Techno India NJR Institute of Technology, Udaipur

A 45 Days Industrial Training Report

Submitted to
Techno India NJR Institute of Technology
Towards the partial fulfillment of
The degree of
Bachelor of Technology
In
Mechanical Engineering

Session: - 2019-2020

Submitted To: Submitted By

Dr. Pankaj K Porwal (16ETCME019)
Principal & Head of Department

Department of Mechanical Engineering

Techno India NJR Institute of Technology
Udaipur (Raj.)
August -2019

CERTIFICATES
ACKNOWOLEDGEMENT
 Abstract

To understand the programming and operating og cnc milling and cnc turning
To be able to prepare CNC part programs for machining 2-D workpieces.
To understand the structure and flow of a CAM s
INDEX
 I
INTRODUCTION
1.1 Introduction

Computer Numerical Control (CNC) is a specialized and versatile form of Soft

Automation and its applications cover many kinds, although it was initially developed
to control the motion and operation of machine tools.

Computer Numerical Control may be considered to be a means of operating a machine

through the use of discrete numerical values fed into the machine, where the required
'input' technical information is stored on a kind of input media such as floppy disk, hard
disk, CD ROM, DVD, USB flash drive, or RAM card etc. The machine follows a
predetermined sequence of machining operations at the predetermined speeds necessary
to produce a workpiece of the right shape and size and thus according to completely
predictable results. A different product can be produced through reprogramming and a
low-quantity production run of different products is justified

Fig.1-1 CNC Machine Centre (Courtesy of Agie Charmilles)

The definition of CNC given by Electronic Industry Association (EIA) is as follows:

A system in which actions are controlled by the direct insertion of numerical data at
some point. The system must automatically interpret at least some portion of this data.
In a simple word, a CNC system receives numerical data, interpret the data and then
control the action accordingly.

1.2 History

In 1947, numerical control was evolved and started when John C. Parsons of the Parsons
Corporation, Travel city, Michigan, a manufacturer of helicopter rotor blades was not
able to make his templates fast. At that time, he invented a way o coupling computer
equipment with a jig borer. In 1952 MIT i.e. Massachusetts Institute of technology took
over the total job and the term numerical control was evolved at MIT.

Why use CNC machines?

CNC machines have the wide range of applications and this becomes an important
feature of using CNC machines. It is widely used in metal cutting industry to
manufacture the following type of products:

The CNC machines helped in producing parts with complicated outlines.

They were used in manufacturing parts that require good repeatability.
They helped in generating parts that require costly jigs and fixtures.
Also used in manufacturing parts that requires several engineering modifications.
It helps in producing the products which cannot be efficiently produced by human beings.

Some common or basic types of CNC machines used in firms or industries are:

Drilling device
Punching device
Grinding device
Laser cutting device
Water jet cutting device
Industrial robot
Electro discharge device

2.2 BENEFITS

1. CNC machines can be used continuously 24 hours a day, 365 days a year and only
need to be switched off for occasional maintenance.

2. CNC machines are programmed with a design which can then be manufactured
hundreds or even thousands of times. Each manufactured product will be exactly the
same.

3. Less skilled/trained people can operate CNCs unlike manual lathes / milling machines
etc. which need skilled engineers.

4. CNC machines can be updated by improving the software used to drive the machines

5. Training in the use of CNCs is available through the use of ‘virtual software’. This is
software that allows the operator to practice using the CNC machine on the screen of a
computer. The software is similar to a computer game.

6. CNC machines can be programmed by advanced design software such as

Pro/DESKTOP®, enabling the manufacture of products that cannot be made by manual
machines, even those used by skilled designers / engineers.

7. Modern design software allows the designer to simulate the manufacture of his/her
idea. There is no need to make a prototype or a model. This saves time and money.
8. One person can supervise many CNC machines as once they are programmed they can
usually be left to work by themselves. Sometimes only the cutting tools need replacing
occasionally.

9. A skilled engineer can make the same component many times. However, if each
component is carefully studied, each one will vary slightly. A CNC machine will
manufacture each component as an exact match.

2.4 DRAWBACKS
1. CNC machines are more expensive than manually operated machines, although costs
are slowly coming down.

2. The CNC machine operator only needs basic training and skills, enough to supervise
several machines. In years gone by, engineers needed years of training to operate center
lathes, milling machines and other manually operated machines. This means many of the
old skills are been lost.

3. Less workers are required to operate CNC machines compared to manually operated
machines. Investment in CNC machines can lead to unemployment.

4. Many countries no longer teach pupils / students how to use manually operated lathes /
milling machines etc... Pupils / students no longer develop the detailed skills required by
engineers of the past. These include mathematical and engineering skills.
 II
CNC MILLING MACHINE AND THEIR PARTS

2.1 CNC MILLING

Milling is the process of cutting and drilling material (like wood or metal). A milling
machine, regardless of whether it’s operated manually or through CNC, uses a rotating
cylindrical tool called a milling cutter. It is held in a spindle and can vary in form and
size.

The main difference between a milling machine and any other drilling machine is the
ability to cut in different angles and move along different axes. For this reason, there are
several kinds of milling machines, which are designated by number of movement axes:

 2-axis milling machines can cut holes and slots in the x- and z-axes. In other
words, this machine will only cut vertically and horizontally (but only in one
direction).
 3-axis milling machines add the y-axis. This is the most common variety of
milling machine. You can cut vertically and, in any direction, but an object like a
sphere will need to be done one half at a time. This is because, even with three
axes, it’s not possible to cut from below.
 4-axis milling machines are more complex because they add the ability to rotate
the x-axis, similar to a lathe.
 5-axis milling machines incorporate rotation in both the x- and y-axes. This is the
most complete milling machine you can have. It allows you to shape bones,
aerospace structures, car models, medical products, and pretty much anything else
you can imagine.
 CNC milling machines can have any number of axes (2 to 5) but are operated
through a computer. No manual operation required.
2.2 CNC MILLING PARTS
A CNC milling machine mainly consists of following parts:
I. Frame
The frame supports the machine and provides rigidity to resist cutting forces.
Typically, there is a base with a detachable column.
CNC Milling Machine Frames are most commonly made of cast iron. Other
possibilities include weldments with epoxy granite fill and aluminum.

II. Table
The table is where a work holding solution of some kind holds the workpiece for
machining. Most milling machine tables use T-Slots to attach work holding to the
table. You can make a T-Slot table even more useful and versatile by mounting a
Fixture Plate on it.
III. Spindle
The spindle is the heart of any milling machine. It consists of a rotating assembly
with a taper where tool holders may be installed.
A motor with optional transmission of some kind rotates the spindle.
IV. Axes
The axes of a CNC Milling Machine allow motion using Cartesian coordinates
programmed via g-code and via manual jogging from the control panel.
Generally, there are 3 axes that correspond to X, Y, and Z. An optional 4th Axis is
an accessory for CNC Milling Machines. 5 axis milling machines are possible but
not very common in the DIY CNC world.
V. CNC Controller
The CNC Controller is the brains of the machine. It contains the electronics that
drive the axis motors to move the axes.
 CNC Controllers are responsible for accepting G-Code and manual inputs from
the CNC Control Panel and converting that into the proper signals to control the
Axis Stepper or Servo Motors.

VI. CNC Milling Machine Accessories

a. Coolant
b. Way Oiler
c. Powered Drawbar
d. Enclosure
e. 4th Axis

A CNC MILLING MACHINE

 III
CNC MILLING PROGRAMMING
3.1 What is CNC milling programming?
CNC programming (Computer Numerical Control Programming) is utilized by
manufacturers to create program instructions for computers to control a machine tool.
CNC is highly involved in the manufacturing process and improves automation as well as
flexibility.

3.2 M Codes and G Codes of the CNC Milling

3.2.1 G Code
G Code is a Geometric Code, which is used for make a geometry/profile of a
component having cylinder/bar in CNC Lathe or Rectangular Plates in CNC Milling and
CNC WEDM.
G Code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G04 Dwell
G17 X Y plane selection
G18 Z X plane selection
G19 Y Z plane selection
G28 Return to reference position
G30 2nd, 3rd and 4th reference position return
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation + direction
G44 Tool length compensation – direction
G49 Tool length compensation cancel
G53 Machine coordinate system selection
G54 Workpiece coordinate system 1 selection
G55 Workpiece coordinate system 2 selection
G56 Workpiece coordinate system 3 selection
G57 Workpiece coordinate system 4 selection
G58 Workpiece coordinate system 5 selection
G59 Workpiece coordinate system 6 selection
G68 Coordinate rotation
G69 Coordinate rotation cancel
G73 Peck drilling cycle
G74 Left-spiral cutting circle
G76 Fine boring cycle
G80 Canned cycle cancel
G81 Drilling cycle, spot boring cycle
G82 Drilling cycle or counter boring cycle
G83 Peck drilling cycle
G84 Tapping cycle
G85 Boring cycle
G86 Boring cycle
G87 Back boring cycle
G88 Boring cycle
G89 Boring cycle
G90 Absolute command
G91 Increment command
G92 Setting for work coordinate system or clamp at maximum spindle speed
G98 Return to initial point in canned cycle
G99 Return to R point in canned cycle
3.2.2 M Code
M code is a Machine Code or Miscellaneus Code, which is used for machine
functions in all CNC machines.
M code Description
M00 Program stop
M01 Optional program stop
M02 End of program
M03 Spindle start forward CW
M04 Spindle start reverse CCW
M05 Spindle stop
M06 Too change
M07 Coolant ON – Mist coolant/Coolant thru spindle
M08 Coolant ON – Flood coolant
M09 Coolant OFF
M19 Spindle orientation
M28 Return to origin
M29 Rigid tap
M30 End of program (Reset)
M41 Low gear select
M42 High gear select
M94 Cancel mirror image
M95 Mirror image of X axis
M96 Mirror image of Y axis
M98 Subprogram call
M99 End of subprogram
3.3 Basics of G Code and M Code in a CNC milling program

G21 Matric code

G00 G28 G91 Z0 home position
T1 M6 tool 1change at home position
S2200 M3 spindle speed(rpm) clockwise on
G00 G40 G90 G54 X50 Y50 position of rapid from spindle center
absolute with work offset
G43 H1 Z100 tool height compensation
G00 Z2 rapid travers at 2 mm in z axis
G01 Z0 slow feed motion touch on solid surface
G01 Z10 F50 take depth in material
G01 Y80 F400 Profile on slot machining with cut feed
motion

EXAMPLE :-

Ø10 slot milling tool

G21;
G28 G91 Z0;
T1 M6;
S2200 M3;
G00 G40 G90 G54 X50 Y50;
G43 H1 Z100;
G00 Z2;
G01 Z0 F100;
M97 P11 L10;
G00 Z100;
M30;
N11;
G91;
G01 Z-1 F50;
G90;
G01 Y80 F400;
X80;
X50;
Y20;
X20;
X50;
Y50;
X20;
Y80;
Y50;
X80;
Y20;
Y50;
X50;
M99;

III
OPERATING OF CNC MILLING MAACHINE
3.1 Machine Specification
NAME CNC MILLING MACHINE (MADE IN USA)
CONTROLLER -HASS
MODEL - TOOL ROOM MILL 1(TM1)
MACHINE POWER -4.5 HORSE POWER
MACHINE RATE - X (162), Y (305), Z (300)
MAXIMUM RPM - 4000 RPM
TOOL CHANGE STATION - 10
ISO 4.0
PROGRAM MEMORY - 1 MB
LUBRICATION LITHION GREASE ONCE IN THREE DAYS
PNUMATIC AIR MINIMAM – 100PSI
PANEL CONTROL TEMP – 30 TO 35 DEGREES

TRAVELS S.A.E METRIC

XAxis 30.0 in 762MM
Y Axis 12.0 in 305MM
Z Axis 16.0 in 406MM
Spindle nose to table(max.) 20.0in 508
Spindle nose to table(min.) 4.0in 102
SPINDLE S.A.E METRIC
MAX RATING 7.5HP 5.6KW
Max speed 4000rpm 4000rpm
Max torque 33ft-lbf@1200rpm 45Nm@1200rpm
Drive system Direct speed, belt drive Direct speed, belt drive
Taper CT or BT 40 CT or BT 40
Bearing lubrication Grease packed Grease packed
Cooling Air cooled Air cooled
TABLE S.E.A METRIC
LENGHT 47.8in 1213mm
width 10.5in 267mm
t-slot width 0.630in 16mm
T slot center distance 4.00in 102mm
Number of 3 std t-slots 3 3
Max. weighton table 1000lb 454kg
FEEDRATES S.A.E METRIC
MAX CUTTING 200
RAPIDS ON X