Advanced Machining Process

(Summer Internship 2019)

Brief Summary On Advanced Machining Process

By:

Karan Lal
(1641018263)
Under The Guidance of:
Dr. S. Tripathy

Department of Mechanical Engineering

ITER
SOA
(DEEMED TO BE UNIVERSITY)
1
Table of contents:

Topic Page No
1. Engineering Drawing -------------------------------------------------------------------- 4-6
2. Material Selection ------------------------------------------------------------------------ 7-9
3. Machining -------------------------------------------------------------------------------- 10-11
4. Introduction to CNC --------------------------------------------------------------------- 13
4.1 Working Principle ------------------------------------------------------------------- 13-14

4.2 Parts Of CNC------------------------------------------------------------------------- 15

4.3 Different Operations on CNC ------------------------------------------------------ 16

4.4 CNC Job------------------------------------------------------------------------------- 17

5. Application of CNC Machines ---------------------------------------------------------- 18-19

6. G Code And M Code --------------------------------------------------------------------- 20-21

7. Programmme Performed ----------------------------------------------------------------- 22

8. Master Cam --------------------------------------------------------------------------------- 23

9. What I Learnt for Myself ---------------------------------------------------------------- 24

10. Conclusion ------------------------------------------------------------------------------- 25

2
 CERTIFICATE

This is to certify that Summer Internship 2019 on Advanced

Machining Process has been completed by Karan Lal of
Institute of Technical Education and Research, Bhubaneswar.
He is bonafide student and his entire summer internship was
carried out by him under our supervision. He has nicely done
the projects and results were good.

In our opinion his internship on Advanced Machining Process

has reached the standard fulfilling the requirement for the
award of certificate of the internship programme in
accordance with the regulations of the University.

Dr. Sasmeta Tripathy Dr. DhirendarNath Thatoi

3
 1. ENGINEERING DRAWING

Engineering drawing most commonly referred to as engineering graphics is the art of

manipulation of designs of a variety of components especially those related to
engineering. It primarily consists of sketching the actual component, for example a
machine with its exact dimensions. The scale of dimensions is suitably adjusted so as to
properly fit within the contours of the drawing sheet.
As a Technologist we will inevitably be required to communicate with different people
for different reasons. In some situations, communications will be sufficiently taken care
of by use of plain text. However, in other situations text alone may not suffice and a more
specialized form of communication i.e. technical and engineering drawing may prove
irreplaceable useful.
Drawing is just like photography which is one of the basic forms of visual
communication. Drawing is used to record objects and actions of everyday life in an
easily recognizable manner. There are two major types of drawings: artistic drawings and
technical drawings.
Artistic Drawings: These are a form of freehand representation that makes use of
pictures to provide a general impression of the object being drawn. There are no hard
rules or standards in the preparation of artistic drawings. They are simply drawn by artists
based more or less on one’s talent and skills. Although these drawings are often very
attractive and they find very limited use in the world of science.
Technical Drawings: These are detailed drawings drawn accurately and precisely. They
are pictures that have been prepared with the aid of mathematical instruments in order to
record and transmit technical information. They provide an exact and complete
description of things that are to be built or manufactured. o Technical drawings do not
portray the objects the way they directly appear to the eye o They make use of many
specialized symbols and conventions in order to transmit technical information clearly
and exactly. To understand and correctly interpret technical drawings, one needs to
acquaint oneself with the fundamentals of technical drawing – hence the purpose of this
course.

4
Engineering drawing is the most important aspect of mechanical engineering as it is the
fundamental need to develop the design and assembly of a machine. While the
interpretation of a component in terms of sketching can be done in various methods,
related to descriptive geometry, the three most necessary techniques of drawing or
projection are:

1. Orthographic Projection: In this method the object is placed in space in such a

way that the front view of it is captured in the vertical plane, and the top view of
the same, is captured in the horizontal plane. The projections of the object are
perpendicular with the planar screen and hence the name 'orthographic'.
2. Perspective Projection: This is a simple technique of drawing an object as how
one views it. The observer's eye position, height, and the distance from the object,
all influence the outcome of the drawing. Two sub-methods are adopted for this
projection technique namely Visual Ray Method and Vanishing Point Method.
3. Isometric Projection: This form of projection gives the total detail of the
component under consideration. The basic principle behind isometric projection is
that it involves the consideration of three axes that are inclined to each other
making equal angles (thus the name since iso- means equal) with each other (120
deg). This is followed by transfer of actual dimensions to the isometric scale
involving some basic trigonometric calculations.

Standard Orthographic Projections

Two standards are commonly in use in orthographic projection of drawings; the First
Angle Projection (European projection) and the Third Angle Projection (American
projection). It should be noted that corresponding views are identical in both methods of
projection except for their relative positions on the drawing paper.

5
The First Angle Projection and the Third Angle Projection

6
 MATERIAL SELECTION
In material science engineering understanding the material selection process is the key to
engineering any application and part design. Material selection is the foundation of all
engineering applications and design. This selection process can be defined by application
requirements, possible materials, physical principles, and selection.

The design or function of the part or application is the application requirements. Using
material science physical principles we can change material properties. Three common
physical principles we can use for functional material strengthening are densification,
composites, and alloying. There many manufacturing techniques used to strengthen and
form materials as well. Densification is the most common and necessary way to
strengthen any material. In general, this increases the tensile strength by reducing the
porosity of the material.

The standard composite rule of mixtures is when the standard matrix is soft or pliable and
the reinforcing material is tensile strong. The selection of mixture proportions can be
aimed to achieve optimum mechanical behaviour of the harden product. Selection can
result in the change of the strength, consistency, density, appearance, and durability.

The alloying of metals is one of the oldest and most fundamental material processing
techniques. An alloy is a solid solution that is composed of two or more elements. There
is a solvent (majority composition) and a solute. The solute element can strengthen the
overall solid solution by different element size, density, and other material properties.

Given the application requirements, possible materials, and physical principles we can
select the best material. Thus in the selection of a material: First we decide on the
requirements of the application. Second, we decide on the possible materials we can use
in the application. Third, we decide what changes in the material properties are needed.
Lastly we decide which material out of the possible materials best fulfils the requirements
of the application given possible changes in the material properties.

Basic Facts to Consider for Material Selection in Engineering

Material selection is one of the foremost functions of effective engineering design as it
determines the reliability of the design in terms of industrial and economical aspects. A
great design may fail to be a profitable product if unable to find the most appropriate
material combinations. So it is vital to know what the best materials for a particular
design are. In this aspect engineers use several facts of materials to come to the most
reasonable decision. They are mainly concentrated on the properties of the materials
which are identified as the potential materials for that specific design.

7
1. Mechanical properties
When a certain design is going to be actually produced it must be subjected to a number
of manufacturing practices depending on the material and the design process. At the
completion of production, it must be totally fit for the service phase, too. In order to
predict the reliability of both of these requirements, the materials must be able to
withstand a certain load. Therefore, the material must possess a certain strength and
stiffness. Selected materials are examined for strength and stiffness values, and then
potential materials are further inspected for other desired properties. Material selection is
one of the prime concerns in mechanical engineering design as mechanical engineers
possess great deals with various loads and temperature variations.

2. Wear of materials
Wear is a problem when the materials are contacting each other in a product. So, it must
be ensured that the selected materials have sufficient wear resistance. One of the best
examples for this is designing gears to cope with wear. There are many production
techniques available to improve the wear resistance and make the material is more
suitable for the application. This is also very important factor to consider when selecting
a material for a particular design. In the engineering design process this has to be
considered with great care.

3. Corrosion
The importance of material selection in engineering is clearly visible in corrosive
environments. Also, it is an important engineering design criterion for designs open to the
environment for a longer period of time. Some materials are very likely to be corroded in
the service depending on the service environment. Metals like iron are heavily prone to
corrosion if it not prepared to resist corrosion. Therefore, it must be assured that the
material is capable of being employed for the particular design before selecting it.
Painting or any other surface coating method, cathodic protection, etc. are possible ways
to minimize the effect and increase the service life.

4. Ability to manufacture
Although the material is well capable of using for the design, it may be difficult to
manufacture. This is particularly applicable in mechanical engineering design. If this
selection criteria are neglected the manufacture process might be very costly making it
unprofitable as a commercial product. So before selecting the materials this fact also must

8
be considered. These facts are widely varied with the type of manufacturing method. For
an example, when producing a gear its dimensions must be very accurate. Otherwise the
application may not provide the expected performance. To make the dimensions more
accurate it has to be machined in the production. So, the selected material must able to be
machined with a minimum cost. Otherwise there is no point of selecting that material for
that particular gear.

5. Cost
Cost is a critical fact to consider when selecting materials for a certain design for most
products because they are facing a severe competition in the market. The cost factor can
be neglected when performance is given the top priority. When estimating costs, all the
associated cost factors must be considered to get a more reasonable value. It may involve
the transportation, processing, etc. costs. The end of material selection is not the end of
the design process. The best material may be yet to come. Also, it has to perform desired
functions satisfactorily, not for just one or two days, but for a long period of time. In this
tough test, the design may fail comprehensively. Therefore, the designer has to consider
the ways to improve the performance in all possible aspects. So, the design process and
the material selection are a continuous process unless the manufacturer has no intention
to survive the ever-challenging market battleground.

9
 MACHINING
Machining is a term used to describe a variety of material removal processes in which a
cutting tool removes unwanted material from a workpiece to produce the desired shape.
The workpiece is typically cut from a larger piece of stock which is available in a variety
of standard shapes such as flat sheets, solid bars, hollow tubes, and shaped beams.
Machining can also be performed on an existing part, such as a casting or forging.

Flat Sheet Rectangular Bar

Round tube I-Beam

Parts that are machined from a pre-shaped workpiece are typically cubic or cylindrical in
their overall shape, but their individual features may be quite complex. Machining can be
used to create a variety of features including holes, slots, pockets, flat surfaces, and even
complex surface contours. Also, while machined parts are typically metal almost all
materials can be machined, including metals, plastics, composites, and wood. For these
reasons machining is often considered the most common and versatile of all
manufacturing processes.

10
 Machining includes a variety of processes that each removes material from an initial
workpiece or part. The most common material removal processes is referred to as
conventional or traditional machining are those that mechanically cut away small chips of
material using a sharp tool. Non-conventional machining processes may use chemical or
thermal means of removing material. Conventional machining processes are often placed
in three categories - single point cutting, multi-point cutting, and abrasive machining.
Each process in these categories is uniquely defined by the type of cutting tool used and
the general motion of that tool and the workpiece. However within a given process a
variety of operations can be performed each utilizing a specific type of tool and cutting
motion. The machining of a part will typically require a variety of operations that are
performed in a carefully planned sequence to create the desired features.

Material removal processes

• Mechanical
▪ Single-point cutting
▪ Turning
▪ Planning and shaping
▪ Multi-point cutting
▪ Milling
▪ Drilling
▪ Broaching
▪ Sawing
▪ Abrasive machining
▪ Grinding
▪ Honing
▪ Lapping
▪ Ultrasonic machining
▪ Abrasive jet machining
• Chemical
• Chemical machining
• Electrochemical machining (ECM)
• Thermal
• Torch cutting
• Electrical discharge machining (EDM)
• High energy beam machining

11
 INTRODUCTION TO CNC
CNC (Computer Numerical Control) machining is a subtractive manufacturing
technology: parts are created by removing material from a solid block (called the blank or
the workpiece) using a variety of cutting tools.

The basic CNC process can be broken down into 3 steps. The engineer first designs the
CAD model of the part. The machinists then turn the CAD file into a CNC program (G-
code) and sets up the machine. Finally, the CNC system executes all machining
operations with little supervision, removing material and creating the part.

There are two main types of CNC machining systems: milling and turning. Each is better
suited for manufacturing different geometries.

12
 4.1 WORKING PRINCIPLE
CNC milling is the most popular CNC machine architecture. In CNC milling, the part is
mounted onto the bed and material is removed using rotational cutting tools.

In CNC turning systems (also known as lathes), the part is mounted on a rotating chuck
and material is removed using stationary cutting tools. This way parts with symmetry
along their center axis can be manufactured. Turned parts are typically produced faster
(and at a lower cost) than milled parts.

Typically, CNC turning systems (also known as lathes) are used to create parts with
cylindrical profiles.

Non-cylindrical parts can be manufactured using modern multi-axis CNC turning

canter’s, which are also equipped with CNC milling tools. These systems combine the
high productivity of CNC turning with the capabilities of CNC milling and can
manufacture a very large range of geometries with (looser) rotational symmetry, such as
camshafts and radial compressor impellers.

13
 How the CNC Machine Works?
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. The
computer thus knows what exactly is to be done and carries out all the cutting processes.
CNC machine works like the Robot, which has to be fed with the program and it follows
all your instructions.

Some of the common machine tools that can run on the CNC are: Lathe, Milling
machines, Drilling Machine etc. The main purpose of these machines is to remove some
of the metal so as to give it proper shape such as round, rectangular, etc. In 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 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.

14
 4.2 PARTS OF CNC

• Headstock - Headstock of a CNC lathe machine has the main motor of CNC lathe
machine which drives the main spindle. Chuck is mounted on this main spindle.

• CNC Lathe Bed - The tool turret travel over the CNC lathe bed, which is
specially hardened so any kind of machining can’t affect them.

• Chuck- CNC lathe machine chuck grips the component which are to be machined.
Chuck itself has many parts. Jaws are mounted on the chuck to grip the part.

• Tailstock- Tailstock are mostly used to give an extra gripping force for
component machining. For long components machining they provide extra force
on the other end so machining process can complete smoothly.

• Tailstock Quill- Actually you move the whole tailstock forward or reverse, but in
that way it is not used to grip the part, but tailstock is travelled to a point near the
component and then it is set there, after that you actuate the tailstock quill which
travel either with hydraulic pressure or pneumatic pressure to grip the component.

• Foot Switch or Foot Pedals- Foot switches are used to actual the chuck and
tailstock quill. Through these pedals CNC machinist’s open and close the chuck to
grip the component, the same way tailstock quill is taken to forward position or
reversed through theses pedals.

• CNC Control Panel- The brain of the CNC machine, all the CNC program is
stored inside this panel, CNC machinists control the whole machine through the
keys on this panel. CNC machinist’s stat/stop the machine move axis by pressing
different keys on this panel. They can enter new program by using this panel,
programs can be transferred by using USB port on this panel as well. So, this is the
main part which controls the whole CNC machine.

• Tool Turret- The tool is mounted on the tool turret which are used for component
machining. Tool turrets vary in shapes and number of tools that can be mounted
on them.

15
 4.3 DIFFERENT OPERATIONS ON CNC

• Drills
• EDMs
• Embroidery machines
• Lathes
• Milling machines
• Canned cycle
• Wood routers
• Sheet metal works (Turret punch)
• Wire bending machines
• Hot-wire foam cutters
• Plasma cutters
• Water jet cutters
• Laser cutting
• Oxy-fuel
• Surface grinders
• Cylindrical grinders
• 3D Printing
• Induction hardening machines
• Submerged welding
• Knife cutting
• Glass cutting

16
4.4 CNC JOB

17
 5. APPLICATION OF CNC MACHINES

Metal Removal Industries

The metal removing industries remove the unwanted metals from the raw materials to
give it the desired shape as per the requirements. These can be automotive industries for
who manufactures the Pulleys, shafts, gears, cylinders and many other automotive parts.
It can be of any type of manufacturing industries for making various types of shaped
products which may include round, square, rectangular, threaded or other shaped
products. There are many other types industries where the metal removal works are also
performed. All these metal removal works are performed by different machine tools like
lathe, milling machine, drilling machine, boring machine, shaping machine, reamer, etc.
Conventionally these lathe machines are operated by the operators, but the CNC versions
of all these machines are now used widely. We can carry out almost all machining
operations with the CNC machine. We can also carry out all the turning operations such
as facing, boring, turning, grooving, knurling, and threading on your CNC turning
centers. On our CNC grinders we can carry out the grinding of the internal diameter,
outer diameter, and also the flat surfaces. The Contour Grinding technology enables u to
grind surfaces of all shapes.
Metal Fabricating Industries
There are many small scales or large-scale industries that require many types of thin or
thick plates like steel plates or other metal plates, which are required for various
purposes. In fabrications industry the machining operations are performed on such plates
with the help of CNC lathe machine. In these industries the CNC machines are used for
various machining operations like shearing, flame or plasma cutting, punching, lasers
cutting, forming, and welding and many other types of applications. To bring the plates to
their final shape CNC lasers and CNC plasma cutters are used commonly. To punch the
holes in the plates of all sizes CNC turret punch presses are being used. If you want to
bend the plate so as to give it a final shape, you can use CNC press brakes. In some cases,
the CNC back gages are coupled with the shearing machines, this enables controlling the
length of the plate to be sheared as for different applications.

18
Electrical Discharge Machining (EDM) Industry
The Electrical Discharge Machine removes the metal by generating sparks which burns
the metal. There are two types of EDM with the CNC automation – Vertical EDM and
Wire EDM. The Vertical EDM needs an electrode of the shape and size of the cavity that
is be made in the job. Wire EDM is used to make the punch and die combinations for the
dies set that are used in the industries where fabrication is done.
Other Industries where CNC machines are used
There are many other industries which use CNC machines extensively. Industries like the
wood working industries which perform various operations like routing (similar to
milling operating) and drilling. CNC technology is also used in number of lettering and
engraving operations. There are also CNC machines for the electrical industry such as
CNC coil winders, and CNC terminal location and soldering machines.

19
 6. G CODE AND M CODE
CNC MILLING-

20
CNC TURNING-

21
 7. PROGRAMME PERFORMED

The program performed in the CNC is the border line of the job shown in figure 4.4-

O0001
T0000
M06T04
M03S1500
G00G90G54X0.0Y0.0Z5.0
G00X4.0Y4.0Z5.0
G01Z-1.0F100
X4.0Y96.0
X96.0Y96.0
X96.0Y4.0
X4.0Y4.0
G00Z100
M05
M30

22
 8. MASTERCAM

Mastercam (also MasterCAM) is a suite of Computer-Aided Manufacturing (CAM) and

CAD/CAM software applications. Founded in MA in 1983,[1] CNC Software, Inc. is one
of the oldest developers of PC-based computer-aided design / computer-aided
manufacturing (CAD/CAM) software. They are one of the first to introduce CAD/CAM
software designed for both machinists and engineers. Mastercam, CNC Software’s main
product, started as a 2D CAM system with CAD tools that let machinists design virtual
parts on a computer screen and also guided computer numerical controlled (CNC)
machine tools in the manufacture of parts. Since then, Mastercam has grown into the
most widely used CAD/CAM package in the world.
Mastercam’s comprehensive set of predefined toolpaths—including contour, drill,
pocketing, face, peel mill, engraving, surface high speed, advanced multi axis, and many
more—enable machinists to cut parts efficiently and accurately. Mastercam users can
create and cut parts using one of many supplied machine and control definitions, or they
can use Mastercam’s advanced tools to create their own customized definitions.
Mastercam also offers a level of flexibility that allows the integration of 3rd party
applications, called C-hooks, to address unique machine or process specific scenarios.
Mastercam's name is a double entendre: it implies mastery of CAM (computer-aided
manufacturing), which involves today's latest machine tool control technology; and it
simultaneously pays homage to yesterday's machine tool control technology by echoing
the older term master cam, which referred to the main cam or model that a tracer
followed in order to control the movements of a mechanically automated machine tool.

23
 WHAT I LEARNT FOR MYSELF

In this internship we have learnt various operations of CNC and got a brief knowledge of
the working of a CNC and various operations performed on it and its various parts. We
got the practical knowledge of machines and operations. We also got to know about the
various codes of G-code and M-codes of both CNC milling as well as CNC lathe.
We also learned how to generate G and M codes with the help of MasterCAM software.
We learned about the various safety measures to be taken before the machines are turned
on.
We learned designing of various jobs and their MasterCAM simulation.

24
 Conclusion

In this internship we have learnt various operations of CNC and got a brief knowledge of
the working of a CNC and various operations performed on it and its various parts. We
got the practical knowledge of machines and operations. We also got to know about the
various codes of G-code and M-codes of both CNC milling as well as CNC lathe.

25