1 Abstract

To have better understanding of part manufacturing on computer numeric control

machine and produce a product through the process this lab is performed. Computer
Numerical Control (CNC) machines has become a necessity for industries in the
production sectors especially for machining repeatable and complex parts, making mold,
cutting and bending of metal etc. Some preliminary commands of M and G code are
studied and applied practically on machine to produce the desired shape / motion of the
tool. Commands used include G01, G02, G03, M03, M04, M05, M06 and coordinate
system selection is studied. The M commands are generally regarding tool properties like
speed, direction etc. while G commands are regarding the movement of tool in XYZ
cartesian space. The basic principle backing CNC is quite trivial. The manual motion X,
Y, Z in three axis CNC milling machines is controlled automatically by linking it to a
program on computer. The program directs the motion of cutting tool in accordance with
the given X, Y, Z coordinates. The safety in these kinds of automated machines is of
paramount importance because a little mistake in code input can led to disastrous results.
Its widespread use is due to its automation and extreme accuracy which is impossible or
extremely difficult in manual operation. Overall, the experiment was interesting,
knowledgeable and of high practical importance.
2. Introduction (Background & Theory)
Non-traditional manufacturing processes is defined as a group of processes that remove
excess material by various techniques involving mechanical, thermal, electrical or
chemical energy or combinations of these energies but do not use a sharp cutting tools as it
needs to be used for traditional manufacturing processes. Extremely hard and brittle
materials are difficult to machine by traditional machining processes such as turning,
drilling, shaping and milling. Non Traditional Machining processes, also called advanced
manufacturing processes, are employed where traditional machining processes are not
feasible, satisfactory or economical due to special reasons. Numerical control (NC) refers
to the automation of machine tools that are operated by abstractly programmed commands
encoded on a storage medium, as opposed to manually controlled or mechanically
automated via cams alone. The first NC machines were built in the 1940s and '50s, based
on existing tools that were modified with motors that moved the controls to follow points
fed into the system on paper tape. These early servomechanisms were rapidly augmented
with analog and digital computers, creating the modem computer numerical controlled
(CNC) machine tools that have revolutionized the design process. In modern CNC
systems, end-to-end component design is highly automated using CAD/CAM programs.
The programs produce a computer file that is interpreted to extract the commands needed
to operate a particular machine, and then loaded into the CNC machines for production.
Since any particular component might require the use of a number of different tools,
modern machines often combine multiple tools into a single cell.
2.Theory The theory section contains the important information about cnc milling
machine. Following concepts are discussed in this section:
• Machining • Milling • CNC milling machine
2.1 CNC Milling Machine The milling machine has always been one of the most versatile
machine tools used in industry. Operations such as milling, contouring, gear cutting,
drilling, boring and reaming are only a few of the many operations which can be
performed on a milling machine. The milling machine can be programmed on three axes-
The X axis controls the table movement left or right.
2.1.1 Programming systems Two types of programming modes the incremental system
and the absolute system are used for CNC both systems have applications in CNC. Most
controls on machine tools today are capable of handling either incremental or absolute
programming.
2.1.2 Incremental Incremental program locations are always given as the distance and
direction from the immediately preceding point. In incremental programming, the G91
command indicates to the computer and MCU (Machine Control Unit) that programming
is in the incremental mode.
2.1.3 Absolute Absolute program locations are always given from a single fixed zero or
origin point. The zero or origin point may be a position on the machine table, such as the
corner of the worktable or at any specific point on the workpiece. In absolute
dimensioning and programming, each point or location on the workpiece is given as a
certain distance from the zero or reference point. In absolute programming, the G90
command indicates to the computer and MCU that the programming is in the absolute
mode.
2.1.4 Codes The most common codes used when programming CNC machines tools are
G-codes (preparatory functions), and M codes (miscellaneous functions). Other codes
such as F, S, D, and T are used for machine functions such as feed, speed, cutter diameter
offset, tool number, etc. G-codes are sometimes called cycle codes because they refer to
some action occurring on the X, Y, and/or Z axis of a machine tool. The G01, G02, and
003 codes move the axes at a controlled feed. • GO1 is used for straight-line movement
(linear interpolation). • G02 (clockwise) and 003 (counter clockwise) are used for arcs and
circles (circular interpolation).
M or miscellaneous codes are used to either turn ON or OFF different functions which
control certain machine tool operations. M-codes are not grouped into categories, although
several codes may control the same type of operations such as M03, M04, and M05 which
control the machine tool spindle. • M03 turns the spindle on clockwise. • M04 turns the
spindle on counter clockwise. • M05 turns the indle off.
Operation Modes in CNC Machine
There are three modes of operation in CNC milling machine Table 3-1 Operation modes
in CNC Machine
MDI SINGLE
AUTO
Manual Data Input
Single Line Data Execution Auto Data Execution
In lab mainly MDI mode is used to make the work part.
3. Observations and Results
1.1
Procedure followed
1. The drawing of the workpiece (car tyre's rim) is showed by the instructor.
2. The parameter such as cutting speed, wire diameter, feeder and the usage of cutting
speed is set up by the instructor and the command is transferred to the CNC milling
machine.
3. The workpiece is setup on the vice.
4. The CNC milling machine start to cut the workpiece to desired shape and it left for a
while until it is finished.
5. The results of the workpiece is discussed.
Step 1.
G01X0Y0F30

The lab performed to learn how to manufacture a part on computer numeric control
machine. This is done by learning how to code and how to feed the code in the machine to
get the desired output. Firstly, the most important thing in CNC is to code it properly. G01
command if used in absolute coordinate system provides the linear motion to the tool. G02
and G03 are used for drawing arcs, circles. The one very important thing is to consider the
thickness of the cutting tool. Then the commands are fed into the interface to get the
desired results. While coding the character 'O' and '0' looks very alike so proper
proofreading and checking of code before pressing enter is a good practice. Secondly, the
machine tool is first referenced to a coordinate system. Overall the experiment, was highly
practical, interesting and knowledgeable as well.
CNC machine has several advantages with emphasis on machine tool applications. When
the production application satisfies the characteristics needed, CNC yields many benefits
over manual production methods. The benefits translate into economic saving for the user
company. Some of the advantages are:
i.
ii.
iii.
iv.
Nonproductive time is reduced through fewer setup, less setup time, less workpiece
handling time, and automatic tool changes
Greater accuracy and repeatability
Low scrap produce
Inspections requirements are reduced