Zagazig University, Faculty of Engineering,

Mechatronics Program

“CNC Milling Machine”

Technical Report

By: Hazem Tawfeek Yassen Tawfeek

Level: 400
Under supervision of : Dr. Mahmoud Mohamed Atta
SUMMARY

CNC milling involves cutting a workpiece using computerized and multipoint cutting tools.
Known for its accuracy and precision, the process is an integral part of several industries,
most notable being automotive and aeronautics.

This report explains everything you need to know about the CNC milling process before
choosing it for your project.

INTRODUCTION

Computer Numerical Control ( CNC) machines has become a necessity for industries in the production sectors
in machining repeatable and complex parts, making moulds, cutting and bending of metal plates, fabricating
metal sheet and various other jobs. In this decade, the CNC system is the heart and brain of a CNC machine
which enables the operation of various machine members such as slides, spindles, etc, as per the sequence
programmed into it, depending on the machining operations.

Safety factors

• Wear safety boots.

• Don’t wear any jewellery.
• Follow the procedure correctly.
• Wear safety jacket.
• Make sure that spindle are correctly attached.
• Worker should be train before using this machine.

Advantages and Disadvantages of CNC Machine.

Advantages of CNC Machine:

• Higher flexibility.
• Reduced scrap rate.
• Reliable operation.
• High accuracy.
• Increased productivity.
• Avoid human errors.
• Easy storage of existing programs.

Disadvantages of CNC Machine:

• High initial investment.

• High maintenance requirement.
• Not cost-effective for low volume production.
• Costly setup, skilled operators and programmers.
• Computers, programming knowledge required.
• Longer repair time required as parts are not available locally.
Types of machine
Lathe
The engine lathe, one of the most productive machine tools, has always been an efficient means of producing
round parts. Most lathes are programmed on two axes.

⚫ The X axis controls the cross motion of the cutting tool. Negative X ( X- ) moves the tool towards the
spindle centreline, positive X moves the tool away from the spindle centreline.
⚫ The Z axis controls the carriage travel toward or away from the headstock.

Milling Machine
The milling machine has always been one of the most versatile machine tools used in industry . Operations
such as milling, contouring, gear cutting, drilling, boring, and reaming are only a few of the many operations
which can be performed on a milling machine. The milling machine can be programmed on three axes:

⚫ The X axis controls the table movement left or right.

⚫ The Y axis controls the table movement toward or away from the column.
⚫ The Z axis controls the vertical (up or down) movement of the knee or spindle.
Programming Systems
Two types of programming modes, the incremental system and the absolute system, are used for CNC. Both
systems have applications in CNC programming, and no system is either right or wrong all the time. Most
controls on machine tools today are capable of handling either incremental or absolute programming.

Incremental
Incremental program locations are always given as the distance and direction from the immediately
preceding point. Command codes which tell the machine to move the table, spindle, and knee are explained
here using a vertical milling machine.

In incremental programming, the G91 command indicates to the computer and MCU (Machine Control Unit)
that programming is in the incremental mode.

Absolute
Absolute program locations are always given from a single fixed zero or origin point. The zero or origin point
may be a position on the machine table, such as the corner of the worktable or at any specific point on the
workpiece. In absolute dimensioning and programming, each point or location on the workpiece is given as
a certain distance from the zero or reference point.

In absolute programming, the G90 command indicates to the computer and MCU that the programming is in
the absolute mode.

Programming Format
Word address is the most common programming format used for CNC programming systems. This format
contains a large number of different codes (preparatory and miscellaneous) that transfers program
information from the part print to machine servos, relays, micro-switches, etc., to manufacture a part. These
codes, which conform to EIA (Electronic Industries Association) standards, are in a logical sequence called a
block of information. Each block should contain enough information to perform one machining operation.
Codes
The most common codes used when programming CNC machines tools are G-codes (preparatory functions),
and M codes (miscellaneous functions). Other codes such as F, S, D, and T are used for machine functions
such as feed, speed, cutter diameter offset, tool number, etc. G-codes are sometimes called cycle codes
because they refer to some action occurring on the X, Y, and/or Z axis of a machine tool.

The G01, G02, and G03 codes move the axes at a controlled feedrate.

⚫ G01 is used for straight-line movement (linear interpolation).

⚫ G02 (clockwise) and G03 (counterclockwise) are used for arcs and circles (circular interpolation).

M or miscellaneous codes are used to either turn ON or OFF different functions which control certain
machine tool operations.

M-codes are not grouped into categories, although several codes may control the same type of operations
such as M03, M04, and M05 which control the machine tool spindle.

⚫ M03 turns the spindle on clockwise.

⚫ M04 turns the spindle on counterclockwise.
⚫ M05 turns the spindle off.

Procedure
1. Press the ‘ON’ the inner front of the computer.
2. Wait until the display produced on the screen. Input user name and password.
3. Click on ‘START’and select ‘ PROGRAM’ .
4. Select the program you want to use and start using computer.
5. Turn on the computer machine.
6. Turn CNC machine tool control by pressing the red button on the front panel of the machine.
7. Location of the workpiece on the table and make sure work neatly workpiece.
8. Close the door and turn the switch of machine start / stop to start the operation of the machine.
9. Close switch start / stop when finished machining operations.
10. Remove the workpiece from the work table and clean the surrounding area.
11. Switch off the machine.
12. Close the computer machine.

Reference
• COMPUTER NUMERICAL CONTROL PROGRAMMING FOR MILLING AND LATHE MACHINES
PUBLISHED BY POLITEKNIK SULTAN ABDUL HALIM MUADZAM SHAH.
• www.wikipidia.com/milingmachine
• www.google.com/images/milingmachine