DEPARTMENT OF MECHANICAL ENGINEERING

DJJ40142 MECHANICAL WORKSHOP PRACTICE 4 –CNC

MILLING

Mechanical Workshop Practice-4 course allows student to operate machine tools, precision
grinding, CNC machine and able to work in a clean and safe workshop environment.

Submission of Reports:

Students must complete report and submit ONE (1) week after workshop is carried out. Reports
should be brief and must be submitted in typewritten form (font: Times New Roman,size: 11,
paragraph: Justified, spacing: 1.5). Name of students, and session should be writtenon the
report cover (Appendix A). Reports will be assessed according to Appendix B.

The report should include the following items:

1. Introduction
2. Objective
3. Material/equipment/tools
4. Safety precautions
5. Procedures
6. Result: Task 1 & 2
7. Discussion
8. Conclusion
9. Reference
TASK: PRACTICAL TASK & REPORT (CNC MILLING)

1.0 TASK
To construct programs for CNC machining process using ISO codes or any related
machining software.

2.0 TASK OUTCOME

By the end of this task, student should be able to;
i) Read and visualize drawing part and component.
ii) Identify each point using absolute and incremental coordinate system.
iii) Compose CNC milling program using G and M code.
iv) Compile and/or edit program at CNC milling machine.
v) Construct the 3D part modelling
vi) Generate NC codes suing CADCAM software
vii) Demonstrate safety procedures in the workshop according to the workshop
safety regulation correctly to create a secured environment in an organization
while doing practical work.
viii) Demonstrate ability to work in team to complete assigned tasks during practical
work sessions.

3.0 MATERIAL/EQUIPMENT/TOOLS
i) Part drawing
ii) CNC Machine

4.0 SAFETY PRECAUTION

i) MAKE SURE a supervisor or instructor is present the first time you work this
machine.
ii) NEVER attempt to operate the machines while your senses are impaired by
medication, drugs, alcohol or other substances.
iii) ALWAYS wear safety gear (safety glass, shoes, etc).
iv) DO NOT wear watches, rings, necklaces, ties, etc that are prone to get caught
in the moving parts of the machine.
v) Also, NEVER use gloves which could become caught in the moving parts of
the machine.
vi) MAINTAIN a SAFE DISTANCE from the machine so as to avoid getting
caught in the moving parts of the machine.
vii) ALWAYS keep the machine and equipment CLEAN.
viii) DO NOT remove nor modify safety systems or their functioning on the machine.
ix) PROVIDE an adequate light source. If additional light is needed, do not hesitate
in asking for it.
x) BE AWARE of the position of the EMERGENCY STOP BUTTON.
xi) Loose object on the worktable may be catapulted into the air. REMOVE all
loose objects such as handtools, mandrels, clothes, etc, before starting to work.
xii) STOP the main spindle before proceeding to change tools or workpiece,
adjusting a new workpiece, measuring, changing or adjusting belts, pulleys or
gears, removing swarf or oil, etc.
xiii) ARRANGE tools in order of use.
 xiv) CHECK tools and toolholders on a regular basis. KEEP all tools sharp, as
damaged or weakened tools break easily.
xv) ALWAYS use suitable machining feeds and speeds to avoid tool breakage.
REDUCE speed and feed when unusual noises are noticed.
xvi) NEVER start the machine when the tool is touching the workpiece. AVOID
unnecessary damage to tool and/or workpiece.
xvii) DO NOT operate machine in automatic mode in the beginning. After mounting
the tool, carry out a trial run.
xviii) DO NOT use compressed air to clean or remove dust and swarf from the
machine and its surroundings. ALWAYS use a brush or chip scraper.

5.0 PROCEDURES

1. Review and observe general safety practices outlined in the Machine Shop Equipment
Safety Guidelines.
2. Refer to the manufacturer’s operating manual for all operating procedures.
3. Ensure all safety doors and guards are in place before turning on the machine.
4. Ensure that all body parts are clear of the cutting area prior to Turning the machine
0n. This include keeping long hair tied back and away from the machine.
5. Keep all loose clothing away from the cutting area.
6. Remove any loose rings, bracelets and watches prior to use.
7. Never reach into the cutting area prior to the spindle coming to a complete stop.
8. Ensure all work holders, clamps and vises are tightened
sufficiently in order to hold the work while cutting.
9. Ensure all cutting tools are fastened properly prior to cutting the material.
10. Ensure that all fixed-position components of the machine are tight.
11. Ensure that there are no loose components that can fly from the machine during
operation.
12. Remove all tools and any other loose items from the worktable prior to cutting.
13. Always remove the locking wrench from the vise immediately after using it.
14. Clean the machine after each use. Remove all waste material out of the machine.
15. Oil and lubricate the machine at regular intervals according to
the manufacturer’s specification using the recommended oil type and standards
TASK 1: PRACTICAL TASK

(A)

The Tool is now at the ORIGIN. Using the ABSOLUTE SYSTEM , locate the coordinates for Point 1 to
Point 9 and back again to Point 1.

Point G Code X Y Z
G90 (ABSOLUTE SYSTEM)
1
2
3
4
5
6
7
1
(B)
Figure below shows a component to be machined.
Material: Nylon Material size: 100 x 100x 20mm Feedrate: 400mm/min
Cutter Diameter: 10mm Location: Tool Number 4 Depth of cut: 3mm

Program Sheet
O 1234 ; Program Number
; EOB (End of block)
Home Z axis

Home X and Y axis

Tool Change to Tool No. 2
Spindle rotation clockwise at 1200rpm
G54 - Workshift
G43 - Tool length offset
H04 – Offset number 4
Z30.0 – Safe distance for tool
Absolute system, rapid traverse to work origin
but maintain at height of Z10.0mm
Left Offset H14 or D14 for industrial machines
Moves to point A
Cutting depth 3mm at 400mm/min Feedrate
Straight cut to point B
Circular cut anti-clockwise to point C
Straight cut to point D
Straight cut to point E
Straight cut to point F
Circular cut clockwise to point G
Straight cut back to point A
Tool rises up to Z10.0mm
Offset cancel
Spindle stop
Home for the Z axis
Home for the X and Y axis
Program End
TASK 2: REPORT

1. Figure 1 below shows a component to be machined. Construct 3D part modelling and generate
the NC codes by using any related CADCAM.

6.0 RESULT (TASK 2)

i. CNC PROGRAM
ii. 3D part modelling
iii. NC codes suing CADCAM software

7.0 DISCUSSION (TASK 2)

7.1 As part is to be machined on a harder material, Aluminum, suggest a solution to

machine the part. Discuss adjustment that should be made and write a program based
on your suggestion.

8.0 CONCLUSION
State your conclusions of the task.

9.0 REFERENCES
 DEPARTMENT OF MECHANICAL ENGINEERING

DJJ40142 MECHANICAL WORKSHOP PRACTICE 4

REPORT: CNC MILLING

NAME
REGISTRATION NUMBER
SESSION
LECTURER
MARKS
1. Introduction to CNC (20)
2. Objectives (10)
3. Materials/equipment/tools (5)
4. Safety precautions (5)
5. Procedures (5)
6. Result: Task 1 (100)

Task 2 (20)
7. Discussion (20)
8. Conclusion (10)
9. References (5)
TOTAL MARKS Task 1: /100

Task 2: / 100
COMMENT