VISVESVARAYA TECHNOLOGICAL UNIVERSITY

Belagavi-590018

AN INTERNSHIP REPORT
ON

“CNC PROGRAMMING AND OPERATION”

Submitted in the partial fulfilment of the requirements for the Award
of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
BY
SUKANTO BISWAS

(1RI21ME404)

UNDER THE GUIDANCE OF

Dr.SURESH C H
[Professor]

Department of Mechanical Engineering

R R Institute of Technology
Affiliated to VTU Belgaum and Approved by AICTE, New Delhi, Recognised by Govt. of
Karnataka,
Accredited by NAAC with ‘A+’
Raja Reddy Layout, Chikkabanavara, Bengaluru – 560 090

2023-24
 R R Institute of Technology
Affiliated to VTU Belgaum and Approved by AICTE, New Delhi, Recognised by Govt. of Karnataka,
Accredited by NAAC with ‘A+’
Raja Reddy Layout, Chikkabanavara, Bengaluru – 560 090

Department of Mechanical Engineering

CERTIFICATE
Certified that the project entitled “CNC PROGRAMMING AND
work
OPERATION” carried out by SUKANTO BISWAS (USN: 1RI21ME404), a
bonafide student of R R Institute of Technology in partial fulfillment for the award of
Bachelor of Engineering / Bachelor of Technology in Mechanical Engineering of the
Visveswaraya Technological University, Belagavi during the year 2023-24. It is certified that
all corrections/suggestions indicated for Internal Assessment have been incorporated in the
Report deposited in the departmental library. The project report has been approved as it
satisfies the academic requirements in respect of Project work prescribed for the said Degree

Signature of Guide Signature of HOD Signature of Principal

(Dr.Suresh CN) (Dr. Channabasavaraj (Dr. Mahendra K V)
Asst. professor, S) Head of Department, Principal RRIT,
Dept. of ME, RRIT Dept, of RRIT Bangalore

External Viva

Name of the Examiners Signature with date

1.
DECLARATION

We SUKANTO BISWAS (USN:-1RI21ME404), students of Eight semester in

Mechanical Engineering, R R Institute of Technology, Chikkabanavara, Bangalore -
560090, declare that the project entitled “CNC PROGRAMMING AND
OPERATION”has been carried out by us and submitted in partial fulfillment of the
course requirements for the award of degree in Bachelor of Engineering in
Mechanical Engineering of Visveswaraya Technological University, Belgaum,
during the academic year 2023-24. The matter embodied in this report has not been
submitted to any other university or institution for the award of any other degree or
diploma.

Date: Mr. SUKANTO

BISWAS
Place:
USN: 1RI21ME404
ACKNOWLEDGEMENT

Any achievement, be it scholastic or otherwise, does not depend solely on

individual efforts but on the guidance, encouragement and cooperation of
intellectuals, elders and friends. A number of personalities, in their own
capacities, have helped us in carrying out this project work. We would like to
take this opportunity to thank them all.
First and foremost we would like to thank Dr. Mahendra K V, Principal, RRIT,
Bangalore, for his moral support towards completion of our project work.
We express our gratitude to Dr. Channabasavaraj S Head, Department of
Mechanical Engineering RRIT, Bangalore who has always been a great source of
inspiration.
We are grateful to our project Coordinators Dr.Suresh CN, Asst professor,
Department of ME, RRIT, Bangalore for the support and encouragement lender
throughout the project work.
We are grateful to the guidance and encouragement given by our guide Prof.
Girish T, Assistant Professor and Guide, Department of Mechanical
Engineering, RRIT, Bangalore, who also has helped us in various stages of
project, optimizing the report and making this project a success.
We also extend our sincere thanks to the teaching and non-teaching faculty of the
Department of Mechanical Engineering, RRIT, Bangalore, who have constantly
supported us throughout the course of our project work.
Last, but not the least, we would like to express our deep sense of thanks to
family and friends for their moral support to improve the project work.

Mr. SUKANTO BISWAS

USN: - 1RI21ME404

5
 TABLE OF CONTENT

S.N
DESCRIPTION PAGES
O
ABSTRACT

1. INTRODUCTION 6
PROGRAMMING FOCUS OF CNC LATHE
2. 7-8

EXAMPLE
3. 9-12

COMPUTER NUMERICAL CONTROL(CNC)

4. 13-16
MACHINING TRENDS FOR 2024
HOW TO IMPROVE CNC MACHINING
5. 17-19
ACCURACY AND EFFICIENCY?

6. CONCLUSION 20

LISTOF FIGURES
FIG PAGE
DESCRIPTION
NO NO.
1. CNC LATHE MACHINE 6
2. PART DIAGRAM 9

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 1. INTRODUCTION:

CNC lathe programming for the use of CNC machine tools is the most
important step. Combine the needs of part processing to complete the
automatic programming of CNC lathes, it is able to flexibly use familiar
program instructions to complete reasonable and efficient processing and
support parts with satisfactory accuracy. Compared with other processing
methods, the machining accuracy of CNC lathe is higher. To master
programming skills, you first need to understand the role of various
instructions, and clarify the effects of the combination of instructions, in
order to complete the preparation and control of the program according to
actual needs. In the operation of CNC lathe, reasonable programming and
correct calling of the program are the most important and core content.

FIGURE1:CNC LATHE

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 2. PROGRAMMING FOCUS OF CNC LATHE

Establish a coordinate system in the programming of CNC lathe

In the CNC lathe programming work, in order to show the movement of

each axis of the lathe better, and to describe its movement in a streamlined
language, a standard coordinate system has gradually formed in this
industry and must be strengthened. The coordinate system in CNC lathe
programming includes: machine coordinate system, working coordinate
system, absolute coordinates and relative coordinates. When the machine is
working,its arm must move. This requires a standard to measure its moving
direction and moving distance. Therefore, a coordinate system can be
established on the machine, called the machine coordinate system. Then
determine the working coordinate system. The zero point of the working
coordinate system of the working parts of the CNC lathe is usually set on
the center line of the main shaft and close to the left and right end faces of
the working original. The last very important step is to determine that the
coordinates of all coordinate points in the coordinate system are calculated
according to the coordinates of the same fixed point. When performing the
main lathe operation, it is necessary to pay attention to distinguish between
absolute coordinates and relative coordinates.

Reasonable use of code

We need to use different code to program the corresponding parts in combination

with the actual situation, so that the efficiency of part processing can be
effectively improved,because the requirements for Kyoto are different

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 for different types of parts, in this way, the working efficiency of the part
processing can be effectively improved. As for the method, the instructions that
need to be used can be considered according to the requirements of the parts.
Since the machining requirements of the lathe are various, the programming
instructions are also very large, because in the process of programming, it is
necessary to be familiar with the characteristics of each instruction, so that
complete part processing tasks perfectly.

Improve accuracy

There must be errors in the design of the parts, the parts are difficult to achieve
100% accuracy, and different parts have different errors, so we must pay
attention to this when using CNC lathes to machine parts.In the past,in the case
of processing, it was not usually combined with all the parts, and all were
processed according to a fixed standard, so that the processed parts would have
a large error and the accuracy was seriously insufficient. We can analyze the
basic dimensions of the part first, then program it, and compensate for the error
with different tools, so that the accuracy of the part will be significantly
improved. In addition, tolerance belts and basic dimensions can be adjusted,
which also increases part accuracy.

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 3. EXAMPLE

Actual case analysis

According to the part programming process shown in the figure, the blank
material is 45 steels. (1) Parts drawing analysis the part is composed of outer
cylindrical surface, outer conical surface, circular arc surface and thread. The
shape is more complicated. The Material is 45 steels, and the blank size is
selected 35mm.

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 Determine the clamping method of the work-piece, since the work-piece is a
solid shaft type part, and the length of the shaft is not too long. Therefore, the
right End face and the outer circle of the work-piece are used 35mm as the
positioning Reference. The work-piece is clamped using a common three-jaw
chuck, and the right end of the work-piece is taken as the origin of the work-
piece coordinate system.

Determine the CNC machining tool, machining process and selection of cutting
amount. According to the shape and processing requirements of the part, select
thefollowingtool:T01bit90 externalturningtool,T02isa5mmwidecutting knife,
T30 is a 60  thread turning tool.

CNC lathe end face machining programming and existing problems.

Turning the end face is the first process of turning, which is especially
important. The quality of the end face will seriously affect the smoothness and
dimensional accuracy of the end face of the machined part. At present, in the
machining and machining of end face machining CNC lathe programs, the
machining end faces are usually processed with the following degrees:
N10 T0101 M03 S400; (T01 is a face turning tool)
N20G00X52M08;(Gross outer diameter is 50mm)
N30G01X0F0.15;(F value is selected by material condition)

Obviously, the above program instructions and formats are error-free, but in the
Actual processing process, the end face of the work-piece obtained by
machining is often rough and the processing effect is not satisfactory.Especially
close to the center of the work-piece, if the amount of backing knife is too large,

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 it is prone to a sickle accident, and sometimes even cause personal injury to the
operator. Therefore, analyzing the causes of this problem, finding solutions and
improving procedures is key.

Solution v=r w/1000=2 r n/1000(1). v is the cutting line speed (m\min), D is the
diameter of the machined part, n is the spindle speed. The cutting end face is
proportional to the diameter.When the end face is rough,the linear velocity will
decrease, and the cutting speed of the tool will be inconsistent with the given
spindle speed of the lathe, which will result in a dirty surface of the work-piece,
especially near the center position. The end face is processed by the above
procedure, and the surface roughness of the work-piece cannot be ignored.

When solving this problem, consider using the constant line speed to control the
G96 command. This command is commonly used in surface treatments such as
taper, end face, and arc in lathe machining. The linear velocity of the spindle
specified by S in the G96 command is in m/min. This command is generally
used when the section of the turning disc part or the diameter of the part varies
greatly, so that the diameter can be changed, but the linear speed of the main
shaft does not change, so that the cutting speed is constant, and the surface
roughness of the work-piece remains the Same. . It is known from: n=1000 V/ d
that the smaller d is, the larger n is. Therefore, we have to limit the maximum
linear velocity to the spindle. Expressed with G50 S. Many beginners are
unfamiliar with the G96 instructions, or the understanding is not thorough
enough, so that it is rarely considered to solve such problems with this
instruction.

Effective use of instruction programming must understand the meaning of the

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 G96 command. The so-called constant line speed control mainly means that the
line speed behind S can be kept constant. As the position of the tool changes,the
line speed can be used to calculate the spindle speed. G96 is executed. The
constant line speed control of the main motor realizes constant, stable and
maintenance cutting rate of the work-piece processing process by changing the
rotation speed to ensure the machining accuracy. The G96 needs to use G50 to
set the maximum spindle speed limit. When the weak tangential speed is
constant, it will change with the size of the machined parts. The smaller the
diameter, the easier the spindle speed will be too large, resulting in an accident.
So the program in question can be changed to the following program:

N10G50S2000;(Indicatesthatthemaximumspeedlimitis2000r/min)
N20 G96 M03 S200 T0101; (Indicates that the cutting point line speed control
is less than 200m/min)
N30G00X55 Z0;
N40G01X0F200;(Fvalueisselectedbymaterialcondition)
N50 G97 S400; (The speed is the spindle speed after the constant line speed is
canceled, and the system starts the default G97 program)

When the degree of use of the tool is approaching the center of the workpiece,
theradial feedrateisloweredtoimprovethesurface finish of the machinedpart near
the center of the work-piece. If the spindle speed is constant, the required
precision processing can be completed according to the requirements of the part
processing design, and the F value in the program can be adjusted according to
the processing experience, so as to achieve the desired processing effect.

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 4 Computer Numerical Control (CNC) Machining
Trends for 2024

Manufacturing as a Service Will Increase

Manufacturing as a service (MaaS) has moved into the CNC industry over the past few years,
but it will continue to grow in 2024. MaaS accomplishes manufacturing by using networked
resources. The cost of maintaining and operating the CNC equipment is spread across
subscribers who need the service.

The benefit of MaaS is that companies can be agile, more productive, and save expenses.
COVID-19’s impact will spur companies to look for more supply chain networks via MaaS.
Companies will want to avoid the supply chain disruption they experienced during the
pandemic. Having a more extensive supply chain networkwill future-proof them for whatever
comes next.

4.25-axisand 6-axisMachineUseWillContinuetoExpand

5-axis machines have become more and more cost-effective for factories to use. Its ability to
seamlessly rotate around the X and Y axesis verypopular. However, the6- axis machine
emerged in 2019, and added an additional rotation around the Z-axis, improving efficiency
and speed. This increase leads to faster cut times and more products made in a shorter time
frame. A 6-axis CNC milling machine can decrease cutting time by up to 75%. Zimmerman
Milling created an incredible video that demonstrates the difference between a 5-axis and 6-
axis CNC mill.

Increased Uptime and Longer Life with IoT DONE

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 Hitachi’s recent article argues that IoT use has accelerated due to greater need this year with
social distancing and mask-wearing. The ability to monitorremotely, and to use sensors to
evaluate where in the lifecycle a machine is, became even more critical during the pandemic.

As more sensors have been applied to machines throughout the machine shop floor, their
application has extended. It’s now possible to apply sensors to drill presses, milling and
turning machines, lathes, and more. These sensors, in turn, regularly monitor the various
parts of the machine, providing a heavy data stream of information. This information can
facilitate predictive maintenance.

CNC machines, like any machine, require regular upkeep, as the gears and belts turn.
Historically, equipment has been kept on a regular maintenance schedule; however, when an
unanticipated break occurs, a factory can shut down for hours, as
aspecialistoftenhastobebroughtinfromfaraway.TheIoTsensorscanameliorate some of this
downtime.

For example, the sensors can evaluate vibrations and temperature discrepanciesthat would
indicate the equipment is nearing the end of its use. Downtime can be planned, and factories
can increase their CNC machine efficiency by fixing equipment right before it causes more
problems. Long term, this will extend the lifeof the equipment and lower downtime.
Predictive maintenance allows real-time analysis of the factory floor.

This is only one example of how CNC machines and IoT sensors can assist in factories. More will
come as 5G makes its way into factories.

Digital Twins using VR

Digital twins will become more and more common in 2021. As 2020 came to an end,
Hexagon’s Manufacturing Intelligence division released enhanced NCSimulSoftware. NC
Simul software virtually builds a digital twin so that the real-lifemachine can avoid errors and
decrease setup times.

This new enhancement allows machinists to identify and avoid the 5-axis singularity point
and there by optimizes the NC programming.This has never been possible

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 before. Why does it matter if the CNC machine can avoid the 5-axis singularitypoint? If the
tool vibrates, it can behave irregularly as it nears the singularity point, creating chatter marks
on the component being manufactured. Creating a smooth surface is especially critical with
components such as turbine blades for the aerospace industry.

The ability to predict the 5-axis singularity point will allow programs to be improved by
modifying cutting strategy parameters. The result of this? Manufacturers canmore accurately
complete jobs the first time. This saves time, money, manpower, and supplies.

More Robots and Cobots on the Machine Shop Floor

Robots and cobots (collaborative robots) have been used in CNC machining in the past;
especially as the labour force declines, robots have mitigated some of thestrain felt.
Collaborative robots are effective and versatile and specifically designedto work with
humans.

As machine learning accelerates and continues to be incorporated into the programming,

cobots will be able to accomplish more. Hopefully, this will decrease accidents in the factory.
Humans, however, will still need to assist with running and maintaining the cobots. This
leads us to the next prediction for 2021.

Greater Need for Skilled Workers

There’s already a shortage of skilled workers on CNC machining floors.

Deloitte’s 2021 Manufacturing Industry Report states, “as robots, cobots, and other forms of
automation grow in the production environment, the need for a workforce to manage and
interact with these technologies also increases. These “middle-skill” roles require technical
expertise and regular upskilling.” 28% of the executives surveyed by Deloitte said that
upskilling and building new skills are the largest and hardest challenge they face.
Additionally, are cent McKinseysurvey of manufacturers found that 90% of those surveyed
planned on investing in talent.

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 Smart manufacturing has entered a brand-new phase. In 2021, manufacturers will expand
their tech in ways that empower employees to achieve greater productivity and to improve
their decision-making.

Subsequently,this year will focus on connected workers.

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 5. How to Improve CNC Machining Accuracy and Efficiency?

We all know that a good CNC machine can machining a workpiece with high

accuracy. Besides this, we also consider the other aspects, such as the reasonable

machining route setting, tool selection and correct installation, reasonable selection

of cutting amount, programming skills andrapidcontrol, etc.Then it can improve the

CNC machining accuracy and efficiency.

Programming skills
CNC programming is the most basic work of CNC machining. An experienced

programmer who knows how to write a good programming. He can use the intrinsic

program cleverly, reduce the cumulative error of the CNC system, and use the main

program and subroutine flexibility.

In the process of complex mold processing, we generally use a multi-piece form of

processing. If there are several same shapes, we should use the relationship between the

main program and the subprogram, and use the subroutine repeatedly in the main

program until the machining is completed. Then we can ensure the consistency of the

processing dimensions and improve the processing efficiency.

Incrementalcomputing,alsoknownasincrementalcomputation,isasoftware feature

which, whenever a piece of data changes, attempts to save time by only recomputing those

outputs which depend on the changed data.We often use incremental computing to

write a program, but it can produce a certain cumulative errorof continuous

execution of multi-segment programs. Now we try to absolute computing to write a

program,which can reduce the cumulative error of the CNC system and ensure the

processing accuracy.

What is machining accuracy?

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 To explain this concept in easy terms, accuracy refers to the difference between the actual

measurement and measurement from your system.If the difference between the two

is extremely less, then the accuracy of that measurement is too high.

Adjust the process system

Trial cutting-Adjust the blade extension according to the material,and then use the

same material to be used in your project to perform trial cutting. We often use it for

single-piece small batch production.

Adjustment method-We can know the size after adjust the relative positions of the

machine tool, fixture, workpiece and tool. We often use it for mass production.

Reducing the measurement errors

Improve the rotation accuracy of the bearing.

Choose high precision cylindrical roller bearings,multi-oil wedge bearing and

hydrostatic bearings.

Improving the accuracy of the parts with the bearing

Improve the machining accuracy of the box support hole and the spindleshaft journal.

Measure and adjust the radial run out range of the corresponding part to reduce the error

Reducing toolwear
Tool regrinding to extend the life of their tools.

Use special cutting oil for sufficient lubrication Choose the

correct lathe tools for machining

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 Reducing the thermal deformation of the process system
The thermal error of the machine tool is dependent on cutting speed,feed, machining

time and environmental temperature.

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6. CONCLUSION

Reasonable programming and correct calling of programs in CNC

machine tools are the most important and core content. Even if the
programming procedure is correct, the lack of experience will still result
in an unsatisfactory processing result, therefore, CNC lathes not only
greatly reduce the burden on the staff, but also improve work efficiency
and part accuracy. When programming and machining CNC lathes, we
must First establish a coordinate system, plan each part, and then use
different programming instructions according to the size and precision
required by different parts to meet the needs of various parts.
7. References

[1] Z.H.Yu: Thoughts on the Programming and Operation of CNC Lathe

[J], (2015)No.11,p: 299. (In Chinese).

[2] X.Y.Yang,C.L.Cao:CNC lathe programming processing scheme

determination and detail processing in programming(Jiangxi Chemical
Industry) [J], (2014) No.3,p:12-14. (In Chinese).

[3] Quwain, X.W.Xu:Discussion on the Simple Skills of CNC Lathe

Programming [J], (2011)No.8, p: 178. (In Chinese).

[4] G.X.Ren: CNC lathe machining process and programming

operation(Beijing: Mechanical Technology Press) [M].

[5] J.C.Mo: Discussion on the Programming Skills of CNC

Lathe(Guangdong Education) [J],(2015)No.4,p:116-117.(In Chinese).