Manufacturing Technology-I

(January,2024 Semester)

Student Name: EMIRUL AYMAN BIN SAIFUL AMIN

Student ID: 21000018

Lab Name: CNC Lathe and Milling
Lab Group: Group 1
Date: 28/02/2024
Marks:
Instructor Signature:
Safety Agreement
I, named as below, fully understand all the regulations pertaining to the Health, Safety and
Environment in the laboratory and therefore shall abide and follow all the rules and instructions.

Name : EMIRUL AYMAN BIN SAIFUL AMIN

IC/Passport No. : 040904-10-0255
Date : 28/02/2024
Student Signature :
 CNC Lathe
Theory

CNC (Computer Numerical Control) lathe machining represents a transformative advancement in

the realm of manufacturing technology, seamlessly blending cutting-edge automation with
traditional machining principles. At its essence, CNC lathe machining involves the utilization of
computerized controls to orchestrate the precise movements and operations of a lathe machine.
This technology has revolutionized the production landscape by offering unparalleled levels of
accuracy, efficiency, and repeatability in machining processes.

Within the CNC lathe system, critical components such as the bed, spindle, and tool turret are
meticulously synchronized to execute intricate machining tasks with utmost precision. The bed
serves as a stable foundation for mounting the workpiece, while the spindle rotates the
workpiece and accommodates various cutting tools. Additionally, the tool turret or tool post holds
the cutting tools, allowing for swift and precise tool changes during machining operations.

Fundamental to CNC lathe machining is the programming aspect, where intricate design
specifications are translated into machine-readable instructions, typically in the form of G-code.
These instructions govern every facet of the machining operation, including spindle speed, tool
movement, and feed rates. By following these programmed instructions, CNC lathes ensure
consistent and reproducible results, eliminating the variability inherent in manual machining
processes.

CNC lathe machining showcases remarkable versatility, accommodating a diverse array of cutting
tools and workpiece materials. This flexibility enables the production of complex geometries and
intricate components across various industries, ranging from aerospace to automotive
manufacturing. Moreover, the automation capabilities inherent in CNC lathe machining
streamline production processes, minimizing human error and maximizing productivity.

In summary, CNC lathe machining epitomizes the pinnacle of modern manufacturing technology,
embodying precision, efficiency, and innovation. By leveraging computerized controls, precise
movements, and advanced programming capabilities, CNC lathes empower manufacturers to
achieve unparalleled levels of accuracy and productivity in machining operations.
 Programme codes for CNC Lathe

Head
N05 G94 M06 T0101

Body
N10 G00 X0 Z0 M04 S600
N15 G01 X50 F30
N20 G01 Z-40
N25 G01 X80
N30 G01 Z-60
N35 G01 X100
N40 G01 Z-100
N45 G00 X120
N50 G00 Z10.

End

N55 M05
N60 M30

Simulation

.
 MACHINING SETUP

Before commencing machining operations on the CNC lathe machine, a meticulous setup
process is imperative to ensure accurate and efficient production. The setup begins with selecting
the appropriate work holding device, such as a chuck or collet, to securely grip the workpiece.
Careful consideration is given to aligning the workpiece with the machine's spindle axis to prevent
misalignment and ensure uniform machining results. Once the workpiece is firmly clamped in
place, the next step involves selecting and installing the cutting tools required for the machining
operation.

With the workpiece securely fixtured and the cutting tools mounted on the tool turret or
tool post, attention shifts to configuring the CNC control system. This entails inputting specific
parameters into the machine's control panel or computer interface, including tool offsets,
workpiece dimensions, and machining coordinates. Additionally, the CNC program containing the
machining instructions must be loaded into the machine's memory and verified for accuracy
before execution.

After the initial setup steps are completed, the final preparations involve fine-tuning the
machining parameters to optimize cutting performance. This includes setting spindle speeds, feed
rates, and cutting depths according to the material properties of the workpiece and the desired
machining outcomes. Furthermore, coolant systems are activated to lubricate the cutting tools
and dissipate heat generated during machining, enhancing tool life and surface finish quality.

In conclusion, the machining setup on the CNC lathe machine is a critical precursor to
successful machining operations. By meticulously preparing the workpiece, selecting appropriate
cutting tools, configuring the CNC control system, and optimizing machining parameters,
operators can ensure smooth and precise machining processes. This comprehensive setup
approach lays the foundation for achieving high-quality machined components with accuracy and
efficiency.
 MACHINING

Before initiating the machining process on the CNC lathe machine, it's essential to meticulously
configure the machine's control system with the appropriate G-codes. The following codes are used
for the machining operation:

Head
N05 G94 M06 T0101

Body
N10 G00 X0 Z0 M04 S600
N15 G01 X50 F30
N20 G01 Z-40
N25 G01 X80
N30 G01 Z-60
N35 G01 X100
N40 G01 Z-100
N45 G00 X120
N50 G00 Z10.

End
N55 M05
N60 M30

This code sequence directs the CNC lathe machine to execute specific movements and actions to
machine the workpiece. Initially, the machine is instructed to select tool T0101 and set it to rotate
clockwise at a speed of 600 RPM (M04 S600). The machining operation then begins with the rapid
movement (G00) of the tool to the starting position at coordinates X0 and Z0.

Subsequently, the tool engages the workpiece and begins the cutting operation, moving along the
X-axis to a distance of 50mm (N15 G01 X50) at a feed rate of 30 units per minute (F30). It then
progresses downward along the Z-axis to a depth of 40mm (N20 G01 Z-40). This process
continues with subsequent X-axis movements at distances of 80mm, 100mm, and 120mm, while Z-
axis movements progressively increase in depth to -60mm, -100mm, and finally returning to the
initial position at Z10mm.

Upon completion of the machining operation, the spindle rotation is stopped (M05), and the
program terminates (M30), signaling the end of the machining process.

In summary, the provided G-code sequence orchestrates the CNC lathe machine's movements and
cutting actions to shape the cylindrical workpiece into the desired form, adhering to precise
dimensions and machining parameters.
CNC Milling

Theory
CNC (Computer Numerical Control) milling stands at the forefront of modern
manufacturing, offering a highly efficient and precise method for shaping components from a
variety of materials. At its core, CNC milling relies on sophisticated computerized controls to
interpret digital design specifications and execute precise tool movements to remove material
from a workpiece.

In the CNC milling process, the workpiece is securely held in place by a workholding system,
which may include vises, clamps, or fixtures, ensuring stability and accuracy during machining
operations. Mounted on a spindle that can move along multiple axes, cutting tools are guided
by the CNC program to perform a range of operations, including facing, contouring, drilling,
and pocketing.

The versatility of CNC milling allows for the creation of components with diverse shapes, sizes,
and complexities. By employing different cutting tools, toolpaths, and machining strategies,
manufacturers can produce intricate parts with exceptional accuracy and repeatability.

Key features of CNC milling machines include advanced capabilities such as spindle speed
control, coolant systems, and chip evacuation mechanisms. These features optimize
machining performance by adjusting cutting parameters based on material properties and
machining requirements, ultimately enhancing surface finish quality and productivity.

In summary, CNC milling plays a pivotal role in modern manufacturing, empowering

manufacturers to produce precise components efficiently and consistently. Through the
integration of computerized controls and precision machinery, CNC milling machines have
become indispensable tools in a wide range of industries, driving innovation and productivity
in the manufacturing sector.
Programme codes for CNC Lathe

Head
G90 G00 G54 G17 G21 G95
T01 M06
G43 Z50 M08
S1000 M03

Body
G90 G00 X20 Y20
G01 Z-20 F100
G90 G01 X120 Y20
G90 G01 X160 Y60
G90 G01 X160 Y140
G90 G01 X120 Y190
G90 G01 X70 Y190
G90 G01 X20 Y140
G90 G01 X20 Y20
G01 Z50
G90 G00 X250 Y250

End
G90 M09
G90 M05
G90 M30

Simulation
Machining Setup

Before initiating the machining process on the CNC milling machine, a thorough setup
procedure is crucial to ensure precise and efficient production. The setup begins with securing
the workpiece firmly onto the machine's worktable using appropriate clamping mechanisms
such as vises or fixtures. Careful attention is paid to aligning the workpiece with the machine's
coordinate system to ensure accurate machining results.

Next, the cutting tools required for the machining operation are selected and installed onto the
machine's spindle. It's essential to choose the correct tooling based on factors such as material
type, cutting requirements, and desired surface finish. The tools are inserted into tool holders
and secured in place using the machine's tool changer or manual clamping methods.

Once the workpiece and cutting tools are properly positioned, the CNC program containing the
machining instructions is loaded into the machine's control system. This program specifies the
toolpaths, cutting parameters, and other machining details necessary to produce the desired
component. The program is carefully verified for accuracy and completeness to prevent errors
during the machining process.

With the setup completed, final adjustments are made to the machine's operating parameters,
including spindle speed, feed rate, and cutting depths. These adjustments are based on
considerations such as material properties, tooling specifications, and machining requirements.
Coolant systems are also activated to lubricate the cutting tools and dissipate heat generated
during machining, ensuring optimal cutting performance and surface finish quality.

In conclusion, a meticulous machining setup is essential for achieving accurate and efficient
results on the CNC milling machine. By carefully preparing the workpiece, selecting appropriate
cutting tools, and configuring the CNC program and machine parameters, operators can ensure
smooth and successful machining operations. This comprehensive setup approach lays the
foundation for producing high-quality components with precision and consistency.

Machining

Before proceeding with the machining process on the CNC milling machine, a
meticulous setup is essential to ensure precise fabrication of the workpiece. The setup process
involves careful consideration of the workpiece dimensions, tooling selection, and
programming parameters. Let's break down the machining setup using the provided G-codes:

Head:
The initial setup begins by configuring the CNC milling machine with essential parameters. The
G-codes G90, G00, G54, G17, G21, and G95 establish the machine's operating mode,
coordinate system, and unit of measurement. Additionally, tool T01 is selected and prepared
for use with the M06 command, while the cutting depth is set using the G43 Z50 M08
command. Finally, the spindle is activated at a speed of 1000 RPM using the S1000 M03
command, preparing the machine for the machining operation.

Body:
With the machine configured, the machining process begins. The workpiece, initially a cube
with dimensions of 100mm each side, is positioned on the worktable. The cutting tool is moved
to the starting position at coordinates X20 Y20 using the G90 G00 command. Subsequently, the
tool engages with the workpiece, gradually descending along the Z-axis to a depth of -20mm at
a feed rate of 100 units per minute (F100) using the G01 Z-20 F100 command. The tool then
follows a series of programmed X-Y movements to shape the workpiece, moving from one
coordinate point to another until the desired features are achieved.

End:
Upon completion of the machining operation, the tool is retracted from the workpiece, and any
coolant systems are deactivated using the G90 M09 command. The spindle rotation is stopped
with the M05 command, followed by the termination of the machining program with the M30
command.

In summary, the machining setup for the CNC milling machine involves configuring the
machine's parameters, selecting and preparing cutting tools, and programming precise tool
movements to shape the workpiece according to desired specifications. This meticulous setup
process lays the foundation for achieving accurate and efficient machining results.