INDUSTRIAL TRAINING REPORT

ON

Workshop practice on verity of manufacturing unit like, lathe,CNC

DIPLOMA
in MECHANICAL ENGINEERING
at
ARKA JAIN UNIVERSITY, Jharkhand

Submitted By
NAME: - BITTU PRASAD
ENROLLMENT. NO: - AJU/211636

Under the Guidance of

MR.SUSHIL KUMAR
IDTR, Junior Engineer Production Manager

SCHOOL OF ENGINEERING & I.T,

ARKA JAIN UNIVERSITY, JAMSHEDPUR
2023-2024
 DECLARATION BY THE STUDENT

I sincerely declare that:

1. I am the sole writer of this report.

2. The details of training and experience contain in this report describe my involvement
as a trainee in the field of Mechanical Engineering.

3. All the information contains in this report is certain and correct to the knowledge.

Signature: ……………………………………………

Name: ………………………………………………….

Registration No: ……………………………………

Date: ……………………………………………………
 CERTIFICATE
This is to certify that the Industrial Training Report titled " Workshop practice on verity
Manufacturing unit like, Lathe,CNC" in partial fulfillment of the requirement for the award
of the Degree of Diploma in Mechanical Engineering, submitted to ARKA JAIN University,
Jharkhand, is an authentic record of bonafide industrial training work carried out by Mr
Bittu Prasad and submitted under my supervision/guidance.

Mr. Sushil Kumar Prof. Ashwini Kumar

Junior Engineer production manager Assistant Dean
Indo Danish Tool Room ,Jamshedpur School of Engineering & I.T

Date:
Place: Jamshedpur
 ACKNOWLEDGEMENT

I would like to express my utmost gratitude to the AJU for providing an opportunity to pursue
the engineering training as partial fulfillment of the requirement for the degree of Diploma in
Mechanical Engineering. The internship opportunity I had with Indo Danish Tool Room was a
great chance for learning and professional development. Therefore, I consider myself as a very
lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for
having a chance to meet so many wonderful people and professionals who led me through this
internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and
special thanks to the Mr. SUSHIL KUMAR, JUNIOR ENGINEER, MSME Indo Danish
Tool Room who in spite of being extraordinarily busy with his duties, took time out to hear,
guide and keep me on the correct path and allowing me to carry out my project at their
esteemed organization and extending during the training.

I express my deepest thanks to Mr. SUSHIL KUMAR, Junior Engineer, IDTR(Indo Danish
Tool Room), for taking part in useful decision & giving necessary advice and guidance and
arranged all facilities to make life easier. I choose this moment to acknowledge his contribution
gratefully.

I express my deepest thanks to all staffs and employees of Indo Danish Tool Room for taking
part in useful decision & giving necessary advice and guidance and arranged all facilities to
make life easier. I choose this moment to acknowledge their contribution gratefully. I perceive
as this opportunity as a big milestone in my career development. I will strive to use gained
skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with all
of you in the future.
 ABSTRACT

The aim of this training is to get exposed to the Workshop practice on verity of manufacturing
unit like, lathe,CNC

I joined the company as trainee for one month training. In this report, I have highlighted the
challenges that I encountered and the actions taken or solutions to problems during training in
MSME Indo Danish Tool Room, M4 Part Phase 6, Tata Kandra Road, Gamharia (Jamshedpur).

It was a rewarding opportunity for me to learn the work culture as; how the organization work
for the entire project, was structured, its hierarchy, how various departments work in
coordination with one another inside the system to achieve a common target and predetermined
goals, how the superior officers interact with the clients and contractors, how the information is
being delivered from the top to the bottom level employees etc.
 ABOUT IDTR (INDO DANISH TOOL ROOM)

The Indo Danish Tool Room Jamshedpur, a

Government of India Society, established in the
year 1991 under bilateral agreement with
Government of India and Government of
Denmark and assistance from State Government
for providing integrated solution in Tool
Engineering.

IDTR with its state-of-the-art Manufacturing and

Training facilities, CAD/CAM/CAE services
provides solution through focused group of specialist, covering products like Plastic Injection
Mould, Pressure Die Casting Dies, Jigs, Fixture and Gauges, Press Tool for Sheet Metal,
Precision Machining, Hard Material Machining, Laser Calibration, Project Management,
Product Development and Quality Management Consultancy, Training in Tool Engineering,
Machinist, CAD/CAM/CAE & CNC Technology, PLC, VLSI, etc.

The Tool Manufacturing facilities are comparable to finest in the world, while the Training
provided is the best in the country.

Being accredited with prestigious ISO 29990:2010, ISO 9001:2008, and 14001:2004
certificates and capacity to handle the diverse needs of the different industries, make it one
stop shop for providing Total Tooling Solutions for Manufacturing, Training and
Consultancy Services.

The Objectives of IDTR include..

 To impart long-term and short-term training to youngsters in the field of Tool & Die
making course with the latest technologies (and other allied Engineering trades) both
for fresher's and personnel already engaged in this field.
 To provide Consultancy Services primarily to Small scale Units in the field of Tool
Engineering aimed at improving the productivity of the Small Scale Units.
 Special Job Oriented Courses for Women on Metrology.
 To provides common facility services in precision machining / heat treatment and
other technical engineering know-how in tooling to Small Scale Industries in the
Country.
 To design and manufacture Moulds, Tools, Dies, Jigs Fixtures, etc. of high precision
quality.
 To generate employment and provide skilled manpower to Tiny & SSI sector.
We undertake Design and Manufacturing of Jigs, Fixtures, Gauges, Die Casting Dies, Press
Tooling and Plastic Moulds for the Automobile and Engineering sectors and machining of
precision components. Along with this we also conduct 4 years Diploma in Tool and Die
Making, 2 years ITI, and various short term training courses on CAD/ CAM/ CAE, CNC,
PLC, Maintenance, etc.

IDTR (MSME Tool Room) at a Glance

 Plant & Machinery Investment: ? 60 Cr.

 Manpower: 73
 Total plant area: 11.3Acres
 Total Power Supply: 633 KVA with 300 KVA UPS Back up Generator Capacity
(250KVA X 2; 110KVAX 1)
 Well Equipped Computer Labs: 4
 Knowledge/ Information Centre
 Guest House & Hostel Facility for both girls and boys
 TABLE OF CONTENT

PAGE.NO
DECLARATION BY THE STUDENT iii
CERTIFICATE iv
ACKNOWLEDGEMENT v
ABSTRACT vi
INTRODUCTION ABOUT THE COMPANY vii
TABLE OF CONTENTS 1-2

CHAPTER-1:- IN-PLANT TRAINING 3-4

CHAPTER-2:- LATHE MACHINE 5-13

2.1 Introduction
2.2 Types of Lathe
2.3 Some Of Common Lathes Are Described As Under:
2.4 Construction Of Lathe Machine
2.5 Accessories And Attachments Of Lathe
2.6 Lathe Operations

CHAPTER-3:- GRINDING MACHINE 14-16

3.1 Definition
3.2 Construction
3.3 Types of grinders
3.4 Surface Grinding

CHAPTER-4:- INTRODUCTION TO NC DNC AND CNC 17-19

4.1 Numerical control (NC)
4.2 Direct numerical control (DNC)
4.3 Computer Numerical control CNC

CHAPTER-5:- CONTROL PANEL OF CNC 20

CHAPTER-6:- CNC MACHINERIES 21-27

6.1 CNC Lathe
6.2 CNC Milling Machine
6.3 CNC Wire EDM

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CHAPTER-7:- STRUCTURE OF PART PROGRAM 28-32
7.1 M-Codes
7.2 G-Codes
7.3 CNC Machine Start Procedure
7.4 Method of inserting new program

CHAPTER-8:- TYPICAL SAMPLE PROGRAM 33-35

8.1 Sample program on Milling
8.2 Sample program on Turning

CHAPTER-9:- ADVANTAGES, DISADVANTAGES AND APPLICATION OF CNC 36

9.1 Advantages
9.2 Disadvantages
9.3 Applications

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 In-Plant Training

1.1 What is in-plant Training?

An in-plant training (IPT) is a short duration training course provided in any company to help
you get "industry" knowledge and know-how. Its usefulness varies depending on which branch
you are, and which company you do an IPT with.
Certain students only want to show an IPT on their resume, and I'm sure you don't need
me telling you that this will have no value in terms of actual industry exposure or learning. Most
IPTs aren't very useful for software and circuit branches, because most of their jobs will be
computer-based and there is no way that a 2 week IPT will enhance your understanding of the
field. On the other hand, I had friends from Automobile or Mechanical Engineering, who visited
industries for their IPT and got real exposure to the kinds of machinery and equipment that was
used. Anything done for the sake of doing it will not benefit you. "Progress for progress' sake must
be discouraged"

Fig. 1.1 In-Plant Training Room

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 My summer training is follow in following machine given below:-
 Lathe Machine
 CNC Turning Machine
 CNC Milling Machine
 Surface Grinding Machine
 Electrical Discharge Machining

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 Lathe Machine

2.1 Introduction
Lathe is one of the most versatile and widely used machine tools all over the world. It is commonly
known as the mother of all other machine tool. The main function of a lathe is to remove metal
from a job to give it the required shape and size. The job is secure1y andrigid1y held in the chuck
or in between centers on the lathe machine and then turn it against a singlepoint cutting tool
which wi1l remove meta1 from the job in the form of chips.Fig. 2.1 shows the working principle
of lathe. An engine lathe is the most basic and simplest form of the lathe. It derives its name from
the early lathes, which obtained their power from engines. Besides the simple turning operation as
scribed above, lathe can be used to carry out other operations also, such as drilling, reaming,
boring, taper turning, knurling, screw thread cutting, grinding etc.

Fig. 2.1 Working principal of lathe machine

2.2 Types of Lathe

Lathes are manufactured in a variety of types and sizes, from very small bench lathes used for
precision work to huge lathes used for turning large steel shafts. But the principle of operation
and function of all types of lathes is same. The different types of lathes are:
1. Speed lathe
(a) Wood working
(b) Spinning
(c) Cantering
(d) Po1ishing

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 2. Centre or engine lathe
(a) Be1t drive
(b) Individual motor drive
(c) Gear head lathe
3. Bench lathe
4. Tool room Lathe
5. Capstan and Turret 1athe
6. Special purpose lathe
(a) Whee1 lathe
(b) Gap bed lathe
(c) Dup1icating lathe
(d) T-lathe
7. Automatic lathe

2.3 Some Of Common Lathes Are Described As Under:

2.3.1 Speed Lathe
Speed lathe is simplest of all types of lathes in construction and operation. The important parts of
speed lathe are following-
(1) Bed
(2) Headstock
(3) Tailstock, and
(4) Tool post mounted on an adjustable slide.
It has no feed box, 1eadscrew or conventional type of carriage. The tool is mounted on the
adjustable slide and is fed into the work by hand contro1. The speed lathe finds applications where
cutting force is least such as in wood working, spinning, cantering, polishing, winding, buffing
etc.
This lathe has been so named because of the very high speed of the headstock spindle.

2.3.2 Centre Lathe or Engine Lathe

The term “engine” is associated with this lathe due to the fact that in the very early days of its
development it was driven by steam engine. This lathe is the important member of the lathe
family and is the most widely used. Similar to the speed lathe, the engine lathe has all the basic
parts, e.g., bed, headstock, and tailstock. But its headstock is much more robust in construction
and contains additional mechanism for driving the lathe spindle at multiple speeds. An engine
Lenth is shown in Fig. 2.2. Unlike the speed lathe, the engine lathe can feed the cutting tool both
in cross and longitudinal direction with reference to the lathe axis with the help of a carriage,feed
rod and lead screw. Centre lathes or engine lathes are classified according to

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methods of transmitting power to the machine. The power may be transmitted by means of belt,
electric motor or through gears.

2.3.3 Bench Lathe

This is a small lathe usually mounted on a bench. It has practically all the parts of an engine lathe
or speed lathe and it performs all the operations. This is used for small and precision work.

Fig. 2.2 Principal components of a central lathe

2.3.4 Tool Room Lathe

This lathe has features similar to an engine lathe but it is much more accurately built. It has a wide
range of spindle speeds ranging from a very low to a quite high speed up to 2500 rpm. This lathe
is mainly used for precision work on tools, dies, gauges and in machining work where accuracy is
needed.

2.3.5 Capstan and Turret Lathe

The development of these 1athes results from the technological advancement of the engine lathe
and these are vastly used for mass production work. The distinguishing feature of this type of lathe
is that the tailstock of an engine lathe is replaced by a hexagonal turret on the face of whichmultiple
tools may be fitted and fed into the work in proper sequence. Due to this arrangement, several
different types of operations can be done on a job without re-setting of work or tools, anda number
of identical parts can be produced in the minimum time.

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2.3.6 Special Purpose Lathes
These lathes are constructed for special purposes and for jobs, which cannot be accommodated
or conveniently machined on a standard lathe. The wheel lathe is made for finishing the journals
and turning the tread on railroad car and locomotive wheels. The gap bed lathe, in which a section
of the bed adjacent to the headstock is removable, is used to swing extra-large-diameter pieces.
The T-lathe is used for machining of rotors for jet engines. The bed of this lathe has T- shape.
Duplicating lathe is one for duplicating the shape of a flat or round template on to the job.

2.3.7 Automatic Lathes

These lathes are so designed that all the working and job handling movements of the complete
manufacturing process for a job are done automatically. These are high speed, heavy duty, mass
production lathes with complete automatic control.

2.4 Construction Of Lathe Machine

A simple lathe comprises of a bed made of grey cast iron on which headstock, tailstock, carriage
and other components of lathe are mounted. Fig. 2.3 shows the different parts of engine lathe or
central lathe. The major parts of lathe machine are given as under:
1. Bed
2. Head stock
3. Tailstock
4. Carriage
5. Feed mechanism
6. Thread cutting mechanism

Fig. 2.3 Different parts of engine lathe or central lathe

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2.4.1 Bed
The bed of a lathe machine is the base on which all other parts of lathe are mounted. It is massive
and rigid single piece casting made to support other active parts of lathe. On left end of the bed,
headstock of lathe machine is located while on right side tailstock is located. The carriage of the
machine rests over the bed and slides on it.
On the top of the bed there are two sets of guide ways-inner ways and outer ways. The
inner ways provide sliding surfaces for the tailstock and the outer ways for the carriage. The guide
ways of the lathe bed may be flat and inverted V shape. Generally cast iron alloyed with nickel
and chromium material is used for manufacturing of the lathe bed.

2.4.2 Head Stock

The main function of headstock is to transmit power to the different parts of a lathe. It comprises
of the headstock casting to accommodate all the parts within it including gear train arrangement.
The main spindle is adjusted in it, which possesses live centre to which the work can be attached.
It supports the work and revolves with the work, fitted into the main spindle of the headstock. The
cone pulley is also attached with this arrangement, which is used to get various spindle speed
through electric motor. The back gear arrangement is used for obtaining a wide range of slower
speeds. Some gears called change wheels are used to produce different velocity ratio required for
thread cutting.

2.4.3 Tail Stock

Fig. 21.4 shows the tail stock of central lathe, which is commonly used for the objective of
primarily giving an outer bearing and support the circular job being turned on centers. Tail stock
can be easily set or adjusted for alignment or non-alignment with respect to the spindle centre
and carries a centre called dead centre for supporting one end of the work. Both live and dead
centers have 60° conical points to fit centre holes in the circular job, the other end tapering to allow
for good fitting into the spindles. The dead centre can be mounted in ball bearing so that it rotates
with the job avoiding friction of the job with dead centre as it
important to hold heavy jobs.

2.4.4 Carriage
Carriage is mounted on the outer guide ways of lathe bed and it can move in a direction parallel to
the spindle axis. It comprises of important parts such as apron, cross-slide, saddle, compound rest,
and tool post. The lower part of the carriage is termed the apron in which there are gears to
constitute apron mechanism for adjusting the direction of the feed using clutch mechanism and the
split half nut for automatic feed. The cross-slide is basically mounted on the carriage, which
generally travels at right angles to the spindle axis. On the cross-slide, a saddle is mounted in

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which the compound rest is adjusted which can rotate and fix to any desired angle. The compound
rest slide is actuated by a screw, which rotates in a nut fixed to the saddle. The tool post is an
important part of carriage, which fits in a tee-slot in the compound rest and holds the tool holder
in place by the tool post screw.

2.4.5 Thread Cutting Mechanism

The half nut or split nut is used for thread cutting in a lathe. It engages or disengages the carriage
with the lead screw so that the rotation of the leadscrew is used to traverse the tool along the
workpiece to cut screw threads. The direction in which the carriage moves depends upon the
position of the feed reverse lever on the headstock.

2.5 Accessories And Attachments Of Lathe

There are many lathe accessories provided by the lathe manufacturer along with the lathe, which
support the lathe operations. The important lathe accessories include centers, catch plates and
carriers, chucks, collets, face plates, angle plates, mandrels, and rests. These are used either for
holding and supporting the work or for holding the tool. Attachments are additional equipments
provided by the lathe manufacturer along with the lathe, which can be used for specific operations.
The lathe attachment include stops, ball turning rests, thread chasing dials, milling attachment,
grinding attachment, gear cutting attachment, turret attachment and crank pin turningattachments
and taper turning attachment.

Lathe centers
The most common method of holding the job in a lathe is between the two centers generally known
as live centre (head stock centre) and dead centre (tailstock centre). They are made of very hard
materials to resist deflection and wear and they are used to hold and support the cylindrical jobs.

Carriers Or Driving Dog And Catch Plates

These are used to drive a job when it is held between two centers. Carriers or driving dogs are
attached to the end of the job by a setscrew. A use of lathe dog for holding and supporting thejob
is shown in Fig. 21.6. Catch plates are either screwed or bolted to the nose of the headstock spindle.
A projecting pin from the catch plate or carrier fits into the slot provided in either of them. This
imparts a positive drive between the lathe spindle and job.

Chucks
Chuck is one of the most important devices for holding and rotating a job in a lathe. It is
basically attached to the headstock spindle of the lathe. The internal threads in the chuck fit on to

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the external threads on the spindle nose. Short, cylindrical, hol1ow objects or those of irregular
shapes, which cannot be conveniently mounted between centers, are easily and rigidly held in a
chuck. Jobs of short length and large diameter or of irregular shape, which cannot be conveniently
mounted between centers, are held quickly and rigidly in a chuck.
There are a number of types of lathe chucks, e.g.
(1) Three jaws or universal
(2) Four jaw independent chuck
(3) Magnetic chuck
(4) Collet chuck
(5) Air or hydraulic chuck operated chuck
(6) Combination chuck
(7) Drill chuck.

Face plates
Face plates are employed for holding jobs, which cannot be conveniently held between centers or
by chucks. A face plate possesses the radial, plain and T slots for holding jobs or work-pieces by
bolts and clamps. Face plates consist of a circular disc bored out and threaded to fit the nose of the
lathe spindle. They are heavily constructed and have strong thick ribs on the back. They have slots
cut into them, therefore nuts, bolts, clamps and angles are used to hold the jobs on the face plate.
They are accurately machined and ground.

Angle plates
Angle plate is a cast iron plate having two faces machined to make them absolutely at right angles
to each other. Holes and slots are provided on both faces so that it may be clamped on a faceplate
and can hold the job or workpiece on the other face by bolts and clamps. The plates are used in
conjunction with a face plate when the holding surface of the job should be kept horizontal.
.
2.6 Lathe Operations
For performing the various machining operations in a lathe, the job is being supported and driven
by anyone of the following methods.
1. Job is held and driven by chuck with the other end supported on the tail stock centre.
2. Job is held between centers and driven by carriers and catch plates.
3. Job is held on a mandrel, which is supported between centers and driven by carriers and catch
plates.
4. Job is held and driven by a chuck or a faceplate or an angle plate.
The above methods for holding the job can be classified under two headings namely job
held between centers and job held by a chuck or any other fixture. The various important lathe

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operations are depicted through Fig. 21.8 (a), (b) and (c). The operations performed in a lathe
can be understood by three major categories.

Fig. 2.4(a) Lathe operation

(a) Operations, which can be performed in a lathe either by holding the workpiece betweencenters
or by a chuck are:
1. Straight turning 2. Shoulder turning 3. Taper turning 4. Chamfering 5. Eccentric turning
6. Thread cutting 7. Facing 8. Forming 9. Filing 10. Polishing 11. Grooving 12. Knurling
13. Spinning 14 . Spring winding

(b) Operations which are performed by holding the work by a chuck or a faceplate or anangle
plate are:
1. Undercutting 2. Parting-off 3. Internal thread cutting 4. Drilling 5. Reaming 6. Boring
7. Counter boring 8. Taper boring 9. Tapping

Fig. 2.4(b) Lathe operations

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(c) Operations which are performed by using special lathe attachments are:
1. Milling
2. Grinding

Fig. 2.4(c) Lathe operation

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 Grinding machine
3.1 Definition
A grinding machine is a machine tool used for producing very fine finishes or making very light
cuts, using an abrasive wheel as the cutting device. This wheel can be made up of various sizes
and types of stones, diamonds or of inorganic materials. For machines used to reduce particle size
in materials processing see grinding.

3.2 Construction
The grinding machine consists of a power driven grinding wheel spinning at the required speed
(which is determined by the wheel’s diameter and manufacturer’s rating, usually by a formula)
and a bed with a fixture to guide and hold the work-piece. The grinding head can be controlled to
travel across a fixed work piece or the workpiece can be moved whilst the grind head stays in a
fixed position. Very fine control of the grinding head or tables position is possible using a vernier
calibrated hand wheel, or using the features of NC or CNC controls.

Fig. 4.1 grinding machine

Grinding machines remove material from the workpiece by abrasion, which can generate
substantial amounts of heat; they therefore incorporate a coolant to cool the workpiece so that it
does not overheat and go outside its tolerance.. In very high-precision grinding machines (most
cylindrical and surface grinders) the final grinding stages are usually set up so that they remove
about 2/10000mm (less than 1/100000 in) per pass - this generates so little heat that even with no
coolant, the temperature rise is negligible.

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3.3 Types of grinders
These machines include the:-

 Belt grinder, which is usually used as a machining method to process metals and other
materials, with the aid of coated abrasives. Sanding is the machining of wood; grinding is
the common name for machining metals. Belt grinding is a versatile process suitable for all
kind of applications like finishing, deburring, and stock removal

 Bench grinder, which usually has two wheels of different grain sizes for roughing and
finishing operations and is secured to a workbench. It is used for shaping tool bits or various
tools that need to be made or repaired. Bench grinders are manually operated.

 Cylindrical grinder which includes the centerless grinder. A cylindrical grinder may have
multiple grinding wheels. The workpiece is rotated and fed past the wheel/s to form a
cylinder. It is used to make precision rods.

 Surface grinder which includes the wash grinder. A surface grinder has a "head" which is
lowered, and the workpiece is moved back and forth past the grinding wheel on a table that
has a permanent magnet for use with magnetic stock. Surface grinders can bemanually
operated or have CNC controls.

 Tool and Cutter grinder and the D-bit grinder. These usually can perform the minor
function of the drill bit grinder, or other specialist tool room grinding operations.

 Jig grinder, which as the name implies, has a variety of uses when finishing jigs, dies, and
fixtures. Its primary function is in the realm of grinding holes and pins. It can also be used
for complex surface grinding to finish work started on a mill.

3.4 Surface Grinding

This series machine tool is suitable in machine-manufacture trade to grind the plane of various
metal part such as steel, cast iron and nonferrous metal etc. CHARACTERISTIC: The grinding
machine working table’s lengthways moving and grind head’s transverse moving is hydraulic
transmission, the step less velocity modulation; The grind head perpendicular feed for the hand
moves, and have the quick elevating mechanism, and it can lighten labour intensity, raises work
efficiency; The working table slide way is paste the polytetrafluoroethylene soft belt, and the

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wear- resistant is good, and the energy consumption is low; The grinding head perpendicular
feed slide way is paste the poly tetra fluoroethylene soft belt, and feeding sensitivity is high; The
machine tool bed adopts the heat symmetry design, and the heat-distortion is become a little; Using
the oil returning to heat the bed slide way, the slide way straightness keeps unchangeable basically;
The machine tool motion is smooth and steady, the function is reliable and the noise low

Fig. 4.2 Surface grinding machine

Model SG63×12-GM
Table working surface(W×L) 630×1250mm
Max. size of workpiece to be ground(W×L×H) 630×1250×400mm
Table longitudinal travel(hydraulic) 200-1350m
Packing case dimensions（L×W×H） 383×233×262cm

Overall dimensions（L×W×H） 3540×2073×2280mm

Grinding wheel size（O.D×W×I.D） φ400×50×φ203mm

Table "T"slots and width 3 and 22mm

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 INTRODUCTION TO NC DNC AND CNC

4.1 NUMERICAL CONTROL (NC)

Fig.1.1 Numerical Control Systems. Numerical control (NC) systems are hardware controls in which
most of functions are carried out by electronic hardware based upon digital circuit technology.
Numerical Control is a technique for controlling machine tools or processes using coded command
instructions. These coded command instructions are interpreted and converted by NC controller into
two types of signals namely; motion control signals and miscellaneous control signals. Motion
control signals are a series of electric pulse trains that are used to control the positions and the speed
of the machine table and spindle,where as miscellaneous control signals are set of ON/OFF signals to
execute the spindle rotation and direction, control of coolant supply, selection of cutting tools,
automatic clamping and unclamping, etc. In motion control signals, each pulse activates a motion of
one basic length-unit (BLU).

4.2 DIRECT NUMERICAL CONTROL (DNC)

Direct numerical control (DNC), also known as distributed numerical control (also DNC),is a common
manufacturing term for networking CNC machine tools. DNC networking or DNC communication is
always required when CAM programs are to run on some CNC machine control.

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4.3 COMPUTER NUMERICAL CONTROL (CNC)

Fig. 4.3 Block diagram of Computer Numerical control system CNC controls are soft-wired NC
systems as control functions are controlled by software
Programs. Alternatively, Computer Numerical Control is the numerical control system in which
dedicated, stored program microprocessors are built into the control to perform basic and advanced NC
functions. Control signals in CNC systems are in the form of binary words, where each word contains
fixed number of bits, 32 bits or 64 bits are commonly used, representing different axial positions.

A CNC system consists of the following 6 major elements:

a. Input Device
b. Machine Control Unit
c. Machine Tool
d. Driving System
e. Feedback Devices
f. Display Unit

4.3.1 PROGRAMME INPUT DEVICE

The program input device is the means for part program to be entered into the CNC control.
Three commonly used program input devices are punch tape reader, magnetic tape reader, and
computer via RS-232-C communication.

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4.3.2 MACHINE CONTROL UNIT
The machine control unit (MCU) is the heart of a CNC system. It is used to perform the following
functions:
It read the coded instructions, decode the coded instructions. Implement interpolations (linear, circular,
and helical) to generate axis motion commands. and feed the axis motion commands to the amplifier
circuits for driving the axis mechanisms. And it receives the feedback signals of position and speed for
each drive axis. To implement auxiliary control functions such as coolant or spindle on/off and tool
change.

4.3.3 MACHINE TOOL

CNC controls are used to control various types of machine tools. Regardless of which type of machine
tool is controlled, it always has a slide table and a spindle to control position and speed. The machine
table is controlled in the X and Y axes, while the spindle runs along the Z axis.

4.3.4 FEEDBACK SYSTEM

The feedback system is also referred to as the measuring system It uses position and speed transducers
to continuously monitor the position at which the cutting tool is located at any particular instant. The
MCU uses the difference between reference signals and feedback signals to generate the control signals
for correcting position and speed errors.

4.3.5 DRIVE SYSTEM

Drives are used to provide controlled motion to CNC elements drive system consists of amplifier
circuits, drive motors, and ball lead-screws. The MCU feeds the control signals (position and speed)
of each axis to the amplifier circuits. The motors used for CNC system are of two kinds-
1. Electrical -DC or AC Stepper motors and DC or AC servo motors
2. Fluid - Hydraulic or Pneumatic

19 | P a g e
 CONTROL PANEL OF CNC

Fig.5 Control Panel

A CNC machine is normally controlled by a computer and software. However, most CNC machines have a
range of controls for manual use. It is rare for a CNC machine to be used manually as simple operations are
best carried out on cheap/basic/manual machines. When a CNC machine is used manually it is being used well
below its capability and specification.

5.1 RESET BUTTON

The most important control button is usually the reset button. When the CNC machine is turn edon, the reset
button is pressed by the machine operator. This zero the cutter, moving the cutter to coordinates 0, 0, 0 on the
X, And Z axis. In simple terms, the reset button moves the cutter to the corner of the machine, above the work
table.

5.2 MANUAL CONTROL

The cutter can be controlled manually although this is rarely needed. The ‘X’ and ‘Y’ buttons
control the movement of the cutter along the horizontal surfaces. The ‘Z’ buttons control depth and
up / down movement.

5.3 STOP BUTTON

Most control panels have stop buttons. When pressed these stop the machine very quickly.

5.4 SPEED AND FEED

On some CNC machines it is possible to manually vary the speed and feed of the cutter.
 CNC MACHINERIES

The CNC machines which we worked at IDTR are:

 CNC Lathe.
 CNC Milling.
 CNC Wire EDM

6.1 CNC LATHE (FANUC SERIES OI-TC)

6.1.1 SPECIFICATIONS
Table. 6.11 CNC Lathe Specification

EQUIPMENT UNIT RANGE

Made = Fanuc ---- ----

Chuck diameter mm 200

Max. cutting diameter mm 200

Max. cutting length mm 500

Spindle bore diameter mm 55

Spindle rotating speed rpm 45-4000

Main motor power(AC) kW 11

Hydraulic unit powermotor kW 1.5

Chip conveyor motor kW 0.2

Coolant pump motor kW 0.55

Weight Kg 5000
 Fig. 6.11 CNC Lathe.

6.1.2 ABOUT CNC LATHE

Some view lathes as the only universal CNC machine tool because a lathe can make all of the parts
needed for another lathe. A lathe spins the work-piece in a spindle while a fixed cutting tool approaches the
work-piece to slice chips off of it. The act of cutting a work-piece on a lathe is called "Turning".
Computer numerical control (CNC) has been incorporated into a variety of new technologies and machinery.
One such machine of this sort that is used for a wide array of production processes is known as a CNC lathe.
Due to technological advancements, CNC lathes are quickly replacing some of the older and more
traditionally used production lathes, such as the multi-spindle. CNC lathes come with a number of benefits.
They can be easily set up and operated. They offer tremendous repeatability, along with top-notch accuracy in
production.
A CNC lathe is typically designed to utilize modern versions of carbide tooling
and processes. A part can be designed for customization, and the machine’s tool paths are often programmed
using the CAD or CAM processes some prime examples of finished items as a result of using CNC lathe
machines include: Baseball Bats, Bowls, Camshafts, Crankshafts Cue, sticks Dining, Room Table and Chair
Legs, Gun Barrels, Musical Instruments.
6.1.3 PREPARING AND USING OF CNC LATHE
 Checking to make sure the lathe is lubricated and learning to schedule routine maintenance in
accordance with workplace standards.
 Learning to translate product specifications and work instructions into a machine-readable format.
 Establishing criteria for tool selection with efficiency and safety in mind.
 Installing work-piece handling devices and inserting tools into their corresponding slots.
 Learning to load a machining program into the CNC lathe and aligning its data points according to
project requirements.
 Producing sample parts to verify if they match specifications and operator instructions.

6.2 CNC MILLING MACHINE (SEIMENS CONTROLLER)

Fig. 6.2 CNC Milling Machine

6.2.1 SPECIFICATIONS
Table. 6.2.1 CNC Milling specification

CNC controller Siemens control

Axis Motor & Drive AC Servo (1.3 Nm)
Spindle Motor 1 HP with VFD (3PH).
Spindle Motor Speed 100 to 3000 rpm
Lubrication System Automatic (Motorized).
Max. Depth Of Cut. 1 mm Possible.
Axis Control 3 axis.
Axis Plane XY, XZ & YZ.
Max. Rapid Feed 4000 mm/min.
Table Load Capacity 100 Kg.

6.2.2 ABOUT CNC MILLING

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.

CNC milling devices are the most widely used type of CNC machine. Typically, they are grouped by the
number of axes on which they operate, which are labelled with various letters. X and Y designate horizontal
movement of the work-piece (forward-and-back and side-to-side on a flat plane). Z represents vertical, or up-
and-down, movement, while W represents diagonal movement across a vertical plane. Most machines offer
from 3 to 5 axes, providing performance along at least the X, Y and Z axes. Advanced machines, such as 5-
axis milling centres, require CAM programming for optimal performance due to the incredibly complex
geometries involved in the machining process. These devices are extremely useful because they are able to
produce shapes that would be nearly impossible using manual tooling methods. Most CNC milling machines
also integrate a device for pumping cutting fluid to the cutting tool during machining.
6.2.3 PREPARING AND USING CNC MILLING
 Work safely at all times, complying with health and safety legislation, regulations and other relevant
guidelines.
 Plan the CNC machining activities before you start them.
 Load/input the program to the machine controller and check the program for errors using the
approved procedures.
 Mount and set the required work holding devices, work-piece and cutting tools.
 Check that all safety mechanisms are in place, and that the equipment is set correctly for the required
operations
 Run the operating program, and check and adjust the machine tool speeds, feeds and operating
parameters to achieve the component specification.
 Measure and check that all dimensional and geometrical aspects of the component are to the
specification.
 Deal promptly and effectively with problems within your control, and seek help and guidance from
the relevant people if you have problems that you cannot resolve.
 Shut down the equipment to a safe.

6.3 CNC WIRE EDM (MITSUBISHI CONTROLLER)

Fig. 6.3 CNC Wire EDM

6.3.1 SPECIFICATION

Table. 6.31 CNC Wire EDM specification.

DESCRIPTION MITSUBISHI RA90M MITSUBISHI RA90M

(AT)
Max. work piece dimension [mm] 860 x 760 x 160 860 x 760 x 160
(in)
Maximum work piece weight 350 350
Table dimensions 572 x 478 572 x 478
Machining range (X x Y) 320 x 250 320 x 250
Table rapid-feed speed[mm/min] 1300 1300
(in/min)
Wire diameter [mm] (in) 0.2 - 0.3 0.2 - 0.3
Maximum wire feed rate[m/min] 15 15
(in/min)
Maximum work piece thickness 160 -----
[mm] (in)
Taper machining device Standard Standard
Z-Axis stroke (manual operation) 150 150

Max. taper angle [mm] (in) 15 for work piece 100 mm thick 15 for work piece 100 mm thick
Max. machining current 50A 50A
Minimum drive unit [u m](in) 0.05um 0.05um
CNC Controller Mitsubishi 64 bit Mitsubishi 64 bit

6.3.2 ABOUT WIRE EDM

Electrical Discharge Machining (EDM) is a controlled metal-removal process that is used to remove metal by
means of electric spark erosion. In this process an electric spark is used as the cutting tool to cut (erode) the
work piece to produce the finished part to the desired shape.
The wire-cut type of machine arose in the 1960s for the purpose of making tools (dies) from hardened steel.
The tool electrode in wire EDM is simply a wire. The first CNC EDM machine was produced in 1976.

EDM wire cutting uses a metallic wire to cut a programmed contour in a work piece.
Extrusion dies and blanking punches are very often machined by wire cutting. Cutting is always through the
entire work piece. To start machining it is first necessary to drill a hole in the work piece or start from the edge.
On the machining area, each discharge creates a crater in the work piece and an impact on the tool. The wire
can be inclined, thus making it possible to make parts with taper or with different profiles at the top and bottom.
There is never any mechanical contact between the electrode and work piece. The wire is usually made of
brass or stratified copper, and is between 0.1 and 0.3 mm diameter. Depending on the accuracy and surface
finish needed, a part will either be one cut or it will be roughed and skimmed. On a one cut the wire ideally
passes through a solid part and drops a slug or scrap piece when it is done. This will give adequate accuracy
for some jobs, but most of the time, skimming is necessary. A skim cut is where the wire is passed back over
the roughed surface again with a lower power setting and low pressure flush. There can be from one to nine
skim passes depending on the accuracy and surface finish required. Usually there are just two skim passes. A
skim pass can remove as much as 0.002" of material or a as little as 0.0001". During roughing (i.e. the first
cut) the water is forced into the cut at high pressure in order to provide plenty of cooling and eliminate eroded
particles as fast as possible. During skimming (accuracy / finish cuts) the water is gently flowed over the burn
so as not to deflect the wire.

6.3.4 PREPARING AND USING OF WIRE EDM

 Work safely at all times, complying with health and safety legislation, regulations and other relevant
guidelines.
 Plan the CNC machining activities before you start them.
 Load/input the program to the machine controller and check the program for errors using the approved
procedures.
 Mount and set the required work holding devices, work-piece and cutting tools.
 Check that all safety mechanisms are in place, and that the equipment is set correctly for the required
operations
 The whole operation should take place inside water.
 Run the operating program, and check and adjust the machine speeds, feeds and cutting parameters to
achieve the component specification.
 Measure and check that all dimensional and geometrical aspects of the component are to the
specification.
 Deal promptly and effectively with problems within your control, and seek help and guidance from the
relevant people if you have problems that you cannot resolve.
 Shut down the equipment to a safe
 STRUCTURE OF NC PART PROGRAM
In general, several commands are grouped together to accomplish a specific machining operation, hence the
use of a block of information for each operation. Each command gives a specific element of control data, such
as dimension or a feed rate. Each command within a block is also called a word. The way in which words are
arranged within the block is called block format. Three different block formats are commonly used, (Fixed
sequential format, Tab sequential format and Word address format) With this type of format, each type of word
is assigned as address that is identified by a letter code within the part program. Thus the letter code specifies
the type of word that follows and then its associated numeric data is given. For example, the code T represents
a tool number. Thus a word of the form T01 would represent tool number 1. Theoretically, with this approach,
the words in a given block can be entered in any sequence and the controller should be able to interpret them
correctly. With the word address format only the needed words for a given operation have to be included within
the block. The command to which the particular numeric data applies is identified by the preceding address
code. Word format has the advantage of having more than one particular command in one block something
that would be impossible in the other two formats.

 NCODE: Sequence number, used to identify each block with in an NC program and provides a means
by which NC commands may be rapidly located. It is program linenumber. It is a good practice to
increment each block number by 5 to 10 to allow additional blocks to be inserted if future changes are
required.
 G-CODE: Preparatory Word, used as a communication device to prepare the MCU. The G-code
indicates that a given control function such as G01, linear interpolation, is to be requested.
 X, Y & Z-CODES: Coordinates. These give the coordinate positions of the tool.

COMMONLY USED WORD ADDRESSES

 F-CODE: Feed rate. The F code specifies the feed in the machining operation.
 S-CODE: Spindle speed. The S code specifies the cutting speed of the machining process.
 T-CODE: Tool selection. The T code specifies which tool is to be used in a specific operation.
 M-CODE: Miscellaneous function. The M code is used to designate a particular mode of operation for
an NC machine tool.
 I, J & K-CODES: They specify the centre of arc coordinates from starting.
Sequence and format of words: N3 G2 X+1.4 Y+1.4 Z+1.4 I2.0 J2.0 K2.0 F5 S4 T4

7.1 M-CODES

M00Mandatory Program Stop

M01 Optional Program Stop
M02 Program End
M03 Spindle Forward/Clockwise
M04 Spindle Reverse/Counter clockwise
M05 Spindle Stop
M06 Tool change
M07 Mist Coolant On
M08 Flood Coolant On
M09 All Coolant Off
M19 Spindle Orient
M30 Program End and Rewind
M40-M45 Gear Change
M47 Repeat Program from First Line
M48 Enable Feed/Speed Overrides
M49 Disable Feed/Speed Overrides
M98 Subprogram Call
M99 Return from Subprogram / Rewind
7.2 G-CODES
Table. 7.2 G-CODES
 7.3 CNC Machine Start Procedure

• Servo stablizer ON by green push botton

STEP-1

• Door close (CNC M/C)

STEP-2

STEP- • Emergency press

3-

• CNC ON by green push button. (Hydraulic system will be automatically ON)

STEP-4

• Emergency release
STEP-5

• Check alarm, Press Reset if not then rectify.

STEP-6

• Check Hydraulic pressure (40 - 45 bar)

STEP-7

• Check chuck pressure (8-25 bar) & tail stock pressure (8-16 bar).
STEP-8

• Check lubrication level & Pressure. (should be at green level)

STEP-9

STEP- • Check M/C Home position if not then make home

10

STEP- • M/C is Ready for operation

11

Fig. 7.3 Steps involved in starting CNC machine

7.4 Method of inserting new program

Step -1- Select edit mode.

Step -2- Programme protect key (PPK) On

Step -3- Select programme function key

Step -4- Open directory (DIR) by using soft keys in CRT

Step -5- Type programme no. (which programme no. not use -in directory)

Step -6- Then Insert

Step -7- End of block (EOB) Insert.

Step -8- Insert programme sequencly in blocks.

Step -9- Programme protect key (PPK) off

Fig. 7.4 Steps for inserting new program to CNC machine

 TYPICAL SAMPLE PROGRAMS
8.1 Sample program on Milling

Write a part program for milling operations being carried out on a CNC milling machine for the figure shown
below.

Fig. 8.1 Milling sample

Program:
%1000
N1 G90 G54 G43 G17 G0 H1 Z50
N2 M03 S1500
N3 G0 X0 Y0
N4 G01 Z0 F500
N5 M98 P700 L15
N6 G0 G90 Z250
N7 M30
%700
N1 G92 Z-1 G0 F500
N2 G90 X0 Y25
N3 G03 X0 Y75
N4 G01 Y100
N5 X25
N6 G03 X75 Y100 R25
N7 G01 X100
N8 Y75
N9 G03 X100 Y25 R25
N10 G01 Y0 N11 X75
N12 G03 X25 Y0 R25
N13 G0 X0
M99

8.2 SAMPLE PROGRAMME ON TURNING

Write a part program for turning operations being carried out on a CNC turning center. Let us take an exercise:
Figure shows the final profile to be generated on a bar stock by using a CNC turning center. After studying the
required part geometry and features, the main program can be written as follows.

Fig 8.2 Turninig Sample

N1 G21 G99 G40
N2 G28 U0W0
N3 T0101 M06
N4 G92 S1200
N5 G96 M04 S200
N6 G0 X75 Z2
N7 G71 U0.2 R1
N8 G71 P9 Q15 U0.2 W0.2 F0.1
N9 G01 X0 Z0 G42
N10 G01 X20.0 Z-20.0
N11 X20.0 Z-45.0
N12 X40.0 Z-80.0
N13 X40.0 Z-105.0
N14 G03 X70.0 Z-120.0 R15.0
N15 G01 X70.0 Z-160
N16 G01 X100 Z2.0
N17 G28 UO WO
N18 M06 T0202
N19 G92 S2500
N20 G96 M04 S200
N21 G70 P9 Q13 F0.01
N22 X100 G40
N23 M09
N24 M30
ADVANTAGES, DISADVANTAGES AND APPLICATIONS OF
CNC SYSTEMS

9.1 ADVANTAGES
 The manufacturing process can be simulated virtually and no need to make a prototype or a model. This
saves time and money.
 Once programmed, these machines can be left and do not require any human intervention, except for
work loading and unloading.
 These machines can manufacture several components to the required accuracy without any fatigue as in
the case of manually operated machines.
 Savings in time that could be achieved with the CNC machines are quite significant.

9.2 DISADVANTAGES

 CNC machines are generally more expensive than manually operated machines.
 The CNC machine operator only needs basic training and skills, enough to supervise several machines.
 Increase in electrical maintenance, high initial investment and high per hour operating costs than the
traditional systems.
 Fewer workers are required to operate CNC machines compared to manually operated machines.
Investment in CNC machines can lead to unemployment.

9.3 APPLICATIONS

 CNC was initially applied to metal working machinery: Mills, Drills, boring
machines, punch presses etchant now expanded to robotics, grinders, welding machinery, EDM's,flame
cutters and also for inspection equipment etc.
 CNC electrical discharge machining (EDM).
 CNC fabrication machines (sheet metal punch press, bending machine, or press brake)