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0 TITLE: CNC Milling (Non Traditional Machining 2)

2.0 INTRODUCTION

Removal of materials need to use tools that are harder than the material. New
materials have improved mechanical, thermal and chemical properties. Traditional
machining processes such as turning, drilling, shaping and milling sometimes cannot
machine these brittle and extremely hard materials. There are also materials which are
too flexible to resist cutting forces or too difficult to clamp. Besides that, in some
cases, requirements for surface finish and tolerances are very high. Therefore,
non-traditional machining is used to overcome these problems.

Non-traditional machining uses different source of energy to generate

machining action. Examples of the energy source are mechanical, thermal, electrical
and chemical. Sometimes it can also be the combination of these energies. Computer
numerical control (CNC) machining is an example of many types of non-traditional
machining. Many of the operations performed by drilling and cutting machines can be
achieved by milling machining process. A cylindrical rotating cutting tool is used in
milling. A variety of holes and shapes can be created as the cutting tool can move
along multiple axes. There are several types of CNC machine. CNC milling machine
is the most widely used among them.

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2.1 THEORY

NC machines have took the biggest role from manual tools to NC machines. NC
machines is a cutting machine used to perform a removal process of unwanted part in
order do the finishing. Many improvements have been made to the milling machine
such as accuracy and also speed.

There are two classifications of NC machine, which is cutting machines and also
non cutting machines. Cutting machines is machines that that do a removing process
in order to make a finished part. For an instance, milling, turning and EDM machine.
Whereas, for a non cutting machines, the shape of blank material was changed by
force applied to it. For example, a press machine.

As the NC machines develop, it also function to machine a complex part

accurately. Hence, there is addition of numerical controller to the milling machine.
Nevertheless, application of NC has become well known for a rapid productivity.
Therefore, it has been also used in many machines as well such as turning machines
and tapping machines.

NC machine technology also have been used in many factory regarding its
automation. This results in permitting a Flexible Manufacturing System (FMS) by
cooperating machines with productions equipment. For an instance, robots, automated
warehouse and many more. NC machine also used in all motion controlled machines.
For examples, Coordinate Measurement Machines (CMM). NC is the most basic
technology for factory automation.

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3.0 OBJECTIVE

1. To get to know how to design a basic NC program for CNC MIlling purposes and
also to know the process of designing NC program. .
2. To get to know on how the process of machining a product by using the CNC
MIlling machine.

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 4.0 APPARATUS

Rough stock

Figure 4.1: rough stock

CNC Milling
machine

Rough stock

Figure 4.2: CNC Milling Machine

Cutting Tool

Figure 4.3: Cutting tool

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5.0 EXPERIMENTAL PROCEDURE
1) Design a product using CATIA software in laptop.

2) Create Nc programme in CAM and download it to controller.

3) After that, we set the most suitable cutting tool to use for this product which is
3mm diameter cutter, flat end and 2 flute.

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4) Before machining, we setting the datum of the product and the distance of the
product and the cutter according to x, y and z axis.

5) Place the sample to the base of the milling machine. Use double tape for heavy
duty to make sure the sample did not move during the machining process.

6) After setting the cutting tool and work datum setting, start the machining by
using CNC milling machine until the final product finished.

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6.0 RESULT

From this experiment, figure below shows the final product that we manage to obtain.
There were several minor defects occur on the wooden block.

Figure 6.1: Final result

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7.0 DISCUSSION

For this experiment, we were given a wooden block and our task was to engrave a
particular word onto the wooden block. In this case, our class and group. CATIA
software was used to develop the text and then, the codes and program was generated
and transferred to the machine to proceed with the process of engraving.

CNC machining was used in order to execute the final result on the wooden block,
a list of instructions need to be generated by using NC programming. First, the NC
programming was designed by using a CATIA software. The codes used were G
codes and M codes.

G codes normally programmed at the beginning part of the wooden block. It is

generated to determine the movements of the tool’s geometry and also to set the
controller’s operation. Apart from G and M codes, another addresses highlighted in
this process are N: Block Number, F: Feed rate, S: Spindle speed.

During the process of engraving, we were able to discovered that the size of the
tools used to engraved on the wooden block was too big for the type of font that was
chose. Hence, the final result was not very smooth. Some defect and roughness can be
seen on the wooden block. This is due to the size of the tools might be not suitable for
our case.

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8.0 CONCLUSION

This experiment or training proved to be quite useful. This is because we

manage to study the operation of the CNC milling machine, the way the various units
are linked, and become more understand about non-traditional machining process.
This experiment make we realize that engineering is not just the structural description
but more of planning and management. The objective to acquaint us with NC
programming and CNC Milling Machine has been achieved. Milling machines are
being replaced rapidly by this CNC Milling Machine which are more versatile and
have capable of milling, drilling, boring and also tapping with repetitive accuracy.
Milling process will be easier and less times has been taken to complete the process.
Other than that, this machine has ability to produce complex shape with high
dimensional accuracy besides it can reduced the scarp loss. From this experiment, we
can see that NC programming and CNC Milling Machine help a lot in milling
process.

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9.0 RECOMMENDATION

Based on the experiment, to improve the experiment process and the product
quality there are some recommendations that can be done. We thought we could list it
although some of it is not a major problem, so that we can see that there are some
rooms for improvement for the future.

Firstly, vibration is one of the main problem that occur in milling machine
because tit may affect the finishing of a product. For an instance, damages could be
done and seen on a surface finish. By adding work holder such as clamp can help in
decreasing the vibration and it will results in producing a better surface finish,
improved the accuracy of the dimension in NC program. Hence, it is possible to
produce a complex shaped product.

Next, to improve the quality of the product, we have to decreased the value of
step over while the machining process was being setup. It will create a better quality f
product which is a much smoother surface at the curve area. In addition, a smaller size
of cutting tools can be used in order to obtain a smoother surface at curve surface.

Lastly,a datum must be set precisely in order to produce a desired product, or else,
the product might not be as what we planned.

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10.0 REFERENCES

1. Timothy R. Loveless, R.E. Williams, K.P. Rajurkar, “A Study of The Effects

of Abrasive-Flow Finishing on Various Machined Surfaces,” Journal of
Materials Processing Technology, Vol. 47, No. 1-2, 1994, pp. 133-151.

2. Shawasta Das, Shankar Chakborty, “Selection of Non-Traditional Machining

Processes Using Analytic Network Process,” Journal of Manufacturing
Systems, Vol. 30, No.1, 2011, pp. 41-53.

3. J. Paulo Davim, Machining: Fundamentals and Recent Advances, Springer,

London, 2008, pp. 1-3.

4. Seungkil Son, Taejung Kim, Sanjay E. Sarma, Alexander Slocum, “A Hybrid

5-Axis CNC Milling Machine,” Precision Engineering, Vol. 33, No.4, 2009,
pp. 430-446.

5. Chana Raksiri, Manukid Parnichkun, “Geometric and Force Errors

Compensation in a 3-Axis CNC Milling Machine,” International Journal of
Machine Tools and Manufacture, Vol. 44, No. 12-13, 2004, pp. 1283-1291.

6. Serope Kalpakjian & Steven Rschmid (2013), Manufacturing Engineering and

Technology 7th edition, Pearson - Prentice Hall International.

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APPENDIX

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