MECHANICAL ENGINEERING DEPARTMENT JF503 MANUFACTURING WORKSHOP PRACTICE 2

STUDENT NAME NUR NIRDA BINTI YUSUF FARAH FARZANA BINTI ROSLAN MATRIX NUMBER 03DTP11F1040 03DTP11F1047

INTRODUCTION OF CNC LATHE A metal lathe or metal working lathe is a large class of lathes designed for

precisely machining relatively hard materials. They were originally designed to machine metals; however, with the advent of plastics and other materials, and with their inherent versatility, they are used in a wide range of applications, and a broad range of materials. In machining jargon, where the larger context is already understood, they are usually simply called lathes, or else referred to by more-specific subtype names (toolroom lathe, turret lathe, etc.). These rigid machine tools remove material from a rotating workpiece via the (typically linear) movements of various cutting tools, such as tool bits and drill bits. Numerical control or NC, or computer numerical control CNC refers to the automation of machine tools which are operated by programmed commands that are encoded on a storage medium. The cutters are of many different kinds and shapes. The work is fed against the teeth of the cutter, while the feed motion is longitudinal, transverse or vertical, depending on the type of milling machine and the nature of the work. The program is put into the lathe or milling machine and the machine is then ready for production. Some machined components will generally require a number of different tooling applications such as drilling, reaming and tapping etc, and most modern machines will combine tools within a single cell. This cell will move or rotate to apply the required tooling application, and this will also be controlled by the CNC system. With todays modern and complex machines, the machined part or workpiece can be moved from machine to machine automatically with the use of computer controlled robots, or human intervention, but in either case the steps needed to produce any part is highly automated and the finished part will closely match the CAD design. CNC machines were first built in the 1940s and were programmed by using paper tape with holes punched into it at specific points. These early systems were soon overtaken with the augmentation of analogue and digital computers. There is a range of CNC systems that can be fitted to previously manually operate machine tools, and these systems provide a selection of features which can significantly improve the productivity of the machine and the quality of the work that is produced.

ADVANTAGE 1. CNC machines can be used continuously 24 hours a day, 365 days a year and only need to be switched off for occasional maintenance. 2. CNC machines are programmed with a design which can then be manufactured hundreds or even thousands of times. Each manufactured product will be exactly the same. 3. Less skilled/trained people can operate CNCs unlike manual lathes / milling machines etc..which need skilled engineers. 4. CNC machines can be updated by improving the software used to drive the machines 5. Training in the use of CNCs is available through the use of virtual software. This is software that allows the operator to practice using the CNC machine on the screen of a computer. The software is similar to a computer game. 6. CNC machines can be programmed by advanced design software such as Pro/DESKTOP, enabling the manufacture of products that cannot be made by manual machines, even those used by skilled designers / engineers. 7. Modern design software allows the designer to simulate the manufacture of his/her idea. There is no need to make a prototype or a model. This saves time and money. 8. One person can supervise many CNC machines as once they are programmed they can usually be left to work by themselves. Sometimes only the cutting tools need replacing occasionally. 9. A skilled engineer can make the same component many times. However, if each component is carefully studied, each one will vary slightly. A CNC machine will manufacture each component as an exact match.

DISADVANTAGES 1. CNC machines are more expensive than manually operated machines, although costs are slowly coming down. 2. The CNC machine operator only needs basic training and skills, enough to supervise several machines. In years gone by, engineers needed years of training to operate centre lathes, milling machines and other manually operated machines. This means many of the old skills are been lost. 3. Less workers are required to operate CNC machines compared to manually operated machines. Investment in CNC machines can lead to unemployment. 4. Many countries no longer teach pupils / students how to use manually operated lathes / milling machines etc... Pupils / students no longer develop the detailed skills required by engineers of the past. These include mathematical and engineering skills.

OBJECTIVE To develop more understanding about development and princip le of CNC machine. To learn various type of modern CNC machines and CNC modes of operations. To understand the fundamentals of part programmi ng in terms of the v a r i o u s s t e p s needed to be taken for completing a successful CNC program. To understand the different preparato ry (G codes) and miscellaneous f u n c t i o n s ( M codes) as used in CNC part program. To understand the advantages and disadvantages of C N C m a c h i n e s a n d t h e i r applications

EQUIPMENT AND MATERIAL 1. Machine Of CNC MILLING Used to cut off the work piece as we stated in the G-CODE program

2. Cutting Tools

3. VernierCaliper Used to measure the size of milling cutter(cutting tool) manually.

4. Milling cutter(Cutting tools) Used to cut the work piece as we want in which the milling cutter comes in various size with its diameter.

5. Drill Bits Used to hold the milling cutter tightly because it will be spining in high speed.

6. Turning To cool the material handling

CNC CODE AND PROGRAME G-Codes simple definition G00 - Rapid Positioning G01 - Linear Interpolation G02 - Circular Interpolation CW G03 - Circular Interpolation CCW G04 - Dwell G07 - Feedrate Sine Curve Control G10 - Data Setting G11 - Data Setting Cancel G17 - XY Plane Selection G18 - XZ Plane Selection G19 - YZ Plane Selection G20 - Input in Inches G21 - Input in Metric G22 - Stored Stroke Check ON G23 - Stored Stroke Check OFF G27 - Reference Point Return Check G28 - Automatic Zero Return G29 - Return from Zero Position G30 - 2nd Reference Point Return G31 - Skip Function G32 - Thread Cutting G36 - Automatic Tool Compensation G40 - Tool Compensation Cancel G41 - Tool Compensation Left G42 - Tool Compensation Right G46 - Automatic Tool Compensation G50 - Coordinate System Setting G52 - Local Coordinate System Setting G53 - Machine Coordinate System Setting G54 - Workpiece Coordinate Setting 1 G55 - Workpiece Coordinate Setting 2

G56 - Workpiece Coordinate Setting 3 G57 - Workpiece Coordinate Setting 4 G58 - Workpiece Coordinate Setting 5 G61 - Exact Stop Check Mode G62 - Automatic Corner Override G63 - Tapping Mode G64 - Cutting Mode G65 - User Simple Macro Call G66 - User Modal Macro Call G67 - User Modal Macro Call Cancel G70 - Finishing Cycle G71 - Turning Cycle G72 - Facing Cycle G73 - Pattern Repeating Cycle G74 - Drilling Cycle G75 - Grooving Cycle G76 - Threading Cycle G80 - Canned Cycle Cancel G83 - Face Drilling Cycle G84 - Face Tapping Cycle G85 - Face Boring Cycle G87 - Side Drilling Cycle G88 - Side Tapping Cycle G89 - Side Boring Cycle G90 - Absolute Positioning G91 - Incremental Positioning G92 - Threading Cycle G94 - Face Turning Cycle G96 - Constant Surface Speed Control On G97 - Constant Surface Speed Control Off G98 - Feedrate Per Time G99 - Feedrate Per Revolution G107 - Cylindrical Interpolation

M codes simple definition M00 - Program Stop M01 - Optional Program Stop M02 - Program End M03 - Spindle Clockwise M04 - Spindle Counter Clockwise M05 - Spindle Stop M07 - Coolant 1 On M08 - Coolant 2 On M09 - Coolant Off M30 - End Progarm, Return to Start M98 - Call Subprogram M99 - Cancel Subprogram

Program Structure A "CNC Program" is made up of one or more "BLOCKS". Each block contains one or more "WORDS". A word is generally an "ADDRESS REGISTER" followed by a "VALUE". An example of a Block is N540 G2 X30 Y-20 R-12 M8 It contains the words N540, G2, X30, Y-20, R-12 and M8. The Addresses N, G, X, Y, R and M are used with the values 540, 2, 30, -20, -12 and 8 The machine control executes each block in turn. Additionally the words in a block are executed in a specific order. For example an M code instruction is executed before any axis movement in the block, so in the above block the coolant will come on at the start of the axis travel. Some controls only allow each address letter once in a block, others allow a number of codes in the same block. Some controls also demand leading zeros on values and codes, for example G02 not G2. A block starts with a block number, it is normal practice to start at one hundred and go up in tens. This allows extra blocks to be added easily. Generally it is only necessary to program changes, once a mode has been programmed it will remain active until another code from the same group is programmed.

Programming, Interpolation CNC machines use G0, G1, G2 and G3 to determine the interpolation method to use when moving to points. G0 and G1 are linear interpolation, G0 at rapid G1 at a feedrate specified in the F register. G2 and G3 are circular interpolation, G2 clockwise and G3 counter clockwise. G4 is a dwell or pause for a specified amount of time. The method of determining the time is very different depending on the machine so no further details will be given here. G0, G1, G2 and G3 are group modal. G4 is active for that block only.

Linear Rapid G0 In this mode the machine will move as fast as the longest travelling axis will allow to the programmed point. All the axes move to simultaneously meet at the programmed point.

Linear Feedrate G1 In this mode the machine will move at a feedrate defined by F to the programmed point. All the axes move to simultaneously meet at the programmed point.

Circular Clockwise Feedrate G2 In this mode the machine will describe an arc in the two axes according to the current plane. The arc will be clockwise according to the current plane. If the third axis is programmed then the motion will be helical along the tool length axis. The movement will be at a feedrate. There are two methods of determining the radius of the arc, either the radius is programmed using the R register or the centre is described using the I, J and K registers. Radius method.

WORKING PROCEDURES

Load the part program into the lathe if it is not already there. On newer machines, use a USB drive to transfer programs from a computer to the machine. With old machines, you may need to use a serial connection to the computer or even an 3.5-inch floppy disk. Load the work piece into the lathe. Make sure the chuck or collet has a tight grip on the work piece. Load the necessary tools into the lathe. The tools you will need for a given program, as well as the turret slots in which they should be placed, will have been determined at the time the program was written. If you will be using a program you did not write, consult the programmer if you have any questions about which tools to use. Turn on the coolant pump and move the nozzle so the coolant stream is hitting the tip of the tool. Repeat this step for each tool. Set the tool offsets. Slowly bring each tool toward the tool setter on the lathe until you hear a beep. Record the tool's position in the tool offset screen under the appropriate tool number.Repeat this procedure to set the X and Z offsets for each tool. For some programs, you will also have to record the tip radius of certain cutting tools in the tool offset screen. The tip radius should be found either marked on the tool or in the documentation for the tool. Set the work offset. Rotate the turret to one of the cutting tools for which you have set the tool offset. Start the spindle and manually jog the cutter so that it faces off the end of the workpiece, leaving a smooth surface. Record the tool's position under the Z axis work offset. Run the part program. Watch the machine to make sure the program works as intended. Be ready to stop the machine immediately if something goes wrong.

WORKING SAFETY PROCEDURES

A. SAFETY

1. Wear personal protective equipment. a) Ensure door is closed when flying chips are present. b) Wear rubber gloves when working with coolant. 2. Be very careful while filing, emerying and when using a deburring tool. 3. Do not operate the lathe wearing loose clothing, finger rings or other jewelry. Long hair must be tied up or tucked. 4. Never attempt to remove chips by hand, turn off the spindle and use a chip hook or a brush. 5. Never polish a part with emery cloth wrapped around your hand, hold the emery cloth using your thumb and forefinger only. 6. When emerying a threaded part, use a course grit sandpaper to minimize the surface to surface contact, which will reduce the tendency for the emery cloth to want to grab.

B. OPERATING

1. Know where the emergency stop button is located on your machine before operating. 2. Try to eliminate long, stringy chips when machining as they can be easily caught up in the chuck, always exercise proper chip control. 3. Know machine speeds and feeds, if you are unsure please ask your Supervisor. 4. Make sure cutting tools are used properly and for their intended application. 5. Do not try and fix the machine if there is a problem, ask your Supervisor to contact

plant maintenance. 6. Ensure the lathe you operate and tooling is used with respect at all times. 7. Never use compressed air to clean the lathe, as small particles may become embedded into parts of the machine causing damage, use a soft bristle brush. 8. Never leave a running (spindle turning) lathe unattended.

NOTE: Should an incident occur it is imperative it is reported to your Supervisor, or when unavailable, to another supervisor within the area. Please leave all as it is so a review can take place.

CONCLUSIONS

After a practice, we have to recognize machine CNC Turning 'closer. We can learn how to use CNC Turning machines using the code 'G' and 'M' as well as understand the uses and functions of the machines' CNC Turning. Spirit of cooperation between members of each group can be cultivated during practice and practice proper safety measures during practice.

1. We can understand how the use of CNC lathe machine at work project. 2. We can complete the project according to project design and project dimensions. 3. Made to achieve the project objectives and in accordance with our requirements. 4. Understand what has been taught in theory and in practice can be machined. 5. We can solve the problems during the project coordinate system before we make a simulation. 6. We can understand how to enter data (key-in) program at CNC Lathe machine control panel. 7. We can use the machine CNC lathe skills to the project. 8. Able to produce ideas for the design of this CNC project.

REFERENCES

1. CNC Machines 2. Manufacturing Technology