LABORATORY MANUAL

MEC89D
CNC MACHINES AND AUTOMATION
LABORATORY

MEC89D Page 1
Contents

Experiment 1: Preparation of work instruction for the operator along with necessary safety
precautions. ..................................................................................................................................... 3
Experiment 2: Study the constructional details of CNC lathe....................................................... 5
Experiment 3: Study the constructional details of CNC Milling Machine. .................................. 7
Experiment 4: Study the constructional details of ATC................................................................ 9
Experiment 5: Use of software for turning operations on CNC turning center. ......................... 12
Experiment 6: Use of software for milling operations on CNC milling machine Centre. .......... 15
Experiment 7: Develop a part programme which include Plain Turning, Facing, Taper Turning
and Circular Interpolation operations and perform on the CNC turning center. .......................... 18
Experiment 8: Develop a part programme which include the various milling operations and
make the job on CNC milling machine simulator like Plain milling, Slot milling, Contouring and
Pocket milling ............................................................................................................................... 21
Experiment 9: Develop a part programme which includes Canned cycle and make the
simulation on the simulator. .......................................................................................................... 24
Experiment 10: Develop a part programme which includes Subroutine and do the simulation on
the software. .................................................................................................................................. 26

MEC89D Page 2
 Experiment No. 1

Experiment 1: Preparation of work instruction for the operator along

with necessary safety precautions.

Equipment Required: Nil

Learning Objectives: To know about basic instruction those are necessary while performing the
work on CNC machine.

Outline of the Procedure:

• Keep in mind that machinery capable of cutting metal is inherently dangerous.
• Operator should be present at the time of operation of the machine.
• Make sure the work piece is adequately clamped.
• Make sure the cutting tool is adequately clamped for the job being performed
• Always wear safety glasses when around the machine.
• Loose clothing, rings or watches should not be worn when operating machine.
• Use extreme caution while operating the machine as high current is used.

G code Meaning
G00 Rapid traverse
G01 Linear interpolation
G02 Circular interpolation CW
G03 Circular interpolation CCW
G40 Tool radius compensation Cancel
G41 Tool radius compensation Right
G42 Tool radius compensation Left
G50 Start Do loop
G51 Stop Do loop
G70 Inch dimensioning
G71 Metric dimensioning
G80 Canned cycles Cancel
G81 Canned cycles Start
G90 Absolute coordinate system
G91 Incremental coordinate system
G94 Feed rate inch/mint or mm/mint
G95 Feed rate inch/rev. or mm/rev.
G98 Fixed reference
G99 Floating reference
M code Meaning
M00 Programmestop
M01 Optional stop
M02/M30 End of program

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 M03 Spindle start CW
M04 Spindle start CCW
M05 Spindle stop
M06 Tool change
M07 Coolant type 1 ON
M08 Coolant type 2 ON
M09 Coolant OFF
M98 Call Sub-programme
M99 Cancel sub-program

Required Results:
1. Student will be familiarized with the various precautions and work instructions.
2. Knowledge about the Control panel by repetitive usage.
3. Students will be familiarizing with the different Codes.
4. Students will learn about the various codes of CNC which can be used to communicate with
the machine.

Date of Performance Worksheet of the student Registration Number:

……………………. ……………………………
Experiment: Preparation of work instruction for the operator along with necessary safety
precautions.

Observation Table - G and M codes

Sr. No. G code Meaning M code Meaning
1
2
3
4

Learning outcome:

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 4
 Experiment No. 2

Experiment 2: Study the constructional details of CNC lathe.

Equipment Required: CNC lathe machine

Learning Objectives: To understand the special constructional requirement of CNC machines.

Outline of the Procedure:

Present day machine tools are varied in design. We have the well-known conventional machine
such as lathe, milling etc. NC machines are special purpose machines. The selection of a
particular type of machine tool is based upon the overall efficiency and economy of the series it
rends to the factory output.
However in the design of all the machine there are common features e.g operational cutting feed
and speed of motions, gear boxes, constructional elements like slide ways, bed, spindles are quite
similar in these machine.

Important parts of CNC lathe machine:

• Bed/base
• Legs
• Slideways/saddle
• Head stock
• Tail stock
• Tool magazine - Turret/tool post
• Control panel
• Machine control unit MCU
• Machine door
• Servo motor
• Work table
• Spindle/chuck
• Steady rest
• Follower rest
• Feedback system
• Power supply
• Automatic tool changer
• Coolant pipes

Required Results:
• After the completion of the experimental study students will be able to justify the special
constructional requirement of the CNC machine.
• Students get the Knowledge about the various parts and their functioning in CNC
machine.
• Thus the overview and basic function of CNC machine were studied.

MEC89D Page 5
Cautions:
• Clean the instrument machine before using.
• Do not wear loose clothes.
• Do not even try to touch anything unknown.
• Do not put your weight on the instruments.
• Do not lean on to the machine.
• Follow the operative instructions strictly.

Date of Performance Worksheet of the student Registration Number:

……………………. ……………………………
Experiment: Study the constructional details of CNC lathe.

Observation Table

Sr. No. Machine part Function

1
2
3
4

Calculations: Nil
Result and Discussion: Nil
Error Analysis: Nil

Learning outcome:

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 6
 Experiment No. 3

Experiment 3: Study the constructional details of CNC Milling Machine.

Equipment Required: CNC milling machine

Learning Objectives: To understand the special constructional requirement of CNC machines.

Outline of the Procedure:

Present day machine tools are varied in design. We have the well-known conventional machine
such as lathe, milling etc. NC machines are special purpose machine. The selection of a
particular type of machine tool is based upon the overall efficiency and economy of the series it
rends to the factory output.
However in the design of all the machine there are common features e.g operational cutting feed
and speed of motions, gear boxes, constructional elements like slide ways, beds, spindles are
quite similar in these machine.

Important parts of CNC milling machine:

• Bed/base
• Column
• Slideways
• Spindle
• Tool magazine – Drum type
• Control panel
• Machine control unit MCU (swing around type)
• Machine door
• Servo motor
• Work table
• Coolant pipes
• Automatic tool changer
• Oil/air filters
• Power supply
• Air-conditioner
• Chip pan

Required Results:
• After the completion of the experimental study students will be able to justify the special
constructional requirement of the CNC machine.
• Students get the Knowledge about the various parts and their functioning in CNC
machine.
• Thus the overview and basic function of CNC machine were studied

MEC89D Page 7
Cautions:
• Clean the instrument machine before using.
• Do not wear loose clothes.
• Do not even try to touch anything unknown.
• Do not put your weight on the instruments.
• Do not lean on to the machine.
• Follow the operative instructions strictly.

Date of Performance Worksheet of the student Registration Number:

……………………. ……………………………
Experiment: Study the constructional details of CNC Milling Machine.
Observation Table

Sr. No. Machine part Function

1
2
3
4

Calculations: Nil
Result and Discussion: Nil
Error Analysis: Nil

Learning outcome:

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 8
 Experiment No. 4

Experiment 4: Study the constructional details of ATC.

Equipment Required: Automatic Tool Changer

Learning Objectives: To understand the special constructional details of ATC.

Outline of the Procedure:

The CNC machines are designed to perform a number of operations in a single setting of the job.
A number of tools may be required for making a complex part. In a manual machine, the tools
are changed manually whenever required. In a CNC machine, tools are changed through
programme instructions. The tools are fitted in a tool magazine or drum. When a tool needs to be
changed, the drum rotates to an empty position, approaches the old tool and pulls it. Then it
again rotates to position the new tool, fits it and then retracts. This is a typical tool changing
sequence of an automatic tool changer (ATC).
The concept of the ATC is that the range of tools for a specific job shall be made available for
automatic selection and positioning.

Magazine: It is used to store the cutting tools. It provides space for tool storage.

Types of magazine:
1. Turret Head Type: used in drilling and turning machines
2. Drum Type: For holding small number of tools usually not more than 30, Stored on
periphery of drum and tool search speed is faster.
3. Chain Type: For more number of tools (40 or more), tools search speed is less.
As soon as the tool selection command is received by the system, the selected tool comes to a
fixed place known as tool change position. The selected tool is transferred to the spindle from
magazine after the previous tool is transferred to the magazine from spindle. This is called tool
change cycle.

Types of ATC:

MEC89D Page 9
Main parts of ATC system:
• Tool magazine
• Indexable spindle
• Tool changing arm
• Driving motor – servo motor
• Control panel
• Machine control unit
• Cutting tools

Advantages of Automatic Tool Changer

• Lines changed in seconds instead of hours.
• Increase operator safety by changing tools automatically.
• Change tools in seconds for maintenance and repair.
• Increase flexibility.
• Heavy and large multi-tools that are automatically exchanged.

Required Results:
1. After the completion of the experimental study students will be able to justify the special
constructional requirement of the ATC.
2. Students get the Knowledge about the various parts and their functioning in ATC.
3. Thus the overview and basic function of ATC machine were studied.

Cautions:
• Clean the instrument machine before using.
• Do not wear loose clothes.
• Do not even try to touch anything unknown.

MEC89D Page 10
 • Do not put your weight on the instruments.
• Do not lean on to the machine.
• Follow the operative instructions strictly.

Date of Performance Worksheet of the student Registration Number:

……………………. ……………………………
Experiment: Study the constructional details of ATC.

Observation Table

Sr. No. Main part of ATC Function

1
2
3
4

Learning outcome:

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 11
 Experiment No. 5

Experiment 5: Use of software for turning operations on CNC turning

center.

Equipment Required: SINUMERIK 802DT software for CNC turning.

Learning Objectives: To familiarize the Students with the controlling methodology of

SINUMERIK 802DT.

Outline of the Procedure: By following the instruction students will be demonstrate with the
controller software. The procedure is as follows:

MEC89D Page 12
Required Results:
All the controlling panels are familiarized.

Parameter: Nil.
Relationships to be determined: Nil
Graphs/Plots: NA

Cautions:
• Keep in mind that machinery capable of cutting metal is inherently dangerous.
• Operator should be present at the time of operation of the machine.
• Make sure the work piece is adequately clamped.
• Make sure the cutting tool is adequately clamped for the job being performed
• Always wear safety glasses when around the machine.
• Loose clothing, rings or watches should not be worn when operating machine.
• Use extreme caution while operating the machine as high current is used.

Date of Performance Worksheet of the student Registration Number:

……………………. ……………………………
Experiment: Use of software for turning operation on CNC turning center

Diagram:

Program:

MEC89D Page 13
Learning outcome:

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 14
 Experiment No. 6

Experiment 6: Use of software for milling operations on CNC milling

machine Centre.

Equipment Required: Sinumerik 802DM and FanucOiM software for PC.

Learning Objectives: To familiarize the Students with the controlling methodology of

Sinumerik 808DM milling and drilling controller.

Outline of the Procedure: By following the instruction students will be demonstrate with the
controller software. The procedure is a follows.

MEC89D Page 15
Required Results:
All the controlling panels are familiarized.

Parameter: Nil.
Relationships to be determined: Nil
Graphs/Plots: NA

Cautions:
• Keep in mind that machinery capable of cutting metal is inherently dangerous.
• Operator should be present at the time of operation of the machine.
• Make sure the work piece is adequately clamped.
• Make sure the cutting tool is adequately clamped for the job being performed
• Always wear safety glasses when around the machine.
• Loose clothing, rings or watches should not be worn when operating machine.
• Use extreme caution while operating the machine as high current is used.

Date of Performance Worksheet of the student Registration Number:

……………………. ……………………………
Experiment: Use of software for milling operations on CNC milling machine center

Diagram:

MEC89D Page 16
Program:

Learning outcome:

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 17
 Experiment no. 7

Experiment 7: Develop a part programme which include Plain Turning,

Facing, Taper Turning and Circular Interpolation operations and
perform on the CNC turning center.

Equipment Required: Vernier Caliper, Steel rule, Marking instrument

Learning Objectives: To familiarize the students regarding the CNC turning, taper turning,
facing and circular interpolation processes.

Outline of the Procedure:

1. Part to be machined as per the drawing.
2. Measuring and marking of the part.
3. Generating the Part programmefor the below drawing.
4. Preparing machine for the working and ensuring safety precautions.
5. Holding of part.
6. Inserting the part programmefor the machining of work piece.
7. Inspecting the machined work piece.

Required Results:
1. Dimensions obtained should be accurate.
2. Knowledge about the machine and controlling panel by repetitive usage.
3. Obtaining repeatability in dimensional accuracy.

Parameter: as per the drawing.

Relationships to be determined: Nil.
Graphs/Plots: NA

Cautions:
1. Keep in mind that machinery capable of cutting metal is inherently dangerous.
2. Operator should be present at the time of operation of the machine.
3. Make sure the work piece is adequately clamped.
4. Make sure the cutting tool is adequately clamped for the job being performed
5. Always wear safety glasses when around the machine.
6. Loose clothing, rings or watches should not be worn when operating machine.
7. Use extreme caution while operating the machine as high current is used.

MEC89D Page 18
Date of Performance Worksheet of the student Registration Number:
……………………. ……………………………
Experiment: Develop a part programme which include Plain Turning, Facing, Taper
Turning and Circular Interpolation operations and perform on the CNC turning centre.

Diagram:

Program:

MEC89D Page 19
Learning Outcome

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 20
 Experiment No. 8

Experiment 8: Develop a part programme which include the various

milling operations and make the job on CNC milling machine simulator
like Plain milling, Slot milling, Contouring and Pocket milling

Equipment Required: Sinumerik 808D simulation software.

Learning Objectives: To familiarize the students regarding the CNC milling operation.

Outline of the Procedure:

1. Prepare the programme as per drawing.
2. Perform necessary operation before starting the Simulation of milling operation.
3. Inserting the part programme for the machining of work piece.
4. Inspecting the simulation of milling operation on the work piece.

Required Results:
1. Dimensions obtained should be accurate.
2. Knowledge about the machine and controlling panel by repetitive usage.
3. Obtaining repeatability in dimensional accuracy.

Parameter: Nil.
Relationships to be determined: Nil
Graphs/Plots: NA

Cautions:
1. Keep in mind that machinery capable of cutting metal is inherently dangerous.
2. Operator should be present at the time of operation of the machine.
3. Make sure the work piece is adequately clamped.
4. Make sure the cutting tool is adequately clamped for the job being performed
5. Always wear safety glasses when around the machine.
6. Loose clothing, rings or watches should not be worn when operating machine.
7. Use extreme caution while operating the machine as high current is used.

MEC89D Page 21
Date of Performance Worksheet of the student Registration Number:
……………………. ……………………………

Experiment: Develop a part programme which include the various milling operations and make
the job on CNC milling machine simulator like Plain milling, Slot milling, Contouring and
Pocket milling.

Diagram:

Program:

MEC89D Page 22
Learning Outcome:

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 23
 Experiment No. 9

Experiment 9: Develop a part programme which includes Canned cycle

and make the simulation on the simulator.

Equipment Required: CNC simulator for Drilling machine.

Learning Objectives: To familiarize the students regarding the CNC drilling operation by using
canned cycle.

Outline of the Procedure:

1. Prepare the programme as per drawing.
2. Perform necessary operation before starting the Simulation of drilling operation.
3. Inserting the part programme for the machining of work piece.
4. Inspecting the simulation of milling operation on the work piece.

Required Results:
1. Dimensions obtained should be accurate.
2. Knowledge about the machine and controlling panel by repetitive usage.
3. Obtaining repeatability in dimensional accuracy.

Parameter: Nil
Relationships to be determined: Nil.
Graphs/Plots: Nil

Cautions:
1. Keep in mind that machinery capable of cutting metal is inherently dangerous.
2. Operator should be present at the time of operation of the machine.
3. Make sure the work piece is adequately clamped.
4. Make sure the cutting tool is adequately clamped for the job being performed
5. Always wear safety glasses when around the machine.
6. Loose clothing, rings or watches should not be worn when operating machine.
7. Use extreme caution while operating the machine as high current is used.

Observation

Calculations: Nil

Result and Discussion:

Error Analysis:

MEC89D Page 24
Date of Performance Worksheet of the student Registration Number:
……………………. ……………………………
Experiment: Develop a part programme which includes Canned cycle and make the simulation
on the simulator.

PROGRAM Learning Outcome

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 25
 Experiment No. 10

Experiment 10: Develop a part programme which includes Subroutine

and do the simulation on the software.

Equipment Required: Vernier Calliper, Steel rule, Marking instrument.

Learning Objectives: To familiarize the students regarding the CNC turning, taper turning,
facing and circular interpolation processes by using subroutine.

Outline of the Procedure:

1. Part to be machined as per the drawing.
2. Measuring and marking of the part.
3. Generating the Part programme for the below drawing.
4. Preparing machine for the working and ensuring safety precautions.
5. Holding of part.
6. Inserting the part programme for the machining of work piece.
7. Inspecting the machined work piece.

Required Results:
1. Dimensions obtained should be accurate.
2. Knowledge about the machine and controlling panel by repetitive usage.
3. Obtaining repeatability in dimensional accuracy.

Cautions:
1. Keep in mind that machinery capable of cutting metal is inherently dangerous.
2. Operator should be present at the time of operation of the machine.
3. Make sure the work piece is adequately clamped.
4. Make sure the cutting tool is adequately clamped for the job being performed
5. Always wear safety glasses when around the machine.
6. Loose clothing, rings or watches should not be worn when operating machine.
7. Use extreme caution while operating the machine as high current is used.

Date of Performance Worksheet of the student Registration Number:

……………………. ……………………………

Experiment: Develop a part programme which includes Subroutine and do the simulation on the
software.

MEC89D Page 26
 Program Using Subroutine Program without Subroutine

Sr. No. Parameter (Scale from 1-10, 1 for very poor and 10 Marks Max.
excellent) obtained Marks

1 Understanding of the student about the procedure/apparatus 20

2 Observations and analysis including learning outcomes 20
3 Completion of experiment, Discipline and Cleanliness 10
Signature of Faculty 50

MEC89D Page 27