PROJECT REPORT

PROJECT TITLE: CNC & CAM PROJECT

COURSE NAME: COMPUTER INTEGRATED MANUFACTURING

COURSE CODE: MCE – 4303

SUBMITTED BY:
STUDENT NAME STUDENT ID

SUBMITTED TO: DOCTOR

DATE: DD/MM/YYYY
Table of Contents

INTRODUCTION.................................................................................................................................3

METHEDOLOGY................................................................................................................................4

CAD DRAWING...................................................................................................................................5

MACHINE USED.................................................................................................................................6

TOOL USED & MATERIAL OF WORKPIECE..................................................................................7

DESIGNING.........................................................................................................................................8

NC PROGRAM.....................................................................................................................................9

MACHINING WORK PROCESS.......................................................................................................14

CHALLENGES AND LEARNING OUTCOMES..............................................................................15

CONCLUSIONS.................................................................................................................................15

REFERENCES....................................................................................................................................16

TABLE OF FIGURES

Figure 1: CAD Drawing.......................................................................................5

Figure 2: CNC Milling machine...........................................................................6

Figure 3: Flat end mill cutter................................................................................7

Figure 4: Screenshots of created 3D Model.........................................................8

Figure 5: CNC End milling Operation................................................................14

INTRODUCTION
The objective of this project is to manufacture a workpiece on CNC machine by using
NC programing. In order to manufacture the workpiece, it was needed to perform a step-by-
step procedure. First of all, a drawing of the workpiece is created using Solidworks software
and later on a 3D model of the drawing was created on Solidworks. After that, to manufacture
the workpiece, NC programing is done on CNC machine and with the help of that, final
workpiece was manufactured.

The report is divided into four main sections. In the first section of the report, a CAD
drawing of the workpiece is presented, which was created with the help of Solidworks
software. In the second section of the report, selection of material for the workpiece,
information of machine and selection of the tools is described. The next section of the report
consists of NC coding for the machining of the workpiece. A complete NC program of the
machining process is presented in this section. The fourth and final section of the report,
consist of a discussion about challenges and outcomes that we faced during the whole project
work. A conclusion of manufacturing of given workpiece on CNC machine is provided in this
section.

SolidWorks is a computer-aided design (CAD) software used for designing 3D

models and assemblies. It is widely used in engineering, manufacturing, and product design
industries for creating complex models and drawings. CNC stands for Computer Numerical
Control, which is a computer-controlled machine used for cutting, carving, milling, drilling,
and other machining operations. CNC machines use pre-programmed instructions to control
the movement of tools and parts, resulting in precise and accurate manufacturing processes.

SolidWorks and CNC machines are often used together in product design and
manufacturing processes. SolidWorks can be used to create 3D models and assemblies that
are then converted into machine-readable code and executed by the CNC machine. This
allows for precise and efficient manufacturing of parts and components.

3D printing, also called additive manufacturing, is a method for creating three-

dimensional objects from a digital design file. It works by adding successive layers of
material, such as plastic, metal, or ceramic, until the final object is formed. The process starts
with the creation of a digital model using computer-aided design software, which is then
loaded into the 3D printer. The printer reads the design and begins to build the object layer by
layer.
 3D printing has transformed manufacturing by making it possible to create highly
intricate and customized objects with great precision. It has numerous applications across a
range of industries, and it also has the potential to reduce waste and improve sustainability in
manufacturing processes.

METHEDOLOGY
In order to manufacture the workpiece, it was needed to follow a stepwise procedure.
These steps are followings:

 Creating the CAD drawing of the workpiece:

In order to create the drawing of the workpiece, we used a CAD software which is
solidworks. The drawing of the workpiece should be of high precision and accurate
dimensions. We used absolute dimensioning to create the CAD drawing of the
workpiece. To create the CAD drawing, we open the Solidworks software and
selected the drawing parameters such as the unit system, scale, and paper size. Then,
the basic outline of the workpiece was drawn using lines, circles, arcs, and other
geometrical shapes. We located the dimensions and annotations to define the size,
shape, and position of the workpiece features.
 Creating 3D model of the workpiece:
After creating the 2D drawing of the workpiece, the next step is to create the 3D
model of the workpiece. In order to do that, we use the ‘extrude’ feature in the
solidworks software. The steps are followings:
 Create 3D models of the workpiece using extrusion, revolve, loft, and other
modelling tools if needed.
 Apply materials, colours, and textures to the workpiece surfaces to make it
more realistic.
 Check the drawing for errors or inconsistencies and correct them as needed.
 Save the CAD drawing in the desired format, such as DWG, DXF, or PDF.
 Print or export the drawing as needed for further use or sharing.
 Creating NC program:
The created 3D model of the final object will be manufactured by performing the
machining operation on an Aluminium workpiece on CNC milling/drilling machine.
To perform the machining operation on CNC machine we ned to create the G code
 programming first. And based on that programming, the workpiece will be machines
and final object will be manufactured.

CAD DRAWING
the created CAD drawing of the final object that needs to be manufactured is
following:

Figure 1: CAD Drawing

MACHINE USED
The CNC milling machine that was available in the college workshop. The
measurements and requirements for the part are precisely defined by CAD software.
Engineers and designers rely on it to study, improve, and approve design prototypes. It allows
them to thoroughly test their ideas without needing to build a prototype on a machine. CAD
software was used to design many of the things on the market today. Once a part has been
demonstrated to be acceptable, it must be transferred to a CNC machine programming
language. This is accomplished through the use of CAM, computer aided manufacturing,
which converts the CNC machine's instructions into either general or miscellaneous code, G-
Code or M-Code.

The milling process begins by placing the workpiece into the work surface or holding
device of the CNC machine. The milling tools are then attached to the machine's spindle.
Depending on the specifications set from CAD, the milling process might be either horizontal
or vertical. After securing the workpiece, downloading the programming, and attaching the
tool, the operator activates the programme and the milling process begins.

The workpiece is handled, shifted, rotated, and positioned for the cutting tool's work
based on CAD instructions. The cuts can take three forms: a slow feed into a stationary tool,
the tool moving across a stationary workpiece, or a combination of the two. The climb
milling process, in which the workpiece and the cutter both move in the same direction, is
used by the majority of CNC machines. The typical milling process involves moving the
cutter and workpiece in opposite directions.

Figure 2: CNC Milling machine

TOOL USED & MATERIAL OF WORKPIECE
To perform the machining operation, we used Flat end milling cutter with diameter of
30 mm. In the NC program, the tool is specified as tool type 1 i.e., T01. The tool was made
up of carbide material. End mills are a type of milling cutter, a cutting instrument used in
industrial milling. It differs from a drill bit in its application, geometry, and manufacturing.
While a drill bit can only cut in one direction, most milling bits can also cut in both
directions. Not all mills can cut axially; those that do are known as end mills. End mills are
utilised in a variety of milling operations, including profile milling, tracer milling, face
milling, and plunging.

Figure 3: Flat end mill cutter

A milling cutter's cutting surfaces are typically made of a robust, temperature-resistant

material that wears slowly. Surfaces of a low-cost cutter may be built of high-speed steel.
Cemented carbide is a more expensive but slower-wearing substance. So, to avoid glazing the
tool, we utilised aluminium as the workpiece material.

Because aluminium is dimensionally stable, you can remove a large portion of it

while keeping residual stress under control. You will achieve a superb polish using carbide
tooling and contemporary coolants, and it may be bead blasted for a matt surface or anodized
for a uniform aesthetic finish and improved corrosion protection. Aluminium is lighter than
most metals, making it an excellent choice for weight reduction.
DESIGNING
The designing of the workpiece was done with the help of Solidworks software. The
3D model of the work is shown below:

Figure 4: Screenshots of created 3D Model

NC PROGRAM
The designing of the workpiece was done using Solidworks software. To machine the
workpiece, NC program was developed. The program is shown below:

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I-1.399 J0.272 I1.399 J-0.272 I-1.399 J0.272
%
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G17
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M9
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T1 M6
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S10000 M3
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M9 X44.039 Y45.272 Z-0.314 X46.836 Y44.729 Z-3.91 X44.039 Y45.272 Z-7.505

I-1.399 J0.272 I1.399 J-0.272 I-1.399 J0.272
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Z10 I1.399 J-0.272 I-1.399 J0.272 I1.399 J-0.272

Z5 X44.039 Y45.272 Z-0.627 X46.836 Y44.729 Z-4.222 X44.039 Y45.272 Z-7.818

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MACHINING WORK PROCESS

The machining process that was involved during the manufacturing of final object
was milling operation using end milling cutter. The second machining process that was
involved was drilling operation.

MILLING:
 CNC milling is a versatile machining process that includes scraping off parts of a
workpiece with revolving cutters until the required form is attained. End mills, face mills,
slab mills, fly cutters, and other types of milling cutters are the most frequent.

End mills are unique among these cutting instruments, with numerous applications.
They are specialised milling tools for end milling processes. End milling is the process of
making axial cuts into a workpiece with a specialised cutting instrument called an end mill. It
is a type of milling process used for manufacturing die cavities, profiles, slots, contours,
shoulders, and other milling elements.

End mills, like many other cutting tools, have several cutting teeth on the points but
extra cutting teeth on the sides. As a result, they are appropriate for end-cutting and
peripheral cutting. These mill cutters can create precise cuts, making them useful for a variety
of applications such as engraving and machine part production.

Figure 5: CNC End milling Operation

DRILLING:

CNC drilling is a type of machining that uses a revolving cutting tool to create round
holes in a stationary workpiece. The holes are often drilled to accommodate machine screws
or bolts used in assembly. However, depending on the design of the component, they can be
employed for aesthetic purposes. The machine code, once placed into the CNC machine,
governs how the CNC machine and equipment move and work during the drilling operation.
The operator can begin the drilling process once the machine code has been loaded and the
machine has been set up.

Figure 6: CNC Milling Operation

FINAL WORK
The final finished product after the machining is shown in the figure below:
CHALLENGES AND LEARNING OUTCOMES
As useful and important as this technology is in modern metal manufacture, it has
limitations, just like any tool, trade, or person. And, while there are still some issues with
CNC machining that may arise in particular circumstances, these obstacles may be solved
with the appropriate strategy. Some challenges that we faced during the project work and
their learning outcomes are the followings:

 COMPLEX GEOMETRY
The geometry of the final product was a little complex. So, it demands a very good
precision skill to be machined. To overcome this challenge, we used only one tool
with accurate NC program. We were able to learn to overcome the complex geometry
challenges using different interpolations and absolute dimensioning.
 DATA PROCESSING
CNC machining, because to its mechanical nature, can work well within the
hardware constraints. However, the software that runs the system may have an impact
on performance. In some circumstances, the speed at which the computer delivers
instructions to the equipment under control is the bottleneck for how fast CNC
machining works. This is readily remedied with a software upgrade.
 SIZABLE COST
Due to use of CNC machine and Carbide flat end milling cutter tool, the cost of
production increased but we overcome that by using aluminium as workpiece
material. Other than cost effective, aluminium have so many benefits for CNC milling
operation.
CONCLUSIONS
We have performed the CIM project and we were able to overcome all the challenges
and manufacture the final product. During the project, we have learned a complete process of
manufacturing an object. We have started from basic 2D CAD drawing and then created a 3D
model using the Solidworks software. Then we have successfully created a NC program to
machine the workpiece into final product on CNC milling machine. Overall, we were able to
learn about all phases of manufacturing process. We learned about making drawing, 3D
model, NC program and finally Operating the CNC machine.

REFERENCES
[1] Hansen, Allan; Arbab, Farhad (April 1992). "An algorithm for generating NC tool
paths for arbitrarily shaped pockets with islands". ACM Transactions on Graphics. 11
(2): 152–182. doi:10.1145/130826.130832. S2CID 2388266.
[2] Held, Martin (1991). "A geometry-based investigation of the tool path generation for
zigzag pocket machining". The Visual Computer. 7 (5–6): 296–308.
doi:10.1007/BF01905694. S2CID 1057336.
[3] Kramer, Thomas R. (1992). "Pocket Milling with Tool Engagement Detection".
Journal of Manufacturing Systems. 11 (2): 112–123. CiteSeerX 10.1.1.57.3646.
doi:10.1016/0278-6125(92)90042-E.
[4] Persson, H. (May 1978). "NC machining of arbitrarily shaped pockets". Computer-
Aided Design. 10 (3): 169–174. doi:10.1016/0010-4485(78)90141-0
[5] A treatise on milling and milling machines. Cincinnati, Ohio: Cincinnati Milling
Machine Company. 1922. Retrieved 2013-01-28.