STUDY OF MILLING MACHINE

Study No: 1
DATE:

Aim:
To study the various components, parts and types of milling machine

Introduction:
A milling machine to tool that removes metal as that is feed against a rotating multipoint
cutter; the cutter rotates at a high speed and the cutting edge to remove metal at a very fast rate.

Specification:
Surface of tube -
Distance between T slots -
Longitudinal travel of the tool -
Vertical adjustment of the table -
Cross travel of the table -
Taper in the spindle -
Dia of the milling arbors -
Range of spindle speed -
Number of feed -
Motor -
Floor space -

Types of milling machine:

Milling machines are classified as follows:

1. Column and knee type:

a. Plain milling machine
b. Universal milling machine
c. Horizontal and vertical milling machine

1
2. Plano miller
Manufacturing or fixed bed type milling machine
Special type
a. Rotary table
b. Drum type
c. Planetary type
Universal milling machine:
The universal milling machine is similar in all respects to the horizontal plain milling
machine except for additional swiveling movement for table. The table is mounted on a swivel
base. The table can be lifted up by 45 degree on the universal milling machine has the following
movement.

1. Vertical movement through the knee

2. Cross wise movement through the saddle
3. Longitudinal movement of the table
4. Angular movement of the table.
The table of this machine has all the four movement of the universal milling machine.
In addition it has one more adjustment for the table. The table can also be swirled about

2
horizontal axis “xx” parallel to the spindle. In this machine a knee has the swiveling
arrangement using additional swiveling arrangement we can machine tapered gear etc…
Parts of milling machine:
Base:
Base if a milling machine is cast iron accurately machined on its top bottom surface and
serve as a member for all other parts rest on it.
Column:
It is the main supporting frame movement vertically no the base of the form vertically face of
the column and is accurately machined and is provided with dove tail equal way for supporting
knee
Table:
The table rests on the ways of the saddle and travel longitudinally. The top of the tube
is accurately finished and T-slot is provided from damping the work.
Spindle:
It is located at the upper part of the column and receives power from motor. Through
gear it is transfer into arbor. The accuracy of metal machining by the cutter is depends on
primarily on the accuracy strength and rigidity of the spindle.

Knee:
The knee is a right gray iron casting the slide up and down on the vertical ways of the
column face. An elevating screw mounted on the base that the knee effects the adjustment of
height. The knee houses the fed mechanism of the table and different control to operate it. The
top face of the knee type forms a slide way for the saddle.

Over hanging arm:

The hanging arm is mounted on the top of the column extents beyond the column face
and serves as a bearing support for the other end of the arm. The arm is adjusted table so the
bearing support may be provided nearest to the cutter.

Fount brace:
This is an extra support that is fitted between the knee and even arm ensure.

3
Types of milling cutter:
1. Plain milling cutter
a. Light duty
b. Heavy duty
c. Italic
2. Side milling cutter
3. Metal slitting saw
4. Form cutter
a. Convex milling cutter
b. Concave milling cutter
c. Corner rounding
d. Gear cutter
5. Angle milling cutter
6. End milling cutter
7. T-slot milling cutter
8. Wood raff key slot
9. Fly cutter
10. Tap and reamer cutter.

Fundamental of the milling process:

Peripheral milling:
It is the operation performed by the milling cutter is produce of a machined surface
parallel to the axis of the rotation.

Up milling:
It is also called as conventional milling is the process of removing metal by a cutter
which is rotated against the direction of the work piece.

Down milling:
It is also called, as climb milling is the process of removing metal by a cutter, which is
rotated in the same direction of travel of work piece.

4
Face milling:
The face milling is the operation performed by a cutter is produce a flat machine surface
perpendicular to the axis of the rotation of the cutter.

End milling:
The end milling may be considered as the combination of peripheral and face milling
operation.

Milling key ways grooves and slots:

The operation of producing of key way, grooves and slots of various shape and can be
performed in a milling by using a plain milling cutter.

5
Gear cutting:
The gear cutting operation is performed in a machine by using formed relief cutter; the
cutter may be cylindrical type or end mill type. The cutter profile corresponds exactly with the
teeth space of the gear.
Equally spaced gear teeth are cut on a gear slank by holding the work on a universal
dividing head and operation performed in a milling machine.

Milling Operation:

1. Plain milling, Face milling, Slide milling, Straddle milling, Angular milling,
Gang milling, Form milling, Profile milling, End milling, saw milling, Helical
milling, Cam milling, Thread milling

RESULT:

Thus, the various types, parts, tools and operation of milling machine were studied.

6
 STUDY OF CYLINDRICAL GRINDING MACHINE

Study No: 2
DATE:

Aim:
To study the various parts, types and principles of cylindrical grinding machine.

Specifications: -
Maximum grinding length -
Maximum height of center -
Maximum swing over table -
Maximum grinding diameter -
Maximum table travel -
Work head swivel on either side -
Work head motor with 1440-rpm -
Morse taper -
Traverse movements of wheel head -
Size of grinding wheel -
Wheel head motor with rpm -
Motor rpm of wheel head & work head -
Floor space -
Approximate weight in Kgs -
Introduction:
The work is held between centers and rotated at the required speed. The longitudinal
feed is given to the work piece. The transverse movement of the lower table obtains this. The
feed should not be more then the wheel with.
Feed is approximately (1/2)-(2/3) of wheel with b. the traverse movement of the wok
piece is adjusted so that the wheel does not clear off the ends of the work. The work piece travel
should reverse when 2/3 of the wheel face is in contact with the work piece.

7
 Parts of

8
cylindrical grinder:

Base:
The base or bed rests on the floor and supports all the parts. It is of box like
construction. It houses table drive mechanism on the top of the bed. There are length wise and
machined guide ways.
Table:
There are two types of table one is lower table and other is upper table. The table
movement can be obtained by power. Adjustable trip dogs are damped in longitudinal slots as
the side of the table. These trip dogs actuate the table-reversing lever, maximum angle of swivel
is 10 either side.
The swiveling is used for grinding tapers the upper has length wise T-slots for tilting the
headstock and tailstock.
Headstock:
It is mounted on the upped table. They have centers. The job is held between the centers.
The work piece is driven by headstock through dog as driven pin. Work piece can be held using
chuck in the headstock
Wheel heads:
It carries a grinding wheel as the driving motor. The wheel head is placed cover the bed
at it back side. It is mounted on the slide. It can be moved perpendicular to the side ways. The
movement is the cross feed.
Cross feed:
The grinding wheel is feed in the work by hand or power as determined by the
arrangement of the crosshead control lever.
Principle of grinding operations:
Plane cylindrical grinding:
In a plane cylindrical grinding the following movements takes place.
• Rotation of the cylindrical work piece about its axis.
• Rotation of the grinding wheel about its axis.
• Longitudinal feed movements of the work, past the wheel face.
• Movement of wheel into the work, perpendicular to the axis of the work piece to give
depth of cut

9
Taper grinding:
Taper grinding is done by two methods. Small tapers can be ground by swiveling the
upper table. This can be done in both plain and universe grinding machines. Step tapers can be
ground by swiveling the headstock both these can be done only in a universal grinders.
Grinding of small tapers of a long work piece. The work piece is held between centers.
The upper table is given through the table. Depth of cut is given by the cross movement of the
grinding wheel.
Transverse grinding:
The work is reciprocated as the wheel feeds to produce cylinders longer than the width
of the wheel face.

Plunge grinding:
The work rotates in a fixed position as the wheel feeds to produce cylinders of a length
equal to or shorter than the width of the wheel. This has the important advantages that the
cylindrical shape can be produced as easily as straight cylinders in a single plunge of the wheel
simply by forming the periphery of the wheel.

RESULT:
Thus the details about cylindrical machine, types, various parts and principles
cylindrical grinding machine are studied.

10
 STUDY OF SURFACE GRINDING MACHINE
Study No: 3
DATE:

Aim:
To study the detail about the surface-grinding machine its parts, types work holding
devices and specification details.
Introduction:
Surface grinders a re mainly used to grind flat and plane surface. They are also to grind
irregular curved, tapered and other formed surface. Machine guide ways piston rings, valves,
dies, surface plate etc. Are some of the parts which are finished by surface grinding.
Specifications:
Table size -
Working surface of tube -
Grinding capacity -
Maximum longitudinal table traverse -
Maximum cross traverse -
Maximum vertical traverse -
Sire of grinding wheel -
Spindle speed -
Power -
T- Slots -
Types:
1. Horizontal spindle reciprocating table
2. Horizontal spindle rotary table
3. Vertical spindle reciprocating table
4. Vertical spindle rotary table

11
1. Horizontal Spindle Reciprocating Table:

a. Base:
The
base is a
rectangle box
like casting it
houses the
driving
mechanism
inside it has a
horizontal
guide ways at
the top. The

12
guide ways are perpendicular to the column.
b. Wheel head:
It is mounted on this column. It has an independent motor for driving the wheel. The
wheel head can slide up and down along the vertical guide ways of the column. This vertical
adjustment of the wheel head is done manually.
c. Table and spindle:
The saddle is mounted over the base. It can move along the guide ways on the base
perpendicular to the column. The gives cross feed to the work. The table slides on the
horizontal guides on the saddle. This movement is parallel to the face of the column. This gives
longitudinal feed to the work. There are ‘T’ slots on the top of clamping work piece.
2. Horizontal Spindle Rotary Table:
In this machine a rotary table is used. A small work piece is clamped over the table. The
table rotates with the work piece the wheel head is reciprocates slowly about its axis. This is
cross feed to over the entire work piece on the table. The wheel head is lowered to the
require depth of cut. The periphery of the grinding wheel takes the cut. The machine is used
for small and medium size of work.

3. Vertical Spindle Reciprocating Table

The work piece is clamped on the reciprocating worktable using magnetic chuck or
fixture. The grinding wheel rotates about the vertical axis. A cup-grinding wheel is used. A
longitudinal and cross feeds are given through the table. The face or slide of the grinding wheel
cut the material. The wheel head is lower down for giving the depth of cut.

4. Vertical Spindle Rotary Table:

The grinding machine is used for grinding large quantity of small work piece. The work
piece held on the rotary table. The rotary table rotates with the work piece. The vertical
spindle carries a cup type wheel. The grinding wheel is lowered form giving the depth of
cut.

Work holding device:

1. Work holding and supporting device
2. Equipment for contours grinding
3. Attachment to improve grinding result
4. Measuring and sizing devices

13
Support devices:
1. Steady rests
2. Magnetic chuck
3. Chucks and fixtures.

Equipment for contour grinding:

They include wheel dressing and attachment using master cams and template from cam
and shape.
Measuring and sizing devices:
They range from simple measuring device to continuous reading gauge. It controls the
feeding of machines.

RESULT:

Thus, the details about the surface grinding machine, its parts, type, work holding
devices and specification details were studied.

14
 STUDY OF CNC

Study.NO:4
DATE:

COMPUTER NUMERICAL CONTROL

Basic components of an NC system:

An operational numerical control system consists of the following three basic components:
1. Program of instructions
2. Controller unit, also called a machine control unit (MCU)
3. Machine tool or other controlled process.
The program of instructions serves as the input to he controller unit, which in turn
commands the machine tool or other process to be controlled. We will discuss the three
components in the sections below.
Program of instructions:
The program of instructions is the detailed step-by-step set of directions, which tell the
machine tool what to do. It is coded in numerical or symbolic from on some type of input
medium that can be interpreted by the controller unit. The most common input medium today is
1-in-wide punched tape. Over the years, other forms of input media have been used, including
punched cards, magnetic tape, and even 35-mm motion picture film.

There are two other methods of input to the NC system, which should be mentioned. The
first is by manual entry of instructional data to the controller unit. This method is called manual
data input, abbreviated MDI, and is appropriate only for relatively simple jobs where the other
will not be repeated. The second other method of input is by means of a direct link with a
computer. This is called direct numerical control, or DNC.
The program of instructions is prepared by someone called a part programmer. The
programmer’s job is to provide a set of detailed instructions by which the sequence of
processing steps is to be performed. For a machining operation, the processing steps involve the
movement between the cutting tool and the work piece.

15
Controller unit:
The second basic component of the NC system is the controller unit. This consists of the
electronics and hardware that read and interpret the program of instructions and convert it into
mechanical actions of the machine tool. The typical elements of a conventional NC controller
unit include the taper reader, a data buffer, signal output channels to the machine tool, feedback
channels from the machine tool, and the sequence control to coordinate the overall operation of
the foregoing elements. It should be noted that nearly all-modern NC systems today are sold
with a microcomputer as the controller unit. This type of NC is called computer numerical
control (CNC).
The tape reader is an electromechanical device for winding and reading the punched tape
containing the program of instructions the data contained on the tape are read into the data
buffer. The purpose of this device of this device is to the store the input represents one complete
step in the sequence of processing elements.
The signal outputs are the observation to the servomotors and other controls in the machine
tool. Through these channels, the instructions are sent to the machine tool machine tool from
the controller unit. To make certain that the instruction have been properly executed by the
machine, feedback data are sent back to the controller via feedback channels. The most
important function of this return loop is to assure that table and work parts have been properly
located with respect to the tool.
Sequence controls coordinate the activities of the other elements of the controller unit. The
tape reader is actuated to read data into the buffer from the tape, signals are sent to and from the
machine tool, and so on. These types of operations must be synchronized and this is function of
the sequence controls.
Machine tool or other controlled:
The third basic component of an NC system in machine tool or other controlled process. It
is the part of the NC system which performs useful work. In the most common examples of an
NC system, one designed to perform machining operations, the machine tool consists of the
worktable and spindle as well as the motors and controls necessary to drive them. It is also
including the cutting tools, work fixtures, and other auxiliary equipment need in the machine
operation,
NC machine range in complexity from simple tape-controlled drill presses to highly
sophisticated and versatile machining centers. The NC machining centre was first introduced in

16
the late 1950s. it is a multifunction machine which incorporates several time saving features
into is capable of performing a verity of different operations, drilling tapping, reaming, Milling,
and boring. The tools are kept in a tool drum or other holding device. When the tape calls a
particular tool, the drum rotates to positions the tool for insertion into the spindle. The
automatic tool changer then grasps the tool and places it into spindle chuck. The machine table
can orient the job so that it can be machined on several surfaces, as required. Finally, a fourth
feature possessed by some machining centers is the presence of two tables or pallets on which
the work piece can be fixtures. While the machining sequence is being performed on one work
part, the operator can be unloading the previously completed piece, and loading the next one.
This improves machine tool utilization because the machine not has to stand idle during loading
and unloading of the work parts.

TYPES OF CNC MACHINES

1. Vertical Machining Centres
2. Horizontal machining centres
3. Machining centres with indexing heads
4. Multi-axis machining centres
5. Unmanned machining centres
6. Head changer machines
7. Plano millers
8. Milling machines
9. Drilling machines
10. Horizontal Axis Turning machines
11. Vertical axis Turning Machines
12. Surface grinders
13. Cylindrical grinders
14. Tool and cutter grinders
15. Fixed RAM Electro Discharge machines
16. Wire EDM
17. Punching and nibbing machines with plasma arc or laser beam machining
18. Forming machine
➢ Pipe bending machines
➢ Sheets bending machines

17
 ➢ Stretch forming machines
➢ Flow forming machines
19. Gear cutting machines
➢ Gear hobbing machine
➢ Gear shaping machine
➢ Gear grinders
20. Coordinate measuring machines
21. Inspection systems
22. Welding systems
23. Packing equipment

NC PART PROGRAMMING

NC part programming is concerned with the planning and documentation of the

sequence of processing steps to be performed on a Numerical Control machine. It is usually
accomplished by a person whose title is part programmer. The panning portion of part
programming requires knowledge of machining (or other processing technology for which the
NC machine is designed) as well as geometry and trigonometry. The sequence of processing
steps in NC involves a series of movements of the processing head with respect to the machine
table and work part.

The documentation portion of part programming involves the input medium that is used
to transmit the program of instructions to the NC controller unit (the MCU). The most common
input medium is used over the last 30 years is 1” –wide punched tape. Recently other ways of
entering the program to the MCU have been developed. The use of magnetic tape and floppy
disks has been growing in popularity since they represent more modern storage technologies for
numerical control. The advantage of these input media is their much higher data density. For
example, one floppy diskette is capable of storing the equivalent of several thousand feet of
punched tape.
In addition, techniques for transmitting the program directly from a central computer to
the individual machines in the factory have been introduced. This form of program input is
called direct numerical control (DNC)

18
NC WORDS
Following is a list of the different types of words used in the formation of block. Not
every NC machine uses all the words. Also, the manner in which the words in a block are given
in the order below:
SEQUENCE NUMBER (N-WORDS). This is used to identify the block
PREPARATORY WORK (G-WORDS)
This word is used to prepare the controller for instructions that are to follow.
For example, the word G02 is used to prepare the NC controller unit for circular interpolation
along an arc in the clockwise direction. The preparatory word is needed so that the controller
can correctly interpret the data that follow it in the block. Come typical examples of G-words
are given in the Table below.
Some Common G-Words
CODE PREPARATORY FUNCTIONS
G00 Used with countering systems to prepare for a point to point operation
G02 Linear interpolation in contouring systems
G03 Circular interpolation, clockwise
COORDINATES (X-, Y-, Z-, WORDS):
These give the coordinate positions of the tool. In a two-axis system, only two of the
words would be used. In a four –or-five-axis machine, additional a-words, b-words would
specify the angular positions.
FEED RATE:
This specifies the feed rate in a machining operation. Units are mm/min or inch/min.
CUTTING SPEED:
This specifies the cutting speed of the process, the rate at which the spindle rotates.
Units are revaluations per minute. In a machining operation it is usually desirable for the tool
engineer to specify the speed in terms of the relative speed of the tool and work. The units
would be metre per minute. It is there necessary for the part programmer to make the
conversion from using the machining process equations given.
TOOL SELECTION:
This word would only be needed for machines with a tool turret of automatic tool
changer. The t-word specifies which tool is to be used in the operation. For example, T05 might
be the designation of 6mm drill bit ion turret position 5 on an NC turret drill.

19
MISCELLANEOUS FUNCTION:
The m-word is used specify certain miscellaneous or auxiliary functions which may be
available on the machine tool. Of course, the machine must posses the function that is being
called. A partial but representative list of is given below. The miscellaneous function is the last
work in the block. To identify the end of instruction, an end of block (EOB) symbol is punched
on the tape.

Some typical M-Words:

CODE MISCELLANEOUS FUNCTIONS
M03 Start spindle in clockwise direction
M04 Start spindle in counter clockwise direction
M05 Stop spindle
TAPE FORMATS:
The organization of words within blocks is called the tape format. Three tape format seem
to enjoy the most widespread use:
1. Word address format
2. Tab sequential format
3. Fixed block format
The tape format refers to the method of writing the words in a block of instruction. Within
each format there are variations because of differences in machining processes, type of
machine, features of the machine tool, and so on.
WORD ADDRESS FORMAT:
In this format, a letter precedes each word and is used to identify the word type and to
address the data to a particular location in the controller unit. The X-prefix identifies an X-
coordinate word; an S-prefix identifies spindle speed and so on. The standard sequence of
words for two-axis NC system is
M-word
G-word
X-word
Y-word
F-word
S-word
T-word
EOB

20
 However, since the type of word is designed by the prefix letter, the words can be presented
in any sequence. Also, if a word remains unchanged from the previous block or is not needed, it
can be deleted from the block.
FUNCTION (G CODES)
G Codes are instruction describing machine tool movements.
G00 Fast Traverse
G01 Linear interpolation (cutting feed)
G02 Circular Interpolation (clockwise)
G03 Circular Interpolation (counter clockwise)
G04 Dwell
G20 Imperial (Input in Inches)
G21 Metric (input in mm)
G28 Go to Reference
G40 Cutter Compensation Cancel
G41 Cutter Compensation Right
G42 Cutter Compensation Left
G50 Coordinate Setting
G70 Finishing Cycle
G71 Stock Removal in Turing
G72 Multiple Facing
G73 Pattern Repeating
G74 Peck Drilling
G76 Multiple Thread
G81 Drilling Cycle
G90 Turning Cycle
G94 Facing Cycle
G96 Const. Surface
G97 Var. Surface
G98 Feed per Minute
G99 Feed Per Rev

MISCELLANEOUS FUNCTION (M CODES)

M Codes are instructions describing miscellaneous functions like calling the tool,
spindle rotation, coolant on etc.,
M00 Program Stop
M01 Optional stop
M02 Program end
M03 Spindle On
M05 Spindle Stop
M06 Tool Change
M08 Coolant On

21
 M09 Coolant Off
M10 Vice Open
M11 Vice Close
M13 Spindle Forward, Coolant on
M15 Spindle Reverse, Coolant on
M25 Quill Extend
M26 Quill Retract
M30 Programme End
M38 Door Open
M39 Door Close
M98 Subprogram call
M99 subprogram exit
G00 FAST TRAVERSE
A G00 causes linear motion to the given position at the maximum federate from the current
position.
Examples: G00 X0.0 Z0.0
G01 LINEAR
A G01 causes linear motion to the given position at the last specified federate from the current
position.
Examples: G01 X30.0 Z-1.0 F100.0
G01 X0.0
G02 CLOCKWISE ARC
A G02 causes a clockwise arc to the specified position.
Examples: G01 X20 Z-10 F120
G03 X30 Z-15 R5.0
G02 X40 Z-20 I15
G03 COUNTER CLOCKWISE ARC
A G03 causes a counter clockwise arc to the specified position.
Examples: G01 X20 Z-10 F120
G03 X30 Z-15 R5
G02 x40 Z-20 K-5
G04 DWELL
A G04 causes the program to wait for a specified amount of time.
The time can be specified in seconds with the “X” or “U” prefix or in milliseconds with the “P”
prefix.
Examples: G04 X1.5
G04 U1.5
G04 P1500
G21 METRIC
A G21 causes positions to be interpreted as being in metric units (mm). This is can only be at
the start of the main program.

22
 G28 GOTO REFERENCE POINT
A G28 causes a fast traverse to the specified position and then to the machine datum.
Examples: G28 X34.0 Z5.0
G28 U0 W0
G40 CANCEL COMPENSATION
A G40 Cancels tools nose radius compensation.
G41 COMPENSATE RIGHT
A G41 enables tool nose radius compensation to the right of the programmed path.
G42 COMPENSATE LEFT
A G42 enables tool nose radius compensation to the left of the programmed path.
G70 FINISHING CYCLE
A G70 causes a range of blocks to be executed, and then control passes to the block after the
G70. The “P” and “Q” values specify the “N” block numbers at the and end of the profile.
Examples: G70 P10 Q20
G71 MULTIPLE TURING
A G71 causes the profile to be roughed out by turning. Control passes on to after the last block
of the profile. Two G71 blocks are needed to specify all the values.
Examples: G71 U2 R1.5
Specifies a depth of cut (radius) of 2 and an escape of 1.5.
G72 MULTIPLE FACING
A G72 causes the profiles to be roughed out by facing. Control passes on to after the last block
of the profile.
Two G72 blocks are needed to specify all the values.
Examples: G72 W2. R1.5
Specifies a depth of cut specify the “N” block numbers at the start and end of the profile.
G72 P10 Q20 U1.0 W1.0
The “U” and “Q” values specify the “N” block numbers at the start and end of the profile.
The “U” and “W” specify the distance and direction of the finishing allowance on the X and Z
axis.

G90 TURNING CYCLE

A G90 is the diameter cutting cycle
It is the equivalent of
• Rapid to X position
• Fred to Z position.
• Feed to start X position.
• Rapid to start Z position.
I an “R” value is specified tapering will be performed. The initial rapid move will be to the X
position plus the “R” value (Radius)
G96 CONSTANT SURFACES SPEED
G96 Enables constant surface speed.
Examples: G96 S100
Sets the surfaces speed to 100 meters a minute.
G98 FEED PER MINUTES
G98 stets the feed per minute mode. This is the default.
Example: G98
G99 FEED PER REVOLUTION
G99 sets the feed per revolution modes.

23
 M00 Program Stop
A cycle operation is stopped after a block containing M00 executed.
Examples: M00
M01 Optional Stop
Cycle operations is stopped after a block containing M01 is executed. This code is only
effective when the optional stop switch on the machine control panel has been pressed.
Examples: M01
M02 Program end
Stopes the spindle. Turns the coolant off. Terminates the CNC program.
Examples: M02
M03 Spindle Forward
Starts the spindle spinning forward at the last specified spindle rate.
Examples: M03 S1200
M04 Spindle Reverse
Starts the spindle spinning forward at the last specified rate.
Example: M04 S1200
M05 Stop Spindle
Stops the spindle without changing the spindle speed.
Example: M05.
M06 Tool change
The “T” prefix causes a tool change; it need not be paired with an M06”.
The left most digit of the “T” ignoring zeros selects the new tool.
Example: M06 TO200
And T20
And T2
All select tool 2.

M98 Subprogram call

M98 causes another program to be executed.
The “P” value specifies the program number and the number of times to execute it.
The rightmost 4 digits are the program number.
The digits to the left are the number of repetitions.
There can be up to 999 repetitions, if the value is omitted it is called once.
Example: M98 P12 and M98 P10012 both execute cnc program 12 once.
M99 Subprogram Exit
Returns control to the program that called the current program.
If a “P” value is specified then execution begins from the block with the same “N” number,
otherwise it is from the block after the subprogram call.

If an M99 is specified in the main program then the execution is from the start of the program.
Example: M99
Returns to the block following the call.
M99 P10
Returns to the block with “N” value 10.

24
Tabulation:

S.No Date Name of the experiment Page No Remarks Signature

1 Contour milling using vertical

milling machine

2 Spur gear cutting in milling

machine

3 Helical Gear Cutting in milling

machine

4 Gear generation in hobbing

machine

5 Gear generation in gear shaping

machine

6 Plain Surface grinding

7 Cylindrical grinding

8 Tool angle grinding with tool and

Cutter Grinder

9 Measurement of cutting forces in

Milling / Turning Process

10 CNC Part Programming.

25
Ex. No: 01 CONTOUR MILLING USING VERTICAL MILLING

DATE: MACHINE

Aim:

To study the contour milling using vertical milling machine on a work

piece

Results

Thus the contour milling using vertical milling machine is studied .

26
Ex. No: 02 SPUR GEAR CUTTING IN MILLING MACHINE

DATE:

Aim:
To perform spur gear cutting using vertical milling machine on a
work piece.
Calculation:
Z = No. of teeth = 23
m = module = 2 mm
Blank Diameter = (Z + 2) m
= (23 + 2) 2 = 50 mm
Tooth Depth = 2.25 m
= 2.25 * 2 = 4.5 mm
Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23

27
PROCEDURE:
Calculate the gear tooth proportions.
Blank diameter =(Z+2)m
Tooth depth = 2.25 m
Tooth width = 1.5708 m
where,
Z = Number of teeth required
m = module Indexing Calculation Index
crank movement = 40 / Z
The dividing head and the tail stock are bolted on the machine table.
Their axis must be set parallel to the machine table.
The gear blank is held between the dividing head and tailstock using
a mandrel. The mandrel is connected with the spindle of dividing
head by a carrier and catch plate.
• For giving depth of cut, the table is raised till the periphery of the
gear blank just touches the cutter.
Then the table is raised further to give the required depth of cut.
The machine is started and feed is given to the table to cut the first
groove of the blank.
After the cut, the table is brought back to the starting position.
Then the gear blank is indexed for the next tooth space.
This is continued till all the gear teeth are cut.

RESULT:
The given work piece as is subjected to gear generating operation
to become a finished work piece

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Ex No: 3 HELICAL GEAR CUTTING IN MILLING MACHINE
DATE:

Aim:
To perform Helical Gear Cutting using milling machine on a
work piece.
Material used
Cast iron

Tools required
1. Vertical Milling machine
2. vernier caliper
3. Holding Materials
4. Milling Tools
HELICAL GEAR FORMULAS
To Obtain Having Formula
Transverse Diametral Pitch Number of Teeth (N) & p = N/D
(P) Pitch Diameter (D)
Normal Diametral Pitch (Pa) P = PNCOSw
Helix Angle (w )
Pitch Diameter (D Number of Teeth (N) & D=N/P
Transverse Diametral Pitch
(P)
Normal Transverse Diametral Pitch PN = P / COS
Diametral Pitch (PN) (P) & Helix Angle
Normal Circular Tooth Normal Diametral Pitch (PN) = 1.5708/PN
Thickness (t)
Transverse Circular Pitch (pt) Diametral Pitch (P) Pt = /P
(Transverse
Normal Transverse Circular Pitch (p) Pn = pt Cos
Circular Pitch (pn)
Lead (L) Pitch Diameter and Pitch L= D/ Tan
Helix Angle
PROCEDURE:
The dividing head and the tail stock are bolted on the machine table.
Their axis must be set parallel to the machine table.
The gear blank is held between the dividing head and tailstock using
a mandrel. The mandrel is connected with the spindle of dividing
head by a carrier and catch plate.
The cutter is mounted on the arbor. The cutter is centred accurately
with the gear blank.

29
 Set the speed and feed for machining.
For giving depth of cut, the table is raised till the periphery of the
gear blank just touches the cutter.
The micrometer dial of vertical feed screw is set to zero in this
position.
Then the table is raised further to give the required depth of cut.
The machine is started and feed is given to the table to cut the first
groove of the blank.
After the cut, the table is brought back to the starting position.
Then the gear blank is indexed for the next tooth space.
This is continued till all the gear teeth are cut.

RESULT:
The given work piece as is subjected to gear generating operation to
become a finished work piece

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Ex No: 04 GEAR GENERATION IN HOBBING MACHINE
DATE :

AIM:
To machine a Spur Gear using a gear Hobbing machine.

MATERIALS REQUIRED:
Cast iron blank

TOOLS REQUIRED:

1. Gear Hobbing machine

2. Hob
3. Gear tooth vernier
4. Spanners

CALCULATION:

Z = No. of teeth = 23
m = module = 2 mm
Blank Diameter = (Z + 2) m
= (23 + 2) * 2 = 50 mm
Tooth Depth = 2.25 m
= 2.25 * 2 = 4.5 mm
Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23

Gear Hobbing

31
 Fig 01 Before Gear cutting

Fig 02After Gear cutting

PROCEDURE:

RESULT:

The given work piece as shown in fig (1) is subjected to gear

generating operation to become a finished work piece as shown in fig (2). In
gear Hobbing machine

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Ex. No: 05 GEAR GENERATION IN SHAPING MACHINE
DATE:

AIM:
To machine a Spur Gear using a gear Hobbing machine.
MATERIALS REQUIRED:
Cast iron blank

TOOLS REQUIRED:
1. Gear Shaping machine
2. Gear tooth vernier
3. Spanners
PROCEDURE:
The given work piece is held firmly on the spindle of the gear
shaping machine
The workpiece is set at an angle to shaping tool angle for cutting
spur gear.
The change gears are set for the desired speed of work piece and
The machine is switched on.
The work piece and Shaper are allowed to remove the metal at
the desired speed.
The work piece is given full depth of cut equals to the tooth
depth.
The cutter is given feed for the full width of the work.
After machining all gear teeth on the blank the machine is
switched off.
The gear teeth are checked using a gear tooth vernier.
CALCULATION:
Z = No. of teeth = 23
m = module = 2 mm
Blank Diameter = (Z + 2) m
= (23 + 2) * 2 = 50 mm
Tooth Depth = 2.25 m = 2.25 * 2 = 4.5 mm
Indexing Calculation = 40 / Z = 40 / 23 = 1 17/23

33
 Fig 01 Before Gear cutting

Fig 02After Gear cutting

RESULT:
The given work piece as shown in fig (1) is subjected to gear generating
operation to become a finished work piece as shown in fig (2). In gear
Shaping Machine.

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Ex. No: 06 PLAIN SURFACE GRINDING
DATE:
AIM:

To perform a Plain surface grinding operation on the given work piece

for the given dimensions.

REQUIREMENTS
1. Grinding Machine
2. Work Piece 100x50x6 mm MS Plate
3. Grinding Wheel

At first work piece is placed in the magnetic chuck.

The work piece should be light weight so that it cannot be
removed from the magnetic chuck easily.
Various arrangements regarding the positions of work piece is
done.
Grinding wheel and grinding spindle are kept in position with the
work piece.
Before switching on the motor, necessary steps should taken. For
proper grinding process wheel speed, work speed, transverse
speed of the wheel in feed, area of contact is to be noted.
While running the area of contact is adjusted accordingly to the
spindle in order to remove the surface.
It is done slowly to remove the materials on the both sides.
In surface grinding the stock removal rate is given by
Q = bdy
Where
d =depth of cut (m)
b =width of cut (m)
y =work velocity (m/s)
q =rate of stroke (m3/s)

35
 BEFORE GRINDING

AFTERGRINDING

RESULT:
Thus, the surface grinding is done for the given dimensions.

36
Ex.No: 07 CYLINDRICAL GRINDING
DATE:

AIM:

To grind the cylindrical surface of the given materials as per the given
dimensions

REQUIREMENTS:

1. Grinding Machine
2. Grinding Wheel
3. Work Piece 4. Steel rule.
5. Outside calipers.
6. Cutting tool.
PROCEDURE:

The given work piece is first fitted in the chuck of the lathe.
By fitting the tool in tool post the work piece will be reduced to
given dimensions.
First reduce the diameter to 23mm size then reduced the diameter
to 15mm and 18mm at the middle.
By facing the work piece to the tool work piece is reduced to
70mm.
After the preliminary lathe operation, the work piece is held in
the ends of the cylindrical grinder.
The grinding wheel is turned on and it is moved towards the work
piece such that the surfaces of the cylindrical position are grinded
to +-0.2mm.

37
 BEFORE GRINDING

AFTER GRINDING

RESULT:
Thus, the required dimension of cylindrical surface is obtained.
38
Ex.No: 08 TOOL ANGLE GRINDING WITH TOOL AND CUTTER GRINDER

DATE:

AIM:

To Study about the angle grinding with tool and cutter grinder on the
given work piece for the given dimensions.

REQUIREMENTS

1. Grinding Machine
2. Work Piece
3. Grinding Wheel

PROCEDURE:

At first work piece is placed in the magnetic chuck.

The work piece should be light weight so that it cannot be
removed from the magnetic chuck easily.
Various arrangements regarding the positions of work piece is
done.
Grinding wheel and grinding spindle are kept in position with the
work piece.
Before switching on the motor, necessary steps should taken. For
proper grinding process wheel speed, work speed, transverse
speed of the wheel in feed, area of contact is to be noted.
While running the area of contact is adjusted accordingly to the
spindle in order to remove the surface.
It is done slowly to remove the materials on all surface of the
work piece

RESULT:
To Study about the angle grinding with tool and cutter grinder on the
given work piece for the given dimensions.

39
Ex.No: 09 MEASUREMENT OF CUTTING FORCES IN MILLING /

DATE: TURNING PROCESS

AIM:

To measure the cutting forces for the given cutting conditions.

TOOLS AND EQUIPMENTS REQUIRED:

Lathe , Milling
Tool Dynamometer

PROCEDURE:

The Lathe Tool Dynamometer is initially set to zero reading.

The known depth of cut is given and take the readings of P x and
Pz force components from the Lathe Tool Dynamometer.

Calculate the resultant cutting force

P = Sqrt (Px2 + Pz2)

Repeat the same procedure to get few more readings and

calculate the mean cutting force.

Repeat the same procedure for different depth of cuts.

RESULT:

Thus, the cutting forces are measured for different depth of cuts.

40
Ex.No: 10 CNC PART PROGRAMMING
DATE:

AIM:

To Study about the CNC part programming

41
RESULTS:

Thus, the Study about the CNC part programming has been
completed

42
 VIVA QUESTIONS AND ANSWERS
1. What is a lathe?
Lathe is a machine, which removes the metal from a piece of work to the required shape
&size.
2. What are the various operations can be performed on a lathe?
Turning, thread cutting, Grooving, Facing, Drilling, Forming Boring, Knurling,
Recessing, Chamfering, and Tapping
3. What are principle parts of the lathe?
Red, headstock, tailstock, carriage, cross slide, tool post
4. What are the types of headstock?
Back geared type, all geared type
5. State the various parts mounted on the carriage?
Saddle, compound rest, cross slide, tool post.
6. What are the four types of tool post?
Single screw, Open side, four bolts, four ways.
7. What is an apron?
The integral part of several gears, levers clutches mounted with the saddle for moving
the carriage along with lead screw while thread cutting.
8. State any two specification of lathe?
1. The height of centers from the bed
2. The maximum length of the bed
9. List any four types of lathe?
1. Engine lathe2. Bench lathe 3. Tool room lathe 4. Semi automatic lathe 5.
Automatic lathe.
10. What is a semi-automatic lathe?
The lathe in which all the machining operations are performed automatically and
loading and unloading of work piece, coolant on or off is performed manually
11. What is copying lathe?
The tool of the lathe follows a template or master through a stylus or tracer.
12. State the various feed mechanisms used for obtaining automatic feed?
1. Tumbler gear mechanism 2. Quick change gearbox
3. Tumbler gear- Quick change gearbox 4. Apron mechanism
13. List any four holding devices?
1. Chucks 2. Centers 3. Face plate 4. Angle plate
14. What are the different operations performed on the lathe?
Centering, straight turning, rough turning, finish turning, shoulder turning, facing,
chamfering, knurling, etc
15. Define the term ‘Conicity’?
The ratio of the difference in diameters of tapers its length k= D-d
D-smaller dia2.D-bigger dia3.L-length of the work piece
16. State any two specifications of Capston lathe & turret lathe?
1. Number of spindle speed
2. Number of feeds for the turret or saddle
17. Compare the advantage of Capston lathe & turret lathe?
1. Heavier & larger work piece chucking can be done
2. More rigid hence it withstand heavy cuts

43
18. What is tooling?
Planning of operations sequence & preparation of turret or Capston lathe are termed as
tool- layout or tooling.
19. What are the three stage of a tool-layout?
1. Planning & scheduling 2. Detailed sketching of various machining operation
sequence 3. Sketching the plan showing various tools.
20. What are the different drives used in copying lathe?
1. Mechanical drives 2. Air drives 3. Hydraulic drives.
21. What are the components that can be turned on a copying lathe?
1. Cam shaft 2. Crank shaft 3. Journal bearings
22. What is shaper?
The machine, which is having a reciprocating type of machine tool with a single point
cutting tool, used to produce flat surfaces called as Shapers.
23. List any four important parts of a Shaper?
Table, Tool head, Ram, Cross rail.
24. How the feed & depth of cut is given to the shaper?
Feed is given by rotating the down feed screws of tool head depth of cut is given by
rotating by raising or elevating the table.
25. Mention any four-shaper specification?
1. Maximum length of stroke 2. Type of driving mechanism
3. Power of the motor 4. Speed &feed available
26. How the planer differs from the shaper?
In planner-the work reciprocate while the tool is stationary
In shaper-the tool reciprocate while the work is stationary
27.What is meant by drilling?
Drilling is the process of producing hole on the work piece by using a rotating cutter
called drill.
28. What is gang -drilling machine?
When a number of single spindles with essential speed & feed are mounted side by side
on one base and have common worktable is known as gang –drilling machine.
29. Mention any four specification of drilling machine?
1. Maximum size of the drill in mm that the machine can operate
2. Table size of maximum dimensions of a job can mount on a table in square
meter
3. Maximum spindle travel in mm
4. Number of spindle speed & range of spindle speeds in r.p.m
30. List any four machining operations that can be performed on a drilling machine?
1. Drilling2. Counter sinking 3. Tapping 4. Trepanning
31. What are the different ways to mount the drilling tool?
1. Fitting directly in the spindle 2. By using a sleeve 3. By using a socket 4. By means
of chucks.
32. What is boring?
Boring is a process of enlarging &locating previously drilled holes with a single point
cutting tool.
33. Specify the importance of jig boring machine?
1. A jig boring machine is a precision boring machine used for boring accurate holes
at proper center to center distances.

44
 2. The machining accuracy of holes produce by this machine tool lies with in a range
of 0.0025mm.
34. State the purpose of grinding?
1. To remove small amount of metal from work pieces & finish then to close tolerances.
2. To obtain the better surface finish.
35. What is the function of cutting fluids?
1. It is used to cool the cutting tool & the work piece.
2. It improves the surface finish as stated earlier.
3. It causes the chips to break up into small parts.
36. What are the properties of cutting fluid?
1. High heat absorbing capacities.
2. It should have good lubricant properties.3. High flash point.
37. What are the specifications of the milling machine?
1. The table length &width.
2. Number of spindle speeds &feeds.3. Power of driving motor.
38. Mention the various movements of universal milling machine table?
1. Vertical movement-through the knee.
2. Cross vise movement-through the saddle.
39. What are the cutter holding devices?
1. Arbors 2. Adaptors 3. Collets
40. List the various type of milling attachment?
1. Vertical milling 2. Universal milling 3. High speed milling 4. Rotary , 5.
Slotting 6. Rack milling
41. Write any ten nomenclature of plain milling cutter?
Body of cutter, cutting edge, face, fillet, gash, lead, land, outside dia, root dia, cutter
angles.
42. What are the advantages of milling process?
1. It does not require a backlash eliminator.
2. Mild surface does not have built up edge.
43. List out the various milling operations?
1. Plain or slab milling. 2. Face milling.3. Angular milling. 4. Gang milling. 5.
End milling. 6. Gear cutting.
44. What does term indexing mean?
Indexing is the process of dividing the periphery of a job into equal number of divisions.
45. What are the three types dividing heads?
1. Plain or simple.2. Universal. 3. Optical.
46. What is cam milling?
Cam milling is operation of producing cams in the milling machine by the use universal
dividing head &a vertical milling attachment.
47. What are the other forming methods for manufacturing gears?
1. Gear cutting by single point form tool.2. Gear cutting by shear speed shaping process.
3. Gear broaching.4. Template method. 5. Gear milling using a formed end mill.
48. List the gear generating process?
1. Gear shaping process.2. Gear planning process. 3. Gear hobbing process.
49. Mention the applications of gear shaping process?
1. Gear shaping used for generating both internal & external spur gears.
2. Helical gears can also be generated using special attachments.

45
50. What are the limitations of gear hobbing?
1. Internal gears cannot be generated.
2. Hobbing process cannot be applied very near to shoulders.
51. What are the advantages of gear planning process?
1. Any given model can be cut using a single cutter.
2. It is a simple flexible &accurate method of generating gears.
52. List the various gear finishing processes?
1. Gear shaving.2. Gear burnishing.3. Gear grinding.4. Gear lapping.
53. Mention the advantages &limitations of gear shaving process?
Advantage: The process can be used for both internal & external gears.
Limitations: This process is only applicable to unhardened gears.
54. What are the purposes of gear grinding process?
1. To improve the surface finish of teeth.
2. To increase the accuracy of the teeth.
55. What is gear lapping?
Gear lapping is also employed for hardened gear teeth by an abrasive action.
56. Explain the cutting shaping process?
The required shape of metal is obtained by removing the Unwanted material from the
work piece in the form of chips is called cutting shaping. Ex: turning, drilling, milling, boring,
etc
57. Mention the various parts of single point cutting tool?
1. Shank, 2. Face, 3. Flank, 4. Base, 5. Nos, 6. Cutting edge
58. What is tool signature?
The various angles of tools are mentioned in a numerical number in particular
order. that order is known as tool signature.
59. What is cutting force?
The sheared material begins to flow along the cutting tool face in the form of small
pieces. The compressive force applied to form the chip is called cutting force.
60. What are the factors affecting the mach inability?
1. Chemical composition of work piece material.2. Microstructure of work piece material.
61. What is mach inability index?
It is the comparison of mach inability different material to standard material. US
material standards for 100% mach inability are sae1112 hot rolled steel.
Mach inability index I=Cutting speed of metal investigated for 20 minutes tool life
Cutting speed of standard steel for 20 minutes tool life.
62. How tool life is defined?
Tool life is defined as time elapsed between two consecutive tool retargeting. During
this period tools serves effectively and efficiently.
63. What are the factors affecting tool life?
1. Cutting speed2. Feed & depth of cut
3. Tool geometry4. Tool material
64. Express the tailor’s tool life equation?
Tailors tool life equation: VTn=C
V=Cutting speed in m/min :T=Tool life in minutes :C=Constant n=Index depends upon tool &
work.

46