COLLEGE NAME: - GOVERNMENT POLYTECHNIC RAJKOT&

NEAR AJI DAM, BHAVANAGAR ROAD,

RAJKOT 360 003.

PROJECT TITLE:- ALL PROBLEMS RELATED TO POWER CUTT-OFF

DURING WORKING ON CNC MACHINE

NAME:- SHAH AMAN J.

E.NO:- 096200319012

DIV:- MECHANICAL-A

GROUP:- AB-14

DATE:- 14-05-2012
 KRISHNA INDUSTRY
DATE-11/05/2012

PLACE-RAJKOT

To WHOM SO EVER IT MAY CONCERN.

This is certifying that group AB-14 diploma mechanical final

year students of government polytechnic Rajkot and near aji dam,
bhavanagarroad. They have done project work in the company on “CNC
MACHINE”. They are good team member and good attitude during working
period. They were effort regularly and find its problem solution. That’s
solution more benefit’s our company. Our company had Problem in CNC
MACHINE DURING POWER CUTT-OFF then after that’s problem
solution completed in ten week. These candidates were worked hard and
censoriously in this project.
GROUP MEMBER

 Goswami Sagar .
 Shah Aman .
 VadherVaibhav .
 Gosai Rahul .
 Gohel Abhishek.
 Darji Jimit.

SO, OUR COMPANY SINCEREALY THANK’S THIS GROUP...

SINGETURE OF SIGNETURE OF
M.D H.O.D
 GUJARAT TECHNOLOGICAL UNIVERSITY
CERTIFICATE

This is to Certify that the IDP project part2on

“ALL PROBLEMS RELATED TO POWER CUTT-OFF
DURING WORKING ON CNC MACHINE“

Have been submitted by,

GOSWAMI SAGAR
Of 6thsem. mechanical student of Government
Polytechnic Rajkot.
Of Gujarat Technological University
In year 2012-13 under my supervision and my
guidance.

Guide H.O.D. of
Mechanical-engineering
department
 ACKNOWLEDGEMENT

 The present of this report give me the feeling. As the

frontier toward achieving a Diploma Mechanical
Engineering. The activity of going through industrials
orientation has bridged the gap between the academics
and practical real life work for me. It has prepared to
apply my self to become good. It professional, naturally, it
requires lot of people support to me.

 I sincerely thank Mechanical department for the

academic advancement, it has provided to me during last
Semester and finally provide me and opportunity for
project work.

 I thank Prof. Mr. K.L.MAKWANA in Government

Polytechnic Rajkot for their support through for project.

 Last but not the list, We would like to thank lab.

Teachers, friends and my parent who had helped me
indirectly through out project duration and have been the
source of Encouragement.
 ABSTRACT

CNC IS MOST EFECTIVE MACHINE FOR PRECISION AND

MASS PRODUCTION.
IT IS BLESSING FOR MASS PRODUCTION INDUSTRIES. WITH
HELP THIS MACHINE WE PRODUCE PARTS WITH HIGH
ACCURACY.
IN THIS REPORT, WE HAVE TRIED TO BRING INTO FOCUS
IMPROVES EFICIENCY OF CNC MACHINES.IT IS A NECESSARY
FOR INDUSTRIES.WE ALSO TRIED TO BRING ADVANCE
TECHNOLOGY FOUND OUT NOW A DAY FOR REDUCING
FAULT DURING OPERATION ON CNC MACHINE LIKE POWER
CUTT-OFF BY BEST AFFORT , WE TRY TO FOCUS NECESITY OF
SUBJECT . WE HOPE THAT OUR REPORT IS ONE STEP AHEAD
IN THIS DIRECTION.
 INDEX

NO PARTICULAR PAGE
NO
01 Introduction 07
02 CHAPTER-1 09
03 INDUSTRIES INTRODUCTION 09
04 PROBLEM INDENTIFICATION 10
05 DEFINITION 12
06 CHAPTER-3 14
07 THE WHOLE INDUSTRIAL 14
PROBLEM
08 PROBLEM STUDY 15
09 CHAPTER-4 16
10 SOLUTION OUTLINE 16
11 CHAPTER-5 18
12 SOLUTION 18
13 DESCRIPTION/SPECIFICATION 22
14 CNC MACHINE SPECIFICATION 24
15 CONCLUSION 25
16 APPENDICES 26
17 EXPECTED BENEFITS 27
18 PHOTOGRAPHS 28
19 REFERANCES
20 LOG BOOK
21 SCHEDULE OF VISITING IN
INDUSTRY
 INTRODUCTION

INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM

STUDENT PARTICULARS

FIRST NAME GOSWAMI SAGAR

LAST NAME GOSWAMI PRASHANTBHAI
MOBILE NO. 1 9173308859 2
EMAIL goswamisaga25@gmail.com

COLLEGE GOVERNMENT POLYTECHNIC RAJKOT

BHAVANGAR ROAD, NR,AJI DAM
RAJKOT -360002
PH-0281-2387391

BRANCH MECHANICAL ENGG.- MORNING

SEMESTER 6th YEA 2012
TEAM NAME AB-14 EN NO:-096200319001
SIGNATURE
OF STUDENT

INDUSTRY PARTICULARS

---------------INDUSTRY COORDINATOR---------------
NAME ABHISHEK GOSWAMI
SHARDANAGAR 1, NEAR SNK SCHOOL,
UNIVERSITY ROAD.
CONTACT RAJKOT,360002
RAJKOT-360002
ADDRESS
MOBILE NO. 9998985451
EMAIL mascotrajkot@gmail.com

---------------INDUSTRY---------------
NAME KRISHNA INDUSTRY
“KRISHNA INDUSTRY”, BEHIND PARINE FURNITURE,
GONDAL ROAD.
ADDRESS RAJKOT-360002

CONTACT OFFIC N/A MOBI 9998985451

NAME OF INDUSTRIAL SHAPAR
COMPANY
LOGO

2nd Floor, ACPC Building, L. D. College of Engineering Campus, Navrangpura, Ahmedabad,(Gujarat)India-

380015.Phone:91-79-26300699,Email:gtu_innovation_council@gtu.edu.in M:VI9909959336
INDUSTRY DEFINED PROBLEM STATEMENT FORM

TITLE OF PROBLEM/PROJECT

“ALL PROBLEMS RELATED TO POWER CUT-OFF DURING WORKING ON

CNC MACHINE“

INDUSTRIES AT RAJKOT.

DISCIPLI MECHANICAL

PROBLEM SUMMARY

 The problem summery may be a concise description of the industry related

technical issues which can state the problem, which the student has found out
while visiting the industry
DETAILED DESCRIPTION OF PROBLEM

 The problem statement has to be well defined in 3-5 pages with detailed
facts and figures as and when possible. The description can have
figures/inputs from floor persons from industries/ parameters related to
specific domain of technology.
EXPECTED OUTCOME

 The students while interacting with industry persons have to note

down the expected out comes (in 1-2 page) from that particular industry due
to the proposed innovation either in product or processes. This will gauge the
industrial needs and students progress while working on the final year project.
OTHER DESCRIPTION (IF ANY)

 The students are advised to do some literature research related

to the corresponding problem/innovation both before and after visiting the
industry/MSME during summer vacation. They have to suggest some
suggestions about the issues based on literature research of corresponding
problems/projects in feasible cases.

The format of documentation may be slightly modified as per the need of

specific branch. For example in the documentation of any industrial waste, one
may have to state. (Composition of waste, type of waste (Solid, Liquid, Gas,
Semi-Solid), quantity of waste etc.

The problem/project reports are scouted from Industries have to be submitted

to Departmental HODs of corresponding GTU College in softcopy. GTU will
evaluate them in August 2011 as a part of Curriculum.
 CHAPTER-1

INDUSTRIES INTRODUCTION

1. KRISHANA INDUSTRIES,

MACHINE & TYPE CNCDX 200and use of the job clamp X, Y, Z axis
and drill.

PRODUCT MANU. BEARING OF COMPUTER ACCESERIES

PRODUCTION 10000 PARTS/MONTH

RATE
WESTAGE RATE 24 PARTS/MONTH (IN TURNING PROCESS)

SIZE OF UNIT SMALL SCALE

 Bhavani industry : - punching process, forging, tata

motors gear mechanism.

 Jyoticnc: - manufacturing vmc, cnc, and hmc

machines.

 chaitany industry :-manufacturing and assembly

lathe machines.
 CHAPTER-2
PROBLEM INDENTIFICATION

KRISHNA INDUSTRY

As a part of 6th Semester IDP PROJECT PART 1 in

which problem identification in industry, we have
visited KRISHNA INDUSTRY Rajkot for the problems
occurring in the CNC MACHINE DURING POWER
CUTT-OFF. So fault identification in CNC MACHINE we
have taken as part of project -1. As a part of 6 th
semester we are trying to solve this problem in IDP
PROJECT PART 2.
JYOTICNC MATODA GIDC

PADMAVATI DIESEL ENGINE:-

 nozzle problem

 lubrication problem

 heating problem

 valve choke up

DEFINITION
CNC Machining Intro

CNC machining is short for computer numerical

control machining. It refers to a computer controller
that reads code and instructions and drives a
machining tool in order to make a product according
to specific requirements. Imagine a robot that can
make several different products based on a specific
set of instructions given to it.

CNC machining is a tool or a device that is critical to

an industrial system. It is used to aid the design and
the manufacturing of a product. These CNC
machines are programmable to meet the specific
requirements of users. They can run overnight and
can continue to work without any intervention
whatsoever. You’ll be able to sleep at night and leave
the machine to do the work for you. Going further,
error detection software has been developed to notify
users if something has gone wrong in any situation.
You’ll know when something goes wrong and you
will be able to correct any errors as soon as possible.

CNC machines are controlled from a software

environment. This is usually a CAM software
package or a computer aided manufacturing software
package. Through this kind of software, paperwork is
reduced. There is no need to put the design on paper.
Instead, after the object or product is designed using
the software, it is sent straight to manufacturing.
If you’ve heard the term paperless organization then
this is one concrete example.

CNC machining allowed manufacturers to do curve

cuts as easy as straight cuts. Three dimensional
 structures were also as easy to build with the
introduction of CNC machining into the industry.

Human intervention in the making of products was

reduced dramatically. Their intervention on several
manufacture A side from the ease of use that CNC
machining has given its users, the consistency and
the quality of the output has also been improved.
With this technology, the likelihood of errors has
been dramatically reduced.
 CHAPTER-3

THE WHOLE INDUSTRIAL PROBLEM

 TOOL CHANGER ATC PROBLEM

 DC MOTOR PROBLEMS
 POWER SUPPLY PROBLEM
 DOOR INTER LOCK CIRCUIT PROBLEM
 POWER UP PROBLEM
 POWER CUTT-OFF PROBLEM
 PROBLEM STUDY

 Cnc machine is basically depend on our

input data like depth of cut, angles etc.
 It reads data one by one for example it
reads first data of depth of cut, then it complete
the operation.
 now when the power has gone then cnc
machine stops its working in current position.
 when power arrived ,its not remember last
data…so its start working from starting again.
 so its waste of time ,material and power. so
its effect on economy and production rate of
factory.
 CHAPTER-4
The Problem solution Outline ( with
circuit , analysis the Industry.)

SOLUTION OUTLINE
1. COUNTER BALANCE

This would be a system in which the moving z-axis weight is counter-

balanced by an equal weight placed on the opposite side of the gantry
connected such that when the router moves up, the counter-weight
moves down and vice-versa.

 Advantages:

1. Less wear on Z-axis ball screws.

2. Equal power required to move the z axis up vs down. Therefore, equal

speed and acceleration potential for up vs. down motion.
2. LOOK AHEAD FUNCTION

If WE mill 3D surfaces from CAD/CAM data, look-ahead

may be the single greatest productivity feature your CNC
control can (or may not) offer. Look-ahead for 3D milling
may be referred to as "automatic feed rate override,"
"geometric intelligence" or other things, but the bottom
line is that look-ahead can improve your overall milling
productivity dramatically.
 CHAPTER-5

SOLUTION

1. COUNTER BALANCE

High performance CNC micro machining centers used to

fabricate small high precision parts from plastics, metals,
glass, and ceramics require extreme control of forces and
speeds. Micro machining equipment manufacturers with
the need for tight control of small incremental
movements along with low forces, high speeds and
extreme levels of repeatability and resolution are
discovering the benefits of air bearing technology used to
provide zero friction counterbalancing. A counterbalance
removes the effect of vertical masses in the system and
protects from damage in power- off situations. A
counterbalance system is often used to reduce the weight
and drag inherent in the linear motor driver and
associated linear bearing guide systems; however
mechanical counterbalance devices often exhibit more
friction than is ideal. a counterbalance device allows the
use of lower cost and smaller linear motor drives which
helps to reduce heat and the adverse effects of differing
thermal expansion rates.
Key Applications:

Counterbalancing and safety for vertically positioned

linear driven motor masses, filament & wire tensioning,
positioning  and manipulating optics, liquids, delicate
devices, super sensitive force control, , Measuring weight,
creep, tensile strength and calibration.

Counter balance
2. LOOK AHEAD FUNCTION

• FOR PREVENT THIS PROBLEM WE USE COUNTER

BALANCING AS MECHANICAL SIDE BUT FOR MORE
ACCURACY WE ASLO USE A LOOK AHEAD FUNCTION
FROM THE SOFTWARE SIDE.

How It Works

• Look-ahead does just what its name implies; it looks

ahead of the data it needs to mill at any given
moment to verify that the CNC will be able to handle
the demands the path will put on the machine. If the
data check reveals that there may be a problem, feed
rates for intermediate points along the contour are
added, adjusting the feed rate downward to the
maximum feed rate that will still yield an accurate
surface.

• Look-ahead must evaluate the data ahead in several

different ways. The most obvious check is whether
the next point location deviates from the current
path. In the simplest case, if the next point simply
extends the current path further along a line and
there is no deviation, no deceleration is required.
Likewise, if the next point is at a 90-degree deviation
from the current path, the axis must be stopped
completely.
• With today's dense data for 3D forms, the overall
problem is not so simple. Milling data points that are
only 0.004 inch apart at 400 imp feed rates can really
get a CNC into trouble. To stop from 400 imp, a
typical machine might require 0.4 inch.

• This means that 100 blocks of CNC data must be

checked to foresee vector changes. Each point and
each combination of points between the current
point and the maximum deceleration distance for
each axis must be checked. Each tiny move between
here and there may need a different feed rate to be
calculated to press the performance envelope for
speed while maintaining the part integrity. No set
rule exists to say that X number of blocks is enough
to look ahead. The amount of look-ahead required is
dynamic, changing with different part details,
different accuracy requirements, different machine
performance and so on. However complex this data
evaluation is, though, the faster and more thorough
it is, the better the CNC can walk the fine line of
performance and accuracy. In any case, it must all
work transparently for the operator, without any
penalty of time or effort. The operator should not be
able to cause any violation through program input or
operational oversight.
 Description/specification of process of
Resources & machine used for
solution.

TYPES OF CNC MACHINE

CNC Mills

 These machining centers use computer controls to cut

different materials. They are able to translate programs
consisting of specific number and letters to move the
spindle to various locations and depths. Many use G
code, which is a standardized programming language
that all CNC machines understand, while others use
proprietary languages created by their manufacturers.
These proprietary languages are often simpler than G
code, but not transferable to other machines.

CNC Lathes

 Lathes are machines that cut metal that is often turning

at fast speeds. CNC lathes are able to make fast, precision
cuts using index able tools and drills with complicated
programs for parts that normally cannot be cut on
manual lathes. These machines often include 12 tool
holders and coolant pumps to cut down on tool wear.
CNC lathes have similar control specifications and can
read G code as well as the manufacturer's proprietary
programming language.
 CNC Grinders

 Grinding metal is a process that uses a coated wheel that

slowly removes metal to create a part. Through the years,
grinding was done on a manual machine, but with the
advent of CNC technology, the grinding process has
advanced dramatically. Enter the program, which
includes the various passes that the wheel will make, and
hit start. It is one of the easiest types of CNC machines to
work with as they often only contain a single grinding
wheel.
 CNC Lathe machine with detailed
specifications

Item Unit Specifications

Max. swing over bed mm 360
swing over carriage mm 205
Max. length of work
mm 750  1000  1500
piece
Spindle bore mm 52
Taper of spindle bore rpm No.6
Range of spindle speed
mm/min 52--1210
,class 16
Fast axial movement
speed 5000 
mm/min
X axis, 6000
Z axis
Work feed speed
3—2500
X axis, mm
6--3000
Z axis
Min setting speed
0.005
 X axis,  
0.010
Z axis
Rotary Stations of tool
  4(standard)
carrier
Travel of tailstock
  150mm
quill         (mm)

Taper of tailstock quill   Mohs 5#

Motor power kw 4kw

GSK (or Siemens and
CNC system  
Fanuc)
Machine total weight kg 1350
Packing size (mm) mm 2025*1005*1466(750)
 EXPECTED BENEFITS

 To decrease Production Cost.

 To save Production Time.

 To Prevent Fail machining tool.

 To Increase Safety in Industry.

 To Increase Production Rate and Quality.

 These are no life damage in running operation.

 We can increase the life of turning tool.

 The running cost of industries can be decrease.

PHOTOGRAPHS OF DIFFERENT CNC
MACHINE PARTS

Automatic Pallet Changer

Automatic Tool Changer

CNC Console

Linear Motion Guide ways

 REFERANCES

http://www.machinetoolhelp.com

 Devices
 Feed
 Use of guiding bushings
 Material
 Condition of machine
 Rigidity of set-up
 Finish Required
 Installation of parts
 Machine specification
 Problem trouble shooting

http://www.carmon.it/home_en.htm

 COOLANTS/CUTTING FLUIDS/OIL
 PROBLEMS
 LOG BOOK

DATE INDUSTRIES

18-8-2011 BHAVANI INDUSTRIES

22-8-2011 KRISHNA INDUSTRIES

13-9-2011 CHAITANYA MACHINE TOOLS IND.

27-9-2011 RUPKALA GEAR IND.

09-10-2011 JYOTI CNC LTD.

17-10-2011 K.S.DISEL IND

At End, we select project in KRISHNA

INDUSTRIES. We have visited daily 3 hours in
industry. We have visited 4 weeks in industry.
SCHEDULE OF VISITING IN INDUSTRY

DATE WORK STUDENT NAME

21/08/2011 PERMISSION OF ALL MEMBER

COMPANY
22/08/2011 DISCUSS WITH GOSWAMI SAGAR
H.R.STAFF SHAH AMAN
23/08/2011 COLLECTION OF GOSAI RAHUL
INFORMATION DARJI JIMIT
VAIBHAV VADHER
25/08/2011 VISITING RAW GOSWAMI SAGAR
MATERIAL GOHEL ABHISHEK
DEPARTMENT
28/08/2011 VISITING VADHER VAIBHAV
PRODUCTION GOSAI RAHUL
DEPARTMENT
30/08/2011 MACHINARY SHAH AMAN
INFORMATION DARJI JIMIT
GOSWAMISAGAR
GOHEL ABHISHEK
04/09/2011 COLLECTION OF VADHER VAIBHAV
INFORMATION GOSIA RAHUL
DATA,IMAGES
05/09/2011 PRODUCT DARJI JIMIT
INSPECTION SHAH AMAN
DEPARTMENT
06/09/2011 DISCUSS WITH SIR GOSWAMI SAGAR
11/09/2011 SEARCHING ON VADHER VAIBHAV
NET GOSAI RAHUL
20/09/2011 PREPARATION OF GOHEL ABHISHEK
PROJECT SHAH AMAN
SUMMARY
11/11/2011 VISIT OF ALL MEMBER
COMPANY FOR
PROJECT FILE
15/11/2011 LAYOUT OF VADHER VAIBHAV
COMPANY DARJI JIMIT

16/11/2011 DISCUSS WITH ALL MEMBER

GROUP MEMBER
20/11/2011 GO TO COMPANY SHAH AMAN
AND CAPTURING GOSWAMI SAGAR
VIDEO &PHOTO
PROJECT REPORT SEMESTER V