2

T-SDI, APSSDC
GAYATRI VIDYA PARISHAD COLLEGE OF ENGINEERING (A)
VISAKHAPATNAM
2023

A REPORT ON INTERNSHIP

PROGRAM at GVPCE(A), APSSDC

SIEMENS(TSDI)

MADHURAWADA, VISAKHAPATNAM-530048

Submitted to the GAYATRI VIDYA PARISHAD COLLEGE OF ENGINEERING (AUTONOMOUS),

Visakhapatnam
In partial fulfilment of the requirement for the award of

B-Tech IN MECHANICAL ENGINEERING

Submitted by

SAYYED IMRAN
21131A0394
Under the esteemed guidance of trainers from APSSDC

CH. SANYASI RAO

3

CERTIFICATE

This is to certify that SD.IMRAN bearing Roll: 21131A0394, a bonafide

student at GAYATRI VIDYA PARISHAD COLLEGE OF
ENGINEERING (AUTONOMOUS), Visakhapatnam
district, has completed an internship program at "APSSDC
SIEMENS-GVPCE", Visakhapatnam as a part of his V Semester ME course work
and has submitted the internship report to the institution in partial fulfilment
of the requirement for the Award of B-Tech in Mechanical Engineering during
period of 22 May 2023 – 10 June 2023.

During the above-mentioned period his conduct and performance were

Formed to be......................................

Supervisor Head of the Department

Mr. V.S.Siddharth Dr. B.Govinda Rao
M.Tech.( VIT) B.E., M.E.,Ph.D
Assistant Professor Professor

Department of Mechanical Engineering Department of Mechanical Engineering

4

ACKNOWLEDGEMENT

I would like to take this opportunity to express my profound sense of

gratitude to Principal Prof. Dr. A.B. Koteswara Rao M.Tech.(NIT-Warangal),
Ph.D. (IIT-Delhi) GAYATRI VIDYA PARISHAD COLLEGE
OF ENGINEERING AUTONOMOUS), Visakhapatnam.

I have great pleasure in expressing my deep sense of gratitude to our Head of the
Department and our guide Dr. B.Govinda Rao B.E, M.E, Ph.D. Department of
Mechanical Engineering, GAYATRI VIDYA PARISHAD COLLEGE
OF ENGINEERING (AUTONOMOUS), Visakhapatnam.

I would like to express my special thanks of gratitude to my trainer Ch. Sanyasi Rao,
who gave me the golden opportunity to do this internship program in APSSDC,
which helped me learn so many new things, Knowledge and Hands-on Experience.

I thank all the staff members of our department & the college
administration who helped me carry out this internship successfully.

Sincerely,
SAYYED IMRAN
5

S.NO CONTENT PAGE NO

CNC LATHE

1 Introduction about CNC lathe 1-2

2 Control panel board of CNC machine 3-5

3 Codes for Siemens control CNC machines 6-7

4 Absolute and incremental co-ordinates 8-8

5 Tooling system in CNC lathe 9-10

6 Datum setup 11-12

7 Format of a programming 13-13

8 Programming 14-26

9 Machine maintenance 27-28

CNC MILLING

10 Introduction about CNC milling machine 29-29

11 Control panel of the milling machine 30-32

12 Codes for Siemens 33-33

13 Tooling system 34-34

14 Datum setup 35-37

15 Manual programs 38-38

16 Cycle programs 39-43

17 Maintenance of milling 44-44

18 Hands-on application 45-46

1
1

LATHE MACHINE
1.INTRODUCTION ABOUT CNC LATHE

CNC LATHE MACHINE

 CNC machining is a process used in the manufacturing sector that involves the use of computers
to control machine tools.

 CNC stands for (COMPUTER NUMERICAL CONTROL).

 The control model of this machine is SINUMERIC 828D from Siemens.

 Now a days in all industries CNC machines are only used because of fast manufacturing.

 In this machine, there are two axis, X-axis and Z-axis.

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2
DIFFERENCE BETWEEN CONVENTIONAL LATHE AND CNC LATHE MACHINE
Conventional lathe
 It consumes more time
when compared tothe CNC
lathe.
 It does not give more
accurate dimensions than
the CNC machine.
 There is less production
in conventionallathe.
 In this the operations are
done manually by
theoperator.
 For this machine needs
skilledoperators to
make every single part.
 The cost of this machine is
less whencompared to the
CNC
lathe.
CNC lathe
 It consumes less time when
compared tothe conventional
lathe.
 It gives the more accuracy
dimensions thanthe conventional
lathe.
 There is more production in
CNClathe.
 In this the operations are done
automatically by giving
programming.
 For CNC machine for programming
skilled operator is required and for
machinerunning less skilled operator
is needed.
 The cost of this machine is very
high whencompared to the
conventional lathe.
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3

Safety precautions
1. protect your eyes by wearing safety glasses.
2. Make sure that your area is free from chips, oil and coolant spills, air hoses or anything that
may get inyour way and make u to fall or slip.
3. Make sure that all cutting tools.
4. work holding equipment is tight before running the spindle or moving the
slides. 5.All maintenance and repair work should be done with the power off.
6.If any work requires power on, extreme care should be
taken. 7.Check the main pressure of the hydraulic/ pneumatic
system.
Warnings and cautions
1.Do not press POWER UP/RESTART on the control panel until after the installation is complete.
2.Do not attempt to operate the machine before all the installation instructions have been completed.
3.Windows must be replaced if damaged or severely scratched.
4.Improperly clamped parts at high velocity may puncture the safety door. Reduced rpm is required
to protect the operator when performing dangerous operations.
Advantages
1. High Accuracy e.g., Aircraft parts
2. Less paperwork, faster prototype
production 3.Production rate is very high
4. More safe, higher productivity, better quality
Disadvantages
1. Costly setup
2.Skilled operators
3.Computers, Programming knowledge required
4.Maintenance is very difficult

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4

Control panel board of CNC machine

CONTROL PANEL

Emergency stop
It is pressed when any dangerous situation occurs while machining and in any
emergency situations. For emergency stop push thebutton and for releasing rotate it in
clockwise direction.

Feed operator and spindle speed

These mode selector switches are feed operator and spindle
speed. Feed operation regulator is used to control the feed of the
cutting tool. Spindle regulator is used to control the speedof the
spindle.

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5

Tail stock
This button is used to move the tail stock outside and inside. When we press the
TSOUT button tail stock will comes out and when we press the TSIN button tail
stock comes its original position.

Execution keys
These keys are used to start and stop the execution programsfor machining the
components.RST button is used to reset the machine. CYST (cycle start) and
CYSP(cycle stop).

Spindle operation keys

These operation keys are used to rotate the spindle inclockwise or in anti-
clockwise direction.
SPFOR= spindle clockwise direction
SPREV= spindle in anti-clockwise direction
SPSTP= spindle stop
SPORT= spindle orientation

Axismovable direction switches

The axis switches are used to move the axis in a positive and negative
direction. In this when you press RPD and any direction button
simultaneously then the axis will move much faster.

Mode selector switch

This mode selector switch is used to select the various modes likeMEM, SBK, MDI,
MPG mode, JOG, and ZRN modes.
5

Manual pulse generator (MPG)

This mode is worked when it is in x1 or x10 or x100 in mode selectorand it is
used to move the tool in x-axis and z-axis by manually rotating this hand
wheel. Axis selector switch is in MPG mode whichis used to select the axis.

Coolant keys
These keys are used to on and off the coolant manually by pressing these keys.
Coolant on (CLON) and coolant off(CLOFF).

Turret status indicator

It is used to indicate the active tool number in the turretstation, and
it indicates the tool number.

Machine status indicator

It is used to indicate the status of a machine. While it is in ongoingprocess
green light will glow and if any errors came in machinered will glow and after
completion job it shows yellow light.

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6

CODES FOR SIEMENS CONTROL CNC MACHINES

Introduction
 There are two types of codes are

there 1.G-codes (Geometrical codes)

2.M-codes (machine codes)

 Generally, G codes GEOMETRICAL codes are writen in and performed by the CNC
machine processor and operate the motion control part of the control.
 The M codes are MACHINE codes, these operate most of the basic electrical control functions such
asCoolant, Tool changers, safety circuits etc,.
 By using these g-codes and m- codes we can prepare the programs for performing theoperations on
the CNC machines.
 The programming is the most important to the CNC machines for performing operations.
 By using these codes, we can prepare programs for the following operations
▫ Facing
▫ Turning
▫ Step turning
▫ Boring
▫ Drilling
▫ Internal threading
▫ External threading

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7

IMPORTANT G-CODES AND M-C0DES

GEOMETRICAL CODES MACHINE CODES
G00= linear interpolation of rapid
traverse rate. M00=program stop.

G01=linear interpolation at feed M01=optional stop.

rate. G02=circular interpolation M02=program end.

(CW). M03=spindle normal rotation.

G03=circular interpolation (CCW). M04=spindle reverse

G04= Dwell time rotation. M05=spindle stop

G18=ZX plane selection. rotation.

G17=XY plane selection. M06=tool change.

G19=YZ plane selection. M07= Oil shot on

G21=Input system in metric M08=coolant on.

G40=tool radius compensation M09=oil shot/coolant off.

off. G54=first settable zero offset. M19= Spindle orientation

G71=metric dimension data M30=program end.

input. G74= Reference point M80=High pressure coolant on

approach G75=fixed point M81= High pressure coolant

approach. off M84= Coolant shower on

G90=absolute command M85= Coolant shower off

G91= Increment command

G96=constant surface speed

control. G94=feed F in mm/min.

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8

ABSOLUTE AND INCREMENTAL CO-ORDINATES

Introduction
1. In absolute programming the end point of a motion is programd with reference

to the program zero point.

2.Co-ordinates are specified as X, Z.
3.X co-ordinate is the diameter of the part.
4.In incremental programming the end point is specified with reference to the current
tool position.
5.Co-ordinates are specified as U, W.
6.U is the incremental diameter of the part.
Example

Absolute traverse from p1 to p2, then to

p3 X 30.0 Z-20.0
X 40.0 Z-30.0
Incremental traverse from p1 to p2, then to
p3X 0.0 Z -20.0
X 30.0 Z -10.0
Incremental mode programming is seldom used.

Note: In this we mostly used only absolute command in both milling and lathe.

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9

TOOLING SYSTEM IN CNC LATHE

There are two different tools are
there 1.OD (outer diameter) turning
tool

2. ID (inner diameter) turning tool

OD tools
In OD tools there are different types of tools such as
1.Roughing tool
2.Finishing tool
3.External threading
tool
For selection of OD tools there is some designation for tools example given below
1.Roughing tool
PCLNR 2020 M 12
P=Insert clamping type
C=Insert shape
L=insert entering angle
N=insert clearance
angle R= hand of holder
2020=shank size
M=tool holder length
12=Insert cutting edge length

For roughing
insert SPKN 22 04
08
S=shape of insert
P=clearance angle
K=tolerance of insert
N=insert geometry
22=insert width
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10

Finishing tool SVJBL 2020

K 16
Insert
YBC251

OD thread SER 2020 K

16
Insert
16 ERM AG 60 ISO TT 9030

ID TOOLS
In ID tools there is different types of tools such as
1.Drilling tool
2.Boring tool
For selection of ID tools there is some designation for tools example given below
1.Drilling tool
TDR 2200-25 T2-06 DIA 20
Insert
SPMG 0602 04 0G TT 9030

2.Boring tool
S12 M SC LCR
06
Insert
CCMT 0602 04 FG TT 8115

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11

DATUM SETUP
Introduction
Datum setup means taking offset for the two axes. Offsets are the distances the cutting tool needs to
travel, from its 'Home' position to the Workpiece datum in X & Z.

To tell the machine where the material is we will change to Tool number 1 and move the tool to the
front face of the billet, this is the Z datum. We will then find the centre of the billet; this is the X
datum. The Z and X datum positions will be stored, this is the Work Piece Offset. If more than one
tool is to be used, we will change to each tool and set the positions for each tool relative to Tool
number 1. These are the Tool Offsets.

Taking offset to the Z-axis:

First move the tool to the front face of the workpiece and touch the tool slowly to the workpiece
then,
>go to offset option on the CNC machine
>press the tool measure option at the right top
side of the screen

select the Z option on the right side of the

screen
>enter the 0.0 value in the middle box on
the screen
>press the set length option on the CNC machine
Then there is a change in the z active values and the Z-axis is in offset position

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12

Taking offset to the X-axis:

First move the tool to the front face of the workpiece and touch the tool slowly to the workpiece
then,
>go to offset option on the CNC machine
>press the tool measure option at the right top side of the screen
select the X option on the right side of the screen
>enter the diameter of the workpiece in the middle box on the screen and press the input
>press the set length option on the CNC machine
Then there is a change in the X active values and the X-axis is in offset position

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13

FORMAT OF A PROGRAM
7.1 Introduction
If we want to prepare the program there is some format.
we must use some letters for preparation of program that given below

N= Block number or specifies the start of the block

G= preparatory function
M= miscellaneous functions
X= X-axis co-ordinate
Z = Z-axis co-ordinate
R= radius of arc
S= spindle speed or cutting speed
F= feed rate
T= tool number
G18 G40 G54 G71---------------------Initial codes
G75 X0 Z0-------------------------------Home position
LIMS= 1000------------------------------Limit speed
S300 M3---------------------------------Spindle speed and direction of spindle
T1 D1 M8--------------------------------------------Tool change and coolant on
G0 X65
Z10 G0
X60 Z0
G01 X-2
G0 X60 Z10Facing program for removal of 1MM stock from 52 mm to
51mm G01 Z-1 length of the workpiece
G01 X-2
G0 X65 Z 10
G75 X0 Z0 M9----------------------Home position and coolant off
M5 spindle stop
M01 Optional stop
M30 Program end

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14

PROGRAMMING

For CNC machines there are two types of

programs Manual programs
Cycle programs

Manual program
Manual programming involves numerous calculations and verifications without the use of a computer. The
program must program in the same language the CNC machine will execute, creating a step-by- step order of
commands that makes the machine run accordingly. This requires the programr to visualize the machining
operations that will be carried out in the part program.

Cycle program
A canned cycle is a way of conveniently performing repetitive CNC machine operations. Canned cycles
automate certain machining functions such as drilling, boring, threading, pocketing, etc... Canned cycles are so
called because they allow a concise way to program a machine to producea feature of a part.A canned cycle is
also known as a fixed cycle. A canned cycle is usually permanently stored as a pre-program in the machine's
controller and cannot be altered by the user.

Manual programs for CNC lathe machine

By using manual programming, we can prepare the programs for following operations
Facing
Turning
Step
turning
Boring
Drilling

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15

Facing manual programming:

G18 G40
G54 G71
G90 G94
G75 X0 Z0
LIMS=1000

G96 S300
M03 T01 D1
M08
G0 X65 Z10
G0 X60 Z0
F0.35 G01 Z0
G01 X-2
G0 X60
Z5 G01 Z-
1 G01 X-2
G0 X60
Z5 G01 Z-
2 G01 X-2
G0 X65
Z10 G01 Z-
3 G01 X-2
G0 X65
Z10 G75
X0 Z0 M09
M0
1
M0
5
M3
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16
0

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17

Turning manual program

G18 G40 G54

G71 G90 G94
G75 X0 Z0
LIMS=1000
G96 S300
M03 T01 D1
M08
G0 X65 Z10
G0 X60 Z0
F0.35 G01 Z-70
G0 X65
Z5 G01
X59.5 Z -
70
G0 X65
Z5 G01
X59
Z-70
G0 X65
Z5 G01
X58.5 Z-
70
G0 X65
Z5 G01
X58
Z-70
G0 X65
Z5 G01
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18
X57.5 Z-
70
G0 X65
Z5 G01
X57
Z-70

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19

Step turning manual program

G18 G40 G54
G71 G90 G94
G75 X0 Z0
LIMS=1000
G96 S300 M03
T01 D1
M08
G0 X65 Z10
G0 X60 Z0 F0.35 Z-10
G01 Z-60 G0 X65 Z5
G0 X65 Z5 G01 X45
G01 X59 Z-10
Z-40 G0 X65 Z5
G0 X65 Z5 G75 X0 Z0
G01 X58 M09
Z-40 M05
G0 X65 Z5 G01 X50 M01
G01 X57 Z-20 M30
Z-40 G0 X65 Z5
G0 X65 Z5G01 X49
G01 X56Z-10
Z-40G0 X65 Z5
G0 X65 Z5G01 X48
G01 X55 Z-10
Z-40G0 X65 Z5
G0 X65 Z5G01 X47
G01 X54Z-10
Z-20G0 X65 Z5
G0 X65 Z5G01 X46
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20

8.2.4 Drilling manual program

G18 G40 G54

G71 G90 G94
G75 X0 Z0
LIMS=1000
G96 S300 M03
T01 D1
M08
G0 X65 Z10
G0X0 Z5 F0.35 G0 Z-5
G01 Z-1 G01 Z-11
G0 Z2 G0 Z-5
G01 Z-2 G01 Z-12
G0 Z2 G0 Z-5
G01 Z-3 G01 Z-13
G0 Z2 G0 Z-10
G01 Z-4 G01 Z-14
G0 Z2 G0 Z-10
G01 Z-5 G01 Z-15
G0 Z2 G0 Z5
G01 Z-6 G75 X0 Z0
G0 Z2 M09
G01 Z-7 M05
G0 Z2 M01
G01 Z-8 M30
G0 Z2
G01 Z-9
G0 Z2
G01 Z-10

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21

Boring manual program

G18 G40 G54

G71 G90 G94

G75 X0 Z0
LIMS=1000
G96 S300 M03
T01 D1
M08
G0 X65 Z10 G01 X24 G0 X28
G0 X19 Z-30 Z2
Z5 G0 X23 G01 X30
G01 Z-30 Z2 Z-10
G0 X18 G01 X25 G0 X28
Z2 Z-30 Z2
G01 X20 G0 X24 G75 X0 Z0
Z-30 Z2 M09
G0 X19 G01 X26 M05
Z2 Z-20 M01
G01 X21 G0 X25 M30
Z-30 Z2
G0 X20 G01 X27
Z2 Z-20
G01 X22 G01 X26
Z-30 Z2
G0 X20 G01 X28
Z2 Z-20
G01 X23 G0 X27
Z-30 Z2
G0 X21 G01 X29

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22

Threading manual program

G18 G40 G54
G71 G90 G94
G75 X0 Z0
LIMS=1000
G96 S300
M03 T01 D1
M08
G0 X45 Z5
G92 X40 Z-25
F2.3 X39.8
X39.6
X39.4
X39.2
X39.0
X38.8
X38.6
X38.4
X38.2
X38.0
X37.9
X37.8
X37.7
5
X37.7
0
X37.6
9
G0 X45
Z20 M09
M0
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23
1
M0
5

Page | 23
24

CYCLE PROGRAMS
FACING PROGRAM
Go to the new block
go to various option down in the
display go to option blank
give the details of the work
piece press the accept key and
. go back to the program Enter the
machine Setup codes
G18 G40 G54
G71 G90 G94
G75 X0 Z0
LIMS=1000
G96 S300 M03
T01 D1 M8
again, go to the turning option below the display
go to the option stock removal
enter the machining details and work piece detailsin
press the option accept and go back to the program the
machine setup codes
G75 X0 Z0
M09
M01
M05
M30

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25

STEPTURNING CYCLE PROGRAM

Go to the new program
Go to various
option Go to blank
option
Give the details of the work piece press the work
piece Go back to the program Enter the
machine setup codesG75 X0
Z0
LIMS=1000
G96 S300 M03
T1 D1 M8
Go to the option counter
turning Go to the counter
option and
Go to option counter call and select labels
After that enter the alphabets as like as AAA in lab 1 and BBB in lab 2
This means that used in profile programming which we have to done
the operations is starting and ending codes.
After that press the option accept
then go to option counter turning and go to option stock
removal then give the details of the machining and work piece
details
press the option accept and enter the profile
programAAA: GO1 X0 Z0
G03 X10.5 Z-5.2
CR=5 G01 X25.5 Z-10
G02 X10.5 Z-22.5
CR=7.5 G01 X15.5
G01 Z-25.2
G01 X10.5
G01 Z-27.2
G01 X 15.5
G01 Z-29.2
G01 X25.5 Z-32.2
G02 X15.5 Z-50.2
CR=15 G01 Z-53.2
G01 X35.5 Z-
60.2 G01 Z-63.2
DDD:

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26

DRILLING CYCLE PROGRAM

Go to the new
program Go to various
option Go to blank
option
Give the details of the work piece press the work piece
Go back to the program Enter the machine
setup codesG75 X0 Z0
LIMS=1000
G96 S300
M03 T1 D1
M8
Go to the option drilling below the display
Enter the details of the machining and work piece details
press the option accept and go back to the programenter the machine
setup codes
G75 X0 Z0
M09
M0
1
M0
5
M3
0

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27

BORING CYCLE PROGRAM

Go to the new
program Go to various
option Go to blank
option
Give the details of the work piece press the work piece
Go back to the program Enter the machine
setup codesG75 X0 Z0
LIMS=1000
G96 S300
M03 T1 D1
M8
Go to the counter option and
Go to option counter call and select labels
After that enter the alphabets as like as AAA in lab 1 and BBB in lab 2
This means that used in profile programming which we have to done the operations isstarting and
ending codes.
After that press the option accept
then go to option counter turning and go to option stock removal
then give the details of the machining and work piece details selectthe ID in PRG
press the option accept and enter the profile program
AAA:
G0 X50 Z5.0

G01 X50 Z0
f0.32 G01 Z-3.0
G01 X45 Z-
8.0 G01 Z-
18.0 G01 X35
G01 X31 Z-20
CR=2 G01 Z-28.0
G01 X27 Z-
31 G01 X25.5
G01 Z-40
BBB:

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28

EXTERNAL THREADING CYCLE PROGRAM

Go to the new
program Go to various
option Go to blank
option
Give the details of the work piece press the work
piece Go back to the program Enter the machine
setup codesG75 X0 Z0
LIMS=1000
G96 S300 M03
T1 D1 M8
Go the option turning below the display and select thread
Enter the details of the machining process and select the externalthread option
Enter the machine ending codesG75 X0 Z0
M09
M01
M05
M30

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29

INTERNAL THREADING CYCLE PROGRAM

Go to the new
program Go to various
option Go to blank
option
Give the details of the work piece and select the pipe option inblank
Go back to the program Enter the machine
setup codesG75 X0 Z0
LIMS=1000
G96 S300 M03
T1 D1 M8
Go the option turning below the display and select thread
Enter the details of the machining process and select the externalthread option
Enter the machine ending codesG75 X0 Z0
M09
M01
M05
M30

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30

MACHINE MAINTENANCE
We must maintain the machine.
There is a different type of maintenance they are by daily, weekly, monthly, quarterly, half yearly
and yearly
Daily maintenance
1. chuck greasing
2. lubrication pump oil level chuck
3.Hydraulic unit main
pressure--35kgs/cm 4.Lubrication unit
pressure--15kgs/cm 5.Front door rail
cleaning
6. chuck pressure
7.lubrication of tail
stock

Weekly maintenance
1.Lubrication oil level in FRL
unit 2.Cleaning of air filter
3.Coolant tank or filter
cleaning 4.Functioning of
spindle motor 5.Cleaning of
spindle belt

Quarterly maintenance
1.Temperature inside the control
panel<35degrees 2.Lubrication pump suction or
inlet filter cleaning 3.Hydraulic oil temperature <
60
4.Checking of run out/noise in spindle, tailstock
5.Spindle front cover cleaning
6.Chuck(jaw stroke)
7.Chuck/cylinder (run out)
8.Hydraulic power pack/ transmission box oil
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31
level 9.Cleaning of panel inside
10.Cleaning of machine lamp

Page | 31
32

Half yearly maintenance

1.Check for any cable breakage/damaged
shielding 2.Relay terminal Screw tightness
3.Coolant motor, chip conveyor
4.Servo motor connector
tightness
5.Check if any abnormal noise/vibration /heat generation in power pack and ball
scerw 6.Hydraulic power pack--oil replacement
7. Axis, spindle drive belts tension

8. Hydraulic power pack suction, Inlet filter

cleaning 9.Electrical control panel cleaning
10.Proper functioning of gear
changing 11.Slide seals adjustment
12.Disassemble and cleaning of the
chuck 13.Cracks in hydraulic hoses
14.Hollow cylinder coolant drain port
cleaning 15.Lubrication distributor oil flow
checking

Yearly maintenance
1.Check battery(system)
voltage 2.Cleaning of PCB's
3. Cleaning of all proximity/limit
switches 4.Cable routing check
5.Fan filters replacement
6.Electrical loose
connections 7.Backlash
check
8.Chuck cylinder disassemble and clean
9.Check for smooth movement of axes
10.solenoid valve/power pack over
heating 11.Machine level

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MILLING MACHINES (VMC)

INTRODUCTION ABOUT CNC MILLING MACHINE (OR) VMC
Introduction

CNC MILLING MACHINE

 CNC machining is a process used in the manufacturing sector that involves the use of computers to control machine tools.
 CNC stands for (COMPUTER NUMERICAL CONTROL).
 The control model of this machine is SINUMERIC 828D from siemens.
 Now a days in all industries CNC machines are only used because of fast manufacturing.
 In this machine there is three axis X-axis, Y-axis and Z- axis. In this X-axis and Y-axis are bed moving directions and Z-
axis is for tool moving up and down.
 In this machine we use an air compressor. Because the tool changing is done using pressurized air only.

Difference between conventional and CNC milling

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Conventional milling
 It consumes more time
when compared tothe CNC
lathe.
 It does not give more
accurate dimensions than
the CNC machine.
 There is less production
in conventionallathe.
 In this the operations are
done manually by
theoperator.
 For this machine needs
skilledoperators to
make every single part.
 The cost of this machine is
less whencompared to the
CNC lathe.
CNC milling or VMC
 It consumes less time when
compared tothe conventional
lathe.
 It gives the more accuracy
dimensions thanthe conventional
lathe.
 There is more production in
CNClathe.
 In this the operations are done
automatically by giving
programming.
 For CNC machine for programming
skilled operator is required and for
machinerunning less skilled operator
is needed.
 The cost of this machine is very
high whencompared to the
conventional lathe.
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CONTROL PANEL OF THE CNC MILLING MACHINE

CONTROL PANEL

Emergency stop
It is pressed when any dangerous situation occurs while machining and in any
emergency situations. For emergency stop push thebutton and for releasing rotate it in
clockwise direction.

Feed operator and spindle speed

These mode selector switches are feed operator and spindle
speed. Feed operation regulatoris used to control the feed of the
cutting tool.
Spindle regulator is used to control the speed of thespindle.

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Execution keys
These keys are used to start and stop the execution programs for machining the
components.RST button is used to reset the machine. CYST (cycle start) and
CYSP (cycle stop).

Spindle operation keys

These operation keys are used to rotate the spindleclockwise or in an anti-
clockwise direction.
SPDLL CW= spindle clockwise direction
SPDL CCW= spindle in counterclockwise
direction SPDL STOP= spindle stop

Coolant keys
These keys are used to turn on and off the coolant manually by pressingthese
keys. Coolant on (CLNT ON) and coolant off (CLNT OFF).

Axis movable switches

The axis switches are used to move the axis in a positive and negativedirection. In this
when you press Rapid and any direction button simultaneously then the axis will
move much faster.

Mode selector switch

This mode selector switch is used to select the various modes like MEM,SBK, MDI, MPG
mode, and axis selector x-axis, y-axis and z-axis.

Manual pulse generator (MPG)

This mode works when it is in x1 or x10 or x100 in mode selector and it is used to move the
tool in x-axis and z-axis by manually rotating this hand wheel. Axis selector switch is in MPG

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Air compressor
Air compressor is used to compress the air and it will send to the machine
with pressure of 5-6 bar. because machine needs that pressure. In the
machine compressed air isused to change the tool.

ATC (automatic tool changer)

ATC means automatic tool changer in CNC machine tools to improve
the production and tool carrying capacity of the machine. ATC
changes the tools very quickly, reducing the nonproductive
time.Generally, it is used to improve the capacity of the machine to
work with a number of tools.

Tool magazine
Tool magazine - centered automatic tool changer is one of the keys to the success of thedesign of CNC machine
tools. Tool magazine is used to store all cutting tools used by CNC machine tools and delivers the tool to be
used to the position of tool changing under the controlof CNC system.

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CODES FOR SIEMENS CONTROL CNC MACHINES

3.1There are two types of codes are there

G-codes (geometrical codes)

M-codes (machine codes)

 Generally, G codes GEOMETRICAL codes are writen in and performed by the CNC
machine processor and operate the motion control part of the control.
 The M codes are MACHINE codes, these operate most of the basic electrical control functionssuch
as Coolant, Tool changers, safety circuits etc,.
 By using these g-codes and m- codes we can prepare the programs for performing theoperations on
the CNC machines.
 The programming is the most important to the CNC machines for performing operations.
 By using these codes, we can prepare programs for the following
operations 1.Facing
2.Rectangular spigot
3.Circular spigot
4.Rectangular Pocket
5.Circular pocket
6.Drilling

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MILLIN
G
4.1 Types of tools
Face milling cutter:

R 490 100 Q 32 14 M 050

R = Right hand rotating cutter

490 = Manufacturer cutter
code 100 = cutter diameter
Q = Mounting type
32 = Arbor
diameter
14 = Insert cutting edge
length M = Close pitch
050 = Cutter length

Insert

490 R 14 04 08 M P M
490 =Manufacturer cutter
code R = Right hand insert
14 = Cutting edge
length 04 = Insert
thickness
08 = Corner radius
M = Edge
performance P = Insert
grade
M = Operation

End mill cutter tool

`HES 41 20 T TT 55 25 DIA 12

Drilling tool
SHD 3068 TT 9030 DIA 6.8

Collet chuck holder

TT1 BT40 CCHK ER 32X70

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DATUM SETTING
troduction
Datum setup means taking offset for the three axis. Offsets are the distances the cutting tool needs to
travel, from its 'Home' position to the Work piece datum in X, Y & Z.

To tell the machine where the material is we will change to Tool number 1 and move the tool
to the side face of the work piece to the X or Y axis.We will then find the centre of the work
piece this is Z datum. The X, Y and Z datum positions will be stored, this is the Work Piece
Offset. If more than one tool is to be used we will change to each tool and set the positions for
each tool relative to Tool number 1. These are the Tool Offsets.

Taking offset for Z-axis:

>Firstly select the mode to MPG
>in MPG hand wheel select the Z axis
>move the tool in negative direction that means to the downwards direction
>touch the tool slowly to the work piece
>go to the option offset in the machine panel board
go to the option tool measure and enter the 0.0 value in Z-axis
>then press the set length option and the offset value will be saved in the machine.

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TAKING OFFSET TO THE X-AXIS

>Firstly select the mode to MPG

>in MPG hand wheel select the Z-axis
>move the tool in negative direction that means to the downwards direction
>select the X-axis and move the bed in negative direction
>touch the tool slowly to the work piece
>go to the option active values in the machine display again go to option relative values
>then press the option set relative and enter 0.0 value
>move the tool to the opposite side of the work piece and touch it
>now note down the saved value and make the value half and move the X-axis
to value which we calculated. Then it will the zero offset in X-axis.

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TAKING OFFSET TO THE Y-AXIS

>Firstly select the mode to MPG

>in MPG hand wheel select the Z-axis
>move the tool in negative direction that means to the downwards direction
>select the Y-axis and move the bed in negative direction
>touch the tool slowly to the work piece
>go to the option active values in the machine display again go to option relative values
>then press the option set relative and enter 0.0 value
>move the tool to the opposite side of the work piece and touch it
>now note down the saved value and make the value half and move the Y-axis
to value which we calculated. Then it will the zero offset in Y-axis.

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Manual programs in CNC milling machine

troduction

For all operations in milling had only one type of program. Now a days manual programs
are rarely used. Mostly CYCLE programs are used. It is an easy process whencompared to
the manual programs.
xample:

G71 G94
G75 Z0
G75 X0 Y0
LIMS=100
0 G96 S300
M3M06
T10 D1 M8
M06
G0 G90 G54
Z10 G0 X0 Y0
G0 Z1.0
G01 X-50
F100 Z-1.0
G01 Y50
G01 X50
G01 Y-50
G01 X-50
G01 Y 0
G01 Z10
G01 X0
G75 Z0
G75 X0 Y0
M09
M05
M30

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CYCLE PROGRAMS IN CNC MILLING

MACHINE

Facing cycle:
>First go to the option various
go to the blank option and give the details of the work
piece enter the machine set up codes
after that go to option milling
select the option facing at the side of the display
>Give the details of the machining of facing
>Press the accept option
>enter the machine ending codes

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Rectangular pocket:
>First go to the option various
go to the blank option and give the details of the work
piece enter the machine set up codes
after that go to option milling
select the option pocket milling at the side of the
display and again got t option rectangular pocket
>Give the details of the machining of rectangular pocket
>Press the accept option
>enter the machine ending codes

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Circular pocket:
>First go to the option various
go to the blank option and give the details of the work
piece enter the machine set up codes
after that go to option milling
select the option pocket milling at the side of the
display and again got t option circular pocket
>Give the details of the machining of circular pocket
>Press the accept option
>enter the machine ending codes

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Drilling:
>First go to the option various
go to the blank option and give the details of the work
piece enter the machine set up codes
after that go to option drilling
>Give the details of the machining of drilling
>Press the accept option
again go select the position of the drilling like circle , angle, straight etc,..
>enter the machine ending codes

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Multi Spigot :
>First go to the option various
go to the blank option and give the details of the work
piece enter the machine set up codes
after that go to option milling
select the option multi spigot milling at the side of the
display and again, got to the option rectangular or circle
spigot
>Give the details of the machining of spigot
>Press the accept option
>enter the machine ending codes

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MAINTENANCE OF MILLING MACHINE

Daily maintenance:
1. check the functioning of AC
unit. 2.check the air pressure(5-
bar) 3.check the exhaust fan

Weekly maintenance:
1.clean the lubrication oil level in FRL
unit 2.clean the tool pot and tool shank
4.clean the air filter and fan of electrical
cabinet 5.clean the air filter in AC unit.
6.clean the coolant tank and filter

Quarterly maintenance:
1.clean the ATC
magazine 2.clean the
machine lamp
3.clean the lubrication pump suction
filter 4.check the hoses and electrical
cables

Half yearly maintenance:

1. clean the wipers
2. clean the electrical control
panel 3.clean the FRL unit
4.greeze the ATC gears, cams, cam followers ,
magazine 5.check the wipers adjustment
6.check the servo motor connector tightness
7.check the position coder connector tightness
8.check the relay terminal
9.check the proximity switch
10.check the spindle belt
tension
11.check the lubrication distributer oil
flow 12.replace the hydraulic oil

Yearly maintenance:
1. check the battery voltage
2. check the PCB's proximity and limit
switch 3.check the cable routing
4.check the electrical loose
connections 5.check the machine
leveling
6.replace the fan filters in control panel
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7.replace the wipers

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481

HANDS-ON APPLICATION

On milling
By using these programs the operations below are done.

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471

. CONLUSION
During my internship in CNC lathe and CNC milling machine operations, I gained
invaluable knowledge and skills in precision machining. I learned the importance of
precision, attention to detail, and the ability to interpret technical drawings. Additionally,
I acquired proficiency in setting up and operating both types of machines, including
tool selection and workpiece fixturing. This experience has not only enhanced my technical abilities
. but also underscored the significance of safety protocols in a machining environment.
Overall, my internship provided me with a solid foundation in CNC machining, which I
can apply to future endeavors in the field of manufacturing and engineering.

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