MECHANICAL ENGINEERING DEPARTMENT

WORKSHEET DJJ40142 MECHANICAL WORKSHOP PRACTICE 4 (CNC MILLING)

Title : POCKET MILLING

Introduction :

this would include plotters, vinyl cutters, 3D printers, milling machines and others. CNC
stands for Computer Numerically Controlled and basically means that the physical
movements of the machine are controlled by instructions, such as co-ordinate positions
that are generated using a computer.

cutting tool which moves in 3 or more axes (X, Y and Z) to cut-out or carve parts in different
types of materials. The information on these pages will focus on what are typically referred

machines too.

CNC milling is a specific form of computer numerical controlled (CNC) machining.

Milling itself is a machining process similar to both drilling and cutting, and able to achieve
many of the operations performed by cutting and drilling machines. Like drilling, milling
uses a rotating cylindrical cutting tool. However, the cutter in a milling machine is able to
move along multiple axes, and can create a variety of shapes, slots and holes. In addition,
the work-piece is often moved across the milling tool in different directions, unlike the
single axis motion of a drill.

Objective :

Student should be able to:

1. Construct programs for EDM and CNC machining process using ISO codes or any
related machining software. (P5, PLO3)
 2. Demonstrate safety procedures in the workshop according to the workshop safety
regulation correctly to create a secured environment in an organization while doing
practical work and ability to work in team to complete assigned tasks during practical
work sessions. (A3, PLO7).

Machine and Tools :

CNC Machine (Milling), Vernier Caliper, HSS Flat Mill (End Mill), Edge Finder, Tool
Presetter & Piece of Paper.

Acceptance Limit :
Length : ± 0.05 mm
Height : ± 0.05
mm Thickness :±
0.05 mm

Materials :
Teflon 110.8mm x 110.8 mm x 11 mm

Comparison between Conventional & CNC Machine

 SA F E T Y OP E R A T I N G PR O C E D U R E S
C N C Mi l l in g M a ch i n e
DO NOT use this machine unless a lecturer has instructed you in its safe use and operation and has given permissi

Safety glasses must be worn at Long and loose hair must be

all times in work areas.
Sturdy footwear must be worn at
all times in work areas.
Rings and jewellery must not
be worn.
contained.
Close fitting/protective clothing
must be worn.
Gloves must not be worn
when using this machine.

PRE-OPERATIONAL SAFETY CHECKS

1. Ensure no slip/trip hazards are present in workspaces and walkways.
2. Locate and ensure you are familiar with the operation of the ON/OFF starter and
Emergency Stop Button (if fitted).
3. Do not leave equipment on top of the machine.
4. Check that machine guards are in position.
5. Ensure cutter is in good condition and securely mounted.
6. Check coolant delivery system to allow for sufficient flow of coolant.
7. Faulty equipment must not be used. Immediately report suspect machinery.
OPERATIONAL SAFETY CHECKS
1. Keep clear of moving machine parts.
2. Never leave the machine running unattended.
3. Follow correct clamping procedures keep overhangs as small as possible and check
work piece is secure.
4. Set the correct speed to suit the cutter diameter, the depth of cut and the material.
5. Before making adjustments and measurements or before cleaning swarf accumulations
switch off and bring the machine to a complete standstill
HOUSEKEEPING
1. Switch off the machine.
2. Remove milling cutters and store them safely
3. Leave the machine and work area in a safe, clean and tidy state.
POTENTIAL HAZARDS
Sharp cutters
Moving components hair/ clothing entanglement
Eye injuries
Skin irritation
Metal splinters and burrs
Flying debris
Machine Description and Work piece Specification

MEGAZINE TOWER LAMP

SIDE DOOR
EMERGENCY STOP BUTTON

HANDLE

CONTROL PANEL
MAIN DOOR

COOLANT TANK

MACHINE DESCRIPTION

Milling Practice

Using G90/G91, G01/G02,/G03 and G40/G41/G42 program the moves required to mill the
contour of this part. To enable cutting of the entire step in one axial pass, you will need to
make a calculation to select the correct minimum diameter end mill. Use pocket mill
directional cutting for this exercise. For a minimum of two out of three of the radii, you
must use R commands for programming. The material is Aluminium Alloy. The depth of the
pocket is 5 mm. The overall part thickness is 10.8 mm.
 PRACTICAL TASK 1

PRACTICAL TASK 2

WORKPIECE SPECIFICATION
Practice Result:

PROGRAME SHEET (PRACTICAL TASK 1)

NAME: CLASS:
O ;
N1 N13 N25
N2 N14 N26
N3 N15 N27
N4 N16 N28
N5 N17 N29
N6 N18 N30
N7 N19 N31
N8 N20 N32
N9 N21 N33
N10 N22 N34
N11 N23 N35
N12 N24 N36

PROGRAME SHEET (PRACTICAL TASK 2)

NAME: CLASS:
O ;
N1 N13 N25
N2 N14 N26
N3 N15 N27
N4 N16 N28
N5 N17 N29
N6 N18 N30
N7 N19 N31
N8 N20 N32
N9 N21 N33
N10 N22 N34
N11 N23 N35
N12 N24 N36
Practice Test:

i. Always stop the machine before making measurements or cleaning out chips.
True False

ii. It is permissible to leave the ANY KEY in the machining area.

True False

iii. Stop the machine before

a. Attempting to make adjustments or measurements.
b. Trying to remove accumulated chips.
c. Before opening or removing guards and covers.
d. All of the above.

iv. The milling machine is a very versatile machine tool. It can be used to

a. drill, bore, and cut Triangle, Square, Polygon shapes

b. machine flat surfaces
c. machine irregularly shaped surfaces
d. All of the above
e. None of the above

v. G code command for G02 is represent for

a. Circular Interpolation Clockwise.
b. Circular Interpolation Counterclockwise.
c. Linear Interpolation.
d. All of the above.