Course detail

CNC Machining Strategies

FSI-GSC Acad. year: 2027/2028 Summer semester

The course focuses on the design, implementation, and evaluation of CNC machining strategies using CAD/CAM systems, industrial control systems, and specialized metrology equipment. Students gain practical experience in programming machining and measurement systems, as well as in evaluating the quality of machined components.

Programming for the manufacture and quality evaluation of workpieces according to selected machining strategies:

  • shop-floor oriented NC programming based on CAD drawings (Sinumerik),
  • ISO NC programming based on CAD drawings, including canned cycles and parametric programming (Sinumerik, Datron NEXT, etc.),
  • CAM programming based on 3D component models (Autodesk Inventor CAD/CAM),
  • programming of an optical profile projector using DXF files (SOL 311 / InSpec),
  • programming of templates for automated evaluation of surface texture parameters (TH CCI / TalyProfile),
  • CMM programming (Eclipse 1000 / Calypso).

The course integrates knowledge from machine tool design, CNC manufacturing, and industrial metrology into a unified process for the design, implementation, and evaluation of the production of mechanical components.

Component design in a CAD environment is applied through model examples of machined parts, with emphasis on design-for-manufacturing principles and integration with CAM programming. Individual machining strategies are subsequently compared in terms of manufacturing productivity, geometrical accuracy, surface integrity, and the achieved product quality.

Language of instruction

Czech

Number of ECTS credits

4

Supervisor

Ing. Aleš Polzer, Ph.D.

Department

Institute of Production Machines, Systems and Robotics

Entry knowledge

The student is expected to be able to:

  • navigate engineering technical documentation,
  • interpret dimensional and geometrical tolerances according to the ISO GPS system,
  • explain the fundamental principles of metal cutting processes,
  • determine basic cutting conditions,
  • create CAD models of mechanical components and utilize them in manufacturing process planning,
  • explain the basic principles of CNC control systems and the structure of NC programs,
  • be familiar with the fundamental functions of CAD/CAM systems.

Rules for evaluation and completion of the course

Assessment Methods and Criteria

Credit with classification will be awarded based on the results of individually completed assignments (e.g., design, NC programming, and measurement tasks) carried out within tutorials and laboratory exercises.

The final assessment will evaluate both theoretical and practical knowledge acquired during the course through a short written test (5–10 questions) and an individual practical task (30–60 minutes) performed in a CAD, CAM, CMM, or CNC machine control system environment.

Attendance at tutorials and laboratory sessions is compulsory and monitored. Missed tutorial or laboratory sessions may, upon agreement with the instructor, be compensated by completing an individually assigned professional task. A maximum of four unexcused or non-compensated absences per semester is permitted.

Successful completion of the course requires active participation in tutorials, submission of an individual machining and measurement project, successful completion of the final test, and achievement of at least 50 points out of 100.

Assessment Breakdown

  • Active CNC programming and laboratory assignments during the semester: 40 points
  • Individual machining and measurement project: 30 points
  • Final knowledge test: 30 points

Total: 100 points

Grading Scale

  • A: 90–100 points
  • B: 80–89 points
  • C: 70–79 points
  • D: 60–69 points
  • E: 50–59 points
  • F: fewer than 50 points

Aims

Upon successful completion of the course, students will be able to:

  • design CNC machining strategies with respect to productivity, manufacturing accuracy, and surface quality,
  • develop, simulate, and optimize NC programs using industrial control systems and CAM software,
  • design, conduct, and evaluate measurements of geometrical accuracy, geometrical tolerances, and surface texture using coordinate and specialized metrology systems,
  • analyze measurement data, determine the causes of observed deviations, and propose corrective actions to improve product quality,
  • prepare manufacturing process documentation and professionally justify the proposed technological solution.

Study aids

Study materials are available in the BUT Moodle Learning Management System (LMS) and include:

  • lecture and tutorial presentations,
  • laboratory exercise materials,
  • instructional materials for Sinumerik programming,
  • instructional materials for the Datron NEXT system,
  • CAD/CAM datasets for practical assignments,
  • CMM measurement manuals and guidelines.

The study programmes with the given course

Programme N-VSR-P: Production Machines, Systems and Robots, Master's, compulsory-optional

Type of course unit

 

Laboratory exercise

26 hours, compulsory

Syllabus


  1. Basic technological calculations of cutting forces and their application to CNC machine tools (selection of cutting parameters using electronic catalogues, machining calculators, etc.).


  2. Basic technological calculations of cutting forces and their application to CNC machine tools (measurement of workpiece deformation caused by machining force loads using CMM Eclipse 1000 / Calypso).




  3. Cutting tools for machining operations (machine tool design requirements, influence on machining technology, surface texture and workpiece geometry, tool wear analysis using DinoLite / DinoCapture and SOL 311 / InSpec).




  4. Determination of cutting conditions for machining operations (assessment of cutting tool wear using DinoLite / DinoCapture and SOL 311 / InSpec).




  5. Cutting forces, machinability, and workpiece deformation (CMM Eclipse 1000 / Calypso).




  6. Individual machining and measurement project:



    • Design of a CAD model and technological process plan for a component.

    • Development and optimization of an NC program.

    • Simulation and verification of the NC program.

    • Execution of component machining and measurement.

    • Evaluation of component quality and identification of the causes of detected deviations.




  7. Surface texture of a milled workpiece (Surftronic / TalyProfile).




  8. Surface texture of a stratified surface (TH CCI / TalyProfile).




  9. Demonstration of machining and measurement processes.



Computer-assisted exercise

26 hours, compulsory

Syllabus



  1. Classification of workpiece and cutting materials, machinability, workpiece quality, and its measurability (ISO GPS matrix).




  2. Cutting forces in individual machining operations, their analytical calculation, force transmission through the machine tool structure, and the influence of cutting-force action on workpiece quality (brief overview of CNC and CMM machines and instruments).




  3. Methods of tool and workpiece clamping on CNC machine tools, fundamental principles, and their influence on machine and workpiece loading (CNC, SOL 311, TH CCI, Eclipse 1000).




  4. Mechanisms of self-excited vibrations (chatter) in machining and technological methods for their suppression (TH CCI, Eclipse 1000).




  5. Machining strategies for prismatic workpieces on vertical machining centres (Sinumerik, Inventor CAM, Calypso).




  6. Machining strategies for prismatic workpieces on horizontal machining centres (Sinumerik, Calypso).




  7. Machining strategies for prismatic workpieces on gantry machining centres (Sinumerik, Calypso).




  8. Machining strategies for workpieces on multifunctional milling centres (Sinumerik, Calypso).




  9. Machining strategies for rotational workpieces on turning centres with horizontal and vertical spindle axes (Sinumerik, Calypso).




  10. Machining strategies for rotational workpieces on multifunctional turning centres (Sinumerik, Calypso).




  11. Machining strategies on horizontal boring machines (contact and non-contact profile surface texture measurement using TalyProfile).




  12. Machining strategies on grinding machines (areal non-contact surface texture measurement using TH CCI).




  13. Machining, measurement, and quality evaluation strategies for large-scale workpieces.