Experiment 8

Title: Manufacturing lab computer numerical control (CNC) Milling

Aim of study: Writing simple CNC milling program and simulate the toolpath

BACKGROUND
In the1950s, the Department of Defense commissioned MIT produced the first NC
(numerical control) machine. CNC (computer numerical control) technology matured
in the mid-1980s with the development of relatively cheap microprocessors and
electronic memory to replace punched tape.
The term numerical control is a widely accepted and commonly
used machine that enables an operator to communicate with machine tools through a
series of numbers and symbols (which are refed to as CNC codes).
The CNC code is a special relatively simple computer language that a CNC machine
can understand and execute. They tell the machine what moves to execute, one by one,
as well as controlling other machine functions such as spindle and feed speeds, coolant.
The most common language is G-code or ISO code, a simple alphanumeric
programming language developed for the earliest CNC machines in the 1970s

METHODOLOGY
Laboratory equipment: A CNC milling machine, a desktop, spindle, C_501from lyrics
electronics. The milling machine: Milling is the process of using a rotating tool to
remove material along a contour or line. It has traditionally been used to create flat
surfaces and straight edges on prismatic work pieces. Milling is used in industrial
Operations such as milling, contouring, gear cutting, drilling, boring, and reaming,
these are only a few of the many operations which can be performed on a milling
machine. The milling machine can be programmed on three axes: The X axis controls
the table movement left or right. The Y axis controls the table movement toward or
away from the column.
The Z axis controls the vertical (up or down) movement of the knee or spindle
The C-501: this is for processing of foams, plastics hard wood and soft metal products.
The spindle: is the part of the machine that holds the cutting tool (in the case of a
milling machine) and rotates by means of an electric motor. The two most popular
spindle nose styles are the Caterpillar (CAT), or V-flange, and the BT
THEORITICAL BASES:
Computer numerical control (CNC) programs are made up of codes that are read by the
control to perform various functions. There are two fundamentally different types of
codes found in an CNC part program the first type of code controls machine functions
and settings. The second type of code is used to modify and perform machining
functions.
These two functions are the PREPARATORY (G) FUNCTION and the
MISCELLANEOUS(M) FUNCTION. Generally, the G codes are written in and
performed by the CNC machine processor and operate the motion control part of the
control.
The M codes are MACHINE codes, these operate most of the basic electrical control
functions such as Coolant, Tool changers, safety circuits etc., the M, S & T codes are
written in a separate PLC processor, both processors usually communicate with each
other over a common bus.
The tool changer and spindle are both configured to suit a particular machine specific.
G-codes and M-codes are simple instructions that the programmer will write to make
the machine behave in a certain way. There are dozens of G-codes and M-codes used
to perform everything from complex machining operations to mundane tool changes.
However, just a few codes, if learned, will get most of the work done
G and M coding starts with words and ends with numbers.
A block in an NC program is a line of code that is constructed from words. Each word
is made up of letters (or addresses) and numbers that are related to the letter. For
example, the letter X refers to the X-axis. The number that follows it indicates a
coordinate along the X-axis.
The words that make up an NC coding starts with an alphabet which indicates the
function and the process parameters
And the number that follows thus indicates the mode of function, coordinate value.
The Cartesian coordinate system is used to define points in space by establishing
directions (axes) and a reference position (origin). Coordinate systems can be
rectangular or polar. Axes establish the X direction and the Y direction. The point at
which the two axes cross is called the origin. A coordinate is a distance along an axis
or axes from the origin. Any point in space can be located relative to a known position
using coordinates. In order to machine a work piece on a CNC machine tool, we need
to establish a coordinate system in relation to the work piece to be machined. In NC
programming, they establish the position of cutting tools in relation to the work piece.

WORKING PRINCIPLE OF CNC MACHINES

It contains two distinct controls, one is CNC controller which doses the function of
program decoding interpolation, diagnostics machine actuation etc. Another is
programmable logic controller (PLC), which dose spindle on off, coolant on off, turret
operation etc.
The slides are moved by their own feed drive (AC or DC) servomotors or through balls
screw and nut drive. The feed drive controllers the feed drive motors. Suitable
transducers fitted either to the table or motor measure the slide position. Also the
position is monitored and checked through the feedback transducers to ensure the
accuracy of positioning. Spindle is provided with stepped motors of AC or DC. A
suitable control is used to vary is speed of the spindle motor. A suitable fed back device
attached to the shaft monitors the speed.
Features of CNC machines
1. Part program input may be through keyboard.
2. Part program is entered in to the computer and stored in the memory.
Then it is used again and again.
3. The part program once entered can be edited for any errors or design changes.
4. Graphical display of the cutter path and shape of the finished job before actually
running the program is possible (simulation).
5. Tool wear compensation is possible.
6. Able to get machine utilization information’s like number of components produced,
time per component, time for setting the job etc.,
7. Sub-program facility for repetitive machining sequences also possible.

AN EXAMPLE OF A PROGRAMMED CNC CODING