ME 8462- MANUFACTURING TECHNOLOGY

LAB-II

NAME :

CLASS :

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 SYLLABUS
MANUFACTURING TECHNOLOGY LAB – II

OBJECTIVES:
To Study and acquire knowledge on various basic machining operations
in special purpose machines and its applications in real life manufacture of
components in the industry
STUDY I
STUDY OF MILLING MACHINE & GEAR GENERATION PROCESS
STUDY II
STUDY OF GRINDING MACHINE
STUDY III
STUDY OF CNC MANUAL PART PROGRAMMING
LIST OF EXPERIMENTS:
1. Contour milling using vertical milling machine
2. Spur gear cutting in milling machine
3. Helical Gear Cutting in milling machine
4. Cylindrical grinding
5. Plain Surface grinding
6. Measurement of cutting forces in Turning/Milling Process
7. Gear generation in Hobbing Machine
8. Tool angle grinding with tool and Cutter Grinder
9. Gear generation in Gear Shaping Machine
10. Centerless Grinding Process
11. CNC Part Programming.
BEYOND THE SYLLABUS
1.Centreless Grinding
2. Measurement of cutting forces in Milling Process
OUTCOMES: Upon the completion of this course the students will be able to
CO1 use different machine tools to manufacturing gears
CO2 Ability to use different machine tools to manufacturing gears.
CO3 Ability to use different machine tools for finishing operations
CO4 Ability to manufacture tools using cutter grinder
CO5 Develop CNC part programming
 LIST OF EXPERIMENTS

1. Contour milling using vertical milling machine

2. Spur gear cutting in milling machine

3. Helical Gear Cutting in milling machine

4. Cylindrical grinding

5. Plain Surface grinding

6. Measurement of cutting forces in Turning Process

7. Measurement of cutting forces in Milling Process

8. Gear generation in Hobbing Machine

9. Tool angle grinding with tool and Cutter Grinder

10. Gear generation in Gear Shaping Machine

11. Centerless Grinding Process

12. CNC Part Programming.

 INDEX

S. No. Date Title of Experiment Marks Signature

 SAFETY IN WORK SHOP
SAFETY-INTODUCTION:

Generally accidents do not happen they are caused. Most accidents are available. A good
craftsman, having knowledge of various safety precautions, can avoid accidents to himself
and to his fellow workers and protect the equipment from any advantage. To achieve this, it is
essential that every person should follow safety procedures.

Safety in a workshop can be broadly classified into 3 categories

1. General safety

2. Personal safety

3. Machine safety

SAFETY PRECAUTIONS TO BE OBSERVED IN MACHINE SHOP

General Safety

1. Keep the floor and gangways clean and clear.

2. Move with care in the workshop, do not run.

3. Don’t leave the machine which is in motion.

4. Don’t touch or handle any equipment /machine unless to do so.

5. Don’t walk under suspended loads.

6. Use the correct tools for the job.

7. Never direct compressed air at yourself or at your co-worker.

8. Ensure adequate light in the workshop.

9. Clean the machine only when it is not in motion.

10. Know everything about the machine before you start it.

Personal safety:
 1. Wear a one piece overall or boiler suit.
2. Keep the overall buttons fastened.
3. Wear safety shoes or boots and goggles.
4. Cut the hair short.
5. Don’t wear a ring, watch or chain.
6. Never lean on the machine.
7. Don’t clean hands in the coolant fluid.
8. Don’t remove guards when the machine is in motion.
9. Don’t use cracked or chipped tools.
10. Don’t start the machine until:
1. The work piece is securely mounted
2. The feed machinery is in the neutral
3. The work area is clear.
Machine safety

1. Switch of the machine immediately if something goes wrong.

2. Keep the machine clean.

3. Do not attempt operating the machine until you know how to operate it properly.

4. Do not adjust the stroke, tool or the work piece unless the power is off.

5. Stop the machine before changing the speed.

6. Disengage the automatic feeds before switching off.

7. Check the oil level before starting the machine.

8. Never start a machine unless all the safety guards are in position.

9. Take measurements only after stopping the machine.

10. Use wooden planks over the bed while loading and unloading heavy jobs.
 STUDY I

MILLING MACHINE AND GEAR GENERATION PROCESS

INTRODUCTION

Milling is a process of removing metal by feeding the work against a rotating multipoint

cutter. The machine tool intended for this purpose is known as milling machine.

It is found in shops where tools and cutters are manufactured. The surface obtained

by this machine tool is superior in quality and more accurate and precise.

Eli Whitney designed a complete milling machine in 1818. In the year 1861 Joseph

Brown, a member of Brown and Sharp company developed the first universal milling
machine.

ADVANTAGES AND DISADVANTAGES OF A MILLING MACHINE

ADVANTAGES:

1. The metal is removed at a faster rate as the cutter has got multiple cutting edges and rotates
at a higher speed.

2. It is possible to perform machining by mounting more than one cutter at a time.

3. The table of the machine can be moved to an accuracy of 0.02mm.

4. It is very useful since various cutters and precise tools can be machined.

5. Special attachments can be mounted on the machine to perform operations that are
performed in other machine tools.

6. The quality of the shop is enhanced with the presence of this machine.

DISADVANTAGES:

1. The cost of the milling machine is high.

2. As milling cutters cost high, the investment for procuring tools is more.

3. The production cost will increase if we carry out the operations performed in a shaper or a
drilling machine with a milling machine.
 COLUMN AND KNEE TYPE MILLING MACHINE

Base

It is made of cast iron and supports all the other parts of the machine tool. A vertical column
is mounted upon the base. In some machines, the base serves as a reservoir for cutting fluid.

Column

It is mounted upon the base and is box shaped. It houses the mechanism for providing drive
for the spindle. The front vertical face of the column is machined accurately to form dovetail
guideways for the knee to move up and down. The top of the column holds an overhanging
arm.

Knee

It slides up and down on the guideways of the column. An elevating screw mounted on the
base obtains this movement. Saddle is mounted upon the knee and moves in a cross direction.

Saddle

It is mounted on the guideways of the knee and moves towards or away from the face of the
column. This movement can be obtained either by power or by hand. The top of the saddle
has guideways for the table movement.
Table

The table is moved longitudinally either by power or manually on the guideways of the
saddle. The trip dogs placed on it control the movement of the table. The table of a universal
milling machine can be swiveled horizontally to perform helical works. The top surface of
the table has got ‘T’ – slots on which the workpieces or other work holding devices are
mounted.

Spindle

It is located in the upper part of the column. It receives power from the motor through belt,
gears and clutches. The front end of the spindle has got a taper hole into which the cutters are
held with different cutter holding devices.

Overhanging arm

It supports the arbor from the top of the column. The arbor is supported by the bearing fitted
within the arbor support. It is also useful while using some special attachments.

Front brace
It is an extra support fitted between the knee and the overhanging arm. It is slotted to allow
the knee to be adjusted vertically.

Arbor

It supports the different types of cutters used in the machine. It is drawn into the taper hole of
the spindle by a drawbolt. One or more cutters are mounted on the arbor by placing spacing
collars between them. The arbor is supported by an arbor support. The arbor is provided with
a Morse taper or self-releasing taper.

Vertical milling machine

It is very similar to a horizontal milling machine in construction as it has the same parts of
base, column, knee, saddle and table. The spindle of the machine is positioned vertically. The
cutters are mounted on the spindle. The spindle is rotated by the power obtained from the
mechanism placed inside the column. Angular surfaces are machined by swiveling the
spindle head.

Types of milling machine

The milling machines are classified according to the general design of the machine.

1. Column and knee type

 Plain milling machine

 Universal milling machine

 Omniversal milling machine

 Vertical milling machine

2. Table type milling machine

3. Planer type milling machine

4. Special type milling machine

Fundamental milling processes

The various milling processes may be grouped under two headings:

1. Peripheral milling 2. Face milling

Peripheral milling

The machining is performed by the cutting edges on the periphery of the milling cutter. It is
classified under two headings

1. Up milling 2. Down milling

Up milling

In this method, the workpiece mounted on the table is fed against the direction of rotation of
the milling cutter. The cutting force is minimum during the beginning of the cut and
maximum at the end of cut. The thickness of chip is more at the end of the cut. As the cutting
force is directed upwards, it tends to lift the workpiece from the fixtures. A difficulty is felt in
pouring coolant on the cutting edge. Due to these reasons the quality of the surface obtained
by this method is wavy. This processes being safer is commonly used and sometimes called
conventio
nal
milling.

Down
milling

The workpiece mounted on the table is moved in the same direction as that of the rotation of
the milling cutter. The cutting force is maximum at the beginning and minimum at the end of
cut. The chip thickness is more at the beginning of the cut. The workpiece is not disturbed
because of the bite of the cutter on the work. The coolant directly reaches to the cutting point.
So the quality of surface finish obtained is high. Because of the backlash error between the
feed screw of the table and the nut, vibration is setup on the workpiece.

Face milling and end milling

During face milling, the machining is performed by the peripheral cutting edges. The surface
obtained by the processes is perpendicular to the axis of rotation of the cutter. End milling is
a process of the machining by milling cutters which have cutting edges both on the end face
and on the periphery.

Cutter holding devices

Depending on the design of the cutter, there are several methods of supporting milling cutters
on the machine spindle.

1) Arbor 2) Collet

3) Adapter 4) Screwed on cutters

Standard milling cutters

There are different types of milling cutters used in a milling machine. A suitable milling
cutter is selected according to the need. They are

1. Plain milling cutter

2. Side milling cutter

3. Metal slitting saw

4. Angle milling cutter

5. End milling cutter

6. ‘T’ – Slot milling cutter

7. Fly cutter

8. Formed cutter

Plain milling cutter

Plain milling cutters are cylindrical in shape and have teeth on the circumferential surface
only. They are used for producing flat surfaces parallel to the axis of rotation of the spindle.
The teeth of the cutter may be straight or helical according to the size. If the width of the
cutter is more, it is called as slabbing cutter or cylindrical milling cutter. They have a central
hole in order to be mounted on the arbor. Plain milling cutters have nicked teeth to break the
chips into small pieces. Helical plain milling cutters are superior to a straight plain milling
cutter.
Side milling cutter

Side milling cutters have teeth on its periphery and also on one or both of its sides. They are
intended for removing metal from the sides of the workpiece. There are different types of side
milling cutters namely face and side milling cutter, half side milling cutter, staggered teeth
side milling cutter, and interlocked side milling cutter. Machining is performed by selecting a
proper milling cutter.

Metal slitting saw

It is intended for cutting narrow, deep slots and for parting off operation. The teeth are cut on
the circumference of the cutter. The width of the cutter is limited. The outside diameter of the
cutter will be upto 200mm and width of the cutter ranges from 0.75mm to 7mm. The side of
the cutter is relieved so that the side may not rub against the work.

Angle milling cutter

The teeth of the angle milling cutter are not parallel to the axis but are at an angle to it. By
using angle milling cutter, inclined surfaces, bevels and helical grooves are machined. There
are two types of angle milling cutter – Single angle milling cutter and double angle milling
cutter.

‘T’ – Slot milling cutter

It is a special form of end mills intended for machining ‘T’- slots. It looks like a side milling
cutter with a shank. The cutters have cutting teeth on the periphery as well as on both sides of
the cutter.

End mill

These cutters have cutting teeth on the end as well as on the periphery of the cutter. It is made
of two parts – body and shank. The shanks of the cutter may be straight or taper. If the cutter
doesn’t have a shank it is called shell end milling cutter. These cutters are useful in
machining long narrow slots, holes and flat surfaces.
Fly cutter

Fly cutter is the simplest form of cutter. It consists of a single point cutting tool attached to
the end of the arbor. The cutting edge may be formed to reproduce a contoured surface. They
are used when standard cutters are not available. The work is done very slowly because of a
single cutting edge.

Formed cutter

Formed cutters have irregular profiles on their cutting edges to produce required outlines on
the work. Concave and convex milling cutters are used to produce convex and concave
surfaces respectively. Using gear milling cutters, gears are machined. Corner round milling
cutters are used for cutting a radius on the edges of the work. With the help of thread milling
cutters threads are milled to a specific form and size. Tap and reamer cutters are used for
producing grooves or flutes in taps and reamers.

Milling cutter materials

The milling cutters are generally made of the following materials.

1. Tool steel - High speed steel (HSS)

- High carbon steel (HCS)

2. Cemented carbide

3. Stellite

In general shop work, the high speed steel cutters are most widely used.

Milling machine operations

The following operations are performed using suitable milling cutters.

1. Plain milling 9. Flute milling

2. Face milling 10. Keyway milling

3. Side milling 11. Drilling & reaming

4. Straddle milling 12. Boring

5. Angular milling 13. Gear cutting

6. Gang milling 14. Thread milling

7. Form milling 15. Cam milling

8. End milling
Plain milling

It is the operation of production of a flat surface parallel to the axis of rotation of the cutter. It
is also called as slab milling. Plain milling cutters and slab milling cutters are used to perform
this operation.

Face milling

The face milling is the operation performed by the face milling cutter rotated about an axis at
right angles to the work surface. End mills and side & face milling cutter are also used at
times to perform this operation. The depth of cut is provided to the table.

Side milling

Side milling is the operation of machining a vertical surface on the side of a workpiece by
using a side milling cutter.
Straddle milling

It is the operation of production of two vertical surfaces on both sides of the work by two side
milling cutters mounted on the same arbor. By using suitable spacing collars, the distance
between the two cutters is adjusted correctly. The straddle milling is commonly used to
produce square or hexagonal surfaces.

Angular milling

Production of an angular surface on a workpiece other than at right angles to the axis of the
milling machine spindle is known as angular milling. Example of angular milling is the
production of the ‘V’ blocks.
Gang milling

It is the operation of machining several surfaces of work simultaneously by feeding the table
against a number of cutters (either of same type or of different type) mounted on the arbor of
the machine. This method saves much of machining time and mostly used in production
work.

Form milling

The form milling is the operation of production of irregular contours by using form cutters.
Machining convex and concave surfaces and gear cutting are some examples of form milling.

End milling

It is the operation of producing a flat surface which may be vertical, horizontal or at an angle
to the table surface. The end milling is performed by a cutter known as an end mill. End
milling is mostly performed in a vertical milling machine.
Flute milling

Flute milling is performed by selecting a suitable cutter in a milling machine. The flutes
found on the drills, reamers and taps are machined by this method.

Keyway milling

The operation of production of keyways, grooves and slots of different shapes and sizes can
be performed in a milling machine by using a plain milling cutter, a metal slitting saw, an end
mill or by a side milling cutter.

Drilling and reaming

The operation of drilling and reaming are performed in a milling machine by mounting drills
and reamers into the spindle of the machine.

Boring

A single point cutting tool is mounted on the arbor to perform boring. By adjusting the single
point cutting tool radially, different diameters of bores are machined.

Gear cutting

Gear cutting operation is performed in a milling machine by using a form cutter. The work is
held between centers on a universal dividing head. A proper gear cutter is selected and the
teeth are cut by DP, module method.

GEAR GENERATION PROCESS

Gear is one of the important machine tool elements which is an integral and inevitable part of
power transmission system. A gear is a round blank having teeth along its periphery. Gears
are used to transfer power or torque from prime mover to the place where it is to be used.
Along with the transmission of power gears also transfer the accurate velocity ratio between
two shafts.

Velocity ratio is defined as the ratio of rpm (revolution per minute) of driven shaft to the rpm
of driver shaft. Power is normally transferred with the help of pair of gears in mesh together,
each of these two are mount on driven shaft and driver shaft.

Velocity Ratio = RPM of driven shaft or driven gear

RPM of gear driver shaft or driver

The gear mounted on the driver shaft is called driver gear and an other gear mounted on the
driven shaft is called driven gear. Driver gear and driven gear both constitute a pair of mating
gears, these gears are identical with reference to all parameters except their diameters and
number of teeth. Two gears mating and transferring power and exact velocity ratio are shown
in Figure 6.1. For any pair of malting gears the mandatory condition is their peripheral speed
should be exactly same.

Driver gear RPM = Nd

Driven shaft Driver shaft

Rpm = Nr

Driver Gear

Figure 6.1 : Power Transfer between Driver and Driven Gears

Gear shaping is one of the gear generating methods. In this process gear tooth are
accurately sized and shaped by cutting them by a multipoint cutting tool. Various gear
shaping processes are listed and then described below:

1. Gear cutting by Gear Shaper.

2. Rack planning process.
3. Hobbing process.
 STUDY II

INTRODUCTION TO GRINDING MACHINE

Grinding Machines
Grinding Machines are also regarded as machine tools. A distinguishing feature of
grinding machines is the rotating abrasive tool. Grinding machine is employed to obtain
high accuracy along with very high class of surface finish on the workpiece. However,
advent of new generation of grinding wheels and grinding machines, characterised by their
rigidity, power and speed enables one to go for high efficiency deep grinding (often called
as abrasive milling) of not only hardened material but also ductile materials.

Conventional grinding machines can be broadly classified as:

(a) Surface grinding machine

(b) Cylindrical grinding machine

(c) Internal grinding machine

(d) Tool and cutter grinding machine

2.1 Surface grinding machine:

This machine may be similar to a milling machine used mainly to grind flat surface.
However, some types of surface grinders are also capable of producing contour surface
with formed grinding wheel.

Basically there are four different types of surface grinding machines characterised by
the movement of their tables and the orientation of grinding wheel spindles as
follows:

• Horizontal spindle and reciprocating table

• Vertical spindle and reciprocating table

• Horizontal spindle and rotary table

• Vertical spindle and rotary table

 2.1.1 Horizontal spindle reciprocating table grinder

Figure 2.1 illustrates this machine with various motions required for grinding action. A disc
type grinding wheel performs the grinding action with its peripheral surface. Both traverse
and plunge grinding can be carried out in this machine

A: rotation of grinding wheel B: reciprocation of worktable

C: transverse feed D: down feed
Fig. 2.1. Horizontal spindle reciprocating table surface grinder

Vertical spindle reciprocating table grinder

This grinding machine with all working motions is shown in Fig. 2.2. The grinding
operation is similar to that of face milling on a vertical milling machine. In this machine a
cup shaped wheel grinds the workpiece over its full width using end face of the wheel.
This brings more grits in action at the same time and consequently a higher material
removal rate may be attained than for grinding with a peripheral wheel.
 A: rotation of grinding wheel B: reciprocation of worktable C: down feed of
grinding wheel

Fig. 2.2. Vertical spindle reciprocating table surface grinder

Horizontal spindle rotary table grinder

Surface grinding in this machine is shown in Fig.2.3. In principle the operation is same as
that for facing on the lathe. This machine has a limitation in accommodation of workpiece
and therefore does not have wide spread use. However, by swivelling the worktable, concave
or convex or tapered surface can be produced on individual part

Fig. 2.3. Horizontal spindle rotary table surface grinder

Cylindrical grinding machine

This machine is used to produce external cylindrical surface. The surfaces may be
straight, tapered, steps or profiled. Broadly there are three different types of
cylindrical grinding machine as follows:

1. Plain centre type cylindrical grinder

2. Universal cylindrical surface grinder

 3. Centreless cylindrical surface grinder

Plain centre type cylindrical grinder

Figure illustrates schematically this machine and various motions required for grinding
action. The machine is similar to a centre lathe in many respects. The workpiece is held
between head stock and tailstock centres. A disc type grinding wheel performs the grinding
action with its peripheral surface. Both traverse and plunge grinding can be carried out in
this machine

Fig. 2.4. Plain centre type cylindrical grinder

Universal cylindrical grinder is similar to a plain cylindrical one except that it is more
versatile. In addition to small worktable swivel, this machine provides large swivel of head
stock, wheel head slide and wheel head mount on the wheel head slide.

External centre-less grinder

This grinding machine is a production machine in which outside diameter of the workpiece
is ground. The workpiece is not held between centres but by a work support blade. It is
rotated by means of a regulating wheel and ground by the grinding wheel.

In through-feed centre-less grinding, the regulating wheel revolving at a much lower surface
speed than grinding wheel controls the rotation and longitudinal motion of the workpiece.
The regulating wheel is kept slightly inclined to the axis of the grinding wheel and the
workpiece is fed longitudinally

Fig. 2.5. External centre-less grinder

 STUDY III
MANUAL PART PROGRAMMING FOR CNC MACHINES
AIM:

To study about the important features, programming structures, codes used in manual
part programming.

INTRODUCTION TO PART PROGRAMMING:

In many of the CNC machines the basic concepts of that machine is to control the
motion of the tool by means of set of instructions, which are prepared by the programmer (or)
operator. The set of programming instructions are called the “program” (or) part
programming of CNC machine tool. These instructions control the movement of the tools and
also the machine control features. The part program of a CNC machining centre consists of
the following features.

 Geometry of a given work piece.

 Motion of the tool with respect to the axis.
 Machine auxiliary components controlling features that is (spindle ON, OFF,
coolant on, off).
 Mode of the programming (absolute or incremental)
 Setting the spindle speed, also the direction of the spindle.
 Using tool number and which type of the tool is used for machining and also clear
idea about the tool feed.
 To describe the machine operation by means of the CNC codes. For example (G02
--- circular interpolation).
 The special feature of the CNC part program is the sub-routine calling and return.
The basic purpose of this type of the sub-programs which are used repeated or
more number of items in batch production that are stored in the common
programming number that are every time simply process by means of sub-
programming method in CNC part programming techniques.
 TECHNIQUES OF THE CNC PART PROGRAMS:

The Basic Important step in the concepts of the CNC procedure is the part
programming preparation. This part programming generation process basically depends upon
the machining type (2D or 3D), process type (turning (or) milling, etc) and also the
availability of the system, of the automation techniques,

Which are present in the current industry. Part programming of CNC production machines
comprises the collection of all data required to produce the part, the calculation of a tool path,
along which the machine which could be converted to an acceptable form for a particular
machine control unit.

Different methods can be employed in the preparation of CNC programs depending

on how a particular company has organized in its CNC programming, and also depending on
what additional data processing aids are available.

CNC PART PROGRAMMING METHODS:

 Programming in the planning department of the particular company.

 Programming in the workshop.
 Manual programming.
 Computer-assisted part programming (CAPP).
 Higher level programming languages (CAM software like CAPSMILL, MASTER
CAM, EDGE CAM, etc.,)

INTRODUCTION TO MANUAL NC PROGRAMMING:

In this method the necessary program information is taken directly from the work
piece drawing and set down in the form of program blocks, which are then input to the
control system. Manual programming is suitable only, to develop part programs for 2D.

There are great numbers of companies who exclusively employ manual programming
techniques. If for example, only a few machine tools are used, and if the work performed by
the company is relative or say a company dedicates the use of their CNC equipment to a
limited number of jobs. Once these jobs are programmed, there will be a need to create more
programs.
PROCEDURE FOR MANUAL NC PROGRAMMING:

CAM SYSTEM PROCEDURE:

Creating The Part And Blank Shapes

Performing The Required Operations

Viewing The Tool Path

Generating NC Program

Generating Documents (Cycle Time

Sheet)

PART PROGRAMMING STRUCTURE:

The part program consists of important terms, which are in the form of abbreviations
and expressions that are simply called the codes of the programming.

The four basic terms used in the CNC programming are character, word, block, and
program.

The character is the smallest unit of CNC program. These are the alpha – numerical
program input that consists of digit, letter and symbol. The following figure shows the rule of
the CNC programming character.The next term of the part programming is the word. It is a
combination of alpha – numerical characters, creating a single instruction to the control
system. Normally, each word begins with a capital letter that is followed by a number
representing a program code or the actual value. The typical words indicate the axes position,
feed rate, preparatory commands, miscellaneous functions and many other definitions.
PART PROGRAMMING FORMATS:

The three main important part programming formats are

 Tab sequential format (NC only)

 Fixed format (NC only)
 Word addressing format (NC or CNC).
Only the early control systems use the tab sequential or fixed formats, both of them
disappeared in the modern CNC part programming systems after 1970 onwards.

The word address format is based on a combination of one letter and one or more
digits. In some applications, such a combination can be supplemented by a symbol, such as a
minus sign or a decimal point. Each letter, digit or symbol represents one character in the
program and in the control memory. This unique alpha-numerical arrangement creates, a
word, where the letter is the address, followed by numerical data with or without symbols.
The typical words for example is given below

G00 – Rapid Traverse

G01 – Linear interpolation

G02 – Circular interpolation – clockwise

G03 – Circular interpolation – counter clockwise

G21 – Dimensions are in mm

G28 – Home position

M03 – Spindle ON in clockwise direction

M05 – Spindle stop

M06 – Tool change

M10 – Chuck open

Individual word or instructions grouped together to form sequences of

programming code. Each sequence that will process a series of instructions simultaneously
forms as unit called a sequence block or simply block. The series of blocks arranged in a
logical order that is required to machine a complete part or a complete operation is the part
program also known as a CNC program.
NC PROGRAMMING BASICS:
A NC program comprises a series of commands with which the CNC machine tool is
instructed to manufacture a certain tool. For each machining process on a CNC machine tool,
the NC program has a command with relevant information. These commands are alpha –
numerically coded, i.e. they consist of letters, numbers and characters.

NC PROGRAMMING STANDARDS (ISO):

The ISO-Norm 6983 strives for standardizing the NC – programming of machines in

the production area. This is limited to standardizing certain commands as well the general
structure of a NC – program. CNC control manufacturers have considerable liberty for
incorporating their own NC-commands in their controls. The general structure of an NC-
program according to ISO 6983 is illustrated.

STRUCTURE OF A PROGRAM BLOCK:

Every NC-block consists of a block number, a number of words as well as a specific

control character, which informs the CNC-control that the NC-block has ended.

Z-
N75 G01 F0.3 S1800 T03 M08 LF
10.75

Invisible
Number of the
Word Word Word Word Word Word block ending
NC-block
character

STRUCTURE OF A PROGRAM WORD:

A word consists of address letters and a number with a plus/minus sign. The
definition and sequence are designated in the programming instructions of the CNC-control
systems. Depending on the address letter, the number either pertains to a code or a value.
Example Address Number Definition

N75 N 75 For the address N, 75 is the number of the NC – block.

For the address G, 01 is a code. The NC-command G01

G01 G 01
is “Moving the tool along a straight line at in feed speed”

For the address Z, -10.75 is a value. Corresponding to the

NC command G01 of the preceding NC block example,
Z-10.75 Z -10.75
this means that the tool is to be moved to the position Z =
-10.75 in the current tool co-ordinate system

The form of numerical entry depends on the CNC control. Z -35.5 is an equivalent to
e.g. the same target co-ordinates as Z-035.500. For most CNC controls, the positive sign ‘+’
can be excluded in the NC-program. Generally, three groups of words in an NC - block can
be differentiated.

Additional and switching

G - functions Co-ordinates
functions

G00 F
X
G01 S
Y
G02 T
Z
G54 M

GROUPS OF PROGRAM WORDS:

The sequence of the words in an NC – block is designated as follows:

S.No Address Definition

1 N Block number

2 G G-functions
 3 X, Y, Z Coordinates

Interpolation
4 I, J, K
Parameter

5 F Feed

6 S Speed

7 T Tool position

8 M Additional functions

SEQUENCE OF PROGRAM WORDS:

Block number N:

The block number is the first word in a block and designates it. It can only be
conferred once. The block number has no influence on the execution of the individual blocks
since they are involved in following the order in which they were entered into the control.

G – FUNCTION:

Together with the words for the coordinates, this word essentially determines the
geometric part of the NC program. It consists of the address letter G and a two-digit code.

COORDINATES X, Y, Z:

The coordinates X, Y, Z define the target points that are needed for travel.

INTERPOLATION PARAMETERS I, J, K:

The interpolation parameters I, J, K are e.g. used to define the center of a circle for
circular movements. They are usually entered incrementally.
FEED F:

The speed at which the tool is to be moved is programmed with the function F; the in
feed speed is usually entered in mm/min. For turning, the unit mm/min pertaining to spindle
rotation can also be used.

SPINDLE SPEED S:

This function is for entering the spindle speed. It can be directly programmed in
rotations per minute.

TOOL POSITION T:
The address T together with a numerical code designates a specific tool. The
definition of this address differs according to the control and can have the following
functions:

 Saving the tool dimensions in the tool offset table.

 Loading the tool from the tool magazine.

ADDITIONAL FUNCTIONS M:

The additional functions, also known as auxiliary functions, primarily contain

technical data that is not programmed in the words with address letters F, S, T. These
functions are entered with the address letter M and a two-digit code.

LIST OF G&M CODES:

G – CODES & M – CODES FOR FANUC TURNING:

G–
Function M – Code Function
Code
G00 Rapid transverse M00 Program stop
G01 Linear interpolation M01 Optional stop
Circular interpolation
G02 (clockwise) M02 End of program
Circular interpolation (anti
G03 clockwise) M03 Spindle rotation (cw)
 G04 Dwell M04 Spindle rotation (ccw)
G20 Input in inch M05 Spindle stop
G21 Input in mm M06 Auto tool change
G28 Go to reference M07 Mist coolant on
G40 Cutter compensation cancel M08 Flood coolant on
G41 Compensation left M09 Coolant off
G42 Compensation right M10 Chuck open
G50 Coordinate system setting M11 Chuck close
G70 Finishing cycle M20/21 ATC arm in/out
G71 Stock removal in turning M22/23 ATC arm down/up
G72 Stock removal in facing M24/25 ATC arm clamping
G73 Pattern repeating M32/33 ATC cw/ ccw
G74 Peck drilling M38 Door open
G75 Diameter drilling M39 Door close
G76 Multiple threading cycle M62/63 Aux 1/2 on
G81 Drilling cycle, spot boring M98 Sub program call
Drilling cycle, counter
G82 boring M99 End of sub program
G83 Peck drilling cycle
G90 Turning cycle
G92 Threading cycle
G94 Facing cycle
G98 Feed per minute
G99 Feed per revolution

G – CODES & M – CODES FOR FANUC MILLING:

G–
Function M – Code Function
Code
G00 Rapid transverse M00 Program stop
G01 Linear interpolation M01 Optional stop
Circular interpolation
G02 (clockwise) M02 End of program
G03 Circular interpolation /(anti M03 Spindle rotation (cw)
 clockwise)
G04 Dwell M04 Spindle rotation (ccw)
G20 Input in inch M05 Spindle stop
G21 Input in mm M06 Auto tool change
G28 Go to reference M07 Mist coolant on
G40 Cutter compensation cancel M08 Flood coolant on
G41 Compensation left M09 Coolant off
G42 Compensation right M10 Work clamp
G50 Coordinate system setting M11 Work unclamp
G73 Fast peck drilling M20/21 ATC arm in/out
G84 Tapping cycle M22/23 ATC arm down/up
G85 Boring cycle M24/25 ATC arm clamping
G90 Absolute Command M32/33 ATC cw/ ccw
G91 Incremental command M38 Door open
G92 Set datum M39 Door close
G94 Feed per minute M62/63 Aux 1/2 on
G95 Feed per revolution M70 X mirror ON
G98 Return to initial position M71 X mirror OFF
G99 Return to R point M80 Y mirror ON
M81 Y mirror OFF
M99 End of sub program M98 Sub program call
OTHER FUNCTION:

Code Function
N Sequence number
X, Y, Z, A, B,
Coordinate axis motion command
C
R Arc radius, thread lead
 I, J, K Coordinate values of arc center
F Feed rate thread lead
S Spindle speed

T Tool number, Tool offset number

B Index table
H Designation of offset number
P, X Dwell time

CANNED CYCLE:

A canned cycle or fixed cycle may be defined as a set of instructions inbuilt or stored
in the system memory to perform a sequence of operations. It is a combination of machine
movements that perform machining operations like drilling, milling, boring and tapping. This
cycle simplifies the program by using a single block with a G-code to specify the machining
operations usually specified in several blocks. It is also called as fixed cycle.

The canned cycle can be brought into action with a single command as much to
reduce the programming time and effort. They are used for respective and commonly used
NC operation.

The canned cycles in CNC lathe programs are also called as multiple repetitive cycles,
as these cycles are called, required some computer memory in order to be useful, so the old
NC machines controlled by a punched tape, cannot benefit from them. A CNC control, on the
other hand, is far more complex. It can read evaluate and process information stored in the
memory in both directions.
CANNED CYCLES FOR TURNING AND MILLING OPERATION:
TYPE OF G–
FUNCTION
OPERATION CODE

G71 Rough cutting cycle – horizontal emphasis

Roughing G72 Rough cutting cycle – Vertical emphasis
G73 Pattern repeating roughing cycle
Finishing G70 Finishing cycle for G71, G72 and G 73

Chip breaking G74 Peck drilling cycle in z-axis – horizontal

cycles G75 Peck grooving cycle in x- axis – vertical
Threading cycles G76 Threading cycle – straight or tapered
G81 Drilling cycle
G82 Drilling cycle with dwell
G83 Peck drilling cycle/ deep drill
G84 Right hand tapping cycle
Milling G85 Boring /reaming cycle
G86 Boring cycle
G87 Back boring cycle
G74 Left hand tapping cycle
G76 Fine boring cycle
Ex.No: 1 Date:

CONTOUR MILLING

AIM:
To machine a contour milling to the given module and number of teeth in the given
work piece.

TOOLS AND EQUIPMENTS REQUIRED:

Milling machine, Vernier caliper, Mandrel.

PROCEDURE:
1. The given work piece is taken and checked for its dimension.
2. The work piece is fixed in the jaw
3. The tool fixed in the tool post of the vertical milling machine is allowed to moves
towards the work piece
4. Proper feed should be given in order to obtain the required product.
5. Remove the job and check its dimensional accuracy

RESULT:
Thus the Contour milling is process is done using vertical milling machine.
Ex.No: 2 Date:

SPUR GEAR MILLING

AIM:
To machine a spur gear to the given module and number of teeth in the given work
piece.

Ø
50

Ø18

TOOLS AND EQUIPMENTS REQUIRED:

Milling machine, Vernier caliper, Mandrel.

PROCEDURE:
1. Calculate the gear tooth proportions.
Blank diameter =(Z+2)m
Tooth depth = 2.25 m
Tooth width = 1.5708 m
where,
Z = Number of teeth required
m = module
2. Indexing calculation
Index crank movement = 40 / Z
3. The dividing head and the tail stock are bolted on the machine table. Their axis must be
set parallel to the machine table.
4. The gear blank is held between the dividing head and tailstock using a mandrel. The
mandrel is connected with the spindle of dividing head by a carrier and catch plate.
5. The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.
6. Set the speed and feed for machining.
7. For giving depth of cut, the table is raised till the periphery of the gear blank just touches
the cutter.
8. The micrometer dial of vertical feed screw is set to zero in this position.
9. Then the table is raised further to give the required depth of cut.
10. The machine is started and feed is given to the table to cut the first groove of the blank.
11. After the cut, the table is brought back to the starting position.
12. Then the gear blank is indexed for the next tooth space.
13. This is continued till all the gear teeth are cut.

CALCULATION:

RESULT:
Thus the required gear is machined using the milling machine to the required number
of teeth.
Ex.No: 3 Date:

HELICAL GEAR MILLING

AIM:
To machine a helical gear to the given module and number of teeth in the given work
piece.

TOOLS AND EQUIPMENTS REQUIRED:

Milling machine, Vernier caliper, Mandrel.

PROCEDURE:
1 Calculate the gear tooth proportions.
Blank diameter =(Z+2)m
Tooth depth = 2.25 m
Tooth width = 1.5708 m
where,
Z = Number of teeth required
m = module
2 Indexing calculation
Index crank movement = 40 / Z
3 The dividing head and the tail stock are bolted on the machine table. Their axis must be
set parallel to the machine table.
4 The gear blank is held between the dividing head and tailstock using a mandrel. The
mandrel is connected with the spindle of dividing head by a carrier and catch plate.
5 The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.
6 Set the speed and feed for machining.
7 For giving depth of cut, the table is raised till the periphery of the gear blank just touches
the cutter.
8 The micrometer dial of vertical feed screw is set to zero in this position.
9 Then the table is raised further to give the required depth of cut.
10 The machine is started and feed is given to the table to cut the first groove of the blank.
11 After the cut, the table is brought back to the starting position.
12 Then the gear blank is indexed for the next tooth space.
13 This is continued till all the gear teeth are cut.

CALCULATION:

RESULT:
Thus the required gear is machined using the milling machine to the required number
of teeth.
Ex.No: 4 Date:

GRINDING TO THE REQUIRED ACCURACY BY CYLINDRICAL

GRINDING

AIM:
To perform operation in a cylindrical grinding machine.

TOOLS REQUIRED:
1. Steel rule
2. Vernier caliper
3. Cylindrical grinding machine

PROCEDURE:
1. The given work piece is taken and checked for its dimension.
2. The work piece is fixed in between the live and dead centre is rotated to a much
lower speed in direction opposite to that of grinding wheel.
3. the instead is provided to the movement of grinding wheel head in to work
piece
4. Remove the job and check its dimensional accuracy

RESULT:
Thus the cylindrical job grinding was done to the required accuracy in a cylindrical
grinding machine
Ex.No: 5 Date:

SURFACE GRINDING
AIM:
To grind the workpiece to the given tolerance using surface grinding machine.

TOOLS AND EQUIPMENTS REQUIRED:

Surface Grinding machine and Micrometer.

PROCEDURE:
1. The given workpiece is checked for its initial dimensions.
2. The permanent magnet worktable is cleaned thoroughly.
3. Keep the workpiece over the worktable and push the lever to “ON” position to hold
the workpiece.
4. The required depth of cut is given by raising the table.
5. The reciprocating and cross feed is given to grind the required length and width of the
workpiece respectively.
6. Finally, the finished workpiece is checked for the given dimensions.

RESULT:
Thus the given workpiece is ground to the given tolerance using surface grinding
machine.
Ex.No: 6 Date:

TOOL DYNAMOMETER
LATHE-CUTTING FORCE MEASUREMENT

AIM:

To study about the cut tool dynamometer used in lathe

APPARATUS REQUIRED:

Centre lathe

Lathe tool dynamometer

Junction box

Attachment for the lathe tool dynamometer

PROCEDURE:

1. First a lathe tool dynamometer is attached on a centre lathe in a cross slide.

2. In lathe tool dynamometer is connected to the display unit by electrical
connection.
3. A job is fixed in between two centres
4. A single point cutting tool attached at the end of the tool dynamometer is allowed
to touch again a revolving job
5. The display unit is adjust by fine adjustment screw in such a way that is shows a
zero reading.
6. While the single point cutting tool force the revolving job the display unit given
the value of cutting force in x, y, z direction.
Fx =Turret force

Fy =Feed force

Fz =Cutting force in N

s.no Depth of cut Fx-Turret force/kgf Fy-Feed force/kgf Fz-Cutting

force/kgf

RESULT:

Thus the tool dynamometer is studied in lathe.

Ex.No: 7 Date:

MILLING – CUTTING FORCE MEASUREMENT

AIM:
To measure the cutting forces in milling process using a side milling cutter

APPARATUS REQUIRED:

Horizontal milling machine ii) Side Milling cutter iii) Milling dynamometer

MATERIAL REQUIRED:

MS or CI work piece of required dimensions

PROCEDURE:

The principal difference between the lathe tool dynamometer and the milling dynamometer is
that, in a lathe the tool is stationary whereas in the milling machine the tool is rotating cutter
Hence here the dynamometer sensing unit cannot be fixed to the tool but could be fixed to
the work piece that is stationary
Work piece is kept on a platform which is mounted over four octagonal rings as shown in
figure
The octagonal ring is mounted with a strain gauge for measuring transverse force and one for
measuring radial force.
In total the setup has four octagonal rings place in strategic positions as shown in the figure.
Hence in total there are four strain gauges measuring transverse force and four for measuring
radial force
As the milling process proceeds, forces in all the three directions are measures by summing
up the data from all the strain gauges and taking average

The results are displayed in the force indicator unit of the dynamometer

The experiment is repeated for various feeds, cutting speeds and depth of cuts

The cutting forces in all three directions are tabulated

s.no Depth of cut Fx /kgf Fy /kgf Fz/kgf

RESULT:

Thus the cutting forces involved in milling operation have been measured using a
dynamometer
Ex.No: 8 Date:

GEAR GENERATION IN HOBBING MACHINE

AIM:
To machine a contour milling to the given module and number of teeth in
the given work piece.

TOOLS AND EQUIPMENTS REQUIRED:

Gear hobbing machine, Vernier caliper.

PROCEDURE:
1. Calculate the gear tooth proportions.
i. Blank diameter =(Z+2)m
ii. Tooth depth = 2.25 m
iii. Tooth width = 1.5708 m
2. where,
i. Z = Number of teeth required
ii. m = module
3. Indexing calculation
i. Index crank movement = 40 / Z
4. The cutter is mounted on the arbor. The cutter is centred accurately with
the gear blank.
5. Set the speed and feed for machining.
6. For giving depth of cut, the table is raised till the periphery of the gear
blank just touches the cutter.
7. The micrometer dial of vertical feed screw is set to zero in this position.
8. Then the table is raised further to give the required depth of cut.
9. The machine is started and feed is given to the table to cut the first groove
of the blank.
10.After the cut, the table is brought back to the starting position.
 11.Then the gear blank is indexed for the next tooth space.
12.This is continued till all the gear teeth are cut.

CALCULATION:

RESULT:
Thus the required gear is machined using the gear hobbing machine to the required
number of teeth.
Ex.No: 9 Date:

TOOL ANGLE GRINDING WITH TOOL AND CUTTER GRINDER

AIM:
To perform tool angle grinding operation with tool and cutter grinding machine.

TOOLS REQUIRED:
1. Steel rule
2. Vernier caliper
3. Tool and cutter grinding machine

PROCEDURE:
1. The given work piece is taken and checked for its dimension.
2. The work piece is fixed in between the live and dead center is rotated
to a much lower speed in direction opposite to that of grinding wheel.
3. The instead is provided to the movement of grinding wheel head in to
work piece
4. Remove the job and check its dimensional accuracy

RESULT:
Thus the tool angle grinding was done to the required accuracy in a tool and cutter
grinding machine
Ex.No: 10 Date:

GEAR GENERATION IN GEAR SHAPING MACHINE

AIM:
To generate gear using gear shaping machine to the given module and
number of teeth in the given work piece.

TOOLS AND EQUIPMENTS REQUIRED:

Gear generation machine, Vernier caliper.

PROCEDURE:
1. Calculate the gear tooth proportions.
i. Blank diameter =(Z+2)m
ii. Tooth depth = 2.25 m
iii. Tooth width = 1.5708 m
2. where,
i. Z = Number of teeth required
ii. m = module
3. Indexing calculation
4. Index crank movement = 40 /Z
5. The cutter is mounted on the arbor. The cutter is centred accurately with
the gear blank.
6. Set the speed and feed for machining.
7. For giving depth of cut, the table is raised till the periphery of the gear
blank just touches the cutter.
8. The micrometer dial of vertical feed screw is set to zero in this position.
9. Then the table is raised further to give the required depth of cut.
10.The machine is started and feed is given to the table to cut the first groove
of the blank.
 11.After the cut, the table is brought back to the starting position.
12.Then the gear blank is indexed for the next tooth space.
13.This is continued till all the gear teeth are cut.

CALCULATION:

RESULT:
Thus the required gear is machined using the gear shaping machine to the required
number of teeth.
Ex.No: 11 Date:

CENTERLESS GRINDING
• Centerless grinding is the process of continuously grinding cylindrical
surfaces, in which the work piece is not supported by centers or chucks
but by a resting blade

• The work piece is ground between two wheels

• The larger grinding wheel does the grinding while the smaller regulating
wheel does not contribute to the material removal process

• The schematic of the Centerless grinding process is shown below

•
• Centerless grinding setup

• The regulating wheel is tilted at an angle i, which in turn regulates the

velocity of axial movement of the cylindrical work piece

•
• Centerless grinding wheels & work piece position
• The relative position of the wheels and the work piece, along with the
inclination of the regulating wheel is shown above

• There are three velocities involved in the above setup. They are

• Velocity of the Grinding wheel, Vg

• Velocity of the regulating wheel, Vr

• Velocity of Feed / axial movement of the work piece against the wheels,
Vf
• The relationship of these three velocities is shown by the following self-
explanatory velocity triangle

Velocity Triangle

• Centerless grinding can be internal or external, traverse feed or plunge

grinding
• But anyway, external is the most common type of Centerless grinding
• Centerless grinding is most suited for mass production and a Centerless
grinding machine is shown below

Centerless Grinding Machine

• The main disadvantage of Centerless grinding process is that, it requires

specialised machinery which can perform no other task
Ex.No: 12 Date:

NC PART PROGRAM FOR FACING, TURNING AND STEP TURNING

AIM:

To write a program and simulate the tool path for the operation involved in the
component as given in the figure using FANUC turning software.

MATERIAL REQUIRED:

Material : Aluminium

Size : Diameter 25mm and Length 70mm

PROGRAM CODE:

[BILLET X25 Z70; (Work piece size of 60mm diameter 150mm length)
G21 G98 G40; (Input in mm, Cutter compensation cancel, Feed per minute)
G28 U0 W0; (Go to reference 0, 0)
G50 S2000;
M06 T01; (Tool change and select tool T0101 from tool kit)
M03 S1200; (Spindle rotates at the speed of 1200 Rpm in clockwise direction)
G00 X26 Z1; (Move tool to 26mm in X axis and 1mm in Z axis from its position)
G90 X24 Z-20 F45; (By turning operation remove 1mm for the length 20 mm)
X23;
X22;
X21;
X20;
X18;
X17;
X16;
X15;
X14;
X13;
X12;
X11;
X10;
M05
;
G28
U0
W0;
M30
;
RESULT:

Thus the manual part program was written to the given dimensions and executed in
CNC
Lathe.
Ex.No: 13 Date:

NC PART PROGRAM FOR RECTANGULAR POCKETING

AIM:

To write a program and simulate the tool path for the operation involved in the
component as given in the figure using FANUC milling software.

MATERIAL REQUIRED:

Material : Aluminum
Size : 90 X 90 X10 m m, Depth of cut -3mm
PROGRAM CODE:

BILLET SIZE 90 X90 X10 mm , Depth of cut - 3mm

G21 G94

G91 G28 Z0
G28 X0 Y0
M06 T01
M03 S1000
G90 G0 X50 Y50
Z10
G172 I40 J30 K0 P0 Q1 R0 X30 Y35 Z-2
G173 I0 K0 P90 S1200 T01 R25 F100 B1500 J200
G0Z10
G91 G28 Z0
G28 X0 Y0
M05
M30
RESULT:

Thus the program for given component drawing was written and checked using
FANUC Milling simulator

VIVA QUESTIONS

1. How do you define tool life?

The time period between two consecutive resharpening, with which the cuts
the material effectively is called as tool life.

2. What is tool signature?

The various angles of tools are mentioned in a numerical number in particular

order. That is known as tool signature.

3. Explain the nose radius?

Joining of side and end cutting edges by means of small radius in order to
increase the tool life and better surface finish on the work piece.
4. What are all conditions for using positive rake angle?

o To machine the work hardened materials.

o To machine low strength ferrous and non-ferrous metals.
o To machine long shaft of small diameters.
o To machine the metal blow recommended cutting speeds.

5. Define – Rake surface and Flenk surface.

The surface along which the chip moves upwards is called Rake angle and the
other surface which is relieved to avoid rubbing with the machined surface is called
Flank surface.

6. Define - Rack angle and clearance angle.

The angle between the rake surface and the normal is known as Rake angle,
and the angle between the flank and the horizontal machined surface is known as the
relief or clearance angle.

7. Name the two systems used in metal cutting to designate the tool shape:

American standards Assosiation. Orthoganal rake system

8. List out the various milling operations?

1. Plain or slab milling. 2. Face milling.3.Angular milling.4.Gang milling.

5. End milling.6.Gear cutting.

9. What does term indexing mean?

Indexing is the process of dividing the periphery of a job into equal number of
divisions.

10. List the various type of milling attachment?

1. Vertical milling2.Universal milling3.High speed milling4.Rotary

11. What are the advantages of gear planning process?

Any given module can be cut using a single cutter.

 The rate of production is higher when compared to forced cutter method. It is
a simple flexible and accurate method of generating gears.

12. What are the limitations of gear hobbing?

1. Internal gears cannot be generated.2.Hobbing process cannot be applied

very near to shoulders

13. State the purpose of grinding?

1. To remove small amount of metal from work pieces & finish then to close
tolerances.

2. To obtain the better surface finish.

The machining accuracy of holes produce by this machine tool lies within a
range of 0.0025 mm.

14. Define the term “grade” used in grinding wheel?

Grade or hardness indicates the strength with which the bonding material
holds the abrasive grain in the grinding wheel.

15. What is meant by dressing &truing?

The process of loading &breaking away the glazed surface so that new sharp
abrasive particles are again present to work for efficient cutting is called dressing.

Truing is a process of trimming the cutting surface of the wheel to run true with the
axis.

16. What is process of lapping?

Lapping is a surface finishing process used for producing geometrically

accurate flat, cylindrical &spherical surfaces.

17. What are the three types dividing heads?

1. Plain or simple.2.Universal3.Optical

18. What are the other forming methods for manufacturing gears?
 1. Gear cutting by single point form tool.2.Gear cutting by shear speed shaping
process.

3. Gear broaching.4.Template method.5.Gear milling using a formed end mill.

19. List the gear generating process?

1. Gear shaping process.2.Gear planning process.3.Gear hobbing process.

20. Mention the applications of gear shaping process?

1. Gear shaping used for generating both internal & external spur gears.

2. Helical gears can also be generated using special attachments.

21. What are the limitations of gear hobbing?

1. Internal gears cannot be generated.

2. Hobbing process cannot be applied very near to shoulders.

22. What are the advantages of gear planning process?

1. Any given model can be cut using a single cutter.

2. It is a simple flexible &accurate method of generating gears.

23. List the various gear finishing processes?

1.Gear shaving. 2.Gear burnishing.

2.Gear grinding.4.Gear lapping.

24. How the centre less grinder operates?

The centre less grinder operates with two wheels as the cutting wheel, to
remove the excess stock and a regulating wheel which is used to control the speed of
rotation of the work and the rate of feed.

25. What are the advantages of centre les grinding?

The work pieces are suppressed through the wheels

 No tendency for chatter and deflection of the work piece. Easy size control of the
work.

No need of chucking or mounting of the work piece.

26. What are the limitations of gear hobbing?

1. Internal gears cannot be generated.

2. Hobbing process cannot be applied very near to shoulders.

27. What does term indexing mean?

Indexing is the process of dividing the periphery of a job into equal number of
divisions

28. Define numeraical control machine

Numerical control machine cane be defined as a form of programmable

machine in which the process are controlled by a program of numbers, letters, and
symbols.

29. What is NC part programming?

NC part programming is the step by procedure of by which the sequence of

processing steps to be performed on the NC machine is controlled by a program of
numbers, letters, and symbols.

30. What is APT language?

APT [automated programming language]is a computer program, it

automatically calculates the tool path, generates program and controls the machine by
receiving general high level languages.

31. What is CNC?

CNC is system consists of a computer, controller and a NC machine tool. Computer is

used to store and edit the program. Controller controls the tool path based on the program.

32. What is meant by machining centre?

 The machining centre is CNC system with automatic tool changing
arrangement that is designed to perform a verity of machining operations, with large
number of cutting tools.

33. What is part program?

Part program is a high level language containing the instructions for

machining a part to various standard words, codes and symbols.

34. What is post processing?

Post processing is a computer program that takes a generalized part program

output and adopts it to a particular machine control unit and machine tool
combination. It is the basic intelligence required to change the program into computer
language.

35. Write the order of instructions in a part program.

Preparatory functionFeed functionTool functionEnd of block

36. What is manual part programming?

Manual part programming is a process of writing programs which consists of a

set of instructions [contains codes, symbols and numbers] to carry out the machining
of the work.

37. What is preparatory function?

It is word address format represented by the letter G, Followed by a numerical

code for the operation of the control unit to instruct the machine tool.

38. What is canned cycle?

Canned cycle simplifies and shortens the programming in such way whenever
any one of the operation is required.

39. What are the major areas to be considered in the design of NC machine tools?

i.Machine structure and frame ii.Location of transduceriii.Slideways

 iv.Elements of transmission and positioning of sliders v.Spindles vi.Tool
holding arrangements

40. What is meant by Machine datum?

It is the origin of the co-ordinate system with the lathe. It is on the mounting
flange of the main spindle and the turning axis. It cannot be changed by the user of the
machine. It is fixed by the manufacturer and programmed into the computer. The
point generally has the coordinates X=0, Z=0

41. What is a canned cycle?

A canned cycle is a combination of machine moves that performs any one

particular machining function such as drilling, milling, boring, tapping, dwell etc.,

42. What is zero suspension?

All CNC machines are equipped with the decimal point input. In order to
simplify program input the leading zero can be omitted. Ex. 12.145 instead of
0012.145

Consecutive zeros after decimal point need not be entered 12 instead of 12.000 and

10.4 Instead of 10.4000

43. Why is the tool nose compensation important?

The carbide insert used in turning operation has a certain corner radius and the carbide tip
tool will break or melt when working. These radii are standardized according to ISO.

44. Explain subroutines.

Program sections required more than one can be defined as subroutines and
stored in the control. They can be called several times in part programs. Geometric
values, feed rates, spindle speeds etc., are defined in subroutines as parameters. These
parameters are assigned actual values before the subroutines are called making it
possible to adopt dimensions and technological data to the actual work piece. A
typical application for subroutines is the machining of similar parts with different
dimensions.
45. What do you mean by machining cycles?

Machining cycles are technology based subroutines for often needed machining
operations such as deep hole drilling, pocket milling etc., in modern CNC systems standard
cycles are available for various types of drilling/boring and milling patterns. The machining
cycles are programmed in the usual NC programming language.

46. What are the steps involved in part programming?

Selecting the coordinate values i.e., Absolute or incremental mode

Selecting units of dimensions

i.e., inches or metric, spindle speed and tool number if necessary

Preparing a program sheet where each block will contain the sequence
number, details of operation and basic information such as preparatory feed codes,
feed rate, miscellaneous M code

47. List some of the canned cycle and mention its use

G81 – Drill cycle G82 – Dwell cycle G79 – Basic mill cycle

G83 – Peck drill cycle G85 – Bore cycle G80 – Cancel Cycle

48. What is the roll of computer in computer in computer aided part programming

Input translation Arithmetic calculations Cutter offset compensators

Post processors