DMM3663 CNC TECHNOLOGY

GROUP PROJECT

LECTURER : DR. NORAZLIANIE BINTI SAZALI

J.P : EN. ASMIZAM
SECTION : M01

GROUP MEMBERS
No. Name ID
1 MUHAMMAD DANIAL IQMAL BIN ZAINUDDIN MB17108
2 MUHAMMAD IRFAN BIN ABDUL JALAL MB17188
3 MUHAMMAD EZZAT BIN MUHAMAD ALIZA MB17101
4 NOOR ERY ERMY BIN NOOR AZUREE MB17102
5 MUHAMMAD HAFIZUDDIN BIN ALIAS MB17219
1.0 INTRODUCTION

Computer Numerical Control (CNC) Machining is a process used in manufacturing

sectors that involve the use of computers to control machine tools. Tools that can be
controlled in this manner includes lathes, mills, and grinders. In CNC machining process, the
CNC machine is controlled by a computer program containing CNC machining language
such as preparatory (G codes) and miscellaneous (M codes) functions that essentially controls
all features such as feed rate, spindle speed on/off, tool change, coordination, location and
coolant on/off. In this group project, a CNC milling machine is introduced to students in
order to complete the project.

1.1 OBJECTIVES

Basically, the objectives of the project are:

 To design a product.
 To create a coding program based on the design of the product.
 To operate a CNC machine for the fabrication of the product.

1.2 SCOPES OF THE PROJECT

In general, this project was conducted to design and fabricate a product using a CNC
machine. A dimension of 100mm x 100mm x 25mm aluminium workpiece was provided to
each group in order to produce a prototype based on the drawing design by using CNC
machine. The design of the product was done using SolidWorks 2017 software. Then, coding
for the product was done in notepad and a simulator is used to check the coding before
proceeding to the fabrication of the product using CNC machine. The coding of the product
involved milling, drilling, and subprogram. In the operation of the CNC machine, tools such
as end mill, center drill, and drill bit are used. From the fabrication, we can determine
whether the coding for the product is correct or not.
2.0 METHODOLOGY

2.1 PROJECT FLOW CHART

There is a planning of the overall progress to assure the project can be finished
smoothly on schedule. The project begins with a brainstorming process. Brainstorming with
group members is important in order to create ideas, solve problems, motivates and develop
teams. Through this process, a sketch design for the product is made based on the ideas given
by group members. After several designs of the product are sketched and considered, the
most suitable design for the product has been chosen in order to product the product. The
selected design is then submitted to the instructor from the laboratory for further revising. If
the design is infeasible, everything will go back to the brainstorming stage. If the design is
feasible, the selected design will be transferred to solid modelling and engineering drawing
using SolidWorks 2017 software.

Once the engineering drawing finished, coding of the product is made according to
the design of the product. The coding is a computer program containing CNC machining
language which is then transferred to the Machine Control Unit (MCU) of the CNC machine.
The CNC machine will then fabricate the product according to the coding. After finishing the
codes of the product, the coding is then transferred to the simulator for the detection of errors.
If the simulation is failed, everything will return to the previous stage, which is the coding of
the product. In other words, if the simulation is successful, this will proceed to the next stage,
which is the fabrication of the product, by transferring the coding into the CNC machine.

After the fabrication stage, when all materials for report writing are gathered, this
proceeds to report writing process and presentation making process. The project is ended
after the submission of the product, final report, and the slide presentation that has been
presented. Figure 2.1 shows the flow chart of this group project.
 Start

Brainstorming

Design Product

No
Product Design
Checking

Yes

Do Coding for the Product

No
Coding Checking
using Simulator

Yes

Fabrication of Product by
CNC Machine

Inspection of the Product

Report Writing and Final

Presentation

Submission of Report and

Presentation Slides

End

Figure 2.1: Project Flow Chart

2.2 SOLIDWORKS DRAWING OF THE PRODUCT
Figure 2.2 shows the 3D drawing of the product while figure 2.3 shows the 2D drawing of the product.

Figure 2.2: 3D Drawing of the Product

Figure 2.3: 2D Drawing of the Product

2.3 CALCULATION INVOLVED

There are several important parameters that need to be considered in this project,
which are feed rate, spindle speed and depth of cut. The workpiece is made of aluminium
material. It is assumed that the cutting speed for an aluminium material is 50. The
calculations formulas that involved in this project are:

𝐹𝐸𝐸𝐷 𝑅𝐴𝑇𝐸 = 𝑛𝑜 𝑜𝑓 𝑡𝑜𝑜𝑡ℎ × 𝑅𝑃𝑀 × 𝑐ℎ𝑖𝑝 𝑙𝑜𝑎𝑑

By using the formulas given, the relevant parameters of the design of the product are
calculated and recorded in the table below:

Table 2.1: Important Parameters of the Product Design

No Process Tool RPM Depth Total Feed rate Remark

(rev/min) of Cut Depth (mm/ min)
(mm) (mm)

1. MILLING End Mill

T1 (Profile Milling) T1: 18 mm 700 12,6,6 24 250 T1
T2 (Profile Milling) T2: 12 mm 800 12,6,26 44 220 T2
2. DRILLING
T3 (Center Center Drill 1000 12,13 25 95.45 T3
Drilling) T3: 5 mm
Drill 700 30 30 50 T4
T4 (Deep Hole T4: 9 mm
Drilling)

Tool Diameter (mm) Name Flute Type

T1 18 Flat end mill 4 High speed steel (coated)
T2 12 Flat end mill 4 High speed steel (coated)
T3 5 Center drill 2 High speed steel
T4 9 Drill bit 2 High speed steel
2.4 CODING OF THE DESIGN N156 G0 Z1.
N158 Y26.081
2.4.1 MAIN PROGRAM (O1234) N160 Z-2.
N162 G1 Z-8. F200.
% N164 X-60.4 F250.
O0000(FINALIST CNC 1) N166 G3 X-55. Y31.481 I0. J5.4
(DATE=DD-MM-YY-10-04-19 N168 G1 Y40.
TIME=HH:MM-16:17) N170 G2 X-40. Y55. I15. J0.
(MCXFILE-G:\CNC\FINALISTCNC N172 G1 X-22.961
1.MCX-5) N174 X22.961
(NC FILE-G:\CNC\FINALIST CNC N176 X40.
1.NC) N178 G2 X55. Y40. I0. J-15.
(MATERIAL-ALUMINUM MM - 2024) N180 G1 Y22.961
( T1 |18. FLAT ENDMILL | H1 ) N182 Y-22.961
( T2 |12. FLAT ENDMILL | H2 ) N184 Y-40.
( T3 |5.0 CENTER DRILL | H3 ) N186 G2 X40. Y-55. I-15. J0.
( T4 |8. DRILL | H4 ) N188 G1 X22.961
N100 G21 N190 X-22.961
N102 G0 G17 G40 G49 G80 G90 N192 X-40.
N104 T1 M6 N194 G2 X-55. Y-40. I0. J15.
N106 G0 G90 G54 X-65.8 Y26.081 A0. N196 G1 Y-22.961
S700 M3 N198 Y22.961
N108 G43 H1 Z5. M8 N200 Y31.481
N110 Z2. N202 G3 X-60.4 Y36.881 I-5.4 J0.
N112 G1 Z-4. F200. N204 G1 X-65.8
N114 X-60.4 F250. N206 G0 Z-3.
N116 G3 X-55. Y31.481 I0. J5.4 N208 Y26.081
N118 G1 Y40. N210 Z-6.
N120 G2 X-40. Y55. I15. J0. N212 G1 Z-12. F200.
N122 G1 X-22.961 N214 X-60.4 F250.
N124 X22.961 N216 G3 X-55. Y31.481 I0. J5.4
N126 X40. N218 G1 Y40.
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N134 Y-40. N226 X40.
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N142 X-40. N234 Y-40.
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N146 G1 Y-22.961 N238 G1 X22.961
N148 Y22.961 N240 X-22.961
N150 Y31.481 N242 X-40.
N152 G3 X-60.4 Y36.881 I-5.4 J0. N244 G2 X-55. Y-40. I0. J15.
N154 G1 X-65.8 N246 G1 Y-22.961
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N254 G1 X-65.8
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N588 G1 X-46.449 Y-10.034
N590 G0 Z-3.
N592 X-49.115 Y2.492
N594 Z-6.
N596 G1 Z-12. F30.
N598 X-48.715 Y3.623 F220.
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N602 X-47.184 Y4.355 I0. J-1.2
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N932 G2 X4.423 Y47.584 I-.4 J-1.131
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N956 G1 X-2.492 Y49.115
N958 G0 Z-7.
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N962 X10.034 Y46.449
N964 G1 Z-12. F30.
N966 X11.166 Y46.049 F220.
N968 G2 X11.967 Y44.917 I-.4 J-1.132
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N2078 G1 X6.5
N2080 G3 X0. Y6.5 I-6.5 J0.
N2082 X-6.5 Y0. I0. J-6.5
N2084 X0. Y-6.5 I6.5 J0.
N2086 X6.5 Y0. I0. J6.5
N2088 G0 Z-12.333
N2090 Z2.
N2092 X2.
N2094 G1 Z-20.222 F30.
N2096 G3 X0. Y2. I-2. J0. F200.
N2098 X-2. Y0. I0. J-2.
N2100 X0. Y-2. I2. J0.
N2102 X2. Y0. I0. J2.
N2104 G1 X6.5
N2106 G3 X0. Y6.5 I-6.5 J0.
N2108 X-6.5 Y0. I0. J-6.5
N2110 X0. Y-6.5 I6.5 J0.
N2112 X6.5 Y0. I0. J6.5
N2114 G0 Z-15.222
N2116 Z2.
N2118 X2.
N2120 G1 Z-23.111 F30.
N2122 G3 X0. Y2. I-2. J0. F200.
N2124 X-2. Y0. I0. J-2.
N2126 X0. Y-2. I2. J0.
N2128 X2. Y0. I0. J2.
N2130 G1 X6.5
N2132 G3 X0. Y6.5 I-6.5 J0.
N2134 X-6.5 Y0. I0. J-6.5
N2136 X0. Y-6.5 I6.5 J0.
N2138 X6.5 Y0. I0. J6.5
N2140 G0 Z-18.111
N2142 Z2.
N2144 X2.
N2146 G1 Z-26. F30.
N2148 G3 X0. Y2. I-2. J0. F200.
N2150 X-2. Y0. I0. J-2.
N2152 X0. Y-2. I2. J0.
N2154 X2. Y0. I0. J2.
N2156 G1 X6.5
N2158 G3 X0. Y6.5 I-6.5 J0.
N2160 X-6.5 Y0. I0. J-6.5
N2162 X0. Y-6.5 I6.5 J0.
N2164 X6.5 Y0. I0. J6.5
N2166 G0 Z5.
N2168 M5
N2170 G91 G28 Z0. M9
N2172 G28 X0. Y0. A0.
N2174 M30
%
# HINTS
START FIRST SEQUENCES
 T1 Diameter 18 flat end mill –
Contour (outside) – 12 depth
 T1 Diameter 18 flat end mill –
Contour (outside) – 6 depth
 T2 Diameter 12 flat end mill –
Pocket (open) – 12 depth
 T2 Diameter 12 flat end mill –
Pocket (standard) – 6 depth
 T3 Diameter 5 center drill –
mark drill – 12 depth
 T4 Diameter 9 drill bit –
through hole – 30 depth
 T1 Diameter 18 flat end mill –
Pocket standard (inside) – 6
depth
 T2 Diameter 12 flat end mill –
Pocket (through hole inside) –
26 depth
2.5 PROCESS FLOW

(A) Initial Preparation for CNC Machining

1. Before any process begins, the CNC machine is cleaned from all the material scraps and
chips by using the blower.
2. The cleaning process is important to ensure that CNC machining process will be going
smoothly without any problem.
3. The clamp is prepared and fit perfectly into the slot.
4. Parallel bars are placed under the workpiece to make sure that the workpiece had been
clamped by 10mm.

(B) Setting Tool Sequence

1. After cleaning the machine, the tools that need to be used are set according to the
following sequence:
2. The first tool is flat end mill, with the diameter size of 18 mm and the coding for the tool,
is M06 T01.
3. The second tool is also the flat end mill, with the diameter size of 12 mm and the coding
for the tool, is M06 T02.
4. The third tool is a center drill with diameter 5 mm and the coding for the tool, is M06
T03.
5. The fourth tool a drill, with the diameter size of 9 mm and the coding for the tool, is M06
T04.

(C) Setting the centre point of the workpiece

1. In this project, the origin has been set at the centre point of the workpiece.
2. So, edge finder is used in order to find the origin of the workpiece.
3. Firstly, the edge finder is moved in x-axis direction to find the actual dimension of the
workpiece in the x-axis.
4. Coordinate is set to be zero once the edge finder stopped shaking when it touches the
surface of the workpiece. The measurement in the x-axis direction is recorded.
5. Step 3 to 4 are repeated in order to get the actual dimension of the workpiece in the y-
axis direction. After getting the measurement in both x-axis and y-axis, the
measurements are divided into two so that the centre point/origin of the workpiece can be
obtained.

(D) Setting Height Compensation

1. In this case, tool presetter is used and placed on the top surface of the workpiece.
2. Firstly, the first tool is lowered in order to touch the surface of the tool presetter until the
scale on the tool presetter to reach zero.
3. After that, a value of Z-50 is set to the offset table in the MCU of the CNC machine.
4. Steps 1 to 3 is repeated for another three tools.

(E) Facing

1. The surface of the workpiece is milled -0.2 mm with the purpose of removing the corrosion
surface of the workpiece.

(F) Milling

1. Firstly, we started with contour process which is to cut the square outside with
requirements below. In this process first tool is used to complete this task.
 Tool 1: 18 flat end mill 2 flute HSS coated
 Depth: 12mm
 Feed rate: 250mm/min
 Spindle speed: 700rpm
 Plunge rate: 200mm/min
Figure 2.4 shows the profile milling on cutting square outside of the workpiece.
 Figure 2.4: Profile Milling (Contour - outside)

2. Second, we proceed with contour process which is to cut circular surface on the top of
workpieces with requirements below
 Tool 1: 18 flat end mill 2 flute HSS coated
 Depth: 6mm
 Feed rate: 250mm/min
 Spindle speed: 700rpm
 Plunge rate: 200mm/min
Figure 2.5 shows the circular profile milling on the top surface of the workpiece.

Figure 2.5: Profile Milling (Circular)

3. Third, we proceed with pocket (open) process which is to cut half oval on the workpieces
with requirements below. In this process, the second tool is used in order to replace the
first tool
 Tool 2: 12 flat end mill 2 flute HSS coated
 Depth: 12mm
 Feed rate: 220mm/min
 Spindle speed: 800rpm
 Plunge rate: 30mm/min
Figure 2.6 shows operation of pocket (open) on the workpiece.
 Figure 2.6: Pocket open

4. The forth process is pocket (standard) which is to make the 4 holes on the top of the
work piece with requirements below
 Tool 2: 12 flat end mill 2 flute HSS coated
 Depth: 6mm
 Feed rate: 220mm/min
 Spindle speed: 800rpm
 Plunge rate: 30mm/min
Figure 2.7 shows the four slots that are milled on the workpiece.

Figure 2.7: Pocket standard

5. The fifth process is center drill which is to mark the 8 holes on the workpiece for easy
operation of next process drill hole with requirements below. In this process, the third
tool is used in order to replace the second tool
 Tool 3: 5 center drill HSS
 Depth: 12mm
 Feed rate: 95.45mm/min
 Spindle speed: 1000rpm
 Plunge rate: 57.25mm/min
Figure 2.8 shows the steps on how to making center drill mark on the workpiece
 Figure 2.8: Center drill

6. The sixth process is drill bit which is to drill the 8 through holes on the workpiece with
requirements below. In this process, the forth tool is used in order to replace the third
tool
 Tool 4: 9 drill bit HSS
 Depth: 30mm
 Feed rate: 50.0mm/min
 Spindle speed: 700rpm
 Plunge rate: 171.84mm/min
Figure 2.9 shows the steps on how drill through hole on the workpiece

Figure 2.9: Drill bit – through hole

7. The seventh process is pocket (standard) which is making the rounded hole on the top
of workpiece with requirements below. In this process, the first tool is used in order to
replace the forth tool
 Tool 1: 18 flat end mill 2 flute HSS coated
 Depth: 6mm
 Feed rate: 200mm/min
 Spindle speed: 700rpm
 Plunge rate: 30mm/min
 Figure 2.10 shows that the making of rounded hole on the top of the workpiece

Figure 2.10: Pocket standard

8. The last process is pocket (standard) which is making the through rounded hole on the
center of workpiece with requirements below. In this process, the second tool is used
in order to replace the first tool
 Tool 2: 12 flat end mill 2 flute HSS coated
 Depth: 26mm
 Feed rate: 200mm/min
 Spindle speed: 800rpm
 Plunge rate: 30mm/min
Figure 2.11 shows the through holes that are drilled on the work piece using pocket
process.

Figure 2.11: Pocket standard - through hole

3.0 RESULTS AND DISCUSSION
3.1 RESULTS
Figure 3.1 shows the prototype that was produced based on the drawing using CNC machine.
From the figure 3.1, it can be seen that the prototype was successfully developed according to
the coding that was made.

Figure 3.1: Fabricated Product

3.2 DISCUSSION

During the completion of this group project, there are several problems faced by every group
member. The first problem faced was the design of the product. Initially, the first iteration
design was the complexity design on the aluminium workpiece provided. However, the
design was rejected by the instructor in laboratory due to the complexity of the design and the
difficulty to fabricate it. Then, in order to counteract this problem, second iteration design
was developed, which is the design that had been used in this project. The finalized design
involved the process such as milling and drilling. But our finished product not really look
nice with look surface roughness because we not used the finishing process due to time taken
take so long as our JP want the finished product less than 40 minutes.

During the operation of the CNC machine, there are several precautions and safety rules that
have been taken seriously throughout the project. First of all, it is necessary to make sure that
the workpiece is properly clamped and secured in the machine. Before the tool starts to mill
the workpiece, ensure that the coolant is turned on and the machine door should be closed to
prevent any injury. After the operation of the machine, the machine is cleaned by removing
all the debris of the workpiece.

3.3 PRECAUTIONS

CNC machine is a machine that doing machining process based on the user programming or
codes. The user just input all the coding and the machine will read it and interprets it by
doing machining. The machine was automatic and will cause less hazard compare than
machining by manually. However, there is still precaution when handling CNC.

Firstly, make sure that the surface at placement of workpiece is clean and free from the metal
scrap. Use the air gun to clean the surface. This to ensure the workpiece will not affected by
the metal scrap as will cause some scratch at the workpiece. This also to ensure the
machining process will be done smoothly without any disturbance.

Next precaution is, make sure that the workpiece has been clamped in a correct way. Use the
parallel bars when clamping the workpiece as it will support and be a stand for the workpiece
to be clamped upper part of the clamp. This to ensure the machining will only occur at the
surface of workpiece and not to the clamp.

After that, when inserting the tools, the user needs to be extra careful when handling the tools
as it was very sharp. Take a cloth and hold the tools when insert it. Mishandling will cause a
serious injury.

4.0 CONCLUSION

In conclusion, a prototype was successfully developed using a CNC machine. The result of
the prototype had indicated that the coding of the product was correct. Despite there are
several problems that we faced in this project, however, all the problems can be solved easily
and the prototype was successfully developed according to the coding. Throughout the
project, it is important to take serious attention on the operation of the CNC machine in order
to prevent any injury. The project also had achieved all the project objectives which had been
stated previously.

5.0 REFERENCE

 http://www.productivity.com/wp-content/uploads/2015/04/Haas-Mill-Operator-
Manual.pdf
 https://www.scribd.com/doc/31287220/CNC-Milling-Machine
 https://www.scribd.com/document/249176626/Report-cnc-milling