MACHINE SHOP LABORATORY REPORT

FRIDAY, MAY 3RD 2019

MODULE 6

CNC LATHES MACHINE

By:
Elin Rachmawati (2017360005)
Gloria Aprilia (2017360006)
Steven Mark Levy (2016360004)
Wahyu Haykal Rahmanda (201736015)

Lecturer: Dr. Belyamin

Laboratory Supervisor: Mr. Ifat
Assistant Laboratory: Aldy Rizky Priyambodo
Mechanical Engineering, Sampoerna University
 Table of Contents

Table of Contents 2
CHAPTER 1: Introduction 3
1.1 Objectives 3
CHAPTER 2: Theoretical Background 4
2.1 CNC Machine 4
2.2 How the CNC Machine Working 4
2.3 CNC Machine Programming 5
2.4 CNC Lathes Machine 6
CHAPTER 3: Technical Description 8
3.1 HAAS TL-1 CNC Lathe Toolroom 2-Axis 8
3.1.1 Specification of HAAS TL-1 CNC Lathe Toolroom 2-Axis 9
3.2 Haas Control 9
3.2.1 Specifications and Features of Haas Control 9
3.3 Solar Thread Pitch Gauge WW-MM 11
3.4 Mitutoyo Vernier Caliper 12
CHAPTER 4: Methodology 13
CHAPTER 5: Results and Analysis 14
5.1 Programming Codes Input 14
5.2 The Specimen Result 15
CHAPTER 6: Conclusion 17
References 18

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 CHAPTER 1
INTRODUCTION

Science and technology have grown rapidly. This progress has also penetrated the world
of manufacturing industries. As an example of this progress, many production machines or
machine tools have used high technology such as drilling machines and saw machines. Progress
in the field of technology in data processing and information is very rapid one of which is a
computer. It can be seen from the use of computers into machines - machine tools such as freis
machines, lathes, grinding machines, and other machines. The results of the incorporation of
computer technology and mechanical technology are often referred to as CNC machines
(Computer Numerical Control).
The examples of CNC machines that are now easily found and often used are CNC
lathes and milling machines. CNC lathes and milling machines are machines controlled by a
control system called computerized numerical control (CNC). Lathe machines are used to cut
shaped metal cylindrical. Milling machines are used to cut metal in the form of square prisms.
Workpieces commonly made on CNC lathes are ordinary multilevel shafts and those that have
grooves or threads, for example, the Vespa front axle. Workpieces made in CNC milling
machines are threaded, grooves and multilevel upright prisms. Nowadays, the use of CNC
machines is almost found in all fields. From the fields of education and research that use such
tools, various useful research results are produced which are not widely used in the daily lives
of many people.

1.1 Objectives
In this experiment, there are some objectives that is needed to be achieved:
a. to understand the working principle of CNC lathes machine.
b. to understand the operation of CNC lathes machine.

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 CHAPTER 2
THEORETICAL BACKGROUND

2.1 CNC Machine

CNC machining is a manufacturing process in which pre-programmed computer
software dictates the movement of factory tools and machinery. The process can be used
to control a range of complex machinery, from grinders and lathes to mills and routers.
With CNC machining, three-dimensional cutting tasks can be accomplished in a single set
of prompts [1].
We have seen that the NC machine works as per the program of instructions fed into
the controller unit of the machine. The CNC machine comprises of the mini-computer or
the microcomputer that acts as the controller unit of the machine. While in the NC machine
the program is fed into the punch cards, in CNC machines the program of instructions is
fed directly into the computer via a small board similar to the traditional keyboard [2].
In CNC machine the program is stored in the memory of the computer. The
programmer can easily write the codes and edit the programs as per the requirements.
These programs can be used for different parts, and they don’t have to be repeated again
and again.
Compared to the NC machine, the CNC machine offers greater additional flexibility
and computational capability. New systems can be incorporated into the CNC controller
simply by reprogramming the unit. Because of its capacity and the flexibility, the CNC
machines are called as “soft-wired” NC [2].

2.2 How the CNC Machine Working

The CNC machine comprises of the computer in which the program is fed for cutting
of the metal of the job as per the requirements. All the cutting processes that are to be
carried out and all the final dimensions are fed into the computer via the program. CNC
machine works like the Robot, which has to be fed with the program and it follows all the
instructions [2]. Some of the common machine tools that can run on the CNC are: Lathe,
Milling machines, Drilling Machine etc.
The traditional methods these machines are operated by the operators who are
experts in the operation of these machines. Most of the jobs need to be machined
accurately, and the operator should be expert enough to make the precision jobs. In the

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 CNC machines the role of the operators is minimized. The operator has to merely feed the
program of instructions in the computer, load the required tools in the machine, and rest
of the work is done by the computer automatically. The computer directs the machine tool
to perform various machining operations as per the program of instructions fed by the
operator.
All the CNC machines are designed to meet very close accuracies [2]. These days,
for most of the precision jobs CNC machine is compulsory. When the job is finished, the
operator does not even have to remove it, the machine does that, and it picks up the next
job on its own. This way the machine can keep on doing the fabrication works all the 24
hours of the day without the need of much monitoring, but of course the operator will have
to feed it with the program initially and supply the required raw material.

2.3 CNC Machine Programming

In CNC, machines are operated via numerical control, wherein a software program
is designated to control an object. The language behind CNC machining is alternately
referred to as G-code, and it’s written to control the various behaviors of a corresponding
machine, such as the speed, feed rate and coordination [1].
Basically, CNC machining makes it possible to pre-program the speed and position
of machine tool functions and run them via software in repetitive, predictable cycles, all
with little involvement from human operators. Due to these capabilities, the process has
been adopted across all corners of the manufacturing sector and is especially vital in the
areas of metal and plastic production.
For starters, a 2D or 3D CAD drawing is conceived, which is then translated to
computer code for the CNC system to execute. After the program is inputted, the operator
gives it a trial run to ensure no mistakes are present in the coding. There are two kinds of
machining in CNC, which are,
a. Open/Closed-Loop Machining System
Position control is determined through an open-loop or closed-loop system. With
the former, the signaling runs in a single direction between the controller and motor.
With a closed-loop system, the controller is capable of receiving feedback, which
makes error correction possible. Thus, a closed-loop system can rectify irregularities in
velocity and position.
In CNC machining, movement is usually directed across X and Y axes. The tool,
in turn, is positioned and guided via stepper or servo motors, which replicate exact

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 movements as determined by the G-code. If the force and speed are minimal, the
process can be run via open-loop control. For everything else, closed-loop control is
necessary to ensure the speed, consistency and accuracy required for industrial
applications, such as metalwork.

b. Fully Automated CNC Machining

In today’s CNC protocols, the production of parts via pre-programmed software
is mostly automated. The dimensions for a given part are set into place with computer-
aided design (CAD) software and then converted into an actual finished product with
computer-aided manufacturing (CAM) software.
Any given work piece could necessitate a variety of machine tools, such as drills
and cutters. In order to accommodate these needs, many of today’s machines combine
several different functions into one cell. Alternately, an installation might consist of
several machines and a set of robotic hands that transfer parts from one application to
another, but with everything controlled by the same program. Regardless of the setup,
the CNC process allows for consistency in parts production that would be difficult, if
not impossible, to replicate manually.

2.4 CNC Lathes Machine

The earliest numerical control machines date to the 1940s when motors were first
employed to control the movement of pre-existing tools. As technologies advanced, the
mechanisms were enhanced with analog computers, and ultimately with digital computers,
which led to the rise of CNC machining [1].
The vast majority of today’s CNC arsenals are completely electronic. Some of the
more common CNC-operated processes include ultrasonic welding, hole-punching and
laser cutting.
A CNC lathe is typically designed to utilize modern versions of carbide tooling and
processes. A part can be designed for customization, and the machine’s tool paths are often
programmed using the CAD or CAM processes. However, a programmer can manually
design a part or tool path as well. The resulting coded computer file is then uploaded to
the CNC machine, and the machine will then automatically produce the desired parts for
which it was programmed to design.
A CNC lathe is controlled by a menu-type interface on a computer. The operator
who manages the process can actually see a visual simulation of how the machine will

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function during the production phase. Based on the manufacturer producing the machine,
CNC lathes are designed in a variety of ways. Most of them have some significant
similarities in their composition. CNC machines are typically completely enclosed for
health and safety reasons of any operators present [4].
Different lathe manufacturers utilize a variety of user interfaces, which can be a
challenge to the operators. But these systems are mostly based on the same principles
across the board since a CNC lathe is programmed to perform similar functions in terms
of what it is intended to manufacture. Like other CNC machines, CNC lathes have become
a major part of the manufacturing industry in recent years. So, it is expected that the
operations of such machines will continue to improve and carry significant weight in this
field.

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 CHAPTER 3
TECHNICAL DESCRIPTION

This chapter will explain the technical description of the machine used during the
process of experiment. The CNC lathes machines which used during the experiment which was
HAAS TL-1 CNC Lathe Toolroom 2-Axis. The CNC lathes machines will be elaborated as
shown below.

3.1 HAAS TL-1 CNC Lathe Toolroom 2-Axis

HAAS TL-1 CNC Lathe Toolroom is a lathe machine which can be operated using a
program which this method called as computerized numerical control (CNC). This lathe
machine is created by HAAS F1™ Team Official Machine Tool. The Figure 3.1.1.1 below
shows the visual of the machine.

Figure 3.1.1 Shows the visual shape of HAAS TL-1 CNC Lathe Toolroom 2-Axis

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 3.1.1 Specification of HAAS TL-1 CNC Lathe Toolroom 2-Axis
The HAAS TL-1 CNC Lathe Toolroom 2-Axis machine has several
specification key points. This machine has a maximum capacity of 406 × 762 𝑚𝑚.
It has a maximum x-axis feed distance of 203mm and z-axis feed distance of 762mm.
It also capable of feeding with a feed rate up to 11.4m/min for both x-axis and z-
axis. The thrust force of this machine is capable to reach 17,321N on x-axis and
8,661N on z-axis. This machine is capable to deliver a power up to 7.5kW with
rotational maximum motion speed at 1,800 rpm and maximum torque at 146 Nm
reached at 355rpm. This machine also capable of running a program with a
maximum program memory of 1 MB through an 15’ colour LCD display monitor.

3.2 Haas Control

The Haas control – hardware and software – is designed and built in-house, and
optimized specifically for Haas machine tools. If there is a problem – Haas Automation
takes full responsibility for the entire machine [5]. The Figure 3.2.1 below shows the visual
of the machine.

Figure 3.2.1 shows the visual shape of Haas Control [5]

3.2.1 Specifications and Features of Haas Control

The Haas Control has several specification key points. This machine can be used
in 3/4/5 axis. The weight of the machine is 24 lbs. This machine has three connectivity,
which are USB, Ethernet, and WiFi [6]. There are several control feature and options
in Haas Control, which are:

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a. On-Board Memory
The NGC has 1 GB of standard program memory. This means you’ll have
the ability to store many programs in the control, eliminating the need for an
external device for program backup. Large programs for complex molds, for
example, can now be run from memory, doing away with the connectivity issues
often experienced when running from DNC or FNC.

b. Easy Network Access

The Haas Control has a simple and intuitive network setup interface.
Connect to your local area network using the built-in Ethernet connection, or
wirelessly via standard WiFi capability. With the Haas Control, there are no
limitations with any common operating system; connectivity is fast and reliable.

c. Wired and Wireless Connection

With Ethernet and WiFi connectivity as standard, connecting your Haas
control to your computer or shop network is incredibly easy. Ethernet is a super
fast and reliable network connection that has replaced the RS-232 serial port.
WiFi offers similar speed and reliability, but without the wires. Using the Net
Share feature in the Haas Control, you can easily share, send, run, and edit
programs from your desktop or Haas control in real time.

d. Lightweight Design
The simulator’s wedge design is light and portable, making it easy to
transport and move; and the wide base and rubber feet make it very stable on
desks and tabletops. The unit’s flat back also simplifies wall mounting, if desired.

e. Visual Programming
VPS is Haas Automation’s proprietary conversational programming system
that uses simple, step-by-step templates and 3D graphics to help the user quickly
create programs for simple machining operations. No knowledge of G-code or
CAM software is required.

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 f. Built-in Connectivity
A built-in USB port allows the use of external USB drives and flash
memory devices for program storage, transfer, and DNC operations. Ethernet and
WiFi connectivity allow easy access to local networks.

g. Mill and Lathe Control

The Haas control simulator can be initialized as both a mill control and a
lathe control. Dual-function keys simplify navigation. The NGC software is
upgradable to future versions.

3.3 Solar Thread Pitch Gauge WW-MM

Solar Thread Pitch Gauge WW-MM is a device to determine the scale of a pitch
from a bolt or similar objects with a pitch. The Figure 3.3.1 below shows the visual shape
of this device used in the experiment done.

Figure 3.3.1 Shows the visual shape of Solar Thread Pitch Gauge WW-MM

This device is capable to determine the scale of pitch as low as 0.25mm up to

6.00mm. This device was used to determine the scale of the pitch from the specimen used
as reference shape to be machined. To use this device, one of the scale in this device was
touched to the pitch and when the scale can fit inside the pitch without wobbling, then the
size was correct.

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3.4 Mitutoyo Vernier Caliper
Mitutoyo vernier caliper is a vernier caliper produced by Mitutoyo company. It
is a device to scale a length of a certain object, outer diameter and inner diameter of a
circular shaped object. Here provided Figure 3.4.1 below to show the visual shape of
vernier caliper.

Figure 3.4.1 Shows the visual shape of Mitutoyo vernier caliper

This device was used to determine the circular diameter of the specimen used as
reference in this experiment, as well as the length. This device has an accuracy of 0.01 mm
at most, making this device as a very accurate device to be a scale.

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 CHAPTER 4
METHODOLOGY

The procedures to operate the CNC Lathe Machine are as follows:

1. The power source cable was plugged in to the power plug.

2. The machine was turned on.
3. Both of lathe machine and CNC interface were calibrated.
4. In the CNC interface, the lathe option was chosen. Then, the code was set up and written
as the desired shape of workpiece.
5. After the code was done, the check button was clicked to check the code and see the
planned final shape of the workpiece.
6. The lathe machine gate was opened.
7. The workpiece was inserted to the working table. The workpiece was placed according to
the configuration on the CNC interface. The workpiece was clamped tightly. Then, the
lubricant hose was set into the suitable place to lubricate the workpiece and cutting tool.
8. The lathe machine gate was closed.
9. The start button on the CNC interface was clicked.
10. After the machining was done, the lathe machine gate was opened.
11. The workpiece was blown by the hand blower to get rid of scrap, chips, and remained
lubricant.
12. The workpiece was taken from the lathe machine and it is done.

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 CHAPTER 5
RESULTS AND ANALYSIS

5.1 Programming Codes Input

CNC machines can only read standard codes agreed upon by industries that make
CNC machines. With this standard code, CNC machine manufacturers can use PCs as self-
produced or recommended inputs. In order to create the expected result, it needs
programming codes input, which is:

0000 ;
(OD THREAD CYCLE);
( SAFETY LINE BELOW );
G00 G54 G18 G40 G80 G97 G99;
(TOOL = 1 / OFFSET = 2);
(WORK OFFSET = 54);
(SPINDLE RPM = 500);
(THREAD LEAD = 1.5);
(THREAD MAJOR DIAMETER = 18.5);
(THREAD MINOR DIAMETER = 16.625);
(THREAD HEIGHT PER SIDE = 0.9375);
(OPTIMIZED “A” VALUE FOR 60 DEGREE THREADS);
(SEE SETTINGS 95, 96, 99 AND 289 ON THE CONTROL);
T102;
G54;
G97 S500 M03;
G00 Z4.5;
G00 X28.66;
M08;
(**WATCH FOR LIVE CENTER INTERFERENCE**);
(RECOMMENDED Z-AXIS START IS 3 THREADS FROM STRAT POINT);
G00 X28.66 Z4.5 M23;
G67 X16.625 Z-603.3 K0.938 D0.234 F1.5 A59;
G00 Z4.5;

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 M09;
G00 G53 X0;
G00 G53 Z0;
M05;
( END OD THREAD CYCLE );
M01;

In that code there are several letters like G, T, M, X, etc. That letter have their own
meaning. G is for regulate the movement which means it will shows the function that must
be done. T is for shows the tool number used. S is for adjusts the rotational speed of the
spindle. M is a modification function. Z is for control the absolute movement in z-axis. X
is for control the absolute movement in x-axis. F is for control the feed rate.
After the code is made, the CNC lathes machine can directly make the specimen
according to the command in the code that has been made. In order to prove that the codes
entered is correct, the “Start” button was pressed and the simulation will run. The
dimension is set in mm.

5.2 The Specimen Result

The input data in CNC lathes machine is required to creates the thread on the
specimen with the desired dimension of pitch, thread, and diameter. The specimen result
is shown in Figure 5.2.1 below.

Figure 5.2.1 The Specimen Result

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Table 5.2.1 Dimension of the Specimen Result

Inner diameter (minor) 16.625 mm

Outer diameter (major) 18.6 mm

Pitch 1.5 mm

Thread height per side 0.9375 mm

The dimension of the pitch can be measured by using Solar Thread Pitch Gauge
WW-MM, and the other dimension can be measured by using Mitutoyo Vernier Caliper.
The CNC lathes machine has high accuracy compared to manual lathe machines, and can
be used to make large quantities of specimens with the same dimensions.

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 CHAPTER 6
CONCLUSION

The CNC lathe machine performs better than the manual lathe machine in terms of
accuracy and safety. By having the Computer Numerical Control feature, the machine can do
precision measurement, stable cutting process, and repeatable cutting pattern. This gives
advantage to the user that the machining of the workpiece is improved by quality (accuracy
and precision) an quantity (the repeatable cutting pattern allows the user to do mass
production). In term of safety, CNC lathe machine is safer because it supports full isolation of
workpiece and cutting tool. Therefore, the user is fairly protected from flying scrap and chip,
splashed lubricant, and even the flying cutting tool (when it fails and breaks).
In the end, this experiment was a success. Students were be able to understand the basic
principle on how CNC lathes machine work. Students were also went through good guidance
by the instructor, to operate and input the various codes which represent the program to execute
the machining process for the designed reference specimen. The instructor provided a manual
book to help students to identify the correct input code for the commands used in the program.

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 References

[1] ASTRO Machine Works Inc. “WHAT IS CNC MACHINING? AN OVERVIEW OF THE
CNC MACHINING PROCESS”. [Online]. Available: astromachineworks.com. [Accessed:
May 12, 2019].

[2] Bright Hub Engineering. “What are CNC Machines? How CNC Machine Works?”. [Online].
Available: www.brighthubengineering.com. [Accessed: May 12, 2019].

[3] Thomas. “Understanding CNC Milling”. [Online]. Available: www.thomasnet.com.

[Accessed: May 12, 2019].

[4] CNC.com. “What is a CNC Lathe and How Does it Work?”. [Online]. Available:
http://www.cnc.com. [Accessed: May 12, 2019].

[5] Haas F1” Team. “The Haas Control”. [Online]. Available: www.haascnc.com. [Accessed:
May 14, 2019].

[6] Haas F1” Team. “Control Simulator”. [Online]. Available: www.haascnc.com. [Accessed:
May 14, 2019].

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