Industrial Training on Production

Shop

I, Ashutosh Kumar Mishra, studying in 7 semester of Bachelor

of Technology in Mechanical Engineering at IIMT College Of
Engineering, Greater Noida, hereby declared that this project entitled
Industrial Training on Production Shop which is being submitted by
me under the guidance of Prof. Dr Devraj kr Tiwari and Prof. KP Singh,
Department Of Mechanical Engineering, IIMT College Of Engineering,
Greater Noida.
I further undertake that the matter embodied in the
dissertation has not been submitted previously for the Industrial
Training.

Place :- Greater Noida

Ashutosh Kumar Mishra

CNC MILLING

At the end of this module, I am able to:

Apply and practice workshop safety

regulations during working in CNC
workshop.

Apply the concept of CNC metal cutting

operation correctly in milling process.

Carry out CNC mill machining procedures

systematically.

Utilize the important parameters in CNC mill

machining operation effectively according
to a given task.

Milling is a cutting operation with a geometrically

specified cutting edge in which the tool makes
the rotating main movement, and the feed as
well as the infeed movement are generally made
by the work part.

Milling operations are classified according to the

position of the milling axis towards the work part,
i.e. between face milling and peripheral milling.
In case of face milling, the milling axis is located
vertically to the machining.

The work part surface is machined by the main

cutting edges. Also, the work part surface is
further finished with auxiliary cutting edges.

Figure 1.1 : Milling Cutting Operation

Figure 1.2 : End Milling

Figure 1.3 : Plain Milling

synchronous and conventional milling

(Figure 1.4 and 1.5) are differentiated.
In case of conventional milling the
rotation direction of the milling tool is
opposite to the feed direction of the work
part.
The milling tool chamfer edge starts with
chip thickness zero.
The milling tool cutting edge slides in front
of the chip chamfer edge until the required
minimum chip thickness has been achieved
for chip building.

Figure 1.4 : Conventional Milling

For synchronous milling the rotation

The tooth of the milling cutter immediately

penetrates into the work part.

Since the milling tool cutting edge is exposed

to impact forces the feed drive needs to be
play free. Several cutters should always be in
operation.

The surface quality is flatter and duller when

synchronous milling is used.

Compared with conventional milling higher

feed movements and cutting speeds within
the same cutting edge life can be achieved.

direction of the milling tool and the feed

movement of the work part are parallel.

Figure 1.5 : Synchronous Milling

Figure 2.6 : Milling Plan

1.3.1 Characteristics of CNC Milling

Machine Tools

Work part machining on CNC machine

tools requires controllable and adjustable
infeed axes which are run by the servo
motors independent of each other.

CNC- milling machines (Figure 1.7) on the

other hand have at least 3 controllable or
adjustable feed axes marked as X, Y, Z.

Figure 2.7 : Controllable NC Axes on a Milling Machine

a)

Coordinate Systems On CNC

Machine Tools
Coordinate systems enable the
exact description of all points on
a work plane or room. Basically
there are two types of coordinate
systems

A Cartesian coordinate system, also

called rectangular coordinate system
includes for the exact description of
the points
Two coordinate axes (two-dimensional

Cartesian coordinate system) or also.

Three coordinate axes (three-dimensional
Cartesian coordinate system), located
vertically to each other

Figure 1.8 : Cartesian Coordinate System

In the Cartesian coordinate system a point is

described, for instance, by its X and Y coordinates.
For rotation symmetrical contours, such as circular
boring patterns, calculating the needed
coordinates requires extensive computing.
In the polar coordinate system a point is specified
by its distance (radius r) to the point of origin and
its angle () to a specified axis. The angle ()
refers to the X axis in the X,Y coordinate system.
The angle is positive, if it is measured
counterclockwise starting from the positive X axis
(Figure 1.9)

Figure 1.9 : Polar Coordinate System (Positive Angle )

Figure 1.10 : Right-Hand-Rule

The specifications of the three axes as well as the three

coordinates are done as a so-called clockwise-rotating
system and follow the right-hand-rule (Figure 1.10). The
fingers of the right hand always show to the positive
direction of each axis. This system is also called the
clockwise-rotating coordinate system.

Machine Coordinate System

The machine coordinate system of the CNC machine

tool is defined by the manufacturer and cannot be

changed.
The point of origin for this machine coordinate system,
also called machine zero point M, cannot be shifted in
its location.

Work Part Coordinate System

The work part coordinate system is defined by the

programmer and can be changed. The location of the

point of origin for the work part coordinate system, also
called work part zero point W, can be specified as
desired.

Figure 2.11 : Machine Coordinate System

System

Figure 2.12 : Work Part Coordinate

The design of the CNC machine specifies

the definition of the respective coordinate
system.
Correspondingly, the Z axis is specified as
the working spindle (tool carrier) in CNC
milling machines (Figure 1.13), whereby
the positive Z direction runs from the work
part upwards to the tool.
The X axis and the Y axis are usually
parallel to the clamping plane of the work
part. When standing in front of the
machine, the positive X direction runs to
the right and the Y axis is away from the
viewer.
The zero point of the coordinate system is
recommended to be placed on the outer
edge of the work part.

Figure 1.13 : Milling Part In Three-Dimensional Cartesian Coordinate System

a) Types of Zero And Reference Points

Table 1.1 : Types of zero and references points

Each numerically controlled machine tool works

with a machine coordinate system.

The machine zero point is the origin of the

machine-referenced coordinate system.

It is specified by the machine manufacturer and its

position cannot be changed.

In general, the machine zero point M is located in

the center of the work spindle nose for CNC lathes
and above the left corner edge of the work part
carrier for CNC vertical milling machines.

A machine tool with an incremental travel

path measuring system needs a calibration
point which also serves for controlling the
tool and work part movements.
This calibration point is called the
reference point R. Its location is set exactly
by a limit switch on each travel axis.
The coordinates of the reference point,
with reference to the machine zero point,
always have the same value. This value
has a set adjustment in the CNC control.

Figure 1.14 : Location Of The Zero And Reference Point For Milling

Structure of an NC-Block (Format)

a)

Unlike the conventional milling machine, a

modern machine tool will be equipped
with a numerical control system. The
machining of a work part can be executed
automatically, provided that each
machining cycle has been described in a
"language" (code) which can be read by
the control system.

The total of coded descriptions relating to

a work part is called an NC-program.

Blocks
Each NC-program consists of a number of socalled blocks, which contain the commands to be
executed. The blocks are consecutively
numbered; each block number consisting of a
letter "N" plus a (e.g. three-digit) numeral. Block
numbers appear at the beginning of each
program line
* Words Address, Value
As a rule an NC block is comprised of several
words. Each word consists of an address (letter)
and a value or code (numerals).

A numeral can either represent a code (e.g. G01:

Linear feed motion) or a real value (e.g. X+60 :
Approaching the target coordinate X=60).
Example of part program:

N110
N115
N120
N125
N130

F95 S850 M03

G00 X+25 Y+30
G01 Z-8
X+105
Y+80

Explanation:

Block-No.

N110
A feed rate of 95 mm/min and a spindle
speed of
850 U/min is
programmed.
N115
The tool is moved in the rapid traverse
motion
from its current position to the
starting point
(X+25 Y+30)t
N120
Infeed in the Z-axis at the programmed
feed rate (G01)
N125
Because G01 is a modal command, the
tool will continue to move at the programmed feed
rate on a
straight line to the target position
X=105
N130
The tool moves in the Y-axis to the target
position Y=80.

The technology data programmed in block N110

(feed rate, speed and sense of cutter rotation) will
be retentive and take effect through blocks N120 to
N130.

Figure 1.15 : Tool motions effected by modal

commands (G01)

G00 Rapid move G0 X# Y# Z# up to 6 axis or G0

Z# X#
G01 Linear feedrate move G1 X# Y# Z# up to 6
axis or G1
Z# X#
G02 Clockwise move
G03 Counter clockwise move
G04 Dwell time
G08 Spline smoothing on, optional L# number of
blocks to
buffer
G09 Exact stop check, spline smoothing Off
G10 Linear feedrate move with decelerated stop
G11 Controlled Decel stop
G17 X Y Plane
G18 X Z Plane
G19 Y Z Plane
G28 move to position relative to machine zero
G53 Cancel fixture coordinate offsets
G54-G59 fixture coordinate offsets 1 through 6

G70 Inch mode

G71 Millimeter mode
G80 Cancels canned cycles and modal cycles
G81 Drill cycle
G82 Dwell cycle
G83 Peck cycle
G84 Tapping cycle
G85 Boring cycle 1 bore down, feed out
G86 Boring cycle 2 bore down, dwell, feed out
G88 Boring cycle 3 bore down, spindle stop, dwell,
feed out
G89 Boring cycle 4 bore down, spindle stop, dwell,
rapid
out
G90 Absolute mode
G91 Incremental mode
G92 Home coordinate reset
G93 cancel home offsets
G98 - G199 User-definable G codes

With each NC-block a number of additional functions (MFunctions) can be programmed, such as machine functions
and switches, e.g. to specify the feed rate, the spindle
speed and the tool change.

List of M Codes

Feed Rate, F
The feed rate is programmed in millimeters per
minute (mm/min). Example: F080.000; Here the
programmed feed rate is 80 millimeters per
minute.
Spindle Speed, S
The spindle speed is programmed in revolutions
per minute (RPM). Example: S500; Here the
programmed spindle speed is 500 revolutions per
minute.
Tool Change, T
A tool change is programmed by a four-digit
number at the address T. The first two positions of
that number indicate the tool position in the
magazine; the last two positions indicate the tool
compensation storage.
Example: T0808; This command effect the
loading of the tool to position No.8 of the current
tool magazine and the reading-in of the
corresponding compensation value storage No.8.

In the CNC Simulator there is a

maximum of 99 magazine positions
available, as well as 99 compensation
value registers. This provides the
opportunity, for example, to assign the
compensation value register No. 36 to
the tool in the magazine position No.
12). The applicable NC-command would
then be programmed as follows: T1236

The following clamping variations can be

distinguished for milling machine.
Jaw Chucking
Magnetic Chucking
Modular Chucking

The milling cutter machine table with its T-slots is

the basis for work part clamping. Depending on
how the work part is to be clamped, the following
clamping devices can be distinguished:

Mechanical clamping devices

Hydraulic clamping devices
Pneumatic clamping devices
Electric clamping devices

Figure 1.16 : Clamping Devices

Figure 1.17 : Clamping Iron And Clamping Bard

Figure 2.18 : Shallow Clamp

Machine vises are easy to use and

reliable. They are used for clamping
smaller work parts. Alignment is
achieved with a measuring gauge.

Figure 1.19 : Machine Vise

Figure 2.20 : Power Transmission

Universal machine vises can be horizontally as well

as vertically turned. Furthermore, there are also
vises that pneumatically generate clamping power.

Figure 2.21 : Precision Sine Vise

Work parts made of iron can be clamped with

electromagnetic devices. The work part is drawn to
the clamping plate after a current is switched on. It
can be easily removed after the current is switched
off.

Figure 1.22 : Electromagnetic Clamping Plate

Milling is a cutting operation with a rotating tool,

whereby the cutting edges are not in operation
all the time. The cutting movement is caused by
the rotation of the tool. Feed direction and
cutting direction do not depend on each other. It
is realized either by the tool or by the work part
or by both of them (Figure 2.23).

The Cutting Speed (Vc) and the Feed Speed (Vf)

is overlap to each other and results in a
continuous cutting operation.

The cutting movement is the movement between the

tool and the work part, generating only one nonrecurrent
chip cut during one rotation without a feed movement.
Cutting speed corresponds to circumferential speed of
the milling tool on the current cutting edge. It is
expressed as Vc and m/min. Under consideration of the
number of rotations of the spindle n the following
formula is received

Vc = * d * n

in m/min

The cutting speed of a cutting tool depends on the

number of the rotations. The direction constantly
changes however during cutting operation.

Figure 1.23 : Cutting Values For Milling

The feed movement together with the

cutting movement enables a constant
chip removal during several rotations. In
milling, the feed can be indicated in
three ways:
Feed speed (Vf) in mm / min
Feed per tooth (fz) in mm
Feed per milling rotation (f ) in mm

Introductio
Also
n known as wire-cut EDM and wire cutting.

A thin single-strand metal wire (usually brass) is fed through the workpiece
submerged in a tank of dielectric fluid (typically deionized water).

Used to cut plates as thick as 300 mm and to make punches, tools, and dies
from hard metals that are difficult to machine with other methods.

Uses water as its dielectric fluid; its resistivity and other electrical properties are
controlled with filters and de-ionizer units.

The water flushes the cut debris away from the cutting zone.

Flushing is an important factor in determining the maximum feed rate for a

given material thickness.

Commonly used when low residual stresses are desired, because it does not
require high cutting forces for material removal.

-four major components

Computerized Numerical Control (CNC)

- The Brains.

Power Supply -The Muscle

Mechanical Section - The Body

Dielectric System -The Nourishment

Better stability and higher productivity .

Higher machining rate with desired
accuracy and minimum surface damage.
Uses in the production of forming tools.
To produce plastics moldings, die castings,
forging dies etc.
Can be applied to all electrically
conducting metals and alloys irrespective
of their melting points, hardness,
toughness, or brittleness.

Special

form of EDM - uses a continuously moving

conductive wire electrode.
Material removal occurs as a result of spark erosion as
the wire electrode is fed, from a fresh wire spool, through
the workpiece.
Horizontal movement of the worktable (CNC)
determines the path of the cut.
Application - Machining of super hard materials like
polycrystalline diamond (PCD) and cubic boron nitride
(CBN) blanks, and other composites.
Carbon fiber composites are widely used in aerospace,
nuclear, automobile, and chemical industries, but their
conventional machining is difficult