1.

0 Title

CNC Milling (Non-Tradiational Machine)

2.0 Objectives

1. To design a basic NC program for CNC Milling.

2. To machine a product using the CNC Milling.

3.0 Introduction

A non-traditional manufacturing process is defined as a group of processes that remove

accessed material by various techniques based on different source of energy. The cutting
source may in the form of mechanical, thermal, electrical or chemical energy or combinations
of these energies without any direct contact of sharp cutting as in traditional machining.
Extremely hard and brittle materials are difficult to machine by traditional machining
processes such as turning, drilling, shaping and milling. Non-traditional machining processes
are graphed in advanced manufacturing processes. It is employed when traditional machining
processes are not feasible and due to certain satisfactory justification to special reasons.

CNC Mills are classified according to the number of axes that they possess. Axes are
labelled as x and y for horizontal movement, and z for vertical movement, as shown in this
view of a manual mill table. A standard manual light-duty mill (such as a Bridgeport™) is
typically assumed to have four axes table x, y, z and milling head z.

The number of axes of a milling machine is a common subject of casual "shop talk" and
is often interpreted in varying ways. We present here what we have seen typically presented
by manufacturers. A five-axis CNC milling machine has an extra axis in the form of a
horizontal pivot for the milling head, as shown below. This allows extra flexibility for
machining with the end mill at an angle with respect to the table. A six-axis CNC milling
machine would have another horizontal pivot for the milling head, this time perpendicular to
the fifth axis. CNC milling machines are traditionally programmed using a set of commands
known as G-codes. G-codes represent specific CNC functions in alphanumeric format

G-code is the common name for the most widely used computer numerical control
(CNC) programming language, which has many implementations. Used mainly in automation,
it is part of computer-aided engineering. This general sense of the term, referring to the
language overall (using the mass sense of "code"), is imprecise, because it comes
metonymically from the literal sense of the term, referring to one letter address among many
in the language (G address, for preparatory commands) and to the specific codes (count sense)
that can be formed with it (for example, G00, G01, G28). In fact, every letter of the English
alphabet is used somewhere in the language, although some letters' use is less common.
Nevertheless, the general sense of the term is indelibly established as the common name of
the language. G-code is sometimes called G programming language.

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CODE DESCRIPTION COROLLARY INFO
G00 Rapid positioning On 2- or 3-axis moves, G00 (unlike G01)
traditionally does not necessarily move in a single
straight line between start point and end point. It
moves each axis at its max speed until its vector is
achieved.
G01 Linear interpolation The most common workhorse code for feeding
during a cut. The program specs the start and end
points, and the control automatically calculates
(interpolates) the intermediate points to pass through
that will yield a straight line (hence "linear"). The
control then calculates the angular velocities at
which to turn the axis lead screws
G02 Circular interpolation, Cannot start G41 or G42 in G02 or G03 modes.
clockwise Must already be compensated in earlier G01 block.
G03 Circular interpolation, Cannot start G41 or G42 in G02 or G03 modes.
counter clockwise Must already be compensated in earlier G01 block.

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4.0 Apparatus

Figure 4.1 : CNC Milling Machine Figure 4.2 : Machine Controller

Figure 4.3 : Catia Software Figure 4.4 : Cutting tools

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 4.1 Industrial Apparatus

Figure 4.5 : CL Compact (CNC Milling Machine/5Axis/Vertical)

The CL kompact is equipped with two motors on its Z axis. The device is ideally used for
high-speed machining and milling of resin models and aluminum molds. The linear axis
consist of X, Y, Z strokes ranging from 2200mm, 2000-3000-4000mm and 1300mm
respectively. The maximum speed is 70m/min on X and Y axis, while 60m/min on Z axis.
The maximum acceleration of the device ranges up to 3m/sec². The rotating axis rotates on
540° (C), +/-120° (A). Its maximum speed is 125°/sec (C) e (A). The axis uses hydraulic
brakes. The positioning accuracy of the rotating axis is 40/60 arcsec.The device uses HSK63A
tool-holder connection. The unit only needs minimal lubrication. Thedevice consist of 24
stations disk type tool magazine. The CL kompact is applied on molds, models, structures,
laminated and composites.

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5.0 Experimental Procedure

1. Sport steering is designed using CATIA software. The design measurement is 60 x 60.
2. The sport steering design is checked by the technician. Rough stock is added to the
sport steering design.
3. Simulation is made to make sure that the specimen is working correctly.
4. Once the design and simulation is completed, the NC program from computer aided
manufacturing (CAM) is transfer to the machine controller using a pen drive.
5. Before the machining is started, the tool setting must be check so that we got the
desired shape of work piece.
6. Work datum setting. The rough stock is set at the x-axis, y-axis, and z-axis using the
cutting tools.
7. Lastly machining process, first stages is rough surface and the second stages is
finishing where the sharp edge is eliminated.

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6.0 Result and Data Analysis

Figure 6.1 : CNC Programing using CATIA (CAM)

Figure 6.2 : Rough Surface Figure 6.3 : Finishing

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 Figure 6.4 : Final Result

NC Programme ( CAM)

% N5850 Y12.773 Z-.075

O1000 N5851 Y13.07 Z-.037
( *********************************************** ) N5852 Y13.279 Z-.019
( * INTELLIGENT MANUFACTORY SOFTWARE WWW.IMS- N5853 Y13.793 Z0
SOFTWARE.COM *) N5854 Z6.
(* IMSPOST VERSION : 7.4R *)
N5855 G0 X14.79 Y5.796
(* USER VERSION : 1 *) N5856 Z-3.447
( ******************************************** ***) N5857 G1 Y0 Z-5. F300.
N1 G49 G64 G17 G80 G0 G90 G40 G99 N5858 Y7.958 F1000.
( TOOL DATA : T1 END MILL D 1 ) N5859 Y7.962 Z-4.782
N2 T0001 M6 N5860 Y7.987 Z-4.471
N3 X51.436 Y66.1 S70 M3 N5861 Y8.058 Z-4.037
N4 G43 Z8.125 H1 N5862 Y8.079 Z-3.942
N5 G1 G94 Z-1.875 F300. N5863 Y8.236 Z-3.412
N6 Y60. N5864 Y8.466 Z-2.881
N7 X60. F1000. N5865 Y8.566 Z-2.702
N8 Y0 N5866 Y8.814 Z-2.301
N9 X0 N5867 Y9.188 Z-1.829
N10 Y60. N5868 Y9.336 Z-1.678
N11 X51.436 N5869 Y9.692 Z-1.338
N12 Y59. N5870 Y10.028 Z-1.085
N13 Y58. N5871 Y10.266 Z-.915
N14 X57. N5872 Y10.946 Z-.546
N15 X57.707 Y57.707 N5873 Y11.693 Z-.265
N16 X58. Y57. N5874 Y12.29 Z-.122
N17 Y41.835 N5875 Y12.537 Z-.075
N18 X57.189 Y43.757 N5876 Y12.806 Z-.04
N19 X57.055 Y44.02 N5877 Y13.142 Z-.012
N20 X54.881 Y47.592 N5878 Y13.544 Z0
N21 X54.709 Y47.833 N5879 Z6.
N22 X51.975 Y51.111 N5880 M5
N23 X51.766 Y51.326 N5881 M30
N24 X48.597 Y54.138 N5882 M2
N25 X48.397 Y54.294 N5883 M30
N26 X46.002 Y55.929 %
N27 X45.749 Y56.076
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 7.0 Discussion of Results

Based from the experiment that have been conducted which is CNC Milling, we have
learn and understand the use and capabilities of computer numerical control (CNC) milling
machine. For the set up of the CNC operation, the computer numerical control is attached to
the milling machine. Firstly, Computer Aided Design (CAD) is used to make a design of a
product. In CAD, it involves a special symbolic programming languages or codes that
determine the coordinate points of corner, edges and surfaces of the work piece. Once the
design is completed, we transfer the coding that we made using ISO NC programmed to the
CNC milling machine. All the data about the process from the beginning to the end is
included in those codes. Wrong coding will damage the work piece. In order to prevent
damage, we need to view the simulation on the CNC screen and do some final editing so that
the milling machine is operating in a good condition as we will obtain perfectwork piece. Any
errors or mistakes will affect the work piece as well as the machine. The machine‟s cutting
tool might break.

The height of cutting tool, cutting fed, cuttingspeed , spindle speed is set up until
suitable with the specimen to avoid error occur during the process. From the experiment, we
can say that our product is perfect and thus our experiment is 100% success. The product
follows the original design and the surfaces are completely smooth. From the product
obtained, the coordinate system plays an important role to make sure the product is not
defected.While CNC milling machines are expensive and complicated, they have a lot of
advantages. These are some advantages of CNC machine:

 It improves automation, removing the need of an operator for all but a few parts of the
work. CNC machines can be left unattended for hours or even days if necessary,
allowing operators to focus on other tasks.
 CNC machines can be used continuously 24 hours a day, 365 days a year and only
need to be switched off for occasional maintenance.
 CNC machines can be updated by improving the software used to drive the machines.
 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

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 8.0 Conclusion

Based from the experiment that had been done, the objective of these experiments has
been achieved. We have learnt how to develop and have more understanding about principle
of CNC machine also the various type of modern CNC machines and CNC modes of
operations. Besides that we has understand the fundamentals of part programming in terms of
the various steps needed to be taken for completing a successful CNC program and different
preparatory (G codes) and miscellaneous functions (M codes) as used in CNC part program.

Then, the important of this experiment is also to ensure that student can determine the
advantage and also disadvantage of CNC milling machine. This is so that we can overcome
all the problem that occurs during the experiment in the future.

9.0 Recommendation

1. Standardized software and instruction manual to all machines either from Japan or
Germany, to make it easier to operator and also the student to handle the machine.
2. Reduce a little bit of size so that can reduce the use of space at workshop.
3. Machines should be equipped with a sensor error in the coding, to avoid miss cut
interval of points if follow the wrong direction on the coding.
4. CNC Milling Machine should be fully integrate or connected with design computer for
ease of use and no need to transfer the coding data by using pen drive.

10.0 References

1. Smid, Peter (2008), CNC Programming Handbook ( 3rd edition), New York: Industrial
Press
2. Reinjtes, J.Francis (1991),Numerical Control: Making a New Technology, Oxford
University Press
3. http://www.cs.cmu.edu/~rapidproto/students.03/dwm3/project2/process.htmlhttp://en.w
ikipedia.org/wiki/G-code
4. http://www.directindustry.com/prod/system-robot-automazione/cnc-milling-machines-
5-axis-vertical-50459-348800.html
5. http://www.thomasnet.com/about/cnc-milling-51276103.html

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Contents
1.0 Title .............................................................................................................................................. 1
2.0 Objectives .................................................................................................................................... 1
3.0 Introduction ................................................................................................................................. 1
4.0 Apparatus .................................................................................................................................... 3
4.1 Industrial Apparatus ................................................................................................................ 4
5.0 Experimental Procedure .............................................................................................................. 5
6.0 Result and Data Analysis ............................................................................................................. 6
7.0 Discussion of Results ................................................................................................................... 8
8.0 Conclusion ................................................................................................................................... 9
9.0 Recommendation ........................................................................................................................ 9
10.0 References ................................................................................................................................... 9

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