LABORATORY WORK REPORT OF 3D SCANNER

WITH MILLING MACHINE FANUC SYSTEM PROCESS

Arranged By:
NAME : M. Alan wijaya

NIM : D20A153005

MECHANICAL ENGINEERING DEPARTMENT

WUXI INSTITUTE OF TECHNOLOGY
WUXI JIANGSU PROVINCE P.R. CHINA
2019

i
 VALIDATION PAGE

This practical report of Laboratory Work has been checked, accepted and
legalized by supervisor, knowing by Head of Mechanical Engineering Department
Wuxi Institute of Technology and Head of Mechanical Engineering Department
Muhammadiyah University Surakarta

Arranged by :
Name : BRILIAN REXA BUANA
NIM : D 200 133 008

Passed in:
Day :
Date :

Supervisor I Supervisor II

(Tang Li Ping) (Yu Zhang Yong)

Knowing,
Head of Mechanical Eng. Department Head of Mechanical Eng. Department
Muhammadiyah University Surakarta Wuxi Institute of Technology

(Ir. Subroto MT) (Zhang Zheng)

ii
 FOREWORD

Thank God Allah SWT that has given His-mercy and guidance, so writer can
accomplish Laboratory Work Report 3D Scanner with Milling Machine Fanuc
System Process.

This Report is written to complete the undergraduate study in Mechanical

Engineering Department of Muhammadiyah University of Surakarta.

The Writer won’t be able to finish this report without any help and guidance from
people that have supported me. Therefore, on this opportunity I would like to say
thankful to:

1. Allah SWT for every blessing that has given, so the writer can finish this report.
2. Mr. Zhang Zheng as Head of Mechanical Eng. Department Wuxi Institute of
Technology
3. Mr. Yu Zhang Yong and Mr. Tang Liping as Supervisor of lecturers.
4. All of my friends who have supported me in this report.

The Writer realizes that this report is still not perfect, because of my weakness on
knowledge and ability. Therefore, the writer would like to get some advice that able to
improve this report.

Finally, the writer hopes this report is useful for everyone that read it.

Wuxi Jiangsu, January 2017

Author

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iv
 CHAPTER I

INTRODUCTION
1.1 Background

In the era of globalization, developments in the fields of engineering,

especially engineering is progressing very rapidly. The education of mechanical
technology needed to address the challenges of progress. The production process
or the subjects studied Mechanical Technology, in case can give an understanding
to be able to practice into the world of work, especially in production machinery.
Within the needs of reverse engineering with significantly developing, the time has
come to have more understanding and application.

Reverse engineering existing software systems has become an important

problem that needs to be tackled. It is defined by Chikosfky and Cross as “the
process of analyzing a subject system to identify the system’s components and
their relationships, and to create representations of the system in another form or
at a higher level of abstraction” [CHIK 90]. It is the prerequisite for the
maintenance, reengineering, and evolution of software systems. Since an unwary
modification of one part of a system can have a negative impact, e.g., break, other
parts of the system, one needs first to reverse engineer, e.g., have an informed
mental model of the software, before the software system can be modified or
reengineered.

Many softwares are usable for Reverse Engineering, therefore three of them
are 3D Win Scanner, Geomagic Studio 12, Geomagic Design X, and for the output
product it requires UG NX 10 for milling machines. 3D scanning is getting popular
in various fields, and its usage is different for each purpose. This means that there
are different kinds of scan data, and many details to understand. Geomagic Studio
delivers the industry’s most comprehensive solution for transforming 3d scan and
probe data, and polygon meshes, into accurate surfaced 3d models for engineering,

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 product design, rapid prototyping and manufacturing. Geomagic Studio delivers
the fastest way to convert 3d scan data into parametric and 3d cad models, and
provides a wealth of features that revolutionize digital modeling and
manufacturing.Geomagic Design X (formerly Rapid form XOR) is an extremely
powerful reverse engineering and 3D modeling software that combines 3D scan
data processing with history-based CAD. Milling machine were first invented and
developed by Eli Whitney to mass produce interchangeable musket parts.
Although crude, these machines assisted man in maintaining accuracy and
uniformity while duplicating parts that could not be manufactured with the use of
a file. Development and improvements of the milling machine and components
continued, which resulted in the manufacturing of heavier arbors and high speed
steel and carbide cutters. These components allowed the operator to remove metal
faster, and with more accuracy, than previous machines. Variations of milling
machines were also developed to perform special milling operations.

During this era, computerized machines have been developed to alleviate

errors and provide better quality in the finished product. With this in mind, based
on the assignment given to re-build some parts and just to scan, the author wants
to identify in detail manufacture the part about reverse engineering related to some
softwares mention above.

1.2 Problem Statement

Computer vision bridges diverse fields from electrical engineering to computer

science to cognitive psychology. Computer vision systems seek to develop
computer models of the real world through processing of image data from sensors
such as video cameras or–as in our case–3-D range scanners. Once the part
processed with the softwares, the next step is making the manufacturing program

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 and process in milling machine. In order to occur the quality performance of the
real part in world with part based on scan.

1.3 Objective of Research

1.3.1 General Objective.

As for general purpose work practices are as follows:
1. Get experience from work practices to be applied in the industrialize
world.
2. Solve problem that occurs in modelling which is specific and complex
3. Study and apply a working procedure scan and modelling also
manufacturing.
1.3.2 Special Purpose.
Find out more about how to modelling the complex part that could not
be measured instantly also to process it in the 3-axis milling machine.
1.4 The Limitation of Problem

To avoid problem expenditure, it needs to set the problem limitation due to be

more understandable by focusing on these factors. These factors are:
1. Understanding the function and operation of 3D Scanner, Geomagic Studio
12, Geomagic Design X.
2. To applicate and operate the Scanner along with the softwares.
3. To produce part of manufacturing program using software UG NX10 and
process with Milling Machine.

3
1.5 Methodology

Start

Literature Review

Preparation

Scan in 3D Win Scanner,file

type STL Transforming 3D
scan and probe
data, and polygon
Geomagic Studio 12 Transforming 3D scan meshes, into
accurate surfaced
Input the type file 3D models

Geomagic Design X, file type STP

Manufactur Program
Adjustment
with UG NX 10

Processing In Milling Machine

Measure and Analyze

Turn Off

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 CHAPTER II

LITERATURE REVIEW
2.1 Computer-Aided Reverse Engineering

CAE through CAD and CAM technologies is the automation of engineering

and fabrication, where a design formalizes ideas through computer modeling and
then fabricates those models into real-world objects. CARE flows in the opposite
direction. CARE creates a computer model of an object through measurements of
the object, as it exists in the real world. In this context, we define CARE as the
reversal of CAE or the ability to generate a CAD model from a real-world tangible
object.
For both industrial and military applications, CARE offers many advantages to
the engineering design, manufacturing fabrication, and field support of a part or
component. For example, CARE allows rapid inspection and validation in real
time at the production line based on the original CAD designs. A production
technician can quickly evaluate tolerances relative to the CAD models. Such
feedback enables tighter control over the manufacturing process or may aid future
redesigns of the component.

Fig.2.1 Computer-Aided Reverse Engineering (CARE) Process

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2.2 3D Win Scan

Sheet-of-light scanners offer the greatest speed advantage in collecting 3-D data
compared to other laser scanners and thus are the most suitable for CARE
applications. Their basic operation is such that the laser projects a line onto the
object of interest, and triangulation among this line, the laser, and a camera yield
3-D measurements. The photograph in Figure a is an example of a laser line
projecting onto a set of objects, and Figure b is an example of a system, the Ranger
Scanner developed by Integrated Vision Products (IVP).

(a) (b)
Fig. 2.2 (a) The laser sheet casts a line on the objects under measurement.
(b) IVP Ranger Scanner or 3D Win Scanner

In the figure, the objects are resting on a conveyor disk plate. This belt is one
method for obtaining a full scan of an object. With the IVP Ranger, as with other
sheet-of-light scanners, a single measurement results in a single line–a profile– of
data. This profile is the 3-D data for points where the laser line falls on the object.
A set of such profiles across the object is necessary to form a complete 3-D
description of the object. In order to occur the point clouds, we must rotate each 3
points of the part to scan the profiles over the entire object. If we stack the resulting
profiles together, we have a 3-D model of the object. The conveyor generates
profile slices of the object. The type of part file is TXT, continue to wrap or clean
the meshes.

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2.3 Geomagic Studio 12

Fig.2.3 The 3D Scan Data or Mesh in Geomagic Studio 12

Geomagic Studio is the industry’s most easy-to-use, intelligent solution for

transforming 3d scan data into highly accurate polygon and native cad models for
reverse engineering, product design, rapid prototyping and analysis.
Intelligent, automated and flexible, geomagic Studio delivers the best
experience and the highest quality 3d data from scan and probe data :
1. The intuitive new Sketch function allows direct creation and editing of
cross-section curves from both point clouds and polygon models.
2. Robust scripting environment extends, customizes and automates functions
with deep access into selected commands in the software.
3. Improved editing, navigation and visualization of point clouds from mid-
and long-range scanners for scene-level 3d models.
4. Remeshing tool enables fast, accurate retriangulation of polygon models for
cleaner, more usable 3d models for digital content creation (dcc) and 3d
printing.
5. Type of file is STL, continue to make the part of model.

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2.4 Geomagic Design X

Fig.2.4 STP File After Process in Geomagic Design X

Geomagic Design X addresses the limitations of existing 3D scan data

processing software by complementing its mesh modeling and NURBS surfacing
capabilities with newly developed CAD modeling capabilities, providing users
with the tools to go from 3D scan data to a parametric CAD model. The
combination of these capabilities enables users to create parametric CAD models
that contain both prismatic and freeform features. By the end of the process, it
ables to perform or transferred to the type file of STP due to the need of production
process.

In understanding of the modeling process in Geomagic Design X . These are

the fundamentals of Geomagic Design X :

1. Mesh Editing
2. Surfacing Modelling
a. Freeform Surface Modeling with Mesh Data
b. Mesh to Boundary Fit Surface
c. Mesh BuildUp Wizard & Auto Surfacing
d. Sheetmetal Modeling with Mesh Data
3. Solid Modeling
a. Simple Solid Modeling with Scan Data
b. Solid Modeling with Mesh Data
c. End-To-End Modeling Process
4. CAD Modeling

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 a. CAD Modeling without Mesh Data
b. CAD Correct Modeling

2.5 Milling Machine

The milling machine removes metal with a revolving cutting tool called a
milling cutter. With various attachments, milling machines can be used for boring,
slotting, circular milling dividing, and drilling. This machine can also be used for
cutting keyways, racks and gears and for fluting taps and reamers. Various process
can be done by Milling Machine are as follows :

Fig.2.5 Some Functions of Standard Milling Machine

Replacement of hard or rigid automation by Flexible automation by developing

and using CNC has made a great break through since mid seventies in the field of
machine tools’ control. The advantageous characteristics of CNC machine tools
over conventional ones are :
 flexibility in automation
 change-over (product) time, effort and cost are much less
 less or no jigs and fixtures are needed
 complex geometry can be easily machined
 high product quality and its consistency
 optimum working condition is possible
 lesser breakdown and maintenance requirement

9
 Fig.2.6 Further Enhanced CNC Milling Machine

2.5.1 Basic Geometry

The kinematic system comprising of a number of kinematic chains of

several mechanisms enables transmission of motions (and power) from the
motor to the cutting tool for its rotation at varying speeds and to the work-
table for its slow feed motions along X, Y and Z directions. In some milling
machines the vertical feed is given to the milling(cutter) head. The more
versatile milling machines additionally possess the provisions of rotating
the work table and tilting the vertical milling spindle about X and / or Y
axes.
Figure shown below typically shows the kinematic diagram of the most
common and widely used milling machine having rotation of the single
horizontal spindle or arbour and three feed motions of the work-table in X,
Y and Z directions. The milling cutter mounted on the horizontal milling
arbour, receives its rotary motion at different speeds from the main motor
through the speed gear box which with the help of cluster gears splits the
single speed into desirably large number(12, 16, 18, 24 etc) of spindle
speeds. Power is transmitted to the speed gear box through Vee-belts and a
safety clutch as shown in the diagram.
For the feed motions of the workpiece (mounted on the work-table)
independently, the cutter speed, rotation of the input shaft of the speed gear
box is transmitted to the feed gear box through reduction (of speed) by
worm and worm wheels as shown.

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 The cluster gears in the feed gear box enables provide a number of feed
rates desirably. The feeds of the job can be given both manually by rotating
the respective wheels by hand as well as automatically by engaging the
respective clutches. The directions of the longitudinal (X), cross (Y) and
vertical (Z) feeds are controlled by appropriately shifting the clutches. The
system is so designed that the longitudinal feed can be combined with the
cross feed or vertical feed but cross feed and vertical feed cannot be
obtained simultaneously.
This is done for safety purpose. A telescopic shaft with universal joints
at its ends is incorporated to transmit feed motion from the fixed position
of the feed gear box to the bed (and table) which moves up and down
requiring change in length and orientation of the shaft. The diagram also
depicts that a separate small motor is provided for quick traverse of the bed
and table with the help of an over running clutch. During the slow working
feeds the rotation is transmitted from the worm and worm wheel to the inner
shaft through three equi-spaced rollers which get jammed into the tapering
passage. During quick unworking work-traverse, the shaft is directly rotated
by that motor on-line without stopping or slowing down the worm. Longer
arbours can also be fitted, if needed, by stretching the over-arm. The base
of the milling machine is grouted on the concrete floor or foundation.

Fig.2.7 Kinematic Diagram of A Milling Machine

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 CHAPTER III

METHODOLOGY PROJECT
3.1 Preparation

1. Part in Real World to Scan

Fig.3.1 Spray The Part before Scan

Procedures to spray the part :
a. Clean the workpiece surface with remover
b. Spray Penetrant on the workpiece surface and keep wet for 5-10
minutes
c. Wipe out excess penetrant on the surface, then clean with cleaner or
water.
d. Post surface dry shake developer until well-distributed, then spray it
from 150-300 mm. Flaw is visible

2. List of equipment and tools requirement :

a. DPT-5; Dye Penetrant Inspectant Materials.
b. END MILL D16
c. END MILL D10
d. END MILL D8
e. BALL-NOSE MILL B10
f. BALL-NOSE MILL B8
g. COUNTERSINKING TOOL D8

12
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 Fig.3.2 Tools of Cutter Requirement for Machining

3. The computer and 3D World Scanner

Once the workpiece surface is dry, put it on top of the conveyor disk
plate.

Fig.3.3 Set Up The Computer and Workpiece

3.2 Procedure in Making Mesh STL File Type of Geomagic Studio 12

1. Select 'Import'
2. Choose all the '.txt' type of files. then 'ok'
3. Set the ratio up to 100%
4. Set the units for the data Milimeters, then okay.
5. The point clouds will show on the Graphic followed with the Model Manager.
6. Choose 1 file we will crop the point clouds, and hide the rest.
7. Select 'Crop' on the tool bar. crop the cloud requireD.
8. Select 'Shade Points'.
9. Select 'Select - Deselect Union'
10. Select Reduce Noise
11. Click on Dialog, Parameters : Free-form shapes
12. Set the Iterations : 5, Deviation Limit : 0.008 mm
13. Then 'OK'

13
 14. On toolbar, choose Alignment, then click Manual Registration
15. Choose n-point, then click the first coulumn with 1 mesh, and the floating or
the second coulumn wiht 2 mesh.
16. Choose 3 points in different arrangement in each meshes, total 6 point.
17. Then from toolbar, select Points, choose wrap.
18. 'Save As', choose type of file with STL.art in Real World to Scan

3.3 Procedure in Modelling Part File STP Type of Geomagic Design X

First, in segmenting region we must follow these procedures :

1. Heal Mesh
2. Global Remesh
3. Decimate
4. Fill Holes
5. Enhance Shape
6. Optimize Mesh

In order to transform the mesh STL type of file into Model Part STP, these are the
following procedures :

1. Segmenting Feature Regions

a. Explanation : You will automatically separate areas with similar
curvature on a mesh into feature regions.
2. Creating a Base Solid Body
a. Explanation : You will design a sketch profile from the mesh and
revolve it to make a main solid body.
3. Creating a Feature Shape
a. Explanation : You will create a rectangular sketch profile from the
mesh and extrude-cut it to remove the top area of the main solid body.
4. Adding Other Features
5. Cutting Feature Shapes
a. Explanation : You will create freeform surface bodies from region
groups and use these surface bodies to cut the main solid body.
6. Adding Fillets
a. Explanation : You will extract a fillet radius from the mesh and apply
it to the main solid body.
7. Save As, type file of STP.

14
3.4 Set Manufacturing Program – CNC Codes using UG NX10

1. Open the part to choose needs to process

2. Set up the stock material
- Sketch based on real stock material dimensions
- Sketch the axis as the guide line
- Select ‘finish’
- Extrude
- Create ctrl+j then choose the blank part, then transparence the stock
material
3. Select 'application' from the toolbar, then choose 'manufacture'
4. Create the operation and adjust with the tools required for the work piece
design, tools tip depth, and 'user define' to cut
5. Set up the MCS (coordinate), work piece (part, blank, and part offset)
6. After we create the operation required for the work piece then we generate to
confirm the operation
7. Continue to post process an NC code

Fig.3.4 Visualise one of Set Up Manufactur Program and CNC Codes

8. After The Work Piece Is Set On Manufacturing Process Program

9. Once We Have Set The Operation We Use
10. Click On The Application From Toolbar
11. Then Choose 'Operation Navigator - Geometry'

15
12. Choose And Right Click On The Operation We Want To Occur The NC
Code
13. Choose 'Post Process'
14. In 'Postprocessor', Choose ''Mill_3_Axis''
15. In Output File, Fill The 'File Name' Then Browse To Place The Program Is
Saved
16. Then Fill ''NC'' In File Extension For Type Of File
17. In Settings, At 'Units' Choose 'Metric/Part'
18. Then 'Ok'
19. Once The NC Code Is Shown, Open The Type Of File In Notepad
20. Delete The First Until Third Line Of Program
21. Input G54 Code Instruction On The 4th Line Before G00
22. Input Distance In Axis Z150 For Safety Of The Tools Processing, After Y
Axis In 4th Line
23. Input G00 Z150 At The 2nd From Last Block, For The Tool To Return
Beginning Point
24. At Last Block, Insert 'M30' To Stop The Process Of Machine
25. The Code Is Ready To Copy To a Drive Then Next Step Is On The Milling
Machine Fanuc System

Fig.3.5 Sub Program Structure – The Codes after Modification for Machine
Requirement

16
3.5 Set of CNC Manufacturing Process
In Fanuc System, some different settings absorbed in writing the program
compared to other type of machine. There are:
1. A part program is written, using G and M codes. This describes the
sequence of operations that the machine must perform in order to
manufacture the component. This program can be produced off-line, away
from the machine, either manually or with the aid of a UG NX 10 system.
2. The part program is loaded into the machines computer, called the
controller. At this stage, the program can still be edited or simulated using
the machine controller keypad/input device.
3. The machine controller processes the part program and sends signals to the
machine components directing the machine through the required sequence
of operations necessary to manufacture the component.

Combining this with the use of a part program enhances the ability of the
machine to perform repeat tasks with high degrees of accuracy

17
 CHAPTER IV

DISCUSSION ANALYZE
4.1 Geomagic Studio 12 – Transfering file to Meshes and Cloud, STL
In order to do the process we need to read and transform it from 3D Scan
Data to Geomagic Studio 12.

Fig. 4.1 Meshes and Point Cloud

After import the txt type of file from 3D Scanner, we must do the
procedures which have been discussed in previous chapter.

Fig. 4.2 Point Clouds and Polygon Models

4.2 Geomagic Design X – Import STL file and Export STP file
In order to do the process we need to read and transform it from Point
Clouds to Geomagic Design X for modelling the part.

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 Fig. 4.3 Model of Part of Minifan

After import the txt type of file from 3D Scanner, we must do the
procedures :

(1) (2) (3) (4)

Fig. 4.4 Tree of Modelling the Part in Geomagic Design X

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4.3 Manufacturing Operation
4.2.1 Machine Coordinate System is On the Top Side of Stock Material
I. Cavity Mill (Facing Stock Material)

Fig.4.5 Facing Top Stock Material

Fig.4.6 Visualizes After Facing with D16

 Tool : End Mill D16

 Spindle Speed : 3000 rpm
 Feed rate : 1500 mm
 Analyze :

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  Time collapsed : 00:18:43
 Put the MCS(Machine Coordinate System) on top of
Work piece, not on top of Stock Material
 Method : Mill Rough – Follow Periphery
 Machining Data
o Surface speed : 471.0
o Feed per Tooth : 0.125
 Range of Depth Cut : 31.69
 Program :

II. Floor Wall

Fig.4.7 Floor Wall

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 Fig.4.8 Visualizes After Floor Wall with D10

 Tool : End Mill D10

 Spindle Speed : 6000 rpm
 Feed rate : 2000 mm
 Analyze :
 Time collapsed : 00:00:42
 Method : Mill Semi Finish – Follow Periphery
 Machining Data
o Surface speed (smm) : 188.0
o Feed per Tooth : 0.0833
 Floor Blank Thickness : 3 mm
 Program :

22
III. Planar Mill

Fig.4.9 Planar Mill 1

 Tool : End Mill D10

 Spindle Speed : 7000 rpm
 Feed rate : 1000 mm
 Analyze :
 Time collapsed : 00:00:14
 Method : Mill Finish – Profile
 Machining Data
o Surface speed (smm) : 219.0
o Feed per Tooth : 0.03571428571429
 Cur level : Constant
Program :

23
IV. Planar Mill

Fig.4.10 Planar Mill 2nd

 Tool : End Mill D10

 Spindle Speed : 7000 rpm
 Feed rate : 1000 mm
 Analyze :
 Time collapsed : 00:00:14
 Method : Mill Finish – Profile
 Machining Data
o Surface speed (smm) : 219.0
o Feed per Tooth : 0.03571428571429
 Cur level : Constant
Program :

24
V. Planar Mill (Cutting the Rest of Outside Part)

Fig.4.11 Cutting the Rest of Outside Part

 Tool : End Mill D10

 Spindle Speed : 6000 rpm
 Feed rate : 2000 mm
 Analyze :
 Time collapsed : 00:00:11
 Method : Mill Finish - Profile
 Machining Data
o Surface speed (smm) : 188.0
o Feed per Tooth : 0.083
 Range Depth : Specify floor of Top Part
 Program :

25
VI. Planar Mill (Making Twice Chamfer with Two Programs)

Fig.4.12 Chamfering Bottom Side

 Tool : Countersinking Tool D8

 Spindle Speed : 5000 rpm
 Feed rate : 300 mm
 Analyze :
 Time collapsed : 00:01:05
 Method : Profile
 Machining Data
o Surface speed (smm) : 125.0
o Feed per Tooth : 0.03
 Specify Floor : Bottom Part and Bottom of The
Extrude Cylinder
 Program :

26
VII. Contour Area (Facing 0.5 cm Depth)

Fig.4.13 Facing Top Side of Top Part

Fig.4.14 Visualizes After Facing Top Side with End Mill D10

 Tool : End Mill D10

 Spindle Speed : 3000 rpm
 Feed rate : 1500 mm
 Analyze :
 Time collapsed : 00:29:45
 Method : Mill Rough - Follow periphery
 Machining Data
o Surface speed (smm) : 471.
o Feed per Tooth : 0.125
 Range Depth Cut : 35 mm
 Program :

27
VIII. Rest Milling

Fig.4.15 Rest Milling

Fig. 4.16 Rest Milling After Appearance

28
  Tool : End Mill D8
 Spindle Speed : 5000 rpm
 Feed rate : 2500 mm
 Analyze :
 Time collapsed : 00: 03:34
 Method : Mill Semi Finish - Follow periphery
 Machining Data
o Surface speed (smm) : 125.
o Feed per Tooth : 0.125
 Range Depth : 35 mm
 Program :

IX. Rest Milling (Facing Floor)

Fig.4.17 Facing Floor

29
  Tool : End Mill D8
 Spindle Speed : 6000 rpm
 Feed rate : 2000 mm
 Analyze :
 Time collapsed : 00: 00:30
 Method : Mill Finish - Follow periphery
 Machining Data
o Surface speed (smm) : 188.
o Feed per Tooth : 0.0833
 Specify Cut Area : Floor of The Top Surface Part
 Program :

X. Fixed Contour

Fig.4.18 Fixed Contour

30
  Tool : Ball-nose Mill D8
 Spindle Speed : 5000 rpm
 Feed rate : 1500 mm
 Analyze :
 Time collapsed : 00: 04:26
 Method : Mill Semi Finish
 Machining Data
o Surface speed (smm) : 157.
o Feed per Tooth : 0.15
 Specified Trim Boundaries : Total 21
 Program :

XI. Fixed Contour (In Order to Obtain More Accuracy)

Fig.4.19 Repetitive Fixed Contour

 Tool : Ball-nose Mill D8

31
  Spindle Speed : 7000 rpm
 Feed rate : 1500 mm
 Analyze :
 Time collapsed : 00: 02:53
 Method : Mill Finish
 Machining Data
o Surface speed (smm) : 131.
o Feed per Tooth : 0.1071
 Specified Trim Boundaries
 Program :

XII. Fixed Contour (In Order to Obtain More Accuracy)

Fig.4.20 Top Side Fixed Contour

32
  Tool : Ball-nose Mill D8
 Spindle Speed : 7000 rpm
 Feed rate : 1500 mm
 Analyze :
 Time collapsed : 00: 01:22
 Method : Mill Finish
 Machining Data
o Surface speed (smm) : 131.
o Feed per Tooth : 0.1071
 Specified Trim Boundaries

XIII. Fixed Contour (In Order to Obtain More Accuracy)

Fig.4.21 2nd Top Side Fixed Contour

 Tool : Ball-nose Mill D8

 Spindle Speed : 7000 rpm
 Feed rate : 1500 mm
 Analyze :
 Time collapsed : 00: 01:22
 Method : Mill Finish
 Machining Data
o Surface speed (smm) : 131.
o Feed per Tooth : 0.1071
 Specified Trim Boundaries

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XIV. Chamfering Top Side

Fig.4.22 Chamfering Top Side

 Tool : Countersinking Tool D8

 Spindle Speed : 5000 rpm
 Feed rate : 300 mm
 Analyze :
 Time collapsed : 00:01:06
 Method : Profile
 Machining Data
o Surface speed (smm) : 125.0
o Feed per Tooth : 0.03
 Specify Floor : Top Part of The Floor
 Program :

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4.4 2nd Geomagic Studio 12 – Transfering file to Meshes and Cloud, STL
In order to do the process we need to read and transform it from 3D Scan
Data to Geomagic Studio 12.

Fig. 4.23 Turbine Impeller Meshes and Point Cloud

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 After import the txt type of file from 3D Scanner, we must do the
procedures which have been discussed in previous chapter.

Fig. 4.24 Turbine Impeller Point Clouds and Polygon Models

4.5 2nd Geomagic Design X – Import STL file and Export STP file
In order to do the process we need to read and transform it from Point
Clouds to Geomagic Design X for modelling the part.

Fig. 4.25 Model of Part of Turbine Impeller

After import the txt type of file from 3D Scanner, we must do the
procedures :

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 (1) (2) (3) (4)

(5) (6)
nd
Fig. 4.26 2 Tree of Modelling the Part in Geomagic Design X

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 CHAPTER V

CONCLUSSION
5.1 Conclusion
From the result of analyzing project, the conclusions are:
1. All milling machines are identified by four basic factors: size,
horsepower, model, and type. The size of a milling machine is based on
the longitudinal (from left to right) table travel, in inches. Vertical, cross,
and longitudinal travel are all closely related as far as the overall
capacity. However, for size designation, only the longitudinal travel is
used. .
2. In order to translate the similar yet complex and specific data, it requires
more softwares such as 3D Scanner, Geomagic Studio 12, Geomagic
Design X, and to make it reality with producing by UG NX10.
3. Reverse engineering is advanced time to time, in order to advance the
production of industrial world and safe time also for perfection of the
part or demands required.
4. Computer vision offers tremendous potential for advancing CARE
technology to a point where an untrained user can generate CAD models
of existing world objects. The caveat, however, is that improvements in
measurement accuracy and commercial maturity are necessary to gain an
advantage.

5.2 Suggestion
From the result of analyzing project, the suggestions are:
1. Once we installed the tools and matched with the operation
manufacturing. We must consider the depth of cutting hole (for thread
or drilling only) with the length of tool's nose and size of tool. For
example if the depth of hole is 25mm, and we need to drill more than
25, like 26. Because the nose of tool is affected the end of cutting hole.
2. In setting the suitable cutter for the operation manufacturing, must
consider the accurate and precise measurement of dimensions and the
work piece cutting path.
3. Must match the exact operation in each of the software, and analyze
after every operation or command has been done, to ensure the safety,
accuracy and precision.

38

38
 REFERENCE
Army Institute for Professional Development. 1988. Milling Machine Operations Sub
course OD1644, 8 Ed. US Army Correspondence

AIPD. CNC Program Manual. Daewoo Heavy Industries and Machinery LTD.

IIT KHARAGPUR. General Purpose Machine Tools. Version 2 ME.

Koschan. A, and friends. Chapter 2 : Methodologies and Techniques for Reverse

Engineering – The Potential for Automation with 3D Laser Scanners. USA :
University of Tennessee

Prof. Dr. S. Ducasse, Prof. Dr. O. Nierstrasz. Object – Oriented Reverse Engineering,
Coarse-grained, Fine-grained, and Evolutionary Software Visualization.
Inauguraldissertation der Philosophisch-naturwissenschaftlichen Fakult¨ at der
Universit¨at Bern

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ATTACHMENT

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Fig. Extra 1 Part After Machining

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Fig. Extra 2 Turbine Impeller Part Import Scan Part

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