MANUFACTURING LAB

A Report on CNC Machine Operations

Prepared By:

Submitted To:

Upendra Ajit Singh

Dr. Abhay Sharma

ME15MTECH11040
1

Contents

Aim

Theory

Experimental Setup

Procedure

Results

Precautions

AIM
To perform drilling, profiling and pocketing operations on a CNC Machine.

THEORY
CNC is the short form for Computer Numerical Control. The CNC machine
comprises of the mini computer or the microcomputer that acts as the controller unit
of the machine.
In CNC machines the program of instructions is fed directly into the computer
via a small board similar to the traditional keyboard. The program is stored in the
memory of the computer. The programmer can easily write the codes and edit the
programs as per the requirements. These programs can be used for different parts, and
they dont have to be repeated again and again.
The main purpose of these machines is to remove some of the metal so as to
give it proper shape such as round, rectangular, etc. In the CNC machines the role of
the operators is minimized. The operator has to merely feed the program of
instructions in the computer, load the required tools in the machine, and rest of the
work is done by the computer automatically.
Tools that can be controlled in this manner include lathes, mills, routers and
grinders. A computer program is customized for an object and the machines are
programmed with CNC machining language (called G-code) that essentially controls
all features like feed rate, coordination, location and speeds. With CNC machining, the

computer can control exact positioning and velocity. CNC machine also has its
appropriate programmable accessories, some examples of which are machining
centres, automatic tool changer, spindle speed and activation, Coolant etc.
Advantages
a. Accuracy
When programmed correctly, CNC machines produce parts to maximise
accuracy, provide good positional accuracy and repeatability, provide a high
degree of quality because of their accuracy and their ability to reuse programs.
b. Simplicity
CNC machines are not all that difficult to use once you learn how.

c. Time
Using CNC machines effectively reduces the amount of time taken.
Disadvantages
a. Cost
Costs quite a lot more than conventional machinery and does not
eliminate the need for expensive tools.

Experimental Setup
Tool holder
Work holding vise
Drill bit (10 mm dia)
Edge finder
Work piece (102 mm x 80 mm)

Procedure
1. Switch on the MCB (Machine Control Board), Machine Power and Air
Compressor.
2. Release Emergency button and press Control ON to activate the controller
system.
To measure the Machine Coordinates (X, Y, Z equal to zero)
3. Select JOG (100) Handle mode in Mode Selector to move axis using Joy Stick.
Set Feed value in FEED OVERRIDE and RAPID OVERRIDE.
4. Select each axis one by one in Axis Selector and move to middle position
approximately using Joy Stick.
5. Select Ref mode in Mode Selector, select individual axes and press Axis+ to
make Machine reference zero.
6. Double click on the POSITION on keyboard to verify machine reference is zero.

To measure the Work Coordinates

7. Bring all axes to the centre position using Joy Stick. Select MDI mode to write
program for spindle rotation by pressing Program key on keyboard. Write
M3S1000 and press INSERT. Press Cycle Start ON (Spindle will start
rotating).
8. Locate the desired origin on the workpiece using Joy Stick and move the Z axis
to touch the workpiece surface.

To measure G54 for X, Y and Z axis

9. Type Z0 and press MEASURE in the function keys. Repeat the same for X0
and Y0.
To write and run manual program on CNC Machine
10. Select EDIT mode in Mode Selector and press Program key on the keyboard.
11. Select DIR using function keys.
12. Type program number and press O-SRH to know the availability of that
program number. (Ex. O0007 Press O-SRH)
13. Type the available program number and press BG-EDIT to write new program.
14. Press BG-END after completion of the program.
15. Select AUTO mode to run the program. Press Cycle Start ON to start the
program execution.
Mounting the workpiece and tool holder
16. Mount the workpiece on the work holding vise by tightening the crew.
17. Attach the tool by tightening it on the tool holder. Push the button Tool DeClamp, insert the holder in the space, the machine will grab the tool holder.
One may also use automatic tool changer by writing a tool change G-Code.
Performing the operation
18. Go to the program written for the respective operation and perform the steps
mentioned earlier to run the program.
19. To use the edge finder, mount it in the tool holder. Make a contact between
edge finder and the workpiece edge using Joy Stick while the spindle is
rotating. Initially edge finder will have an eccentric rotation. Adjust the edge
contact till the rotation of edge finder is no more eccentric but perfectly
coaxial.
20. Set these coordinates as desired in the G54, the steps of which are mentioned
earlier. After this, edge finder can be removed and the tool can be mounted.

To Turn OFF the CNC Machine

21. Press the Emergency button.
22. Turn OFF machine power and Turn OFF MCB.
G-Code for Drilling Operation
O0008;
G0 G90 G54 G17 G40 G49 G80;
G0 G91 G28 Z0;
M03 S2000
G0 G90 G54 X15 Y15;
G0 G43 Z50 M08;
G98 G83 Z-13 Q0.5 R2 F100;
Y65;
X85;
Y15;
G0 G80 Z100;
M09;
M05;
G0 G28 G91 Z0;
G0 G91 G28 Y0;
M30;
G-Code for Profiling Operation
Main Program
O0052
G0 G90 G40 G17 G80 G49;
G0 G91 G28 Z0;
M03 S1000;
G0 G90 G54 X0 Y0;
G43 Z20;
G01 Z0 F500;

M98 P07 L10;

G0 G80 Z50;
M05;
M09;
G0 G91 G28 Z0;
G0 G28 Y0;
M30;
Sub-Program -O0007;
G01 G91 Z-0.2 F20;
G90 G54 G42 X0 F500;
Y80;
X100;
Y0;
X0;
M99;
G-Code for Pocketing Operation
Main Program -O0052
G0 G90 G40 G17 G80 G49;
G0 G91 G28 Z0;
M03 S1000;
G0 G90 G54 X0 Y0;
G43 Z20;
G01 Z0 F500;
M98 P11 L10;
G0 G80 Z50;
M05;
M09;
7

G0 G91 G28 Z0;

G0 G28 Y0;
M30;
Sub-Program
O0011;
G01 G91 Z-0.2 F10;
G01 G90 G54 G42 X5
F500; Y-5;
X-5;
Y5;
X5;
Y0;
X0;
M99;

Results
Drilling Operation

Figure 1: 10 mm dia holes placed 50 mm apart

Profiling Operation

Figure 2: Machined 10 mm material on all sides

Pocketing Operation

Figure 3: 2 mm deep pocket

Precautions
1. Check the air compressor for proper air pressure.
2. Close the CNC door during operation. Do not open the door during
machine operation.
3. Handle JOG mode carefully. Moving axes in JOG 1000 should be avoided.