Lab Manual - Manufacturing Technology

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Contents
I
STUDY OF SPECIAL MACHINES
1 Drilling Machine
2 Milling Machine
10
3 Shaping Machine
11
4 Grinding Machine
14
5 Gear Hobbing
18
6 Slotting Machine
18
7 CNC Part Programming
20
II
31
Exercises
1 Contour milling operation using vertical milling machine
2 Spur gear milling in universal milling machine
3 Helical gear milling in universal milling machine
4 Spur gear cutting in Gear Hobbing machine
5 Spur gear cutting in Gear Shaping machine
10
6 Machining a work piece using a surface grinding machine
12
7 Machining a work piece using a centre type cylindrical grinding machine
14
8 Machining a work piece using a centreless grinding machine
16
9 Tool and cutter grinding operation
18
10 Cutting force calculation using lathe tool dynamometer
20
11 Manual part programming for simple turning in CNC lathe
22
12 Manual part programming for multiple facing in CNC lathe
26
13 Manual part programming for single grooving in CNC lathe
30
14 Manual part programming for simple contour milling
34
15 Manual part programming for mirroring cycle in CNC mill
38
16 Manual part programming for circular and rectangular pocketings
42
17 Manual part programming for drilling in CNC mill
46
General Lab Procedures

The laboratory work is the most important part of this course. It is expected that you be
prepared for it by reading the lab manual before coming to the lab. It is important to
read sections of this manual to completely understand what is going on. This will save you a lot
of time, and keep you from making mistakes. This may determine whether or not you complete
your experiments on time!
When you come to class, inform the instructor/Lab technician of your lab assignment, for
that and he will give you the necessary raw materials and special tools needed in exchange for
your I.D. When you have finished for the day, clean up the machines you used, and turn in your
tools. At the end of every class, the entire shop will be cleaned. NO ONE MAY LEAVE
OR WASH UP UNTIL THE INSTRUCTOR IS SATISFIED THAT THE SHOP
IS CLEAN.
Safety must be exercised at all times while working in the machine shop. If you violate
safety rules, you may be requested to leave the shop, and you may not be able complete the
experiments on time.
General Safety Rules

The following is a list of some basic safety rules that must be followed while you are in the
machine shop. It should not be considered an exhaustive list.
Always wear safety glasses while in the shop.
Do not wear open-toed or open backed shoes of any kind.
Do not use any machine unless you have been instructed in the use of that equipment.
Do not leave machines unattended while running.
Keep your hands away from moving machinery and cutters.
Do not run or yell unnecessarily while in the shop.
Report all spilled fluids immediately: they are an extreme slip hazard.
If you are uncertain about any aspect of a machining operation you wish to perform then
please ask the person in charge before proceeding.
KEEP GUARDS IN PLACE and in working order
REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to see that
keys and adjusting wrenches are removed from tool before turning on.
DONT FORCE TOOL: It will do the job better and safer at the rate for which it was
designed
USE RIGHT TOOL: Dont force tool or attachment to do a job for which it was not
designed.
NEVER LEAVE TOOL RUNNING UNATTENDED,TURN POWER OFF.
Dont leave tool until it comes to a complete stop
Syllabus
LTPC0032
ME6411 MANUFACTURING TECHNOLOGY LAB II

OBJECTIVE
To Study and acquire knowledge on various basic machining operations in special purpose machines and its applications in real life manufacture of components in the industry
LIST OF EXPERIMENTS:
1. Contour milling using vertical milling machine
2. Spur gear cutting in milling machine
3. Helical Gear Cutting in milling machine
4. Gear generation in hobbing machine
5. Gear generation in gear shaping machine
6. Plain Surface grinding
7. Cylindrical grinding
8. Tool angle grinding with tool and Cutter Grinder
9. Measurement of cutting forces in Milling / Turning Process
10. CNC Part Programming.
TOTAL: 45 PERIODS
Part I
STUDY OF SPECIAL MACHINES

1
DRILLING MACHINE
The drilling machine is one of the most important machine tools in a workshop. In a drilling
machine, holes may be drilled quickly and at a low cost. The hole is generated by the rotating
edge of a cutting tool known as the drill, which exerts large force on the work clamped on the
table. The different parts of a radial drilling machine have been illustrated in Fig 1.
The main parts are as follows:
1. Base
2. Column
3. Radial arm
4. Drill head
5. Spindle speed and feed mechanism
BASE
The base of a radial drilling machine is a large rectangular casting that is finished on its top to
support a column on its one end and to hold the work table at the other end. In some machines
T-slots are provided on the base for clamping work when it serves as a table.
COLUMN
The column is a cylindrical casting that is mounted vertically at one end of the base. It supports
the radial arm which may slide up or down on its face. An electric motor is mounted on the
top of the column, which imparts vertical adjustment of the arm by rotating a screw passing
through a nut attached to the arm.
RADIAL ARM
The radial arm that is mounted on the column extends horizontally over the base. It is a massive
casting with its front vertical face accurately machined to provide guide ways on which the drill
head may be made to slide. The arm may be swung round the column. In some machines this
movement is controlled by a separate motor.
DRILL HEAD
The drill head is mounted on the radial arm and drives the drill spindle. It encloses all the
mechanism for driving the drill at multiple speeds and at different speed. All the mechanisms
and controls are housed within a small drill head, which may be made to slide on the guide ways
of the arm for adjusting the position of drill spindle with respect to the work.
Figure 1: Radial drilling Machine and parts are 1. Base, 2. Column, 3. Radial arm, 4. Motor for
elevating the arm 5. Elevating screw, 6. Guide ways, 7.Motor for driving the drill, 8. Carriage,
9. Spindle, 10. Table
Figure 2: Milling machine and its parts 1. Over arm 2. Arbor support 3. Arbor 4. Spindle 5.
Table 6. Saddle 7. Knee 8. Elevating screw 9. Column 10. Base
SPINDLE DRIVE AND FEED MECHANISM

A constant speed motor is mounted at the extreme end of the radial arm, which drives a
horizontal spindle, which runs along the length of the arm, and the motion is transmitted to
the drill head through bevel gears. By train of gearing within the drill head, the speed of the
spindle may be varied. Through another train of gearing within the drill head, different feeds of
the spindle are obtained. In some machines, a vertical motor is fitted directly on the drill head
and through gearbox multiple speed and the feed of the spindle can be obtained.
MILLING MACHINE
Milling is the process of removing metal by feeding the work piece through a rotating multi
point cutter. Milling machine can be used for machining flat surfaces, complex and irregular
areas, surface of revolution, external and internal threads, gear cutting, helical surface of cross
sections. The different parts of a Milling machine have been illustrated in Fig 2.
They are as follows:
1. Base
2. Column
3. Knee
4. Saddle
10
5. Table
6. Spindle
7. Arbor
Fig 2 shows the parts of a standard Milling Machine.
BASE:
It is the foundation of the machine and is that part upon which all parts are mounted. It gives
the machine rigidity and strength.
COLUMN:
It is the main supporting frame. The motor and other driving mechanisms are contained with
in it.
KNEE:
The knee projects from the column and slides up and down on its face. It supports the saddle
and table and partially supported by the elevating screw which adjusts its height.
SADDLE:
The saddle supports and carries the table and is adjustable transversely on ways on top of the
knee. It is provided with graduations for exact movement and operated by power or hand.
TABLE:
The table rests on ways on the saddle and travels longitudinally in a horizontal plane. It supports
the works piece, fixtures and all other equipments.
SPINDLE:
The spindle obtains its power from the motor through motors. Cutters are mounted directly in
the spindle nose.
ARBOR:
The arbor is an accurately machined shaft for holding and driving the arbor cutter. It is tapered
at one end to fit the spindle nose and two slots to fit the nose keys for locating and driving it.
SHAPING MACHINE
SHAPER
The shaper is a reciprocating type of machine tool intended primarily to produce flat surfaces.
These surfaces may be horizontal, vertical, or inclined. The different parts of typical shaper are
shown in Fig 3.
The principal parts of a standard shaper are:
1. Base
2. Column
11
Figure 3: Shaping machine and its parts 1. Table support 2. Table 3. Clapper box 4. Apron
clamping bolts 5. Down feed hand wheel 6. Swivel base degree graduations 7. Position of stroke
adjustment hand wheel 8. Ram block locking handle 9. Ram 10. Column 11. Driving pulley
12. Base 13. Feed disc 14. Pawl mechanism 15. Elevating screw
12
3. Cross rail
4. Saddle
5. Table
6. Ram
7. Tool head
BASE
The base is the necessary bed or required for all machine tools. The base may be rigidly bolted
to the floor of the shop or on the bench according to the size of the machine. It is so designed
that it can take up the entire load of the machine and the forces set up by the cutting tool over
the work. It is made of cast iron to resist vibration and take up high compressive load.
COLUMN
The column is a box like casting mounted upon the base. It encloses the ram driving mechanism.
Two accurately machined guide ways are provided on the top of the column on which the ram
reciprocates. The front vertical face of the column, serves as the guide ways for the cross rail.
The lid on the left side of the column may be opened for inspection and oiling of the internal
mechanism.
CROSSRAIL
The crossrail is mounted on the front vertical guide ways of the column. It has two parallel
guide ways on its top in the vertical plane that is perpendicular to the ram axis. The table may
be raised or lowered to accommodate different sizes of jobs by rotating elevating screw, which
causes the cross rail to slide up and down on the vertical face of the column. A horizontal cross
feed screw, which is fitted within the cross rail and parallel to the top guide ways of the cross
rail actuates the table to move in a crosswise direction.
SADDLE
The saddle is mounted on the crossrail, which holds the table firmly on its top. Crosswise
movement of the saddle by rotating the cross feed screw by hand or power causes the table to
move sideways.
TABLE
The table is bolted to the saddle receives crosswise and vertical movements from the saddle and
cross rail. It is a box like casting having T-slots both on the top and sides for clamping the
work. In a universal shaper the table may be swiveled on a horizontal axis and the upper part
of the table may be tilted up or down.
RAM
The ram is the reciprocating member of the shaper. This is semi cylindrical in form and heavily
ribbed inside to make it more rigid. It slides on the accurately machined dovetail guide ways
on the top of the column and is connected to the reciprocating mechanism contained within the
column. It houses a screwed shaft for altering the position of the ram with respect to the work
and holds the tool head at the extreme forward end.
13
Figure 4: Horizontal type grinder machine
TOOLHEAD
The toolhead of a shaper holds the tool rigidly, provides vertical and angular feed movement of
the tool and allows the tool to have an automatic relief during its return stroke. The vertical
slide of the toolhead has a swivel base, which is held on a circular seat on the ram. The swivel
base is graduated in degrees, so that the vertical slide is set perpendicular to the work or at any
desired angle.
GRINDING MACHINE
Grinding is metal cutting operation performed by means of a rotating abrasive wheel that acts
as a tool. This is used to finish work pieces, which must show a high surface quality, accuracy
of shape and dimension.
SURFACE GRINDER
Surface grinding machines are employed to finish plane or flat surfaces. The different parts of a
horizontal spindle reciprocating table surface grinder are shown in Fig 4.
The principal parts of a horizontal spindle reciprocating table surface grinder are:
1. Base
14
Figure 5: cylindrical grinding machine and its parts 1. Headstock, 2. Grinding wheel 3. Wheel
head 4. Tailstock 5. Upper table 6. Lower table 7. Base
2. Table
3. Wheel head
BASE
The base has a column at the back for supporting the wheel head. The base also contains the
drive mechanisms.
TABLE
The table is fitted to the saddle on carefully machined ways. It reciprocates along ways to
provide the longitudinal feed. T- slots are provided in the table surface for clamping work pieces
directly on the table or for clamping grinding fixtures or a magnetic chuck.
WHEEL HEAD
The wheel head is mounted on the column secured to the base. It has ways for the vertical slide,
which can be raised or lowered with the grinding wheel only manually by rotating a hand wheel
to accommodate work pieces of different heights and to set the wheel for depth of cut. Horizontal,
cross wise movement of the wheel slide with the wheel, actuated by hand or by hydraulic drive,
accomplishes the cross feed of the wheel. The grinding wheel rotates at constant speed; it is
powered by a special built- in motor.
CYLINDRICAL CENTRE TYPE GRINDER

Cylindrical centre- type grinders are intended primarily for grinding Plain cylindrical parts,
although they can also be used for grinding contoured cylinders, fillets and even cams and crank
shafts.
The different parts of a cylindrical centre- type grinder are shown in Fio 5. The principal
parts of a cylindrical centre- type grinder are:
1. Base
2. Tables
3. Head stock
15
4. Tailstock
5. Wheel head
6. Cross-feed
BASE
The base or bed is the main casting that rests on the floor and supports the parts mounted on
it. On the top of the base are precision horizontal ways set at right angles for the table to slide
on. The base also houses the table- drive mechanism.
TABLES
There are two tables lower table and upper table. The lower table slides on ways on the bed
provides traverse of the work past the grinding wheel. It can be moved by hand or power within
desired limits. The upper table that is provided at its center is mounted on the top of the sliding
table. It has T- Slots for securing the headstock and tailstock and can be positioned along the
table to suit the length of the work. The upper table can be swiveled and clamped in position
to provide adjustment for grinding straight or tapered work as desired.
HEADSTOCK
The headstock supports the work piece by means of a dead center and drives it by means of a
dog, or it may hold and drive the work piece in a chuck.
TAILSTOCK
The tailstock can be adjusted and clamped in various positions to accommodate different lengths
of work pieces.
WHEEL HEAD
The wheel head carries a grinding wheel and its driving motor is mounted on a slide at the top
and rear of the base. The wheel head may be moved perpendicularly to the table ways, by hand
or power, to feed the wheel to the work.
CROSS-FEED
The grinding wheel is fed to the work by hand or power as determined by the engagement of
the cross feed control lever.
CENTERLESS GRINDER
Centerless grinding is a method of grinding exterior cylindrical, tapered and formed surfaces on
work pieces that are not held and rotated between centers. The principal elements of an external
centerless grinder are the grinding wheel, regulating wheel and the work rest. Both the wheels
are rotated in the same direction. The work rest is located between the wheels. The work is
placed upon the work rest, and the latter, together with the regulating wheel, is fed forward,
forcing the work against the grinding wheel
16
Figure 6: Through-feed centreless grinding
Figure 7: Through-feed centreless grinding

External centreless grinder
This grinding machine is a production machine in which out side diameter of the workpiece is
ground. The workpiece is not held between centres but by a work support blade. It is rotated
by means of a regulating wheel and ground by the grinding wheel.
In through-feed centreless grinding, the regulating wheel revolving at a much lower surface
speed than grinding wheel controls the rotation and longitudinal motion of the workpiece. The
regulating wheel is kept slightly inclined to the axis of the grinding wheel and the workpiece is
fed longitudinally as shown in Fig. 6.
Parts with variable diameter can be ground by Centreless infeed grinding as shown in Fig. 7a.
The operation is similar to plunge grinding with cylindrical grinder. End feed grinding shown
in Fig. 7b is used for workpiece with tapered surface.
The grinding wheel or the regulating wheel or both require to be correctly profiled to get
the required taper on the workpiece.
Tool and cutter grinder

Tool grinding may be divided into two subgroups: tool manufacturing and tool resharpening.
There are many types of tool and cutter grinding machine to meet these requirements. Simple
single point tools are occasionally sharpened by hand on bench or pedestal grinder. However,
tools and cutters with complex geometry like milling cutter, drills, reamers and hobs require
sophisticated grinding machine commonly known as universal tool and cutter grinder. Present
trend is to use tool and cutter grinder equipped with CNC to grind tool angles, concentricity,
cutting edges and dimensional size with high precision Fig. 8.
17
Figure 8: tool and cutter grinding machine
GEAR HOBBING
Gear Hobbing is a technique that is employed to create gear teeth configurations that are ideal
for use in a wide range of machinery components. In cases where the gear hobbing takes place
in a mass producing environment, gear hobbing is accomplished through the use of precision
gear hobbing machines that ensure that the cut of each tooth on each gear produced meets the
specifications set by the producer. Figure 9 shows the mechanism involved in the gear hobbing
machine.
Generally, a gear hobbing machine will make use of a series of customized bits that help to
create the specific types of cutting and shaping necessary to create gears those posses exactly
the right pitch and circle to work in various types of equipment. A customized bit is used for
a particular size and type of gear hobbing, which helps to ensure that the cuts that are made
into the blank surface of the circle of metal are relatively smooth and uniform.
SLOTTING MACHINE
Slotting machines can simply be considered as vertical shaping machine where the single point
(straight or formed) reciprocates vertically (but without quick return effect) and the workpiece,
being mounted on the table, is given slow longitudinal and / or rotary feed as can be seen in
Figure 10.
In this machine also the length and position of stroke can be adjusted. Only light cuts are
taken due to lack of rigidity of the tool holding ram for cantilever mode of action. Unlike shaping
and planing machines, slotting machines are generally used to machine internal surfaces (flat,
formed grooves and cylindrical).
18
Figure 9: Gear Hobbing machine
Figure 10: Slotting machine
19
CNC Part Programming
INTRODUCTION TO NC (NUMERICAL CONTROL)

Numerical Control is a technique of automatically operating a productive facility, based on a
code of letters, numbers and special characters. Numerical control has been developed out of
the need for higher productivity, lower cost and most precise manufacturing. Numerical control
is essentially an application of the digital technology to control a machine.
INTRODUCTION TO NC MACHINE AND ITS COMPONENTS

NC Machine responds to a series of coded instructions by actuating various drives to required
extents in desired sequence with pre-set speed, feed, etc., without human intervention. Such
instructions are called part programs.
A part program needs to be written for every job to be produced. It instructs the machine to operate in a particular manner. This type of programming is also called manual part
programming since it is performed manually without the help of a computer.
Numerical control programming with the help of some software is called computer-aided part
programming (CAPP) or simply computer-aided manufacturing. Today several softwares are
available which automatically generate the codes for a given part Fig 11.
The Machine Control Unit (MNC) is the brain of an NC machine. The information contained
in the part program is read by the MNC which, in turn, converts the coded information in the
part program into voltage or current pulses of varying frequency or magnitude. These generated
electrical signals control the tool movement and also controls miscellaneous operations such as
flow of coolant, tool changes, door opening/closing and gripping / un-gripping the job.
NC machines usually have their own memory where they can store a program when it is
read by the machine for the first time. For subsequent production of the same part, the machine
need not read the part program again. It uses the program stored in its memory for subsequent
execution. A machine without any memory must read the part program every time. This slows
the production process considerably.
The primary types of memory are RAM (Random Access Memory) and ROM (Read One
Memory). RAM is a volatile memory. It stores information permanently which can be read
any number of times unless the information is deliberately erased or overwritten. In addition
to memory, the MCU also contains hardware and software necessary to read and interpret the
coded program for obtaining the desired movements in the machine.
Since an NC Machine does not have an on-board computer, a separate computer is required
for preparing codes for machining a part. The coded program is usually transferred to the
machine through a punched tape which the machine reads by passing light through it. Presence
and absence of a hole is taken as 1 and 0 binary signals respectively.
ADVANTAGES OF NC MACHINE OVER CONVENTIONAL MACHINE

The principal advantage of an NC machine is the increased and accurate control of the cutting
tool which would be manually very difficult or even impossible in some cases. A simple example is
circular motion of the tool where movements along both X and Y axes need to be simultaneously
controlled while it is virtually impossible to do this manually on a conventional machine, an NC
Figure 11: A typical NC programme
20
Figure 12: Direct Numerical Control system

machine can easily perform this task within the accuracy of microns, that too any number of
times.
DISADVANTAGE OF NC MACHINE
Since an NC machine does not have an on-board computer, a separate computer is required for
preparing codes for machining a part. Besides this, the machine has to read the coded tape
every time a part is to be produced even if the same part is to be reproduced. This results
in loss of time and sometimes error in reading. The tape is usually made of paper, may also
get damaged after repeated use. Moreover, even for a small change the whole tape has to be
re-made.
INTRODUCTION TO CNC (COMPUTER NUMERICAL CONTROL) MACHINE

A CNC machine is essentially an NC machine with a dedicated computer being its integral
part. It has got more flexibility compared to an NC machine. From outside, NC and CNC
machines are not very different. The only apparent difference is the presence of a monitor
(CRT) on a CNC machine which an NC machine does not have. The monitor continuously
displays the machine status to enable us to communicate with the machine. Numerous types of
CNC machines have been manufactured. Out of these, CNC Lathe / Turning Centre and CNC
Milling / MachiningCenter are very commonly used.
ADVANTAGES OF CNC SYSTEM OVER NC SYSTEM

1. In CNC, Software is used for obtaining the basic function leads to increased productivity
and flexibility in manufacturing.
2. CNC machines have the added advantage of reading, storing and editing the part programs.
They also provide graphical capabilities, diagnostic procedures and system troubleshooting. This simplifies the operation and maintenance of CNC machines to a great extent.
INTRODUCTION TO DIRECT NUMERICAL CONTROL (DNC) MACHINE

If a large capacity computer directly controls a number of NC machines, such a system is
called DNC machine. This is useful because in present age of computer-aided manufacturing,
centralized data handling and control is desirable. The main frame computer stores programs
and after processing, sends the control signals to respective NC machines.Fig 12.
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Figure 13: Distributive Numerical Control system
INTRODUCTION TO DISTRIBUTIVE NUMERICAL CONTROL (DNC)

MACHINE
DNC is also the abbreviation for Distributive Numerical Control, which uses a network of computers to coordinate the operations of several machines.
Though expensive, such a system can control the entire manufacturing operation of a company, and thus, it is a step towards automation of the manufacturing system. Fig 13
TOOL MOVEMENT MODES

In an NC / CNC machine, usually the tool moves with respect to the work piece which remains
at the same place. In some cases, e.g., in a milling machine, the workpiece moves with respect
to the tool.
There are three types of motion control used in an NC / CNC machine:
1. Point-to-point placement
2. Axial cut
3. Contour cutting
1. Point-to-point placement Such a control simply places the tool over desired locations in
desired sequence. There is no control over the speed of the tool movement between selected
points, which is always a fast traverse. This type of control can be used in drilling, punching or
similar machines where only the location of the tool at the time of machining is important.
2. Axial Cut This control allows the tool to move along any major axis with desired speed.
Therefore, cutting along X, Y, or Z axis is possible. The limitation being simultaneous motion
along two axes is not possible. So, it cannot make an angular cut. That is why, it is also called
straight cut control. For an angular cut, the job will have to be reoriented so as to make the
cutting direction parallel to one of the axes. A machine, which is capable of performing axial
cuts, also provides point-to-point control.
3. Contour Cutting This is the most flexible but the most expensive type of control. It
permits simultaneous control of more than one axis movement of the tool. So, it is possible to
make any complex contour which is approximated by several small straight line segments within
permissible tolerance band.
22
Figure 14: Straight line approximation of a curve

Straight line approximation of a curve
The contour cutting or contouring control also permits point-to-point and axial cut movements. Milling and turning operations are common examples of contouring control.
DRIVES AND CONTROL LOOPS

The drive motors which control the movement of various axes are of four basic types:
1. Stepper motor
2. AC servo motor
3. DC servo motor
4. Hydraulic servo motor
1. Stepper Motor
Stepper motor is driven by an electrical pulse train generated by the machine control unit.
Rotation of the motor shaft is proportional to the number of pulses it receives, and its angular
velocity is proportional to the frequency of pulses. Stepper motors are used on light duty
machinery where high precision is not required. Since it is possible to regulate the angular
position and the angular velocity of a stepper motor, such motors are used in open-loop control
system.
2. AC / DC Servo Motor
The servo motor can be of AC / DC type. They are used on small to medium-sized CNC
machines. These are variable speed motors that rotate in response to the applied voltage. DC
servo motors are controlled by varying the voltage magnitude. AC servo motors are regulated
by varying the voltage frequency. AC servos can develop more power than DC servos. Larger
machines use servos rather than stepper motors.
3. Hydraulic Servo Motor
Hydraulic servos also are variable speed motors. They produce more power compared to electric
servo motors. Such motors are used on large capacity machines.
23
Figure 15: open loop control system
Figure 16: Closed-loop control system

OPEN-LOOP CONTROL SYSTEM In open-loop control system arrangement, there is no
feedback from the output, and accuracy of the machine depends fully on the response of the
stepper motor. Open-loop control involves less hardware and is relatively inexpensive compared
to closed-loop system.
CLOSED-LOOP CONTROL SYSTEM
A closed-loop control system measures the actual position and velocity of axes and compares
them with the desired values. The difference between the two is the error which is used to
regulate the drive motor.
The control is designed in such a way as to eliminate or reduce the error to a minimum value.
Fig. shows a closed-loop control system using negative feedback. The sensor is usually a rotary
or a linear transducer. Rotary transducers may be connected to the lead screw either directly
or through gears. In case of linear transducers, one part of the device is fixed to the machine
tool structure while the other part is attached to the moving slide.
ACCURACY AND REPEATABILITY

Accuracy is the ability of a machine to produce desired dimensions. Repeatability is the ability to
produce the same part for the same dimensions every time. Repeatability of MCU to differentiate
between closely spaced points is a function of factors such as the controllers bit storage capacity,
drive motor and the type of feedback sensor.
INTERPOLATION SCHEMES
In contouring control, the tool is made to move along a contour such as a circle or other smooth
curves. Some of these curves can be exactly defined mathematically using simple formulae,
whereas more complex ones can only be represented approximately. In any case, the fundamental
problem is that the curves are continuous whereas control is digital. Hence, interpolation is a
very important aspect in contour cutting. To cut along a curve, the curve must be divided into a
series of small straight line segments. The tool is made to trace these straight lines. For obtaining
good accuracy, the number of straight lines must be extremely large. Interpolation schemes have
been developed which calculate the intermediate points automatically for a given curve. The
24
MCU locates the intermediate points and instructs the tool to follow the path defined by joining
these points by straight lines. These straight lines are so small that the resulting contour quite
a smooth curve for all practical purposes. A number of interpolation schemes are available on
various types of machine. They include:
1. Linear interpolation
2. Circular interpolation
3. helical interpolation
4. Parabolic interpolation
5. Cubic interpolation
Out of these, linear and circular interpolations are the most common and are available on
most of the machines.
TOOL CHANGING DEVICES

In a CNC machine, tools are changed through program 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) on a milling machine.
On a lathe machine, the tool magazine only needs to rotate to a new position to allow the
new tool to come in the cutting position. There is no need to change the tool physically. Tool
changing time is of the order of a few seconds. This saves time and thus, increases productivity.
OTHER APPLICATIONS
Computer numerical control has been used in a wide variety of machine tools. In fact, whenever
good accuracy and repeatability is desired and frequent changes in component type is expected,
a CNC machine becomes an ideal choice. Some of the machines where computer numerical
control is used are listed below:
Lathe
Turning centre
Miller
Machining centre
Drilling machine
Gear hobbing machine
Grinding machine
Electro-discharge machine
Welding and cutting
Coordinate measuring machine, etc.
25
Mcode
M01
M03
M04
M05
M30
M98
M99
Functions
Optional Program stop
Spindle start CW
Spindle start CCW
Spindle stop
Programme end & Rewind
Start of Subroutine
End of Subroutine
RECENT ADVANCES
Most of todays CNC controllers, such as FANUC, SINUMERIK, HEIDENHAIN etc., include
software that greatly simplify the programming and diagnostic processes. The graphic display
in these controllers shows the tool movement for the program. This is very useful as one can
verify the tool paths even before actually machining the job.
CO-ORDINATES (X, Y, AND Z WORD)

These give the coordinates positions of the tool. In a two axis system, only two of the word would
be used. In a four or five axis machine, additional a - words and/or b - words would specify
the angular positions. Although different NC systems use different formats for expressing a
coordinate, we will adopt the convention of expressing it in the familiar decimal form. For
example X7 or Y-0.5. Some formats do not use the decimal point in writing the coordinates.
FEED RATE (F)

This specifies the feed in a machining operation. Unit is millimeter per minute.
CUTTING SPEED (S)

This specifies the cutting speed of the process, the rate at which the spindle rotates.
TOOL SELECTION (T)

Theletter T would be needed only for machines with a tool turret or automatic tool changer.
The T number specifies which tool is to be used in the operation .For example T1 may indicate
turning tool in a CNC turret lathe.
MISCELLANEOUS FUNCTION (M)

The letter M is used to specify certain miscellaneous or auxiliary function which may be available
on the machine tool of course, the machine must possess the function that is being called. An
example would be M03 to start the spindle rotation in CW direction. The miscellaneous function
is the last word in the block.
M CODES
M codes are instructions describing miscellaneous functions like calling the tool, spindle rotation,
coolant on etc..,
List of G codes for turning operations are given in the following table.
26
G code
G00
G01
G02
G03
G21
G28
G32
G70
G71
G72
G74
G75
G76
G92
G90
G94
Functions
Rapid Positioning
Linear interpolation
Circular interpolation (CW)
Circular interpolation (ACW)
Metric Programming
Auto. Return to reference point
Thread cutting cycle
Finishing cycle
Stock removal in turning
Stock removal in facing
Peck drilling canned cycle
Grooving cycle
Taper threading cycle
Threading canned cycle
Diameter cutting cycle
Facing cycle
CYCLES USED IN THE CNC LATHE

FACING
Format: G72 W (d) R (e)
G72 P Q U (u) W (w) F
W(d) - Depth of cut in z axis (For trainer lathe, it is max 1 mm
R (e) - Relief amount in x axis
P - Starting block number of theprogram
Q - Final block number of theprogram
U (u) - Finishing allowance in Xdirection
W(w) - Finishing allowance in Z direction
F - Feed rate of cutting
TURNING
G71: STOCK REMOVAL MULTIPLE REPETITIVE CYCLE
Format: G71 U (d) R (e)
G71 P Q U (u) W (w) F
U(d) - Depth of cut in X axis(e) - Escaping amount in X+ direction
P - Starting block number of the programme
Q - Final block number of theprogramme
U (u) - Finishing allowance in X direction
W (w) - Finishing allowance in Z direction
F - Feed rate for cutting
THREAD CUTTING
G 32: THEARD CUTTING OPERATION Format: G32 X Z F
X Threading diameter
Z Thread length
27
F Thread Pitch
G92: THREADING CUTTING CANNED CYCLE
Format: G92 X Z F
X Threading diameter
Z Thread length
F Thread Pitch
G76: TAPER THREAD CYCLE
Format: G76 Paabbcc Q R
G76X Z R P Q F
First Block:
P - is a six digit data entry in three pairs
aa digit - No of finishing cut (01-99)
bb digit - No of leads for gradual pull out(00-99)
cc digit - Angle of thread(00,29,30,60,80 only)
Q - Minimum cutting depth in microns
R - Fixed amount for finish allowance
Second Block:
X - Minor diaofThread=major dia -2*d
d - Depth
Z - End of thread length along z axis in mm
P - Height of thread (d) (one side depth in microns)=500 microns
Q - Depth of first thread inmicrons=25 microns
R - Radial difference between start and end point
F - Pitch of thread
G74 PECK DRILLING CYCLE
Format: G74 R
G74 X Z Q F
X&Z - Final respective coordinates
R - Return amount in mm
Q - Depth of cut in mm
F - Feed rate in mm/min
G75 GROOVING CYCLE
Format: G75 R (1) G75X (U) Z(W) P Q R(2) F
where,
the definitions of R (1) , X (U) , Z (W) , P , Q , R (2) and F are the same as G74.
R(1) is the peck return amount.
X (U) is the diameter of the bore if step over is used (i.e., stepping along the Xaxis to repeat
the peck cycle).
Z (W) is the depth of the bore.
P is the step over in the X axis measured in microns (without sign).
Q is the pecking depth in the Z axis measured in microns (without sign).
R (2) is the retract move at the base of the groove.
28
F is the feedrate.
G70 FINISHING CYCLE:
After roughing operation this cycle is used to achieve the final dimensions. Finish allowance has
to be kept before starting this cycle. The tool path is same as the roughing operation.
Format: G70 P Q
Here,
P= starting block of the roughing cycle.
Q= end block of roughing cycle.
This cycle is normally used after G71,G72& G73 codes.
G71 MULTIPLE TURNING CYCLE:
The G71 code commands a multiple repetitive cycle, sometimes referred to as a canned cycle.
Canned cycles are used within a CNC program to simplify programming, since only the dimensions describing the required component profile are required. The CNC control will then
generate the roughing cuts needed to make this component profile, from within its own memory.
U(d)= Depth of Cut ( For trainer machine it is 1mm).
R(e) = Escaping amount ( After depth of cut, this is the return path for the tool in X +
Direction)
P = Starting block no. of the program for the required shape
Q = Final block no. of the program for the required shape
U(u) = Finishing allowance in X direction.
W(w) = Finishing allowance in Z direction.
F = Feed-rate for cutting.
CNC MILL TRAINER

LIST OF G and M CODES FOR MILLING
29
G code
G00
G01
G02
G03
G12
G13
G15
G20
G21
G40
G41
G42
G43
G54
G80
G81
G83
G90
G91
G94
G95
G98
G99
Functions
Point to Point rapid Positioning
Linear interpolation
Circular interpolation Arc CW
Circular interpolation Arc CCW
Circular Pocketing CW
Circular Pocketing CCW
Polar coordinate system off.
Selecting English unit(Inches)
Selecting Metric unit(millimeter)
Cutter compensation/offset, cancel
Cutter radius compensation/offset- left
Cutter radius compensation/offset- right
Tool length compensation-Positive
Shift of coordinate.
Drilling cycle
Fixed cycle no.1 drill, spot drill
Peck drilling cycle
Absolute dimension input
Incremental dimension input
Feed rate selection per min.
Feed rate selection per revolution.
Tools return position.
Return to R point in canned cycle
M code
M00
M01
M02
M03
M04
M05
M06
M07
M08
M09
M19
M30
M98
M99
Functions
Optional program stop automatic
Optional program stop request
Program end
Spindle ON CW
Spindle OFF CCW
Spindle stop
Tool change
Mist coolant ON(coolant 1 ON)
Flood coolant ON(coolant 1ON)
Coolant OFF
Spindle orientation
End program
Sub program call
Sub program end
30
Part II
Exercises
31
Figure 17: Contour milling
Contour milling operation using vertical milling machine
Aim:
To manufacture the part shown and generate tool path by using vertical milling machine
WORKPIECE REQUIRED:
Billet size: 70 X70X70 mm
PROCEDURE:
The dimensions of the given rod are checked with the steel rule.
The given cast iron block is fixed in the vice provided on the machine table.
An end milling cutter is mounted on the vertical milling machine spindle.
The machine is switched ON
The table is elevated and contour path is made in accordance with given drawinig using
endmill cutter.
The job is removed from the vice.
RESULT:
The given work piece is subjected to contour milling operation to become a finished work piece
as shown in fig (1).
Figure 18: Spur gear
SPUR GEAR MILLING IN UNIVERSAL MILLING MACHINE
AIM :
To machine gear to the given module and number of teeth in the given work piece.
TOOLS AND EQUIPMENTS REQUIRED :

Milling machine, invloute milling cutter, Vernier caliper,Mandrel
PROCEDURE :
1. Calculate the gear tooth proportions.
Blank diameter =( Z + 2 ) m
Tooth depth = 2.25 m
Tooth width = 1.5708 m
where, Z = Number of teeth required and m = module
2. Indexing calculation
Index crank movement = 40 / Z
3. The dividing head and the tail stock are bolted on the machine table. Their axis must be
set parallel to the machine table.
4. The gear blank is held between the dividing head and tailstock using a mandrel. The
mandrel is connected with the spindle of dividing head by a carrier and catch plate.
5. The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.
6. Set the speed and feed for machining.
7. For giving depth of cut, the table is raised till the periphery of the gear blank just touches
the cutter.
8. The micrometer dial of vertical feed screw is set to zero in this position.
9. Then the table is raised further to give the required depth of cut.
10. The machine is started and feed is given to the table to cut the first groove of the blank.
11. After the cut, the table is brought back to the starting position.
12. Then the gear blank is indexed for the next tooth space.
13. This is continued till all the gear teeth are cut.
CALCULATION : Z = No. of teeth = 15
module(m) = 3 mm
Blank Diameter = (Z + 2) m = (15 + 2) 3 = 51 mm
Tooth Depth = 2.25 m = 2.25 * 3 = 6.75 mm
Indexing Calculation = 40 / Z = 40 / 19 = 2 .2/40
RESULT :
The given work piece is subjected to gear milling operation to become a finished work piece as
shown in figure.
4
Figure 19: Helical gear
HELICAL GEAR MILLING IN UNIVERSAL MILLING MACHINE
AIM :
To machine gear to the given module and number of teeth in the given workpiece.

Milling machine, Involute milling cutter, Vernier caliper,Mandrel.
PROCEDURE :
1. The dividing head and the tail stock are bolted on the machine table. Their axis must be
set parallel to the machine table.
3. The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.
5. For giving depth of cut, the table is raised till the periphery of the gear blank just touches
the cutter.
6. Table is titled to the helix angle.
7. The micrometer dial of vertical feed screw is set to zero in this position.
8. Then the table is raised further to give the required depth of cut.
9. The machine is started and feed is given to the table to cut the first groove of the blank.
10. After the cut, the table is brought back to the starting position.
11. Then the gear blank is indexed for the next tooth space.
12. This is continued till all the gear teeth are cut.
module(m) = 3 mm
RESULT :
Helical gear is cut from the given work piece.
SPUR GEAR CUTTING IN GEAR HOBBING MACHINE
AIM :

Gear Hobbing machine, Gear Hobbing cutter, Vernier caliper, Mandrel.
PROCEDURE :
1. 1. Calculate the gear tooth proportions. Blank diameter = ( Z + 2 ) m
where, Z = Number of teeth required m = module
3. Gear box speed setting for work piece and cutter is done
5. The cutter is mounted on the arbor. The cutter is centred accurately with the gear blank.
7. Hobbing machine is switched ON and cutting process strarted
8. This is continued till the gear hob cutter leaves the blank.
m = module = 3 mm
Blank Diameter = (Z + 2) m = (19 + 2) *3 = 63 mm
Tooth Depth = 2.25 m = 2.25 * 3 = 6.75 mm
RESULT :
The given work piece is subjected to gear generating operation to become a finished work piece
as shown in figure.
SPUR GEAR CUTTING IN GEAR SHAPING MACHINE
AIM :

Gear Shaping machine, Gear shaping cutter, Vernier caliper, Mandrel, vise
PROCEDURE :
1. 1. Calculate the gear tooth proportions. Blank diameter = ( Z + 2 ) m
where, Z = Number of teeth required m = module
3. Gear box speed setting for work piece and cutter is done
5. The cutter is mounted on the arbor. The cutter is centered accurately with the gear blank.
7. Gear shaping machine is switched ON and cutting process started
8. This is continued till the gear hob cutter leaves the blank.
CALCULATION : Z = No. of teeth = 23 m = module = 2 mm Blank Diameter = (Z + 2) m
= (23 + 2) 2 = 50 mm Tooth Depth = 2.25 m = 2.25 * 2 = 4.5 mm
RESULT :
The given work piece is subjected to gear shaping operation to become a finished work piece as
shown in figure.
10
Figure 22: surface grinding work piece

11
MACHINING A WORK PIECE USING A SURFACE GRINDING MACHINE
AIM:
To machine a work piece using a surface grinding machine.
MATERIALS REQUIRED:
Mild Steel Flat - 80 X 50 X 10 mm
TOOLS REQUIRED:
1. Surface grinding machine
2. Vernier Caliper
PROCEDURE:
The given work piece is held firmly on a magnetic chuck of a surface grinder.
The machine is started and the grinding wheel is allowed to revolve at a selected speed.
After giving a depth of cut, the work piece is made to reciprocate under the grinding wheel.
The table is fed axially between passes to produce a fine flat surface.
The process is repeated for grinding another side until the desired dimension is achieved.
The dimensions are checked for its given dimensions using a vernier caliper.
RESULT:
The given work piece is subjected to surface grinding operation to become a finished work piece
as shown in figure.
12
Figure 23: cylindrical grinding work piece
13
MACHINING A WORK PIECE USING A CENTRE TYPE

CYLINDRICAL GRINDING MACHINE
AIM:
To machine a work piece using a cylindrical grinding machine.
MATERIALS REQUIRED:
Mild steel polished round rod - 25 X 150 mm
TOOLS REQUIRED:
1. Centre type cylindrical grinder
2. Vernier Caliper
3. Spanners
PROCEDURE:
The given work piece is held between centers.
The machine is switched on and the grinding wheel is allowed to revolve at a selected
speed.
By giving longitudinal and cross feeds the work piece is ground for the required dimensions.
The work piece is removed from the machine and is checked for the given dimensions.
RESULT:
The given work piece is subjected to external cylindrical grinding operation by centre type
cylindrical grinder to become a finished work piece as shown in figure.
14
Figure 24: centreless grinding work piece
15
MACHINING A WORK PIECE USING A CENTRELESS

GRINDING MACHINE
AIM:
To machine a work piece using a centreless grinding machine.
MATERIALS REQUIRED:
Mild steel polished round rod - dia 25 X 150 mm
TOOLS REQUIRED:
1. Centreless cylindrical grinder
2. Vernier Caliper
3. Spanners
PROCEDURE:
The given work piece is held between grinding wheel and regulating wheel and supported
on work rest.
The machine is switched on and the grinding wheel and the regulating wheel are allowed
to revolve at a selected speed.
The work is fed forward and the grinding operation is done.
RESULT:
The given work piece is subjected to grinding operation by centre less type cylindrical grinder
to become a finished work piece as shown in figure.
16
Figure 25: Tool and cutter grinding
17
TOOL AND CUTTER GRINDING OPERATION
AIM:
To grind the cutting tool for the given angles.
MATERIALS REQUIRED:
HSS tool-150mm sq
TOOLS REQUIRED:
1.Tool and cutter grinder
2. Vernier Caliper
3. Spanners
4.Bevel protractor
PROCEDURE:
The given work piece is held between centers.
The machine is switched on and the grinding wheel is allowed to revolve at a selected
speed.
By giving longitudinal and cross feeds the work piece is ground for the required dimensions.
RESULT:
The given work piece as shown in fig (1) is subjected to tool and cutter grinding operation to
get required cutting angle on tool.
18
S.No.
DOC
1
2
3
4
1
2
3
4
(mm)
0.5
0.5
0.5
0.5
0.75
0.75
0.75
0.75
Table 1: Cutting force measurement

Horizontal
Vertical
Resultant
q
Component Component
Px2 + Py2
Px kg
Py kg
Average
kg
NOTE :
1. Pz the main or tangential component, determines the torque on main drive mechanism,
the deflection of the tool and the required power. This component acts in the direction of
the cutting speed.
2. Px the axial component, acts in the direction of the tool traverse and it is at right angles
to Pz . It contributes very little to the power consumption.
3. Py the radial component, acts along the tool shank and perpendicular to the other two
components. It has no share in the power consumption.
19
10
CUTTING FORCE CALCULATION USING LATHE TOOL

DYNAMOMETER
AIM :
To measure the cutting forces for the given cutting conditions.

Lathe Tool Dynamometer, Lathe machine, turning tool and a workpiece
PROCEDURE :
The Lathe Tool Dynamometer is initially set to zero reading.
The known depth of cut is given and take the readings of px and pz force components from
the Lathe Tool Dynamometer.
Calculate the resultant cutting force
p
px 2 + pz 2
Repeat the same procedure to get few more readings and calculate the mean cutting force.
Repeat the same procedure for different depth of cuts.
RESULT :
Thus the cutting forces are measured for different depth of cuts.
20
Figure 26: simple turning work piece
21
11
Manual part programming for simple turning in CNC lathe
Aim:
To manufacture the part shown and generate tool path simulation by using manual part programme in FANUC language.
WORKPIECE REQUIRED:
Billet size: 25 X 70 mm
SPECIFICATION OF SYSTEM USED:

Software:Cut Viewer software.
Hardware:Intel Core i3 Processor, 2GB RAM, 320GB HDD.
PROCEDURE:
Firstly a new file is opened in the software from menu File New.
Simulation is selected from menuMode.
Part Programme is typed in window and then opened and saved with a file name name.
NC0.
The file is opened from File Open.
The software now prompts us to definestock and the same is defined by measuring with
Vernier Caliper.
Again the appropriate cutting tool is defined. Standard tool is selected forturning operation.
It is saved and opened again.
Now the programme can be run to view the tool path simulation.
If found correct, machining is performed by selecting Machining from the menu Mode.
Jog window is opened in which appropriate tool number is selected.
Also zero offsetting is done by using Tool Position tab by moving the tool with respect to
the work piece such that X=0 and Y =0.
The programme is now ready to perform machining.
Billet size: - f 25 x 70
Part Program:
N1
N2
N3
N4
N5
Using Turning Cycle

M03 S2000
G00 X30 Z10
G71 U0.5 R0.5
G71 P5 Q6 U0.1 W0.1 F90
G01 X10 Z0
22
N6
N7
N8
N9
G01 X10 Z-20

G70 P5 Q6 U0.1 W0.1 F70
G00 X30 Z10
M30
Without Turning Cycle

N1 M03 S2000I
N2 G00 X30 Z10
N3 G01 X25 Z0
N4 G01 X24 Z0
N5 G01 X24 Z-20
N6 G01 X25 Z-20
N7 G01 X25 Z0
N8 G01 X23 Z0
N9 G01 X23 Z-20
N10 G01 X24 Z-20
N11 G01 X24 Z0
N12 G01 X22 Z0
N13 G01 X22 Z-20
N14 G01 X23 Z-20
N15 G01 X23 Z0
N16 G01 X21 Z0
N17 G01 X21O Z-20
N18 G01 X22 Z-20
N19 G01 X22 Z0
N20 G01 X20 Z0
N21 G01 X20 Z-20
N22 G01 X21 Z-20
N23 G01 X21 Z0
N24 G01 X19 Z0
N25 G01 X19 Z-20
N26 G01 X20 Z-20
N27 G01 X20 Z0
N28 G01 X18 Z0
N29 G01 X18 Z-20
N30 G01 X19 Z-20
N31 G01 X19 Z0
N32 G01 X17 Z0
N33 G01 X17 Z-20
N34 G01 X18 Z-20
N35 G01 X18 Z0
N36 G01 X16 Z0
N37 G01 X16 Z-20
N38 G01 X17 Z-20
N39 G01 X17 Z0
N40 G01 X15 Z0
N41 G01 X15 Z-20
N42 G01 X16 Z-20
N43 G01 X16 Z0
N44 G01 X14 Z0
23
N45 G01 X14 Z-20

N46 G01 X15 Z-20
N47 G01 X15 Z0
N48 G01 X13 Z0
N49 G01 X13 Z-20
N50 G01 X14 Z-20
N51 G01 X14 Z0
N52 G01 X12 Z0
N53 G01 X12 Z-20
N54 G01 X13 Z-20
N55 G01 X13 Z0
N56 G01 X11 Z0
N57 G01 X11 Z-20
N58 G01 X12 Z-20
N59 G01 X12 Z0
N60 G01 X10 Z0
N61 G01 X10 Z-20
N62G01 X11 Z-20
N63 G01 X11 Z0
N64 G00 X30 Z10
N65 M30
RESULT:
Thus the program was written and executed successfully using FANUC.
Viva-Voce:
What are the controllers used in CNC machines?
State the merits of using cycles in programmes used in CNC machines.
How is the zero setting done?
24
Figure 27: Multi facing and turning Operation
25
12
Manual part programming for multiple facing in CNC lathe
Aim:
WORKPIECE REQUIRED:

Software:Cut Viewer software.
Hardware:Intel Core i3 Processor, 2GB RAM, 320GB HDD.
PROCEDURE:
Simulation is selected from menu Mode.
NC0.
The software now prompts us to define stock and the same is defined by measuring with
Vernier Caliper.
Again the appropriate cutting tool is defined. Standard tool is selected for turning operation.
26
Part Programme:
N1 M03 S2000
N2 G00 X30 Z10
N3 G71 U0.5 R0.5
N4 G71 P5 Q11 U0.1 W0.1 F90
N5 G01 X10 Z0
N6 G01 X14 Z-5
N7 G01 X14 Z-10
N8 G02 X17 Z-13 R3
N9 G03 X20 Z-16 R3
N10 G01 X20 Z-24
N11 G01 X25 Z-29
N12 G70 P5 Q11 U0.1 W0.1 F70
N13 G00 X30 Z10
N14 M30
RESULT:
Thus the program was written and executed successfully using FANUC
Viva-Voce:
What is the disadvantage in using vice in CNC trainer machines?
State the codes for Interpolation Schemes.
State some canned cycles used in machining.
27
28
Figure 28: single grooving operation
29
13
Manual part programming for single grooving in CNC lathe
Aim:
WORKPIECE REQUIRED:

Software: Cut Viewer software.
Hardware: Intel Core i3 Processor, 2GB RAM, 320GB HDD.
PROCEDURE:
NC0.
Vernier Caliper.
Again the appropriate cutting tool is defined. Parting tool is selected for this operation.
30
Single Grooving: Billet size: f 22 x 70 mm (3mm width grooving tool)

Part Programme:
N2
N3
N4
N5
N6
N7
N8
N9
N1 M03 S2500
G10 X23 Z2
G01 Z-10 F50
G01 X22
G75 R0.5
G75 X16 Z-10 P750 Q2000 F15
G00 X30
G00 Z10
M30
RESULT:
Viva-Voce:
How multiple grooving is performed?
What is the format for taper thread cutting?
Name some machines making use of taper threads.
31
32
Figure 29: contour milling 1
Figure 30: contour milling 2
33
14
Manual part programming for simple contour milling
Aim:
WORKPIECE REQUIRED:

Software: Cut Viewer software.
Hardware: Intel Core i3 Processor, 2GB RAM, 320GB HDD.
PROCEDURE:
NC.
The file is opened from menu File Open.
Vernier Caliper.
Again the appropriate cutting tool is defined. Flat end mill is selected for this operation.
the work piece such that X=0 Y =0and Z=0.
i)Simple Contour Milling: Billet size: - 100 x 100 x 10 mm; Depth of cut 0.5 mm
ii)Simple Contour Milling: Billet size: - 100 x 100 x 10 mm; Depth of cut 0.5mm
All Dimensions are in mm.
Part Programmme:
i)
N1 M03 S2500
N2 G00 X25 Y30 Z10
34
N3 G01 Z-O.5 F50

N4 G01 X25 Y25
N5G01 X35 Y25
N6G03 X65 Y25 R15
N7G01 X75 Y25
N8G01 X75 Y30
N9G03 X75 Y70 R20
N10G01 X75 Y75
N11G01 X65 Y75
N12G03 X35 Y75 R15
N13G01 X25 Y75
N14G01 X25 Y70
N15 G03 X25 Y30 R20
N16 G00 Z50
N17 M30
ii)
N1 M03 S2500
N2 G00 X35 Y25 Z10
N3 G01 Z-0.5 F50
N4 G01 X65 Y25
N5 G03 X75 Y35 R10
N6 G01 X75 Y65
N7 G02 X65 Y75 R10
N8 G01 X35 Y75
N9 G03 X25 Y65 R10
N10 G01 X25 Y35
N11 G02 X35 Y25 R10
N12 G01 X35 Y25 Z40
N13 M30
RESULT:
Viva-Voce:
Define Tool Length Compensation and explain its need.
What is concept of Stepper Motor?
35
36
Figure 31: mirroring cycle
37
15
Manual part programming for mirroring cycle in CNC mill
Aim:
WORKPIECE REQUIRED:

Software: Cut Viewer software. Hardware: Intel Core i3 Processor, 2GB RAM, 320GB HDD.
PROCEDURE:
NC.
Vernier Caliper. Here origin is taken at X=50, Y=50 and Z=10 or 20 mm.
the work piece such that X= -50 Y = -50and Z=0 at lower left corner.
N1
N2
N3
N4
N5
N6
N7
N8
N9
Mirroring Cycle: Billet size:-100 x 100 x 10 mm

All Dimensions are in mm
Part Programmme:
M03 S2500
G00 X15 Y15 Z10
M98 P100
M21
M98 P100
M22
M98 P100
M22 M23
M98 P100
38
N10
N11
N12
N13
N14
N15
N16
N17
N18
N19
G00 Z50
M30
O100
G00 X15 Y15 Z5
G01 Z-0.5 F50
G01 X35 Y15
G01 X15 Y35
G01 X15 Y15
G00 Z5
M99
Result:
Viva-Voce:
Define Manual Part Programming.
Define Computer Assisted Programming
39
40
Figure 32: rectangular pocketing

41
16
Manual part programming for circular and rectangular pocketings
Aim:
WORKPIECE REQUIRED
Billet size: 90 X 90X10 mm
SPECIFICATION OF SYSTEM USED

Software: Cut Viewer software. Hardware: Intel Core i3 Processor, 2GB RAM, 320GB HDD.
PROCEDURE:
Firstly a new file is opened in the software from menu File - New.
NC.
Vernier Caliper.
i)Circular Pocketing: Billet size: - 90 x 90 x 10 mm; Depth of cut 3mm
ii)Rectangular Pocketing: Billet size: - 90 x 90 x 10 mm; Depth of cut 0.5mm
Part Programmme: i)Circular Pocketing
N1M03 S2500
N2 G00 X33 Y50
N3 G01 Z-0.5 F50
N4 G13 I2.5 F70
N5 G13 I5
N6 G13 I7.5
42
N7 G13 I10
N8 G13 I12.5
N9 G13 I15
N10 G13 I17
N12 G00 Z10
N13 G01 Z-0.1 F50
N14 G13 I2.5 F70
N15 G13 I5
N16 G13 I7.5
N17 G13 I10
N18 G13 I12.5
N19 G13 I15
N20 G13 I17
N22 G00 Z10
N23 G01 Z-1.5 F50
N24 G13 I2.5 F70
N25 G13 I5
N26 G13 I7.5
N27 G13 I10
N28 G13 I12.5
N29 G13 I15
N30 G13 I17
N32 G00 Z10
N33 G01 Z-2.0 F50
N34 G13 I2.5 F70
N35 G13 I5
N36 G13 I7.5
N37 G13 I10
N38 G13 I12.5
N39 G13 I15
N40 G13 I17
N42 G00 Z10
N43 G01 Z-2.5 F50
N44 G13 I2.5 F70
N45 G13 I5
N46 G13 I7.5
N47 G13 I10
N48 G13 I12.5
N49 G13 I15
N50 G13 I17
N52 G00 Z10
N53 G01 Z-3 F50
N54 G13 I2.5 F70
N55 G13 I5
N56 G13 I7.57
N57 G13 I10
N58 G13 I12.5
N59 G13 I15
N60 G13 I17
N62 G00 Z10
43
ii) Rectangular Pocketing

N1 M03 S2500
N2 G00 X28 Y33
N3 G01 Z-0.5 F50
N4 G01 X62
N5 G01 Y57
N6 G01 X28
N7 G01 Y33
N8 G01 X30 Y35
N10 G01 X60
N11 G01 Y55
N12 G01 X30
N13 G01 Y35
N14 G01 X32 Y37
N17 G01 X58
N18 G01 Y53
N19 G01 X32
N21 G01 Y37
N22 G01 X34 Y 39
N17 G01 X56
N18 G01 Y51
N19 G01 X34
N21 G01 Y39
N22 G01 X36 Y 41
N17 G01 X54
N18 G01 Y49
N19 G01 X36
N21 G01 Y41
N22 G01 X38 Y 43
N17 G01 X56
N18 G01 Y47
N19 G01 X38
N21 G01 Y43
N22 G01 X40 Y 45
N25 M30
RESULT:
Thus the program was written and executed successfully using FANUC
Viva-Voce:
How do you do Rectangular Pocketing using cycle?
What to do if accident occurs during machining?
Where are the pocketing operations used?
44
Figure 33: cnc drilling 1
Figure 34: cnc drilling 2
45
17
Manual part programming for drilling in CNC mill
Aim:
WORKPIECE REQUIRED:
Software: Cut Viewer software. Hardware: Intel Core i3 Processor, 2GB RAM, 320GB
HDD.
PROCEDURE:
NC.
Vernier Caliper.
i) Drilling& Boring Using Absolute Co-ordinates: Billet size: 100 x 100 x 10 mm
Drilling Tool: f6 Boring Tool: f 10
ii) Drilling& Boring Using Incremental Co-ordinates: Billet size: 90 x 90 x 10 mm
Drilling Tool: f 6 Boring Tool: f 10
i)Using Absolute coordinates:
T1
NI M03
N2 G00
N3 G99
N4 G83
N5 G83
S2500
X20 Y20 Z5
G83 X20 Y20 Z-6 Q2 R1 F100
X80 Y20
X80 Y80
46
N6 G83 X20 Y80

N7 G83 X50 Y50
N8 M05 N9 G00 X20 Y20 Z5
T2
N10 M03 S2500
N11 G99 G83 X20 Y20 Z-2 Q1 R1 F100
N12 G83 X80 Y20
N13 G83 X80 Y80
N14 G83 X20 Y80
N15 G83 X50 Y50
N16 G00 Z50
N17 M30 ii)Using Incremental
T1
N1 M03 S2000
N2 G00 X0
N3 G00 Y0
N4 G91
N5 G00 X10
N6 G00 Y10
N7 G00 Z2
N8 G01 Z-8 F50
N9 G01 Z8 F50
N10 G00 X10
N11 G00 Y10
N12 G01 Z-8 F50
N13 G01 Z8 F50
N14 G00 X10
N15 G00 Y10
N16G01 Z-8 F50
N17 G01 Z8 F50
N18 G00 X10
N19 G00 Y10
N20 G01 Z-8 F50
N21 G01 Z8 F50
N22 G00 X10
N23 G00 Y10
N24 G01 Z-8 F50
N25 G01 Z8 F50
N26 G00 X-50
N27 G00 Y-50
N28 M05
coordinates:
N1
N2
N3
N4
N5
T2
G00
G00
G01
G01
G00
X10
Y10
Z-4 F70
Z4 F70
X10
47
N6 G00 Y10
N7 G01 Z-4 F70
N8 G01 Z4 F70
N9 G00 X10
N10 G00 Y10
N11 G01 Z-4 F70
N12 G01 Z4 F70
N13 G00 X10
N14 G00 Y10
N15 G01 Z-4 F70
N16 G01 Z4 F70
N17 G00 X10
N18 G00 Y10
N19 G01 Z-4 F70
N20 G01 Z4 F70
N21 G00 X-50
N22 G00 Y-50
N23 M30
RESULT:
Viva-Voce:
Define the codes for coordinate systems.
State the different cycles used in Drilling
Which menus in Cutviewersoftware is used for dimensioning parts in simulation?
48

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1

Name of the experiment

STUDY OF SPECIAL MACHINES

7 CNC Part Programming

1 Contour milling operation using vertical milling machine

2 Spur gear milling in universal milling machine

3 Helical gear milling in universal milling machine

4 Spur gear cutting in Gear Hobbing machine

5 Spur gear cutting in Gear Shaping machine

6 Machining a work piece using a surface grinding machine

7 Machining a work piece using a centre type cylindrical grinding machine

8 Machining a work piece using a centreless grinding machine

9 Tool and cutter grinding operation

10 Cutting force calculation using lathe tool dynamometer

11 Manual part programming for simple turning in CNC lathe

12 Manual part programming for multiple facing in CNC lathe

13 Manual part programming for single grooving in CNC lathe

14 Manual part programming for simple contour milling

15 Manual part programming for mirroring cycle in CNC mill

16 Manual part programming for circular and rectangular pocketings

17 Manual part programming for drilling in CNC mill

General Lab Procedures

General Safety Rules

ME6411 MANUFACTURING TECHNOLOGY LAB II

STUDY OF SPECIAL MACHINES

SPINDLE DRIVE AND FEED MECHANISM

Figure 4: Horizontal type grinder machine

CYLINDRICAL CENTRE TYPE GRINDER

Figure 6: Through-feed centreless grinding

Figure 7: Through-feed centreless grinding

Tool and cutter grinder

Figure 8: tool and cutter grinding machine

Figure 9: Gear Hobbing machine

Figure 10: Slotting machine

CNC Part Programming

INTRODUCTION TO NC (NUMERICAL CONTROL)

INTRODUCTION TO NC MACHINE AND ITS COMPONENTS

ADVANTAGES OF NC MACHINE OVER CONVENTIONAL MACHINE

Figure 11: A typical NC programme

Figure 12: Direct Numerical Control system

INTRODUCTION TO CNC (COMPUTER NUMERICAL CONTROL) MACHINE

ADVANTAGES OF CNC SYSTEM OVER NC SYSTEM

INTRODUCTION TO DIRECT NUMERICAL CONTROL (DNC) MACHINE

Figure 13: Distributive Numerical Control system

INTRODUCTION TO DISTRIBUTIVE NUMERICAL CONTROL (DNC)

TOOL MOVEMENT MODES

Figure 14: Straight line approximation of a curve

DRIVES AND CONTROL LOOPS

Figure 15: open loop control system

Figure 16: Closed-loop control system

ACCURACY AND REPEATABILITY

TOOL CHANGING DEVICES

CO-ORDINATES (X, Y, AND Z WORD)

FEED RATE (F)

CUTTING SPEED (S)

TOOL SELECTION (T)

MISCELLANEOUS FUNCTION (M)

CYCLES USED IN THE CNC LATHE

CNC MILL TRAINER

Figure 17: Contour milling

Contour milling operation using vertical milling machine

Figure 18: Spur gear