GTTC REPORT 2019

1. INTRODUCTION AND HISTORY

The first Government Tool Room and Training Centre was established at Bangalore in 1972 with the
participation of the Karnataka State Government, in collaboration with the Government of Denmark under the
Bilateral Development Co-operation Agreement. The excellent performance of GTTC Bangalore, led the
Government of Karnataka to expand this organisation and got the second unit of GTTC started in 1992 with
DANIDA assistance.

Proliferation of technology for development of the industries with supply of skilled manpower is the key to
meet the needs of the global requirement. With this the Government of Karnataka encouraged GTTC to start 10
more sub-centres to train in the area of tool and die making in various parts of Karnataka. Among them
Government Tool Room and Training Centre at Hassan was established in 2001.

GTTC is an autonomous society, and a recognised Scientific and Research Organisation by the Government
of India. Govt. Tool Room and Training Centre (GTTC), is serving industry by way of precision tooling and
providing in well trained craftsmen the area of tool and die making

Today, the GTTC have acquired mastery in mould and die making technology and have blossomed into an
epitome of precision and quality in the development and manufacture of sophisticated moulds, dies and tools.

Fully aware of the rapid advancement in technology the world over, the GTTC is periodically adding
new technologies to the existing set of advanced equipment like CAD / CAM, CNC machines for tooling,
Precision Components, Laser for Industries, Rapid prototyping, vacuum casting etc.

GTTC is concentrating on the Integrated Development of the related segments of industries by way of
providing international quality tools, trained personnel.

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2. INTRODUCTION TO NC, CNC AND DNC

2.1 NUMERICAL CONTROL (NC)

Fig. 1. NUMERICAL CONTROL SYSTEM

Numerical control (NC) systems are hardware controls in which most of the functions are carried out by
electronic hardware based upon digital circuit technology. Numerical Control is a technique for controlling
machine tools or processes using coded command instructions. These coded command instructions are
interpreted and converted by NC controller into two types of signals namely; motion control signals and
miscellaneous control signals. Motion control signals are a series of electric pulse trains that are used to control
the positions and the speed of the machine table and spindle, whereas miscellaneous control signals are set of
ON/OFF signals to execute the spindle rotation and direction, control of coolant supply, selection of cutting tools,
automatic clamping and unclamping, etc. In motion control signals, each pulse activates a motion of one basic
length-unit (BLU).

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2.2 COMPUTER NUMERICAL CONTROL (CNC)

CNC machine is a machine that is used for automatic control in the industrial world. This machine is used
to control the performance of other machines used. Both NC (Numerical Control) and CNC (Computer
Numerical Control) is a term used to indicate that a manufacturing equipment; example lathes, milling machines,
etc., numerically controlled based computer that is able to read the instruction code N, G, F, T, and others, where
the codes will be instructed to CNC machines to work in accordance with a program that had been made to do
work-piece to be made, Operation using CNC machines, the accuracy of a product can be guaranteed up to
1/1000 mm (microns) workmanship mass product with exactly the same result at the right time of rapid
machining. CNC functions in this case more displace the work of the operator in a conventional machine tools.
Example: setting work tool or regulate the movement of the chisel until the position is ready to cut, cutting
motion and movement retraced early, and others. Similarly, the setting cutting conditions (cutting speed, feeding
speed and cutting depth) as well as other regulatory functions such as the replacement of a chisel, alteration,
power transmission (number of revolutions of the main shaft), and the direction of rotation of the main shaft,
setting the coolant and so forth. CNC machine tools equipped with a variety of cutting tools that can make
precise work-piece and can interpolate directed numerically (by number). CNC operating system parameters can
be changed through the software program (software load program) as appropriate. CNC has been widely used in
the metal industry. In this condition, CNC mechanical system used to control machines and metal cutting tools.
So how thick and long pieces of metal produced by metal cutting machine, can be set by the CNC machine.

Fig. 2. COMPUTER NUMERICAL CONTROL

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CNC controls are soft-wired NC systems as control functions are controlled by software programs.
Alternatively, Computer Numerical Control is the numerical control system in which dedicated, stored program
microprocessors are built into the control to perform basic and advanced NC functions. Control signals in CNC
systems are in the form of binary words, where each word contains fixed number of bits, 32 bits or 64 bits are
commonly used, representing different axial positions.

A CNC system consists of the following 6 major elements:

1. Input Device
2. Machine Control Unit
3. Machine Tool
4. Driving System
5. Feedback Devices
6. Display Unit

1. Input Device

• The program input device is the means for part program to be entered into the CNC control.

• Three commonly used program input devices are punch tape reader, magnetic tape reader, and
computer via RS-232-C communication.

2. Machine Control Unit

The machine control unit (MCU) is the heart of a CNC system. It is used to perform the following
functions:
It read the coded instructions, decode the coded instructions. Implement interpolations (linear, circular, and
helical) to generate axis motion commands and feed the axis motion commands to the amplifier circuits for
driving the axis mechanisms. And it receives the feedback signals of position and speed for each drive axis. To
implement auxiliary control functions such as coolant or spindle on/off and tool change.

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3. Machine Tool

CNC controls are used to control various types of machine tools. Regardless of which type of machine
tool is controlled, it always has a slide table and a spindle to control position and speed. The machine table is
controlled in the X and Y axes, while the spindle runs along the Z axis.

4. Feedback System

The feedback system is also referred to as the measuring system. It uses position and speed transducers to
continuously monitor the position at which the cutting tool is located at any particular instant. The MCU uses the
difference between the reference signals and feedback signals to generate the control signals for correcting
position and speed errors.

5. Drive System

Drives are used to provide controlled motion to CNC elements drive system consists of amplifier circuits,
drive motors, and ball lead-screws. The MCU feeds the control signals (position and speed) of each axis to
the amplifier circuits. The motors used for CNC system are of two kinds-

• Electrical –DC or AC Stepper motors and DC or AC servo motors

• Fluid - Hydraulic or Pneumatic

In CNC, usually stepper and servo electrical drives are used. They exhibit favourable torque-speed
characteristics and are relatively inexpensive.

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2.21 CONTROL PANEL OF CNC

Fig. 3. CONTROL PANEL

A CNC machine is normally controlled by a computer and software. However, most CNC machines have
a range of controls for manual use. It is rare for a CNC machine to be used manually as simple operations are best
carried out on cheap/basic/manual machines. When a CNC machine is used manually it is been used well below
its capability and specification.

1. Reset Button
The most important control button is usually the reset button. When the CNC machine is turned on, the reset
button is pressed by the machine operator. This zero the cutter, moving the cutter to coordinates 0, 0, 0 on the X,
And Z axis. In simple terms, the reset button moves the cutter to the corner of the machine, above the work table.
If the reset button is not pressed, it is possible that the CNC machine will start cutting the material in the wrong
place or even miss cutting the material and plunge into the work table.

2. Manual Control
The cutter can be controlled manually although this is rarely needed. The ‘X’ and ‘Y’ buttons control the
movement of the cutter along the horizontal surfaces. The ‘Z’ buttons control depth and up / down movement.

3. Stop Button
Most control panels have stop buttons. When pressed these stop the machine very quickly.

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4. Speed and Feed

On some CNC machines it is possible to manually vary the speed and feed of the cutter.

2.3 DIRECT NUMERICAL CONTROL (DNC)

Direct numerical control (DNC), also known as distributed numerical control (also DNC), is a common
manufacturing term for networking CNC machine tools. DNC networking or DNC communication is always required
when CAM programs are to run on some CNC machine control.

3. MACHINERIES

The CNC machines which we worked at GTTC are:

3.1. CNC lathe.

3.2. CNC milling.

3.1. CNC LATHE (FANUC SERIES Oi-TC)

Fig. 4. CNC LATHE

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3.11 SPECIFICATIONS

Table no. 1. CNC LATHE SPECIFICATIONS

EQUIPMENT UNIT RANGE

Chuck diameter Mm 200
Max.cutting diameter Mm 200
Max. Cutting length Mm 500
Spindle bore diameter Mm 55
Spindle rotating speed Rpm 45-4000
Main motor power(AC) KW 11
Hydraulic unit power motor KW 1.5
Chip conveyor motor KW 0.2
Coolant pump motor KW 0.55
Weight KG 5000

Some view lathes as the only universal CNC machine tool because a lathe can make all of the parts
needed for another lathe. A lathe spins the work-piece in a spindle while a fixed cutting tool approaches the
work-piece to slice chips off of it. The act of cutting a work-piece on a lathe is called “Turning”.

Computer numerical control (CNC) has been incorporated into a variety of new technologies and
machinery. One such machine of this sort that is used for a wide array of production processes is known as a
CNC lathe.

Due to technological advancements, CNC lathes are quickly replacing some of the older and more
traditionally used production lathes, such as the multi-spindle. CNC lathes come with a number of benefits. They
can be easily set up and operated. They offer tremendous repeatability, along with top-notch accuracy in
production.

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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 function during the production phase.
Thanks to this technology, the machine operator generally does not need to know as much about the specifics of
the machine he or she oversees compared to what machine operators must know about more traditional lathes that
require some manual labour.

CNC lathes are designed in a variety of ways, based on the manufacturer producing the machine.
However, most have some significant similarities in their composition. A turret is a part of the machine that holds
the tool holders and indexes them accordingly. The spindle is designed to hold the work piece. In addition, there
are slides that allow the turret to move in multiple axes at the same time. CNC machines are typically completely
enclosed for health and safety reasons of any operators present.

There has been considerable growth in the CNC machining industry, particularly when it comes to the
design and use of CNC lathes. 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.

3.12 CNC LATHE PREPARATION

• Checking to make sure the lathe is lubricated and learning to schedule routine maintenance in accordance
with workplace standards.
• Learning to translate product specifications and work instructions into a machine-readable format.
• Establishing criteria for tool selection with efficiency and safety in mind.

• Installing work-piece handling devices and inserting tools into their corresponding slots.

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• Learning to load a machining program into the CNC lathe and aligning its data points according to project
requirements.

• Producing sample parts to verify if they match specifications and operator instructions.

3.2 CNC MILLING MACHINE (SEIMENS CONTROLLER)

Fig. 5. CNC MILLING

3.21 SPECIFICATIONS

Table No. 2. CNC Milling Specifications

CNC controller Siemens control

Axis Motor & Drive AC Servo (1.3 Nm)
Spindle Motor 1 HP with VFD (3PH).
Spindle Motor Speed 100 to 3000 rpm.
Lubrication System Automatic (Motorized).
Max. Depth Of Cut 1 mm Possible.
Axis Control 3 axis.
Axis Plane XY, XZ & YZ.
Max. Rapid Feed 4000 mm/Min.
Table Load Capacity 100 Kg.

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3.22 ABOUT CNC MILLING MACHINE

CNC milling is a specific form of computer numerical controlled (CNC) machining. Milling itself is a
machining process similar to both drilling and cutting, and able to achieve many of the operations performed by
cutting and drilling machines. Like drilling, milling uses a rotating cylindrical cutting tool. However, the cutter in
a milling machine is able to move along multiple axes, and can create a variety of shapes, slots and holes. In
addition, the work-piece is often moved across the milling tool in different directions, unlike the single axis
motion of a drill.

CNC milling devices are the most widely used type of CNC machine. Typically, they are grouped by the
number of axes on which they operate, which are labelled with various letters. X and Y designate horizontal
movement of the work-piece (forward-and-back and side-to-side on a flat plane). Z represents vertical, or up-and-
down, movement, while W represents diagonal movement across a vertical plane. Most machines offer from 3 to
5 axes, providing performance along at least the X, Y and Z axes. Advanced machines, such as 5-axis milling
centres, require CAM programming for optimal performance due to the incredibly complex geometries involved
in the machining process. These devices are extremely useful because they are able to produce shapes that would
be nearly impossible using manual tooling methods. Most CNC milling machines also integrate a device for
pumping cutting fluid to the cutting tool during machining.

3.24 CNC MILLING CONTROL PANEL

At its tenet machine control panel on each brand CNC Milling machine have the same functionality and
usability, usually located on the type of button that is in use, and there are also several function keys and uses a
combination of a few buttons on the panel, because the functionality and usability of each button in the control
panel have in common. The functioning of each button on the panel is discussed below:
1. Emergency Stop
It stops all the operating systems on the machine.
2. Edit
It is used to fix or create a new program or for input and output of the external device.
3. Memory
It is used to perform the execution of the program that has been created (AUTO MODE).
4. MDI
It options for the mode (Manual Data Input).

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5. Handle
It is used to regulate the movement of the axis manually using the handle.
6. Jog
It is used to regulate the movement of the axis manually, the movement speed is set using the "Override feed-
rate" and the movement of the axis is set using switches and buttons select axis.
7. RPD
It is used to regulate the movement of the axis manually, the movement speed is set using the "Rapid Override".
And the movement of the axis is set using switches and buttons select axis.
8. ZRN
It is used to restore the axis to the initial axis machines or point 0 on the machine.
9. Regulation
It is used to decrease or increase the spindle rotation speed manually.
10. Feed-rate Override
It is used to change the speed of feeds between 0% - 150 % of the speed.
11. Spindle Speed
It is used to change the spindle RPM of the engine between 50-120%.

3.3 CNC WIRE EDM (MITSUBISHI CONTROLLER)

Fig. 6. CNC WIRE EDM

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3.31 SPECIFICATIONS

Table no. 3. CNC WIRE EDM SPECIFICATIONS

DESCRIPTION MITSUBISHI RA90M (AT) MITSUBISHI RA90M

Max. work piece dimension 860 x 760 x 160 860 x 760 x 160
[mm] (in)
Maximum work piece 350 350
weight
Table dimensions 572 x 478 572 x 478
Machining range (X x Y) 320 x 250 320 x 250
Table rapid-feed speed 1300 1300
[mm/min] (in/min)
Wire diameter [mm] (in) 0.2 - 0.3 0.2 - 0.3
Maximum wire feed rate 15 15
[m/min] (in/min)
Maximum work piece 160 -----
thickness [mm] (in)
Taper machining device Standard standard
Z-Axis stroke (manual 150 150
operation)
Max. taper angle [mm] (in) 15 for work piece 100 mm 15 for work piece 100 mm
thick thick
Max. machining current 50A 50A
Minimum drive unit [u m] 0.05um 0.05um
(in)
CNC Controller Mitsubishi 64 bit Mitsubishi 64 bit

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3.32 ABOUT WIRE EDM

Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove
metal by means of electric spark erosion. In this process an electric spark is used as the cutting tool to cut (erode)
the work piece to produce the finished part to the desired shape.

The wire-cut type of machine arose in the 1960s for the purpose of making tools (dies) from hardened
steel. The tool electrode in wire EDM is simply a wire. The first CNC EDM machine was produced in 1976.
EDM wire cutting uses a metallic wire to cut a programmed contour in a work piece. Extrusion dies and blanking
punches are very often machined by wire cutting. Cutting is always through the entire work piece. To start
machining it is first necessary to drill a hole in the work piece or start from the edge. On the machining area, each
discharge creates a crater in the work piece and an impact on the tool. The wire can be inclined, thus making it
possible to make parts with taper or with different profiles at the top and bottom. There is never any mechanical
contact between the electrode and work piece. The wire is usually made of brass or stratified copper, and is
between 0.1 and 0.3 mm diameter. Depending on the accuracy and surface finish needed, a part will either be one
cut or it will be roughed and skimmed. On a one cut the wire ideally passes through a solid part and drops a slug
or scrap piece when it is done. This will give adequate accuracy for some jobs, but most of the time, skimming is
necessary. A skim cut is where the wire is passed back over the roughed surface again with a lower power setting
and low pressure flush. There can be from one to nine skim passes depending on the accuracy and surface finish
required. Usually there are just two skim passes. A skim pass can remove as much as 0.002" of material or a as
little as 0.0001". During roughing (i.e. the first cut) the water is forced into the cut at high pressure in order to
provide plenty of cooling and eliminate eroded particles as fast as possible. During skimming (accuracy / finish
cuts) the water is gently flowed over the burn so as not to deflect the wire.

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4. STRUCTURE OF NC PART PROGRAM

In general, several commands are grouped together to accomplish a specific machining operation, hence the
use of a block of information for each operation. Each command gives a specific element of control data, such as
dimension or a feed rate. Each command within a block is also called a word. The way in which words are arranged
within the block is called block format. Three different block formats are commonly used, (Fixed sequential format,
Tab sequential format and Word address format) with this type of format, each type of word is assigned as address
that is identified by a letter code within the part program. Thus the letter code specifies the type of word that follows
and then its associated numeric data is given. For example, the code T represents a tool number. Thus a word of the
form T01 would represent tool number 1. Theoretically, with this approach, the words in a given block can be entered
in any sequence and the controller should be able to interpret them correctly. With the word address format only the
needed words for a given operation have to be included within the block. The command to which the particular
numeric data applies is identified by the preceding address code. Word format has the advantage of having more than
one particular command in one block something that would be impossible in the other two formats.

• N-CODE: Sequence number, used to identify each block with in an NC program and provides a means by
which NC commands may be rapidly located. It is program line number. It is a good practice to increment each
block number by 5 to 10 to allow additional blocks to be inserted if future changes are required.

• G-CODE: Preparatory Word, used as a communication device to prepare the MCU. The G-code indicates that a
given control function such as G01, linear interpolation, is to be requested.

• X, Y & Z-CODES: Coordinates. These give the coordinate positions of the tool.

4.1 COMMONLY USED WORD ADDRESSES

• F-CODE: Feed rate. The F code specifies the feed in the machining operation.

• S-CODE: Spindle speed. The S code specifies the cutting speed of the machining process.

• T-CODE: Tool selection. The T code specifies which tool is to be used in a specific operation.

• M-CODE: Miscellaneous function. The M code is used to designate a particular mode of

operation for an NC machine tool. I, J & K-CODES: They specify the centre of arc coordinates

from starting. Sequence and format of words:

N3 G2 X+1.4 Y+1.4 Z+1.4 I2.0 J2.0 K2.0 F5 S4 T4

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4.2 MACHINE CODES (M-CODES)

M00 Mandatory Program Stop

M01 Optional Program Stop

M02 Program End

M03 Spindle Forward/Clockwise

M04 Spindle Reverse/Counter clockwise

M05 Spindle Stop

M06 Tool change

M07 Mist Coolant On

M08 Flood Coolant On

M09 All Coolant Off

M19 Spindle Orient

M30 Program End and Rewind

M40-M45 Gear Change

M47 Repeat Program from First Line

M48 Enable Feed/Speed Overrides

M49 Disable Feed/Speed Overrides

M98 Subprogram Call

M99 Return from Subprogram / Rewind

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4.3 PREPARATORY FUNCTIONS (G-CODES):

Fig. 7. G-CODES

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5. TYPICAL SAMPLE PROGRAMS

5.1 SAMPLE PROGRAM ON MILLING

Fig. 8. MILLING SAMPLE

N5 G90 G71
N10 M06 T01
N15 G92 X-100 Y86 Z95
N20 G00 X0 Y0 S2500 M03
N25 Z12.5
N30 G01 Z-12.5 F150
N35 X-20 Y30
N40 G02 X10 Y100 R80
N45 G01 X140 Y60
N50 G02 X150 Y0 R50
N55 G01 X0 Y0
N60 G00 Z12.5
N65 G91 G28 Z0 M05
N70 G91 G28 X0 Y0
N75 M30

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6. ADVANTAGES AND DISADVANTAGES AND APPLICATIONS OF CNC

6.1 ADVANTAGES

1. It requires semi-skilled labor.

2. Higher flexibility.

3. The manufacturing process can be simulated virtually and no need to make a prototype or a model. This saves
time and money.

4. Once programmed, these machines can be left and do not require any human intervention, except for work
loading and unloading.

5. These machines can manufacture several components to the required accuracy without any fatigue as in the
case of manually operated machines.

6. Savings in time that could be achieved with the CNC machines are quite significant.

7. Wastage is minimum.

8. Suitable for batch production.

9. Less space is required.

10. More operational safety.

11. Quality of product is high.

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6.2 DISADVANTAGES
1. It requires skilled programmer.

2. It is not suitable for small scale production.

3. Maintenance cost is more.

4. CNC machines are generally more expensive than manually operated machines.

5. The CNC machine operator only needs basic training and skills, enough to supervise several machines.

6. Increase in electrical maintenance, high initial investment and high per hour operating costs than the traditional
systems.

6.3 APPLICATIONS

1. CNC was initially applied to metal working machinery: Mills, Drills, boring machines, punch presses etchant
now expanded to robotics, grinders, welding machinery, EDM's, flame cutters and also for inspection equipment
etc.

2. CNC electrical discharge machining (EDM).

3. CNC fabrication machines (sheet metal punch press, bending machine, or press brake).

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7.NARRATION
The internship training at GTTC Hassan was started on 09/07/2018, on the first day of training they showed us
the GTTC campus and infrastructure of GTTC. All the students were divided into two batches groups and each
batches were allotted with a trainer, and Mr. CHETAN was our trainer. The internship classes were conducted
from 9.30 AM to 1.30 PM. During first 10 days of training they taught us about CNC programming. And they
taught us CNC simulation in lab. After the theory classes are over, during remaining days we were given hands
on training with CNC machines like CNC wire EDM, CNC lathe, CNC milling. And they trained us to how to
prepare, write CNC code in CNC machines and how to perform turning operations in CNC lathe, milling
operation in CNC milling and wire EDM operations to obtain desired model shape using aluminium as raw
material pieces. During internship we had done two models among them we made one turning model and one
milling model. And finally the internship training ended on 07/08/2018 and all the interns were awarded with 4
weeks of internship certificate.

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8. SELF EVALUATION

It was 4 weeks internship on CNC machines. In routine syllabus we had studied only theory about CNC machines, but
this 30 days of internship helped me learn a lot about CNC programming. Before going to GTTC I had not seen a
CNC machines, here I got to see and work with CNC lathe and CNC milling. It started with the basic introduction of
NC and CNC and also about the difference between CNC and NC. I also gained knowledge about the advantages and
disadvantages of CNC. The starting few days the trainer gave a brief introduction about the preparatory functions (G-
codes) and machine codes (M-codes). It was overall a new experience for me and I enjoyed learning new things. The
most enjoyable part of the internship course was that we had few hours of theory sessions followed by practical
sessions. The practical sessions include hands on experience of CNC machines and also they let us practice the
simulations of the written program in simulation lab. I got to know about FANUC control and SEIMENS control in
which CNC lathe and CNC milling is programmed respectively. It was very difficult to learn G-codes and M-codes in
the beginning but after starting writing CNC programs I felt confident about it. Finally 4 weeks internship helped me
to learn lot about CNC machines, CNC programming.

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9.APPENDIX

Fig. 9.
Model
produced
by CNC
turning
machine
Fig. 10.
Model
produced by CNC milling Machine

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10. REFERENCES

• MANUAL OF CNC FROM BHAL JHANSI.

• http://en.wikipedia.org/wiki/computer_numerical_control.
• http://www.seminarprojects.com/cnc.
• Thomsonnet.com
• www.google.com
• www.studymafia.com

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