Engineering Technology

Department

Engineering Workshop
(METE 2222)

Laboratory Manual

Version 1 – May 2021

 Table of Contents

Lab 01 Drilling Machine 1

Lab 02 Riveting 8
Lab 03 Threading 11
Lab 04 CNC Lathe 14
Lab 05 CNC Milling 25
Lab 06 injection molding 43

V.1
 ENGINEERING TECHNOLOGY DEPARTMENT

Drilling Machine
LAB Objectives:

01
1. To understand the components and operation of drill machine.
2. To understand the importance of marking tools for drilling operation.
3. To use marking tools, center punch, and drill machine to drill hole in a plate

1. Introduction:
Drill machine is used to drill holes in a work piece. The tools used in drill machine are called drill
bits. The components of a drill machine are shown in Figure 1.

Figure 1: Components of a drill machine.

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 ENGINEERING TECHNOLOGY DEPARTMENT

2. Equipment and Materials

a. Drilling machine

Figure 2: Drill machine.

1. ON/OFF switch 6. Motor

2. Hand feed 7. Emergency stop button
3. Chuck 8. Table clamp
4. Work table 9. Depth adjustment
5. Base table 10. Pulley guard

Depth adjustment is used to limit the depth for drilling holes. A glass protector is provided for
safety of user in case of flying chips or debris from broken bits. A chuck holds and turns the drill
bit for operation. Chuck is attached to the spindle that rotates it. Spindle gets power from motor.
A hand wheel is used to move the drill bit in z-axis. This enables the turning drill bit to make a
hole in the work piece. A table clamp is also provided to adjust the position of the work table in
3 axis.

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 ENGINEERING TECHNOLOGY DEPARTMENT

b. Vise
Vise is a mechanical apparatus used to secure an object to allow work to be performed on it.
Vises have two parallel jaws, one fixed and the other movable, threaded in and out by a screw
and lever. Vise is important part of drilling operation and requires to be clamped properly before
use.

Figure 3: Vise specifications for holding work piece.

c. Steel Rule

Figure 4: Steel rule

Steel rule are used for measuring distances during marking out.
d. Scriber
Used for marking metals (pencil rubs off but a scriber scratches). Used with a try-square for
marking lengths and widths. Table 1: displays the common process that you will undertake when
marking out with the different materials. This tool must be used on flat service or a straight/true
edge to insure accuracy.

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 ENGINEERING TECHNOLOGY DEPARTMENT

Figure 5: Scriber

Table 1: Process for marking out with different materials.

e. Center Punch
A center punch tool is a special type of punch tool that's used to create a shallow indention in a
work piece for the purpose of drilling. The dent helps to guide the drill so that it doesn't wander
off the middle. It can also be used to make a dent so the engineer divider does not slip when
marking circles on hard materials such as metals.

Figure 6: Center Punch.

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 ENGINEERING TECHNOLOGY DEPARTMENT

f. Spot Drilling
Ideally, the center of a carbide drill should always be the first point to contact your part.
Therefore, a spotting drill should have a slightly larger point angle than that of your drill. If a
spotting drill with a smaller point angle than your drill is used, your drill may be damaged due to
shock loading when the outer portion of its cutting surface contacts the work piece before the
center. Using a spot drill angle equal to the drill angle is also an acceptable situation. Figure 1
illustrates the desired effect. On the left, a drill is entering a previously drilled spot with a slightly
larger angle than its point. On the right, a drill is approaching a spot with an angle that is far too
small for its point.

Figure 7: Spot angles.

Marking Your Spot

A Spotting Drill’s purpose is to create a small divot to correctly locate the center of a drill when
initiating a plunge. However, some machinists choose to use Spotting Drills for a different reason
using it to chamfer the top of drilled holes. By leaving a chamfer, screw heads sit flush with the
part once inserted.

Figure 8: Spot drilling used for chamfer.

Using a larger angle spot drill will allow the drill to find the correct location by guiding the tip of
the drill to the center. If the outer diameter of a carbide drill were to contact the work piece first,
the tool could chip. This would damage the work piece and result in a defective tool. If the two
flutes of the drill were slightly different from one another, one could come into contact before
the other. This could lead to an inaccurate hole, and even counteract the purpose of spot drilling
in the first place

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 ENGINEERING TECHNOLOGY DEPARTMENT

3. Procedure
The complete drilling procedure is explained in the following steps.
1. Marking out. Use marking tools such as scriber, ruler, engineer’s square, compass, etc. to
scribe the exact points where a hole needs to be drilled. Mark out as clearly as possible to avoid
mistakes.
2. Dent using center punch. Use a center punch tool to dent the area of the work piece where
the drill bit will enter. Use a ball pein hammer Figure 4 to tap the head of the punch and this
delivers enough force to the point of the punch to put a small indentation into the surface of the
material.

Figure 9: Ball pein hammer.

3. Chose the appropriate drill bit and spot drill bit. Drill bit is selected based on the material of
work piece and the diameter of the hole. In case of internal threading, the inner diameter is used
for the hole. Select the right drill bit for your application. Spot drill is selected based on the size
of the material, as discussed earlier.
4. Install the spot drill bit in chuck. The spot drill bit needs to be firmly held inside the chuck.
Sometimes a key is used to tighten the chuck to hold the drill bit. In the provided machine, the
chuck is tightened by rotating the dial right above the jaws of the chuck.
5. Secure the work piece in vise. Operate the vise to secure the work piece in vise in the
orientation that provides convenient operation. Make sure the work piece is firmly held and
there is enough clearance below the work piece if the drill bit must go through the work piece.
6. Adjust the worktable Adjust the height of worktable such that the when the hand feed is
lowered, the drill bit tends to go through the work piece. The drill machine should not be
turned ON at this point.

7. Adjust the vise Adjust the vise such that when the hand feed is lowered, the drill bit tends to
go through the work piece at the exact point where drilling is required. In case multiple holes
are to be drilled, step 5 and 6 will be repeated for every new hole. Figure shows dimensions of
the vise.
8. Turn on the machine. Make sure the machine is connected to main power and the
emergency stop is disengaged. Turn on the machine by pressing the ON button.

9. Mark a spot in the location of hole. Operate the hand feed to lower the drill bit and continue
doing so until a spot is made on the surface of the work piece.

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 ENGINEERING TECHNOLOGY DEPARTMENT

10. Turn off machine. Once spot is made, turn off the machine using the OFF button (black).
11. Remove the spot drill bit and install the chosen drill bit for drilling a hole. Repeat steps 4
to 8 using the drill bit.

12. Drill a hole. Operate the hand feed to lower the drill bit and continue doing so until a hole
is drilled through the work piece. Adjust the feed rate depending on the thickness and the
material of work piece. In case the material is very thick, you may need to clear the chips by
retreating the drill bit out of work piece and then drilling in again.
13. Turn off machine. Once a hole is drilled, move the drill bit out of the hole and turn off the
machine using the OFF button (black). This step has to be performed after drilling each hole, DO
NOT let the machine be ON while performing steps 5 and 6 for a new hole. In case of
emergency, you should always be able to turn off the machine using the emergency shut down
button.

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LAB Objectives:
POP RIVETING

02
1. Perform pop riveting process

1. Introduction

Pop riveting is a technique that is used to join thin pieces of metal and it can also be used to
join plastic sheet. The rivet has two parts, the pin and the rivet. The rivet gun is used to pull the
pin through the rivet and as this happens the rivet is deformed slightly so that it joins the metal
or plastic pieces.

Figure 1: riveting tool

This technique is used with metal or plastic sheets and where the joint does not have to be very
strong. It is ideal for joining aluminum or even thin sheet plastic

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2. Theory
There are close to a dozen different rivet types, but we’re focusing on three of the most
commonly used:

Standard rivet: The standard rivet is the most common type of rivet and is probably familiar to
many. It is characterized by a round-head fastener, making it suitable for applications that don’t
require a smooth finish on the surface of the material. Standard rivers are considered some of
the most reliable fasteners and are primarily used because they rarely fail.

Due to the design of a standard rivet, it requires access to both sides of the materials being
fastened. Upon being driven using pneumatics or hydraulics, the tail of a standard rivet is
deformed by a hammer or rivet gun. This serves to fasten the rivet in place and to reduce the
clearance between the rivet and the hole to as small as possible.
Countersunk rivet: Countersunk rivets work very similarly to a standard rivet in that they both
require access from both sides of the structure. The only difference is that the head of a
countersunk rivet is designed in a way that it will become concealed from the surface of the
structure once it has been driven in place. To allow the countersink head to “sink” into the hole,
the hole also needs to be designed accordingly. Countersunk rivets are ideal for applications
that require smooth surface either due to aesthetics or so that they will fit perfectly against
another part.
Blind rivet: A blind rivet (or “pop rivet”) is a rivet used in structures where access to the
structure is only possible from one side. The innovative design of a blind rivet is composed of
two parts: a durable nail-like mandrel, and a weaker and thicker head typically made of
aluminum. Driving a blind rivet will require the use of a rivet gun. The way that a blind rivet
works is that the thick head is driven into the hole being fastened while a rivet gun pulls on the
thin mandrel. This creates a compressive force between the head and the material being
fastened, deforming the head and creating a permanent fastener. The excess length of the
mandrel is then snapped off.

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3. Experimental procedure
1. The two pieces of plastic or aluminum are drilled to a size slightly larger than the rivet
2. The pop rivet is passed through both holes in the sheet.
3. The pin of rivet is inserted in the rivet nozzle and the handles are pulled together. As this
happens the pin head is pulled into the rivet and the end of the rivet is expanded. The handles
are pulled in until the pin breaks off leaving the rivet permanently fixed in position holding the
two pieces of plastic / aluminum together.

Figure 2: riveting steps

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• Tapping in progress

LAB Objectives:
Threading

03
1. Able to perform threading machining process

1. Introduction
There are various methods for generating screw threads. The method chosen for any one
application is chosen based on constraints—time, money, degree of precision needed (or not
needed), what equipment is already available, what equipment purchases could be justified
based on resulting unit price of the threaded part (which depends on how many parts are
planned), etc.

2. Theory
Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be
threaded into the hole. Also, it is used to make thread on nuts. Tapping can be done on the
lathe by power feed or by hand. Regardless of the method, the hole must be drilled with the
proper size tap drill and chamfered at the end. Threading dies are used to form or cut a male
thread on the outside of rods or bars. Threading dies provide precision in cutting and extend
the life of a die by reducing wear. Taps and dies are the tools used for cutting threads.

Figure 1: Threading Die and taping tool

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3. Experimental procedure

1. Determine which thread size you wish to cut

Metric threads, M4, M5, M6, M8, M10 & M12 are commonly used. M4, for example, means the
"standard" M4 thread size: for a bolt, the major diameter would be 4mm, and the pitch would
be 0.70mm.
Smaller than M4 you readily risk breaking taps in your work-piece (taps are harder than drill
bits, so this might mean you've ruined your work-piece).

2. Find out the correct hole size to drill for the thread you wish to tap
Table standard metric tapping drill sizes:

M4 x0.70mm pitch tapping drill 3.3mm

M5 x0.80mm pitch tapping drill 4.2mm

M6 x1.00mm pitch tapping drill 5.0mm

M8 x1.25mm pitch tapping drill 6.8mm

M10 x1.50mm pitch tapping drill 8.5mm

M12 x1.75mm pitch tapping drill 10.2mm

3. Internal Threaded Holes (Using a Tap) steps

1) Check the required pitch using a thread gauge and major diameter using Vernier caliper.
2) Chose the appropriate tap from the toolbox.
3) Adjust the end of tap with the hole you drilled earlier. Turn the tap wrench until the first
cut into the material has been made.
4) Once a grip on the material has been made turn half a turn into the material and then a
quarter turn back this will ensure that the tap doesn’t get clogged with the offcuts of
material and a better thread is created.

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 5) Keep turning until all the way through the material and most of the way through the
thread, there should be no resistance once the cut has been made the full distance
through the material when turning in or out using the tap wrench.
6) Once through the material using this tap repeat the process using the tap.
7) Check the threading using the appropriate bolt.

4. External Threads on Rods (Using a Die) steps

1) Check the required pitch using a thread gauge and major diameter using Vernier caliper.
2) Chose the appropriate die from the toolbox.
3) Fit the die with the sizing information on the die facing up and the top screw fitting into
the slot, making sure all the screws are loose to allow the die to sit flush.
4) Tighten up the screw on the die holder to keep the die in place, ensure all the screws fit
in the indences in the die.
5) Put some Rocol cutting greese on the end of the rod to be threaded,
6) Place the rod in a vice square and tighten, use a set square to ensure the rod is square in
the vice.
7) Place the dice on top of the rod and turn to create the first cut.
8) Once a grip on the material has been made turn half a turn into the material and then a
quarter turn back this will ensure that the die doesn’t get clogged with the offcuts of
material and a better thread is created.
9) Keep turning until the depth of thread is achieved, there should be no resistance once
the cut has been made level and sqaure to the rod
10) Check the threading using the appropriate nut.

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LAB CNC Lathe Machine Operation
Objectives:

04 1. To learn to operate a CNC lathe machine

2. To machine a product according to the given dimensions.

1. Introduction
The development of CNC machining has opened up new possibilities for automated production.
Machining with a CNC lathe is generally much faster than with a conventional lathe. The need for
modern consumers to be different has led to a greater diversity in product models and therefore
smaller batch sizes. The development of the CNC lathe has made this possible. In this exercise
you will use a CNC lathe machine to produce a part with given dimensions.
2. Theory
Numerical control (also computer numerical control, and commonly called CNC) is the automated
control of machining tools (such as drills, lathes, mills) and 3D printers by means of a computer.
A CNC machine processes a piece of material (metal, plastic, wood, ceramic, or composite) to
meet specifications by following a coded programmed instruction and without a manual operator
directly controlling the machining operation.
A CNC machine is a motorized maneuverable tool and often a motorized maneuverable platform,
which are both controlled by a computer, according to specific input instructions. Instructions
are delivered to a CNC machine in the form of a sequential program of machine control
instructions such as G-code and M-code, then executed. The program can be written by a person
or, far more often, generated by graphical computer-aided design (CAD) software and/or
computer aided manufacturing (CAM) software. In the case of 3D printers, the part to be printed
is "sliced", before the instructions (or the program) is generated. 3D printers also use G-Code.
CNC is a vast improvement over non-computerized machining that must be manually controlled
(e.g. using devices such as hand wheels or levers) or mechanically controlled by pre-fabricated
pattern guides (cams). In modern CNC systems, the design of a mechanical part and its
manufacturing program is highly automated. The part's mechanical dimensions are defined using
CAD software and then translated into manufacturing directives by computer-aided
manufacturing (CAM) software. The resulting directives are transformed (by "post processor"
software) into the specific commands necessary for a particular machine to produce the
component and then are loaded into the CNC machine.
Since any particular component might require the use of a number of different tools – drills, saws,
etc. – modern machines often combine multiple tools into a single "cell". In other installations, a
number of different machines are used with an external controller and human or robotic
operators that move the component from machine to machine. In either case, the series of steps
needed to produce any part is highly automated and produces a part that closely matches the
original CAD drawing.

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Machine Bed
The bed of a CNC Lathe or CNC Turning Centre forms the main base for the whole machine. It is
where the different components of the machine are mounted on. For example, the spindle stock
which houses the machine’s main spindle; tailstock body; X and Z axis slide; optional Y-axis; and
sub-spindle.
To ensure longevity, Hwacheon manufactures machine beds using high quality Meehanite cast
iron. These help to limit heat distortion and provides solid mechanical stability. This ensures that
the parts machined are consistently accurate.

Main Spindle
Often known as the heart of a machine tool, the main spindle consists of a spindle assembly and
the spindle drive system. These are some of the moving parts of the CNC machine tool, and they
include motors, gears, and the chuck (more on it later). The C-axis drive which helps to position
the material will also be assembled together with the spindle.
Tool holders are normally installed at the turret disk (a rotating disk allowing tools to be
positioned and switched), they include both fixed and life tool holders. The life tool drive system
is built-in.
To ensure greater quality, Hwacheon manufactures 100% of its own spindles and parts of it.
These can tolerate standard or higher optional rpm ranges, run with minimized vibration levels,
depending on the application requirements.
Sub-Spindle/ Second Spindle
Separate from the main spindle as an option, the sub-spindle works in sync with the main spindle
to complete the first and second cutting operation in a CNC lathe. This improves efficiency and
throughput per cycle. When named as a second spindle, the mechanism has the same capacity
and power as the main spindle.
Designed with the end-users in mind to achieve higher flexibility and performance, sub-spindles
are available optionally on most of Hwacheon’s Hi-TECH Series.

Chuck
A chuck is a vice-like structure that grips the workpieces to be machined. It is attached to the
main spindle that rotates both the chuck and the workpiece.
To achieve greater productivity in manufacturing, you should consider CNC lathes that offer a
variety of options, allowing you to switch to the right tool for your turning jobs. Some of
Hwacheon’s machine tools have the flexibility and size to accommodate extra-long oil pipe
machining and other long shaft applications.

Guide Way
The guide way enables the tool to move horizontally and vertically to achieve a smooth cutting

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process. To ensure durability, rigidity and the highest accuracy are needed for this structure.
Hwacheon incorporates highly rigid solid box guides on all axes for its Hi-TECH line of machines
to cut down time between processes and to enhance machining precision.

Headstock
Comprising the main motor, the headstock holds the main spindle where the chuck is mounted
on. To ensure high performance, you need to consider if your machine tool’s headstock can
handle high torque at low speed. This is an important consideration for tough materials.
For Hwacheon’s Hi-TECH Series, our gear-transmission system provides power and stability. The
transmission assembly and spindle motor are also designed to limit heat and vibration transfer.

Tailstock
Tailstock are used to provide an extra support force on the other end of the component. This is
necessary when machining long and extra-long work pieces (e.g. Shafts).
For Hwacheon’s Hi-TECH Series machines, the tailstock can be programmed to be positioned in
semi-auto mode. This allows it to provide firm support and greater precision to the machined
parts.

Tool Turret
The turret provides the possibility to change the cutting tools required for machining. Hence it is
mounted on the tool turret. The size of the turret is determined by the number and size of tools
that will be mounted on it.
To ensure stability and precision in machining, the turret in, for example, Hwacheon’s Hi-TECH
550 provides a powerful clamping force, offering an index time of 0.2 sec/setup for fast and more
stable machining.

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3. Equipment

1. Homing switch 6. Control panel

2. Chuck and spindle 7. Residual tray
3. Tool changer and tool 8. Door handle
4. Guideway 9. Door lock
5. Emergency stop 10. Computer

11. Home button 14. Knob for spindle speed

12. Hand Sign 15. ON/OFF buttons
13. Tool movement

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3. Procedure
1. Use a hacksaw to cut the nylon rod to 55mm length as shown in figure.

2. Measure the diameter and the length of the work piece after cutting, and note them down.
3. Now turn on the CNC lathe machine using the main switch on the right side of the machine,
as shown in figure.

4. Disengage the emergency stop button (5) by making sure it is pulled out.
5. Click the homing switch (1) to turn on the drive. Wait for the light on home button (11) to
turn on. Click the home button (11) and wait for the tool carrier to move to home position.
6. Make sure the hand sign (12) light is on.
7. Open the safety door by sliding the door handle (8) all the way up.
8. Install the nylon work piece in the chuck (2) using the provided chuck key.

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9. Measure and note down the length of work piece from chuck until the end of the work piece
using Vernier caliper, as shown in figure.

10. Close the safety door by pulling the door lock (9) and sliding the door handle (8) down.
11. Open the Boxford software by clicking the icon on desktop. Check the serial number on
machine the computer is connected to, and select the correct machine on the software, as
shown in figure. Serial number is posted above the main switch on right side of the machine.

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12. You will see a main menu, hovering the mouse over these icons will show description of
what each icon does. Click the first one on left side to start creating the billet profile.

13. To perform facing operation, enter the length you measured in step 9 and the diameter
as measured in step 2. The inside diameter and hole depth remain zero for a solid workpiece.

14. A CAD tool will open with its maximum dimensions equal to what you specified in
previous step. Note that this window allows you to draw half of the product since it is an

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 axisymmetric operation. For facing operation, you have to draw the lines on the extent of the
drawing area. This line represents the material to be removed. Get an approximate
measurement of the uneven part of work piece and cut that part in drawing. Each green box
has a specified distance, i.e. 1mm. The drawn lines should look as the red lines shown in
figure.

15. For other operations, the following drawing tools can be used. For every option there will
be a box to input value.

a. Threading

b. Fillet

c. Chamfer

d. Arc
16. Click file and then save the profile on computer.

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17. Click file and then click process billet to generate the G&M Code for the profile you have
created.

18. Select the material as Nylon (or plastic) and enter the diameter and the length as
collected in the steps 2 and 9.
19. Click process and wait for it to process.
20. Click on simulation ‘play’ button to watch the simulation.
21. Now click on machine icon on the main menu as shown in figure.

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22. Click ok and enter the stick out dimension as collected in step 9.
23. Press the ‘cycle to continue’ green button until the machining begins.
24. Keep an eye on the tool motion and prepare to press the emergency stop any time the
tool is on way to collision with the chuck or any other part.
25. Once the machining is completed, repeat the steps for facing on the other end of the
work piece.
26. Now measure the dimensions of a sample product and draw it in the CAD tool. Repeat
all steps to produce this product.
27. Once the operations are completed, initiate the closing procedure.
a. Home the tool holder.
b. Remove any work piece from the chuck.
c. Clean the residual tray.
d. Oil the guideway as shown in figures below. 2 drops on the guideway in front
and the back using hand.

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24
 CNC Milling Machine
LAB Objectives:
1. To Drfine the machine home point

05
2. To define the datum point in CNC machine
3. To understand different types of clamping

1. Introduction

CNC milling, or computer numerical control milling, is a machining process which employs
computerized controls and rotating multi-point cutting tools to progressively remove material
from the work piece and produce a custom-designed part or product. This process is suitable
for machining a wide range of materials, such as metal, plastic, glass, and wood, and producing
a variety of custom-designed parts and products. This session enables the use of a 3-axes CNC
bench-milling machine with “Fanuc Emulated Control Programming Software” to produce a
given product.

Milling is the process of machining using rotary cutters to remove material by advancing a
cutter into a work piece. This may be done varying direction on one or several axes, varying
cutter head speed, and varying pressure. Milling covers a wide variety of different operations
and machines, on scales from small individual parts to large, heavy-duty gang milling
operations. It is one of the most commonly used processes for machining custom parts to
precise tolerances.

Milling can be done with a wide range of machine tools. The original class of machine tools for
milling was the milling machine (often called a mill). After the advent of computer numerical
control (CNC) in the 1960s, milling machines evolved into machining centers: milling machines
augmented by automatic tool changers, tool magazines or carousels, CNC capability, coolant
systems, and enclosures. Milling centers are generally classified as vertical machining centers
(VMCs) or horizontal machining centers (HMCs).
Vertical Milling Machine
In the vertical milling machine the spindle axis is vertically oriented. Milling cutters are held in
the spindle and rotate on its axis. The spindle can generally be lowered (or the table can be
raised, giving the same relative effect of bringing the cutter closer or deeper into the work),
allowing plunge cuts and drilling. There are two subcategories of vertical mills: the bed mill and
the turret mill.
a) Turret mil
A turret mill has a fixed spindle and the table is moved both perpendicular and parallel to the
spindle axis to accomplish cutting. Some turret mills have a quill which allows the milling cutter

25
(or a drill) to be raised and lowered in a manner similar to a drill press. This provides two
methods of cutting in the vertical (Z) direction: by raising or lowering the quill, and by moving
the knee.
b) Bed mill
In the bed mill, however, the table moves only perpendicular to the spindle's axis, while the
spindle itself moves parallel to its own axis.
c) Horizontal Milling Machine

A horizontal mill has the same sort but the cutters are mounted on a horizontal spindle the
table. Many horizontal mills also feature a built-in rotary table that allows milling at various
angles; this feature is called a universal table.

Most CNC milling machines (also called machining centers) are computer controlled vertical
mills with the ability to move the spindle vertically along the Z-axis.
2. Equipment

MTAB XLMILL is a benchtop 3 axis CNC milling machine with an optional 6 station Automatic
Tool Changer. A stabilizer is used to provide stable power to this machine. The X, Y, and Z axes
travel distances are 225mm, 150mm, and 115mm respectively. Its table size is 360mm x 132mm
and spindle to table distance is 70mm to 185mm

Figure 1: Stabilizer.

1. Inverter
2. Stabilizer

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 Figure 2: XLMILL CNC Milling Machine.

3. Emergency Stop button

4. Door Handle
5. Computer

Figure 3: Milling Machine.

6. Clamps 9. Work Table

7. Datum Plate 10. Spindle
8. T-Slots 11. Work-piece

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Basic Coordination: Reference Points of the MTAB Milling Machines:
M = Machine Zero Point: An unchangeable point established by the machine manufacturer.
Preceding from this point the entire machine is measured. At the same time “M” is the origin of
the coordinate system.
R = Reference Point: A position in the machine working area which is determined exactly by
limit switches. The slide positions are reported to the control by the slides approaching the “R”.
N = Tool mounts reference point: Starting point on the tool holder system and is established by
the machine manufacturer.

W = Workpiece Zero Point: Starting point for the dimensions in the program. Can be freely
established by the programmer and moved as desired within the part program.

Zero Offsets: With MTAB milling machines the machine zero point “M” lies on the left front
edge of the machine table. This position is unsuitable as a starting point for dimensioning. With
the so-called zero offset the coordinate system can be moved to a suitable point in the working
area of the machine.

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Coordinate System: The X coordinate lies to the front edge of the machine table, the Y
coordinate lies parallel to the side edge of the machine table, the Z coordinate is vertical to the
machine table (as shown in figure below). Z coordinate values in minus direction describe
movements of the tool system towards the workpiece, values in plus direction away from the
workpiece, values in plus direction away from the work place.

Coordinate System with Absolute Programming: The origin of the coordinate system lies in the
machine zero point “M” or after a zero offset in the work piece zero point “W”. All target
points are described from the origin of the coordinate system by indication of the respective
X, Y & Z distances.
Coordinate System with Incremental Programming: The origin of the coordinate system
lies at the tool mount reference point “N” or at the tool tip after tool call-up. With
incremental programming the actual paths of the tool (from point to point) are described
3. Procedure

1. Use marking tools to mark out the datum point on the work-piece.
2. Turn on the machine via the main switch (2) on the stabilizer (1).
3. Pull the emergency stop button (3) to disengage it.
4. Open the door of the milling machine by lifting it using the door handle (4).
5. Insert the clamps (6) and the datum plate (7) in the T-slots (8) of the machine table (9)
and slide them in to the center of the table, as shown in the figure.

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6. Use a try square to ensure that the datum plate (7) is set at right angle to the table, as
shown in figure below.

7. Tighten the datum plate (7) by turning the screws using allen key.
8. Place the work-piece aligning it with the datum plate (7) on one side and the clamps (6)
on the other and then tighten the screws on clamps (6) using allen key, as shown in
figure below.

9. Tighten the jaw screws on the sides of the clamps (6) as shown in figure.

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10. Check if the work-piece is secure between the clamps (6) and the datum plate (7).
11. Alternatively, a different clamp may be required for certain work-piece, which can be
installed as shown in the figure below.

12. Fix a non-ATC lever on the hexagonal stud on the top right of the machine, as shown in
figure.

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13. Insert the tool holder in the spindle (10) as shown in figure.

14. Clamp the tool holder in spindle (10) by turning the non-ATC lever counter clockwise by
about 60 degrees and then back to its position, all while holding the tool holder in the
spindle (10).
15. Close the door of the milling machine by pulling it down using the door handle (4).
16. Open CNC Train software on computer (5) and go to “Machine Options” and click
“Machine Link” as shown in figure below.

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17. In the new window type Y and press OK.
18. Click home and then click Z. The headstock of the machine moves up until it reaches its
Z=0 position.

19. After the headstock stops moving, click OK.

20. Now click Y. The table moves outward until it reaches Y=0 position. After the table stops
moving, click OK.
21. Now click X. The table moves towards right until it reaches X=0 position. After the table
stops moving, click OK.
22. Enter the number of the tool in the T window and then click T, as shown in figure below.

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23. The tool change operation will occur as per the tool number entered.
24. After the tool change is completed, click the “Rapid” button. Enter the spindle RPM
value of 500 in the S window and then click S, as shown in figure below.

25. Enter the value of 03 in M window, which is the M code required to run the spindle.
Click M to run the spindle, as shown in figure below.

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26. Click the “Rapid” button and then move the tool close to the work-piece by pressing the
x±, y±, z± controls and observing the tool move towards the work-piece, as shown in
figure below.

27. Reduce the feed rate to 50 by changing the F value to 50 and then click F.
28. Press the x±, y±, z± controls to move the tool very close to the required datum point.
29. Click “Jog” button and change the value to 1mm from the drop down menu, as shown in
figure below.

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30. Click z- to bring the tool closer to the work-piece. Now change the jog value to 0.1mm
and press z- again to move the tool until it touches the work-piece on its surface.
31. Click “Datum” button and then click X, Y and Z to reset them to zero, as shown in the
figure below.

32. The datum is now set at the marked position. Click “File” and “Save Cnc Program”, as
shown in figure below. Click OK.

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33. Click “HOME” button and then click Z. The headstock will move to is Z axes home
position. Click OK.
34. Click “HOME” button and then click Y. The headstock will move to is Y axes home
position. Click OK.
35. Click “HOME” button and then click X. The headstock will move to is X axes home
position. Click OK.
36. Type 05 in the M box to stop the spindle.

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LAB CNC Milling Machine (Part 2)
Objectives:

04 1. New Program CNC Design

2. Import DXF

New Program CNC Design

1. Open the CNCTRAINv8 software on computer.

2. In the new window shown in figure 1, select XLMILL, type the password ‘master’ and press OK.

3. Click on file> New Cnc Program, as shown in figure 2.

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4. Open the material library by clicking the black box icon as shown in figure 3. Insert the appropriate
billet material and dimensions while keeping the billet shift Zero for X, Y, and Z. Click OK.

5. Click the tool option to open tooling select window as shown in figure 4. Select the appropriate
tool, click ‘Update CNCDESIGN’ and then click OK.

6. Click CNC Design menu to open design window as shown in figure 5.

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7. In the design window, click on design files and then click ‘New Drawing’, as shown in figure 6.

8. Use the drawing tools on the left panel to draw the required profile.
9. Click select from the panel at the bottom and click-drag over the entire drawing to select the
profile..
10. Click on ‘TOOL DATA’ as shown in figure 7 and then input the appropriate cutting data values.
Click OK. The start depth is always 0 for a plain billet whereas the end depth depends on the
model. However, the cut depth can be any value from 0 to 1.

11. Click Build CNC option; Select Post Processor option, Select the Fanuc OM then click OK. Then
select Create Tool Path and Click CNC train.

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 12. Click the green button as shown in figure 9 to start the cycle. The simulation should start running
on screen at this point.

Import DXF

1. Open the CNCTRAINv8 software on computer.

2. In the new window shown in figure 1, select XLMILL, type the password ‘master’ and press OK.
3. Click on file> New Cnc Program, as shown in figure 2.
4. Open the material library by clicking the black box icon as shown in figure 3. Insert the appropriate
billet material and dimensions while keeping the billet shift Zero for X, Y, and Z. Click OK.
5. Click the tool option to open tooling select window as shown in figure 4. Select the appropriate
tool, click ‘Update CNCDESIGN’ and then click OK.
6. Click CNC Design menu to open design window as shown in figure 5.
7. In the design window, click on design files and then click ‘New Drawing’, as shown in figure 6.
8. Click design files and then click ‘Import DXF’ as shown in figure 10.

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9. Navigate to the appropriate DXF file in the file explorer and click ‘OPEN’. The profile from DXF will
be seen on the drawing area.
10. Click select from the panel at the bottom and click-drag over the entire drawing to select the
profile.
11. Click on ‘TOOL DATA’ as shown in figure 7 and then input the appropriate cutting data values.
Click OK. The start depth is always 0 for a plain billet whereas the end depth depends on the
model. However, the cut depth can be any value from 0 to 1.
12. Click Build CNC option; Select Post Processor option, Select the Fanuc OM then click OK. Then
select Create Tool Path and Click CNC train.
13. Click File > Save As, and save the file in a known location.
14. Click the green button as shown in figure 9 to start the cycle. The simulation should start running
on screen at this point.

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LAB Injection Moulding Machine
Objectives:

06
1. Understand the injection moulding process
2. Preform the injection molding process

1. Introduction
Surfaces of the 25 Injection Moulding Machine may become hot in use. Please take care when
using the machine, in particular around the nozzle at the end of the heater barrel.
The 25 Injection Moulding Machine is intended for the injection moulding of thermoplastic
materials which can be moulded at temperatures under 200°C. Do not use materials with a
moulding temperature over 200°C. Do not attempt to mould materials with a flash point under
200°C. Always check the MSDS of any material prior to using it in the 25 Injection Moulding
Machine.
If you are in any doubt as to the source and characteristics of a material that you wish to use in
the 25 Injection Moulder, seek advice before loading it into the machine.

2. Theory
Temperature Controller Settings (Brainchild Controller)

Figure 1: Brainchild Controller

Switch on the machine and the temperature controller will illuminate. The upper display
coloured red shows the actual temperature of the injection barrel and the lower green display
is the set temperature, which needs to be set by the operator. Press and hold the up or down
button as appropriate to adjust the set temperature.

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Press the up or down button once makes one digit illuminate more brightly. Press again to
“scroll” the bright digit. Press and hold to increase/decrease the value.

3. Experimental procedure
1. Switch on the machine and set the temperature.
Fit a mould and adjust the mould clamp as described in section 4. Raise the injection ram fully
up and feed granules into the hopper. The granules will spill into the injection barrel. Continue
feeding until the granules are 6- 10mm (1/4” - 1/2”) from the top of the barrel.
Do not fill above this point as surplus granules will be wasted and may melt onto the heated
parts of the machine below

Figure 2: Feeding granules

2. Feeding granules in to the hopper

Allow the granules to heat up fully. For a first run, this may takes 5 - 8 minutes. After this, top
up the granules after each moulding, so that the material at the bottom of the ram is always
hot.

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3. Close the mould using the mould clamp.

Figure 3: mould clamp

4. Smoothly but firmly rotate the capstan to inject the molten plastic into the mould. When the
mould is full, the resistance on the handle will increase significantly. Should you continue to
push at this stage, you will see the mould begin to open under the pressure.

Figure 4: rotateing the capstan to inject the molten plastic

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5. Hold the pressure for approximately 10 seconds. This allows the material in the runner to
“freeze”, preventing the pressurised plastic forcing back out of the mould.

Figure 5: Hold the pressure

6. Return the capstan to its rest position, with the ram raised.
7. Refill the hopper ready for the next injection. Doing this at this stage provides a useful dwell,
to allow the moulding to cool.

Figure 6: Refill the hopper

8. Release the mould clamp. If the tool is fitted with an ejector, lift the handle fully to eject the
part.

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9. Inspect the part

Figure 7: Perfect part

If the moulding has a flash on the lower part, either the mould clamp is too loose, or the pressure
applied to the capstan was too high.

Figure 8: mould clamp is too loose

If the moulding is incomplete, either the pressure applied to the capstan was too low, or the
mould was cold. It can take a few consecutive runs to warm the mould, especially for parts with
thin sections.

Figure 9: moulding is incomplete

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If the surface of the part is rippled, the mould is too cold. When this occurs, the hot plastic hits
the cold mould and freezes. The molten core of plastic then rolls over the frozen skin. This
repeats, giving the rippled effect.

Figure 9: mould is too cold

10. Shutdown and Changing Colors

When the session is finished do not add further granules, simply switch off and allow the machine to
cool. The residual material in the barrel and valve at the injection point will be reheated when next
used. If it is required to change colours the new material can purge the old material out without a
mould in place. This may seem wasteful but it is standard practice and the easiest way of changing
colours. There is normally no need to dismantle the machine for cleaning.

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