automate machine tool operations.

Firstly, a program is written using a computer, and then this program is inputted into the machine. The program specifies the machine’s movement sequence, path, range, and speed parameters, enabling the machining of raw materials into semi-finished or finished parts, thereby achieving automated production.

Essentially, a CNC machine tool functions as a large-scale automatic carving and cutting machine. By pre-setting the desired shapes and parameters on a computer, the machine tool can execute tasks automatically according to instructions, enabling computer-controlled production without manual intervention.

History Of CNC Machines?

During the early stages of its development in the early 15th century, thread lathes and gear cutting machines began to emerge to manufacture clocks and weapons. Concurrently, hydraulic-powered boring machines for cannons also made their appearance.

In the Ming Dynasty during the Wanli era, Song Yingxing’s “Tiangong Kaiwu” recorded the structure of grinding machines, describing a method involving a foot pedal to rotate an iron disc and using sand and water to cut jade.

The Industrial Revolution sparked the emergence and improvement of various types of machine tools, including planers, horizontal milling machines, cylindrical grinders, coordinate boring machines, and thread grinders. For instance, in 1774, Wilkinson invented the world’s first true boring machine, and in 1797, Henry Maudslay, often regarded as the “Father of the British Machine Tool Industry,” manufactured the first screw-cutting lathe.

It’s worth mentioning that during Maudslay’s continuous improvements to the lathe, by 1800, he replaced the triangular iron bar frame with a more robust cast-iron bed and utilized idle wheels and interchangeable gear pairs to cut threads of different pitches without changing the lead screw. This laid the groundwork for modern lathes and held significant historical importance.

By the late 19th to early 20th century, the singular lathe gradually evolved into milling machines, planers, grinders, drilling machines, and other major machine tools, laying the foundation for mechanized and semi-automatic production in the early 20th century.

In the three decades preceding the mid-20th century, mechanical manufacturing technology entered the era of semi-automation, with hydraulic and electrical components being applied to machine tools and other machinery.

In 1951, the world’s first numerically controlled machine tool (a milling machine) was born, marking a significant advancement in machining technology.

Types of CNC Machines

There are numerous varieties and specifications of CNC machine tools, and the classification methods vary. Here’s a brief overview of the classification of CNC machine tools:

1. Based on the number of controlled axes:
   • 3-axis CNC machines: Control movement along three axes – X, Y, and Z.
   • 4-axis CNC machines: In addition to X, Y, and Z, control rotation around one additional axis, often referred to as the A-axis.
   • 5-axis CNC machines: Control movement along X, Y, and Z axes, plus rotation around two additional axes (A and B axes), allowing for more complex machining operations.
2. According to the type of motion control:
   • Cartesian coordinate CNC machines: Movement controlled along linear X, Y, and Z axes.
   • Polar coordinate CNC machines: Motion controlled using polar coordinates, suitable for rotational and circular machining operations.
3. By the type of machining operation:
   • Milling machines: Used for cutting and shaping solid materials using rotary cutters.
   • Turning machines: Used to create cylindrical parts by rotating the workpiece while a cutting tool moves in a linear motion.
   • Grinding machines: Employed for abrasive machining processes to achieve high surface quality and precision.
   • Drilling machines: Utilized for creating holes in workpieces using rotating drill bits.
4. Based on the level of automation:
   • Fully automated CNC machines: Operate without manual intervention once the program is initiated.
   • Semi-automatic CNC machines: Require occasional manual intervention for setup or monitoring during operation.
5. By industry application:
   • CNC machining centers: Versatile machines capable of performing various machining operations, commonly used in industries such as aerospace, automotive, and mold-making.
   • CNC lathes: Specialized for turning operations and used extensively in manufacturing cylindrical components.
   • CNC routers: Primarily used for woodworking, cutting, and engraving operations in industries like furniture manufacturing and signage production.

These are just a few classification methods used to categorize CNC machine tools based on different criteria, providing flexibility in choosing the right machine for specific machining requirements.

Famous Brands Of CNC Machines

Yamazaki Mazak Corporation (MAZAK) – Japan (Established in 1919)

Yamazaki Mazak Corporation (MAZAK) is a globally renowned machine tool manufacturer founded in 1919. The company produces various types of machine tools, including CNC lathes, composite machining centers, vertical and horizontal machining centers, as well as CNC laser systems. Mazak is known for its high speed and precision in the industry and is a key supplier to companies such as Boeing and Russian defense industries.

GF AgieCharmilles CNC Machining Center – Switzerland (Established in 1802)

The Swiss GF AgieCharmilles Group is renowned for the finesse and precision of its products. Whether it’s EDM (Electrical Discharge Machining) machines or milling machining centers, performance, accuracy, and reliability are prioritized, with a commitment to meeting customer demands and machining requirements. At the upcoming CIMT2009 exhibition, we will focus on aerospace, tool and mold manufacturing, and medical devices.

The GF Group operates primarily in three core businesses: piping systems, automotive products, and AgieCharmilles precision machine tools.

GF is divided into three divisions: GF Piping Systems, GF Mold Solutions, and GF Machining Solutions. Established in 1802 and headquartered in Switzerland, the company has branches in 34 countries, with 137 companies, including 59 production facilities. In 2020, sales amounted to CHF 3.18 billion. Particularly in fluid and gas transportation, lightweight casting components, and high-precision manufacturing technology, GF is the preferred partner for global clients.

GROB CNC Machining Center – Germany (Established in 1926)

Global Industry Status: GROB holds an undisputed global leadership position in the manufacturing of automotive powertrain components.

GROB Group is a family-owned enterprise operating worldwide, headquartered in Mindelheim, Germany, with three overseas production facilities in São Paulo, Brazil, Brummen, USA, and Dalian, China. GROB GmbH, headquartered in Mindelheim, Germany, is a globally renowned manufacturer of machine tools and production lines. Whether it’s standard machine tools, complex production systems, assembly units on cutting lines, or fully automated assembly lines, GROB’s processes and technologies are always at the forefront.

Dürr Maier Jig Grinders CNC Machining Center – Germany (Established in 1870)

DMG MORI is an international brand in the machine tool industry, formed through the consolidation of four prominent machine tool companies: Deckel, Maho, Gildemeister, and Mori Seiki. It combines the traditional, precision, and cutting-edge technologies of both German and Japanese machine tool manufacturing. Deckel is renowned for its lathe brand, Maho for milling machines, and Gildemeister for its expertise in both lathe and milling machine production, as well as its exceptional marketing strategies. Gildemeister, founded in Germany in 1870, has been listed on the stock exchange since 1949. In 1994, the company acquired DECKEL (Deckel) and MAHO AG (Maho), leading to the creation of the globally acclaimed “DMG” brand in the machine tool industry. Subsequently, the integration of the German Dürr Maier Jig Grinders and the Japanese Mori Seiki Corporation occurred. This collaboration between German manufacturing (DMG with 143 years of history) and Japanese manufacturing (MORI SEIKI with 65 years of history) formed the new global leader in CNC machine tools – DMG MORI.

Makino CNC Machining Center – Japan (Established in 1937)

Industry Status: Makino is a leading manufacturer of CNC milling machines and machining centers globally, renowned for its precision and innovation.

As one of the earliest producers of CNC milling machines and machining centers in Japan, Makino has earned an excellent reputation in the precision mold and component manufacturing sectors. Its product range spans from three-axis to five-axis machines, available in both vertical and horizontal configurations, catering to a wide spectrum of machining needs from micro to large-scale applications.

In recent years, Makino has further developed a series of high-precision, high-speed five-axis machining centers to meet market demands. These machines offer precision and accuracy comparable to three-axis machines, even the larger iQ500 model breaking new ground by ensuring high precision within micrometer-level requirements.

Haas CNC Machining Center – United States (Established in 1909)

Global Industry Status: Leader in the global market for small to medium-sized machine tools

Haas Automation, Inc. is one of the largest CNC machine tool manufacturers globally, with its primary manufacturing base located in Oxnard, California. As early as 2006, Haas CNC machine tools were producing over 12,500 units annually, marking a milestone in the CNC machine tool industry. Despite Japan’s technological advancements surpassing the United States in the 1970s and 1980s, the U.S. remains at the forefront of the world’s machine tool industry. Throughout the 20th century, the U.S. consistently led in machine tools, and despite Japan’s advancements, the U.S. maintained its prowess. With a renewed emphasis on machining in the 21st century, the U.S. has regained technological ground, at least matching Japan’s level of excellence. Representative machine tool companies in the U.S. include Gleason (a leader in gear manufacturing), Haas (specializing in CNC machine tools), and Hardinge (known for lathes and workholding equipment).

What Is The Cost Of a CNC Machine

There are five crucial elements influencing CNC machine prices, providing insights to help you navigate the complexities of selecting the right machine for your needs while staying within budget.

1. Machine Type: The nature of the CNC machine’s task, such as cutting, shaping, or metalworking, significantly influences its price. Machines tailored for metalwork often come with a higher price tag. It’s crucial to define the specific job requirements to avoid overspending.
2. Size and Capacity: The dimensions and capabilities of the machine play a pivotal role in determining its cost. Larger machines designed for handling sizable workpieces generally incur higher costs. Additionally, factors like precision and cutting efficiency contribute to pricing variations. Assess your requirements and financial constraints when selecting a machine.
3. Brand Reputation and Quality: The reputation and quality standards of the manufacturer are paramount considerations. Established brands may command higher prices, yet they typically offer superior support and durability. Conduct thorough research on the manufacturer’s reputation to gauge the value proposition against the cost.
4. Features and Technological Advancements: Modern CNC machines are equipped with an array of features, such as automatic tool changers and advanced control systems, which elevate their price points. It’s essential to evaluate the necessity of these features for your specific tasks and weigh their value against the increased cost. Generally, machines with more advanced features and technology command higher prices.
5. Customization Options: Certain CNC machines offer customization options to cater to unique requirements, albeit at an additional cost. Consider whether the customization aligns with your work needs and justifies the increased expenditure.

Below is usual price of different kinds of CNC Machines

CNC Milling Machines:

• Entry-level: Typically priced between $10,000 and $30,000, catering to small to medium-sized businesses.
• Mid-range: Ranging from $30,000 to $100,000, offering enhanced capabilities and precision.
• High-end: Advanced models ranging from $100,000 to $500,000, featuring cutting-edge technology and high productivity for large-scale manufacturing.

CNC Lathe Machines:

• Entry-level: Generally priced between $10,000 and $30,000, suitable for basic turning work.
• Mid-range: Priced from $30,000 to $100,000, providing increased versatility for complex turning tasks.
• High-end: With prices ranging from $100,000 to $500,000, excelling in precision and versatility.

CNC Router Machines:

• Entry-level: Priced between $5,000 and $20,000, suitable for small businesses and hobbyists.
• Mid-range: Ranging from $20,000 to $75,000, equipped with additional features for larger projects.
• High-end: Advanced models costing from $75,000 to $200,000, featuring cutting-edge capabilities for industrial use.

CNC Plasma Cutting Machines:

• Entry-level: Typically priced between $10,000 and $30,000, suitable for small to medium-sized metal fabrication businesses.
• Mid-range: Ranging from $30,000 to $100,000, offering improved precision and cutting abilities.
• High-end: With prices from $100,000 to $500,000, providing exceptional precision for demanding metal cutting tasks.

CNC Laser Cutting Machines:

• Entry-level: Costing from $20,000 to $50,000, suitable for precise cutting of materials like metal, plastic, and wood.
• Mid-range: Priced between $50,000 and $200,000, offering advanced laser cutting capabilities and versatility.
• High-end: Top-tier models priced at $200,000 or more, equipped to handle complex and highly precise cutting across various materials.

Advantages And Disadvantages Of CNC Machine

CNC machine tools possess the following advantages:

1. High Precision Machining Capability: Utilizing digital control systems to achieve position control and precise machining parameter settings ensures the quality and accuracy of component machining.
2. Enhanced Production Efficiency: Automation reduces labor and time, while the high precision machining capability minimizes debugging and wear, thereby increasing production efficiency. Automated processing of multiple steps further enhances efficiency.
3. Flexibility and Adaptability: Different programs and parameters can be preset according to processing requirements, making them suitable for machining components of various shapes and sizes.
4. Stable Machining Quality: The digital control system ensures accurate control of machining parameters and processes, avoiding the influence of human factors on machining quality and ensuring the consistency and stability of components.
5. Energy Efficiency and Environmental Protection: Reduced emissions of exhaust gases, wastewater, and waste residue, coupled with lower energy consumption, result in minimal environmental pollution, aligning with modern energy-saving and environmental protection requirements.

Disadvantages of CNC Machines

A. Initial Setup and Programming Time: Despite their advantages, CNC machines require initial setup and programming, which can be time-consuming, especially for complex parts or new projects. This setup time may impact overall production schedules and efficiency.

B. Cost of Equipment and Maintenance: The initial investment in CNC equipment can be significant, and ongoing maintenance costs should also be considered. Regular maintenance is essential to ensure optimal performance and longevity of the machines, adding to the overall cost of ownership.

C. Skill Requirement for Operation and Programming: Operating and programming CNC machines require specialized skills and training. Skilled operators and programmers are needed to maximize the capabilities of CNC equipment, and the shortage of qualified personnel can be a limitation for some manufacturers.

Future Trends in CNC Technology:

As technology continues to advance, several trends are shaping the future of CNC machining:

1. Integration of Artificial Intelligence (AI) and Machine Learning: AI-driven CNC systems can optimize machining processes, predict tool wear, and adjust parameters in real-time to improve efficiency and quality.
2. Enhanced Connectivity and Data Analytics: IoT-enabled CNC machines can communicate with other manufacturing systems, enabling data collection, analysis, and remote monitoring for predictive maintenance and performance optimization.
3. Additive Manufacturing Integration: The integration of additive manufacturing (3D printing) with CNC machining allows for hybrid manufacturing processes, enabling the production of complex parts with improved efficiency and reduced material waste.
4. Improved Precision and Surface Finish: Advancements in machine design, tooling, and control systems are leading to higher precision and better surface finish in CNC machining, expanding the range of applications, especially in industries such as aerospace and medical devices.
5. Sustainable Manufacturing Practices: CNC technology is evolving to support sustainable manufacturing practices, such as energy-efficient operations, recycling of materials, and optimization of cutting parameters to minimize environmental impact.

Conclusion

CNC machines have revolutionized manufacturing with their precision, speed, and versatility. From their inception in the 1940s, they have advanced to become indispensable in industries such as aerospace, automotive, and medical. CNC technology enables the production of complex parts with high accuracy, reducing human error and improving efficiency. As technology continues to evolve, integrating AI and IoT, CNC machines will become even more powerful, offering greater productivity and cost savings. Understanding how CNC machines work and their history is key to staying competitive in modern manufacturing.

Final Thoughts

CNC (Computer Numerical Control) machines have revolutionized the manufacturing industry since their inception in the 1950s. They use computer programs to control the movement of machine tools, enabling high precision and efficiency. From the early days of CNC milling and turning to today’s multi-axis complex machining, CNC technology has significantly improved production speed and accuracy.

As a professional with 15 years of CNC machining service experience, I’ve witnessed the continuous evolution and application of CNC technology. For example, at Ultirapid, we successfully provided high-precision engine components for aerospace clients. By optimizing machine parameters, we reduced machining time by 30% while maintaining stringent tolerance requirements. With extensive experience, our company offers tailored CNC solutions that ensure high-quality results and efficiency for our clients.