Project Report On

CNC LATHE : MRR AND SURFACE ROUGHNESS

OF
Bachelor Of Technology In Mechanical Engineering
BY
RAHUL DAS(34900719022)
AMLAN SARKAR(34900719017) SUJOY DEY(34900719002)
SUPRIYO MONDAL(34900718023) ARIJIT SHIT(34900718054)
Under The Guidance of
Prof. PRASENJIT DAS

COOCHBEHAR GOVERNMENT ENGINEERING COLLEGE

Abstract
Machining is an important manufacturing process that is used
in a wide range of applications. From aerospace applications to
the manufacturing of energy systems and medical robots, we
see a major reliance on machining. In this project we focus on
gaining an improved understanding of the mechanics of
machining by CNC LATHE and the different factors that
contribute to part quality. We acquired primary machine shop
skills that provided us an opportunity to mill and drill a class of
components to specified dimensions and tolerances. Through
hands-on machining, we discovered many different factors
involved in milling, drilling, and the effects they exhibited on
the tolerance and surface finish of a part. The main relevant
factors that we examined were tool selection, speeds, feeds,
and material selection. The extent to which these factors can
influence machining is presented. With CNC machining , three
dimensional cutting tasks can be accomplished in a single set of
prompts. So in todays age of globalization, the knowledge
about CNC LATHE MACHINING is quite optimum for every
single Engineering student and our main goal is to achieve it
and to discover the probable advanced applications of CNC
LATHE machining.
 PROJECT TITLE: CNC LATHE

Q. What is CNC Machine?

Ans: Computerized Numerical Control Machine (Computer +

Numerical control)
> Numerical control is a programmable automation in which process is
control by numbers letters and symbols.
>CNC machining is a process used in the manufacturing sector that
involves the use of computers to control machine tools like Lathes
, mills and grinders.

Q. Why is CNC machining necessary?

Ans: 1.To manufacture complex curved geometries in 2D or 3D was

extremely expensive by mechanical means (which usually would
require complex jigs to control the cutter motions).
2. Machining components with high repeatability and precision.
3. Unmanned machining operations.
4. To improve production planning and to increase productivity.
5. To survive in global market CNC Machines are must to achieve close
tolerances
Q. What are the advantages of CNC
over conventional machines tools?

Ans: i) Parts can be produced in much less time so it is likely to

be less
expensive.
ii) Parts can be produced more accurately.
iii) Need of special tools is eliminated.
iv) Lead time needed is less.
v) Less skilled operator is required.
vi) Accuracy of CNC is very high.
vii) Surface quality obtained is very good.

Q. What is the structure of the Lathes?

Ans: Lathe machining is mainly used for removal

processing and is a
common type of machine tool in the machine tool industry.
Lathes are one of the most versatile machine tools
industry, used to perform a variety of machining
operations.
The lathe is applied to the tool and rotated to perform various operations.
It can be used for turning, tapping, forming turning, spiral cutting, finishing, boring,
passivation spinning, grinding, polishing, etc.
The main function of the lathe is to remove the material from the
workpiece and make the workpiece the desired shape and size. During
the travel of the lathe, the workpiece is rotated against the tool to
achieve material removal and the direction of the tool movement
becomes feed.
The main parts of the lathe are:
1. Headstock:The headstock is usually located on the left side of the lathe and is
equipped with gears, spindles, chucks, gear speed control
levers, and feed controllers.
2. Tailstock: Usually located on the right side of the lathe, the workpiece
is supported at the end.
3. Bed: The main parts of the lathe, all parts are bolted to the bed. It
includes the headstock, tailstock, carriage rails and other parts.
4. Carriage: The carriage is located between the headstock and the
tailstock and contains apron, saddle, compound rest, cross slide and tool
post.
5. Lead Screw: The lead screw is used to move the carriage automatically during threading.
6. Feed Rod: It is used to move the carriage from left to right and vice-versa.
7. Chip Pan: It is present at the bottom of the lathe. Chip pan is
used to collect
the chips that are produced during the lathe operation.
8. Hand Wheel: It is the wheel that is operated by hand to move
a cross slide,
carriage, tailstock and other parts that have handwheel.

>SPECIFICATION OF LATHE MACHINE:

Ans: i) Name of the manufacturing company.
ii) Model name and model number.
iii) Floor space required in square meter.
iv) HP of the machine motor.
v) Speed and speed range of the machine.
vi) Feed and feed range of the machine.
vii) Weight of the machine in Tons.
viii) Cost of the machine in rupees.
ix) Maximum diameter of chuck in mm.
x) Length of the machine bed in m.
xi) Centre to center distance for holding the job in m.
xii) Swing diameter over the carriage in m.
xiii) Swing diameter over the bed.
>Word Address programming:
Ans: The word Address Programming format is a
system characters,
typically letters, arranged into blocks of information. G-Codes,
or
preparatory functions, and M-Codes, or miscellaneous
functions, are
paramount in word address programming.

 G Code:
 Ans: 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.
>CNC Lathe G Code List
G code Description
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation
CCW G04 Dwell
G09 Exact stop
G10 Programmable data input
G20 Input in inch
G21 Input in mm
G22 Stored stroke check function on
G23 Stored stroke check function
off G27 Reference position return
check G28 Return to reference
position G32 Thread cutting
G40 Tool nose radius compensation
cancel G41 Tool nose radius
compensation left G42 Tool nose radius
compensation right G70 Finish machining
cycle
G71 Turning
cycle G72 Facing
cycle
G73 Pattern repeating
cycle G74 Peck drilling
cycle
G75 Grooving cycle
G76 Threading cycle
G92 Coordinate system setting or max. spindle speed setting
G94 Feed Per Minute
G95 Feed Per Revolution
G96 Constant surface speed control
G97 Constant surface speed control cancel
 M Code:
 Ans: M Code is a Machine Code or Miscellaneous Code,
which is used for machine functions in all CNC machines. i.e.
Coolant
on/off, spindle speed on/off, tool change, machine stop
permanent/
temporary etc.
>CNC Lathe M Code List:
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
M08 Coolant on
M09 Coolant off
M29 Rigid tap mode
M30 End of program reset
M40 Spindle gear at middle
M41 Low Gear Select
M42 High Gear Select
M68 Hydraulic chuck
close
M69 Hydraulic chuck open
M78 Tailstock advancing
M79 Tailstock reversing
M94 Mirror image cancel
M95 Mirror image of X axis
M98 Subprogram call
M99 End of subprogram

CNC Programming
>programming consists of a series of instructions in form of
letter codes
Preparatory Codes:
>G codes- Initial machining setup and establishing operating
conditions
>N codes- specify program line number to executed by
the MCU>Axis codes: X,Y,Z- Used to specify motion of the
slide along X,Y,Z
direction
>Feed and speed codes: F and S- specify feed and spindle
speed
>Tool codes: T- specify tool number
>Miscellaneous codes- M codes For coolant control and other
activities
Programming key Letters
O –Program number (used for program Identification)
N –sequence number (used for line identification)
G –preparatory
function X –X axis
designation
Y –Y axis designation
Z –Z axis designation
R –Radius
designation
F – Feed rate designation
S –Spindle speed Designation
H –Tool length offset
Designation D –Tool radius offset
Designation T –Tool Designation
M- Miscellaneous function

Types of CNC Machining

CNC machining is a manufacturing process suitable for a wide variety of
industries, including automotive, aerospace, construction, and
agriculture, and able to produce a range of products, such as
automobile frames, surgical equipment, airplane engines, and hand and
garden tools.
The process encompasses several different computer
controlled machining operations—including
mechanical, chemical,
electrical, and thermal processes—which remove the necessary
material from the workpiece to produce a custom-designed
part or
product. While chemical, electrical, and thermal machining
processes
are covered in a later section, this section explores some of the
most
common mechanical CNC machining operations including:
• Drilling
• Milling
• Turning

CNC Drilling
Drilling is a machining process which employs multi-point drill
bits to produce cylindrical holes in the workpiece. In CNC
drilling, typically the CNC machine feeds the rotating drill bit
perpendicularly to the plane of the workpiece’s surface, which
produces vertically-aligned holes with diameters equal to the
diameter of the drill bit employed for the drilling operation.
However, angular drilling operations can also be performed
through the use of specialized machine configurations and
work holding devices. Operational capabilities of the drilling
process include counterboring , countersinking, reaming, and
tapping.

CNC Milling

Milling is a machining process which employs rotating multi-

point cutting tools to remove material from the workpiece. In
CNC milling, the CNC machine typically feeds the workpiece to
the cutting tool in the same direction as the cutting tool’s
rotation, whereas in manual milling the machine feeds the
workpiece in the opposite direction to the cutting tool’s
rotation. Operational capabilities of the milling process
include face milling—cutting shallow, flat surfaces and flat-
bottomed cavities into the workpiece—and peripheral milling
—cutting deep cavities, such as slots and threads, into the
workpiece.
CNC Turning

Turning is a machining process which employs single-point

cutting tools
to remove material from the rotating workpiece. In CNC
turning, the
CNC machine—typically a lathe or turning machine—feeds the
cutting
tool in a linear motion along the surface of the rotating
workpiece,
removing material around the circumference until the desired
diameter
is achieved, to produce cylindrical parts with external and
internal
features, such as slots, tapers, and threads. Operational
capabilities of
the turning process include boring, facing, grooving, and thread
cu
Characteristics of Common CNC Machining Operations
Machining Operation Characteristics
Drilling • Employs rotating multi-point drill bits
• Drill bit fed perpendicular or angularly
to workpiece
• Produces cylindrical holes in workpiece

Milling • Employs rotating multi-point

cutting tools
• Workpiece fed in same direction as
cutting tool rotation
• Removes material from workpiece
• Produces broader range of shapes

Turning • Employs single-point cutting tools

• Rotates workpiece
• Cutting tool fed along the surface of
the workpiece
• Removes material from the workpiece
• Produces round or cylindrical parts
Other CNC Machining Operations
Other mechanical CNC machining operations include:
• Broaching
• Sawing
• Grinding
• Honing
• Lapping
MATERIAL REMOVAL RATE(MRR):

Material removal rate (MRR) is the amount of

material removed per time unit (usually per minute)
when performing machining operations such as using
a lathe or milling machine . The more material removed
per minute, the higher the material removal rate. The
MRR is a single number that enables you to do this. It is a
direct indicator of how efficiently you are cutting, and how
profitable you are. MRR is the volume of material
removed per minute. The higher your cutting parameters,
the higher the MRR.
Phrased in another way, the MRR is equal to the
volume of residue formed as a direct result of the Shavings from drilling in a
removal from the workpiece per unit of time during a piece of metal.
cutting operation. The material removal rate in a work
process can be calculated as the depth of the cut, times
the width of the cut, times the feed rate. The material
removal rate is typically measured in cubic centimeters
per minute (cm3/min)
What is surface roughness?

Surface roughness is a measure of the average

texture of a part’s surface, in this case, after CNC
machining. There are different parameters used to
define surface roughness. One of the most
ubiquitous of these is Ra (Roughness average), which
is derived from the differences between heights and
depths on a surface. Ra surface roughness is
measured microscopically and is usually in
micrometers (x 10~⁶ m). Note that surface roughness
in this context is different from surface finish. The
surface finish of a machined part can be improved
via various finishing methods such as anodizing,
bead blasting, and electroplating. Surface roughness
here refers to the as-machined surface texture of a
part.
How are different surface roughness options achieved?
A part’s surface roughness after machining is usually not random. Instead,
steps are taken to ensure that a specific roughness is achieved. This means
that surface roughness values are planned in advance. However, not just any
value is usually specified. In manufacturing, there are specific Ra values that
are considered industry standards, as specified in ISO 4287. These are the
values that may be specified during CNC machining. They range from 25 um
to
0.025 um and apply to all kinds of manufacturing and post-processing
operations.

Different roughness values are required for different applications. Lower

surface roughness should only be specified when necessary. This is because
the lower the Ra value, the more machining effort/operations and quality
control will be required. They can significantly drive up machining costs and
time. Post-processing operations aren’t usually applied when specific surface
roughness values are required. This is because these operations cannot be
controlled precisely and may affect the dimensional tolerance of parts.
Surface roughness for CNC milling and turning compared
Surface roughness significantly affects the functionality, performance,
and durability of parts in certain applications. It influences the friction
coefficient, noise level, wear and tear, heat, and adhesiveness of a
part in use. The importance of these factors vary by application, and
so while the surface roughness of a part is inconsequential in certain
applications, it is critical in many others. These applications include
high tension, stress, and vibration scenarios, mating and moving
assemblies, fast rotating parts, and medical implants. As earlier
stated, different levels of surface roughness are required in different
applications.
The following explores the roughness levels that we need to know in
order to select the right Ra value for our application.

3.2 μm Ra
This is the standard commercial machine finish. It is suitable for
most consumer parts and sufficiently smooth, but it contains visible
cut marks. It is the default surface roughness applied unless
otherwise is specified.
3.2 μm Ra is the recommended maximum surface roughness for
parts subject to stress, loads, and vibrations. It can also be used
for mating moving surfaces when the load is light and motion
slow. It is machined using high speeds, fine feeds, and light cuts.
1.6 μm Ra
Usually, there are only slightly visible cut marks with this option. This
Ra rating is recommended for tight fits and stressed parts, and is
sufficient for slow-moving and light load-bearing surfaces. However, it
is not suitable for fast rotating parts and parts subject to intense
vibration. This surface roughness is produced using high speeds, fine
feeds, and light cuts under controlled conditions.
Price: for a standard aluminium alloy (e.g. 3.1645) this option adds
approximately 2,5% to the production price. This could increase with
the complexity of the part

0.8 μm Ra
Considered high grade, this surface finish requires very close
control to produce, costing more. It is required for parts that are
exposed to stress concentration. When the motion is occasional
and the loads are light, then it can be used for bearings.
Price: for a standard aluminium alloy (e.g. 3.1645) this option
adds approximately 5% to the production price. This could
increase with the complexity of the part.
0.4 μm Ra
This is the finest (“least rough” in technical terms) and highest quality
surface roughness that are offered. It is suitable for parts that are
under high tension or stress. It is also required for rapidly rotating
components such as bearings and shafts. This surface roughness
takes the most effort to manufacture and should only be specified
when smoothness is of primary importance.
Price: for a standard aluminium alloy (e.g. 3.1645) this option
adds approximately 11-15% to the production price. This could
increase with the complexity of the part.
OPTIMISATION OF SURFACE ROUGHNESS AND MATERIAL REMOVAL RATE IN TURNING
OPERATION OF MILD STEEL USING TAGUCHI METHOD

TAGUCHI METHOD: Genichi Taguchi could be a Japanese Engineer United

Nations agency has been active within the improvement of Japans industrial
product and processes since the late 1940’s. He has developed each philosophy
and methodology for the method or product quality improvement that depends
principally on applied mathematics ideas and tools, particularly statistically
designed experiments .several Japanese companies achieved nice success by
applying his strategies. Taguchi has received a number of the Japan’s most
prestigious awards for quality action, together with the Deming Prize throughout
the year 1986, he received the foremost prestigious award from the International
Technology Institute-The W.F.Rockwell Honour for excellence in Technology. His
major contribution is that he has combined engineering and applied mathematics
techniques to attain speedy enhancements in reducing the value and increasing
the standard level by optimizing product style and producing processes.
throughout 1983, Taguchi related to prime corporations and institutes of USA (Ford
motor company, XEROX, AT&T, Bell laboratories etc.), Taguchi techniques area unit
referred to as Radial approach to quality, experimental style and engineering
.Taguchi technique refers to the Parameter style, Tolerance style, Quality Loss
perform, style of Experiments exploitation Orthogonal Arrays and
Methodology applied to judge mensuration systems. Pignatiello has known 2
totally different aspects of Taguchi technique 1. The strategy of Taguchi 2.
Ways of Taguchi
Taguchi strategy is that the abstract frame work for coming up with a method or
product style experiment. Taguchi ways check with the gathering of specific
techniques utilized by Taguchi. Taguchi has self-addressed style, Engineering (offline)
also as producing (online) quality. This idea differentiates Taguchi technique from
applied math method management (SPC) that is solely a web internal control
technique
.Taguchi ideas may be reduced into 2 basic ideas 1. Quality losses ought to be outlined
as deviation from target, not conformity to impulsive specifications. 2. To attain high
system quality levels economically needs quality to be designed into product. Quality
is meant, not factory-made, into the merchandise. Taguchi techniques represent a
replacement philosophy. Quality is measured by the deviation of a useful
characteristic from its target price. Noises (uncontrollable factors) can cause such
deviations which end up in loss of Quality. Taguchi techniques request to get rid of the
result of Noises
.The foremost necessary a part of the Taguchi technique is quality loss operates.
Taguchi has found that a quadratic operate (parabola) approximates the behavior of
loss in several cases .when the standard characteristic of interest is to be maximized or
decreased, the loss operates can become a half parabola. Loss happens only if the
products is outside its specification however conjointly when the product falls within
its specification. Taguchi has suggested signal to noise quantitative relation (S/N ratio)
as performance statistics. Signal refers to the amendment in quality characteristics of a
product under investigation in response to an element introduced within the
experimental style. Noise refers to the result of external factors (uncontrollable
parameters) on the result of the standard characteristics.
Steps Involved in Taguchi Method For larger-the-better characteristics, Taguchi
method have been used for a parameter design includes the following steps [2]: 1.
Select a suitable output quality characteristic to be optimized. 2. Select the control
factors and their levels, identify their possible interactions. 3. Select noise factors
and their levels.

4. Select sufficient inner and outer arrays. Control factors assigned to inner array
and noise factors to the outer array. 5. Carry out the experiment. 6. Execute
statistical analysis based on S/N ratio. 7. Predict optimal output performance
level based on optimal control factor level combination, and conduct a
confirmation experiment to verify the result.
 Optimization of Surface Roughness in CNC Turning of Aluminium 6061 Using Taguchi Techniques:

LITERATURE REVIEW

Table 1 elucidates the work done by previous researchers

Ref No. Year Author`s Name Material Input parameter Output Most significant
parameter
1. 2010 M. Kaladhar, K. AISI 202 Austenitic Cutting Speed (111,200m/min) Surface Feed, Nose Radius
Venkata, Ch. Stainless steel 300 Feed (0.15, 0.25mm/rev) DOC Roughness
Srinivasa Rao, K Series 200 Series (0.25,0.75mm), Nose Radius
Narayana rao (0.4,0.8mm)
2. 2011 IIhan Asilturk, AISI 4140 (51 HRC) Cutting Speed Surface Feed, DOC
Harun Akkus (90,120,150m/min) Roughness
Feed (0.18,0.27, 0.36mm/rev)
DOC (0.2,0.4,0.6mm)
3. 2012 M. Kaladhar, K. AISI 304 Austenitic Cutting Speed Surface Feed, Nose Radius
Venkata, Ch. Stainless steel (150,170,190,210m/min) Roughness
Srinivasa Rao Feed (0.15,
0.20,0.25,0.30mm/rev) DOC
(0.5,1.0,1.5,2.0mm), Nose
Radius (0.4,0.8mm)
4. 2013 Harish Kumar MS1010 Cutting Speed Surface Speed, Feed
Mohd. Abbs Dr. 1600,1300,1000RPM) Roughness
Feed (0.04,0.03,0.02mm/rev)
5. 2014 Ranganath Aluminium(6061) Cutting Speed (180,450.710rpm) Surface Speed,
M.S.Vipin,R.S Feed (0.2,0.315,04mm/rev) DOC roughness DOC
Mishra (0.5,1.0,1.5,2.0mm), Nose Radius & MRR
(0.2,0.4,0.6mm)

6. 2015 Ranganath Aluminium Cutting Speed Surface Feed, DOC

 M.S.Vipin,Nand KS1275 (1600,1900,2200rpm) Roughness
kumar, Rakesh Feed(0.12,0.18,0.24mm/rev)
Kumar DOC (0.25,0.5,0.75mm)
7. 2016 ER. Kunthlesh AISI 410 Cutting Speed Surface Feed,DOC
Kumar (8000,10000,12000rpm) Roughness
Feed(1000,2000,3000,mm/
min)DOC(0.75,1.00,1.50mm)

8. 2017 M.Vishnu AA6061-6 Cutting Speed (95m/min) Surface Feed, DOC

Vardhan, G. Feed(0.18,mm/ Roughness
Sankaraiah,M.Yo min)DOC(1.5,0.69mm)
han, H. Jeevan
Rao

9. 2018 M.Vishnu AISI1020 Steel Cutting Speed Surface Feed, DOC

Vardhan, G. (75,80,85,90,95mm/min) Roughness
Sankaraiah,M.Yo Feed(0.1,0.125,0.15,0.2mm/
han, Tooth)DOC(0.5,0.75,1.25mm)

10 2019 G.Moses Titanium Alloy Cutting Speed Surface Feed, DOC

Dayan,R.Hari (100,150,200m/min) Roughness
Kishore, V. Feed(0.10,0.15,0.20mm/
Praveen rev)DOC(0.1,0.2,0.3mm)
11. 2020 CH.Shekar,K.Kish Inconel 718 Alloy
ore,P.Laxminaray
ana
12. 2021 Narendra kumar Stainless Steel
Patel, Tushar
Choudhury