Beruflich Dokumente
Kultur Dokumente
Session
Fall 2014-18
(Mechanical
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Final project report BS mechanical
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Final project report BS mechanical
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Final project report BS mechanical
UNIVERSITY OF SARGODHA
2018
INTERNAL EXAMINER
SIGNATURES: -----------------------------------------------------------
DATE: ------------
EXTERNAL EXAMINER
SIGNATURES: ---------------------------------------------------------
DATE: ------------
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PROJECT
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Contents
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References …………………………………………………………………...71
Bibliography……………………………………………………………...….73
Internet……………………………………………………………………….73
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Chapter 1
Milling Machine
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Milling Machine
1.1 Introduction
Milling is the machining process of using rotary cutters to remove
material from a work piece by advancing (or feeding) the cutter into the work
piece at a certain direction. The cutter may also be held at an angle relative to
the axis of the tool. Milling covers a wide variety of different operations and
machines, on scales from small individual parts to large, heavy-duty gang
milling operations. It is one of the most commonly used processes for
machining custom parts to precise tolerances.
Milling can be done with a wide range of machine tools. The original
class of machine tools for milling was the milling machine (often called a mill).
After the advent of computer numerical control (CNC), milling machines
evolved into machining centers: milling machines augmented by automatic tool
changers, tool magazines or carousels, CNC capability, coolant systems, and
enclosures. Milling centers are generally classified as vertical machining centers
(VMCs) or horizontal machining centers (HMCs).
The integration of milling into turning environments, and vice versa,
begun with live tooling for lathes and the occasional use of mills for turning
operations. This led to a new class of machine tools, multitasking machines
(MTMs), which are purpose-built to facilitate milling and turning within the
same work envelope.
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The cutting surfaces of a milling cutter are generally made of a hard and
temperature-resistant material, so that they wear slowly. A low cost cutter may
have surfaces made of high speed steel. More expensive but slower-wearing
materials include cemented carbide. Thin film coatings may be applied to
decrease friction or further increase hardness.
They are cutting tools typically used in milling machines or machining
centers to perform milling operations (and occasionally in other machine tools).
They remove material by their movement within the machine (e.g., a ball nose
mill) or directly from the cutter's shape (e.g., a form tool such as a hobbing
cutter).
As material passes through the cutting area of a milling machine, the
blades of the cutter take swarfs of material at regular intervals. Surfaces cut by
the side of the cutter (as in peripheral milling) therefore always contain regular
ridges. The distance between ridges and the height of the ridges depend on the
feed rate, number of cutting surfaces, the cutter diameter. With a narrow cutter
and rapid feed rate, these revolution ridges can be significant variations in
the surface finish.
The face milling process can in principle produce very flat surfaces.
However, in practice the result always shows visible trochodial marks following
the motion of points on the cutter's end face. These revolution marks give the
characteristic finish of a face milled surface. Revolution marks can have
significant roughness depending on factors such as flatness of the cutter's end
face and the degree of perpendicularity between the cutter's rotation axis and
feed direction. Often a final pass with a slow feed rate is used to improve the
surface finish after the bulk of the material has been removed. In a precise face
milling operation, the revolution marks will only be microscopic scratches due
to imperfections in the cutting edge.
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CNC context) would be gang milling. All the completed work pieces would be
the same, and milling time per piece would be minimized.
Gang milling was especially important before the CNC era, because for
duplicate part production, it was a substantial efficiency improvement over
manual-milling one feature at an operation, then changing machines (or
changing setup of the same machine) to cut the next op. Today, CNC mills with
automatic tool change and 4- or 5-axis control obviate gang-milling practice to a
large extent.
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and planes. Special cutters can also cut grooves, bevels, radii, or indeed any
section desired. These specialty cutters tend to be expensive. Simplex mills have
one spindle, and duplex mills have two. It is also easier to cut gears on a
horizontal mill. Some horizontal milling machines are equipped with a power-
take-off provision on the table. This allows the table feed to be synchronized to
a rotary fixture, enabling the milling of spiral features such as hypoid gears.
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spindle's axial movement is normal to one plane, with an end mill as the cutter,
lends itself to a vertical mill, where the operator can stand before the machine
and have easy access to the cutting action by looking down upon it. Thus
vertical mills are most favored for die sinking work (machining a mold into a
block of metal). Heavier and longer work pieces lend themselves to placement
on the table of a horizontal mill.
Prior to numerical control, horizontal milling machines evolved first,
because they evolved by putting milling tables under lathe-like headstocks.
Vertical mills appeared in subsequent decades, and accessories in the form of
add-on heads to change horizontal mills to vertical mills (and later vice versa)
have been commonly used. Even in the CNC era, a heavy work piece needing
machining on multiple sides lends itself to a horizontal machining center, while
die sinking lends itself to a vertical one.
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These are built to bore holes, and very light slot or face milling. They are
typically bed mills with a long spindle throw. The beds are more accurate.
This can refer to any mill that has a cutting head mounted on a
sliding ram. The spindle can be oriented either vertically or
horizontally.
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Chapter 2
Concept of CNC
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Concept of CNC
2.1 CNC
CNC means Computer Numerical Control. This means a computer
converts the design produced by Computer Aided Design software (CAD), into
numbers. The numbers can be considered to be the coordinates of a graph and
they control the movement of the cutter.
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Various other codes are also used. A CNC machine is operated by a single
operator called a programmer. This machine is capable of performing various
operations automatically and economically.
With the declining price of computers and open source CNC software, the
entry price of CNC machines has plummeted.
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machine; and then loaded into the CNC machines for production. Since any
particular component might require the use of a number of different tools,
modern machines often combine multiple tools into a single cell.
Modern CNC machines differ little in concept from the original model
built at MIT in 1952. Mills typically consist of a table that moves in the Y-axis
and a tool chuck that moves in X and Z (depth). The position of the tool is
driven by motors through a series of step down gears in order to provide highly
accurate movements, or in modern designs, direct drive stepper motors. As the
controller hardware evolved, the mills themselves also evolved. One change has
been to enclose the entire mechanism in a large box as a safety measure, often
with additional safety interlocks to ensure the operator is far enough from the
working piece for safety operation. Mechanical manual controls disappeared
long ago.
2.3.1 Operations
CNC like systems are now used for any process that can be described as a
series of movements and operations. These include:
Laser cutting
Welding
Friction stir welding
Ultra-sonic welding
Flame and plasma cutting
Bending
Spinning
Pinning
Gluing
Fabric cutting
Sewing
Tape and fiber placement
Routing
Picking and placing (PnP)
Sawing
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Non-productive time is reduced through fewer steps, less setup time, less
work piece handling time and automatic tool changes.
Greater accuracy and repeatability
Lower scrap rates
Inspections requirements are reduced
More complex parts geometries are possible
Engineering changes can be accommodated more gracefully.
Simple fixtures are needed
Shorter manufacturing lead times
Reduced parts inventory
Less floor space required
Operator skill level requirements are reduced
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keyboard. This control unit controls the motion of cutting tool, spindle speeds,
feed rate, tool changes, cutting fluid applications and several other functions of
the machine tool.
Termed as point to point mode. In this mode, the control has the
capability to operate all the three axis, but not necessarily simultaneously.
It would be possible to move the tool to any point (in X and Y axis) and
carry out the machining operation in one axis (Z axis) at that point.
Improvement over point to point mode. The machine tool has the
capability to carry out a continuous motion in each of the axis direction.
A control system, which has simultaneously motion capability any two
axes.
The highest form of control that gives the capability of simultaneous
three or more axes motion.
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N40 G90
Table 2.1
Character Address for
A Angular dimension around X Axis
B Angular dimension around Y Axis
C Angular dimension around Z Axis
D Angular dimension around 3rd feed function
E Angular dimension around 2nd feed function
F Feed function
G Preparatory function
H Unassigned
I Distance to arc center to X
J Distance to arc center to Y
K Distance to arc center to X
L Do not use
M Miscellaneous function
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N Sequence number
O References rewind up
P Third rapid traverse dimension
Q Second rapid traverse dimension
R First rapid traverse dimension
S Spindle speed function
T Tool function
U Secondary motion dimension parallel to X
V Secondary motion dimension parallel to Y
W Secondary motion dimension parallel to Z
X Primary X motion dimension
Y Primary Y motion dimension
Z Primary Z motion dimension
Table 2.2
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G&M CODES
Catego Functi
Code Notes
ry on
Move in a
straight line XYZ of
G00 Motion
at rapids endpoint
speed.
Move in a
straight line
at last
XYZ of
G01 Motion speed
endpoint
commanded
by a
(F)feedrate
XYZ of
Clockwise endpoint
circular arc IJK
G02 Motion
at relative to
(F)feedrate center R
for radius
XYZ of
Counter-
endpoint
clockwise
IJK
G03 Motion circular arc
relative to
at
center R
(F)feedrate
for radius
Dwell: Stop P for
for a millisecon
G04 Motion
specified ds X for
time. seconds
FADAL
G05 Motion Non-Modal
Rapids
Exact stop
G09 Motion
check
Programma
Compensatio ble
G10 n parameter
input
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Turn Polar
Coordinates
G15 Coordinate OFF, return
to Cartesian
Coordinates
Turn Polar
G16 Coordinate Coordinates
ON
Select X-Y
G17 Coordinate
plane
Select X-Z
G18 Coordinate
plane
Select Y-Z
G19 Coordinate
plane
Program
G20 Coordinate coordinates
are inches
Program
G21 Coordinate coordinates
are mm
Reference
G27 Motion point return
check
Return to
G28 Motion home
position
Return from
the
G29 Motion
reference
position
Return to
the 2nd,
G30 Motion 3rd, and 4th
reference
point
Constant
lead
threading
G32 Canned (like G01
synchronize
d with
spindle)
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Tool cutter
compensati
Compensati
G40 on off
on
(radius
comp.)
Tool cutter
compensati
Compensati
G41 on left
on
(radius
comp.)
Tool cutter
compensati
Compensati
G42 on right
on
(radius
comp.)
Apply tool
Compensati length
G43
on compensati
on (plus)
Apply tool
Compensati length
G44
on compensati
on (minus)
Tool length
Compensati
G49 compensati
on
on cancel
Reset all
Compensati scale
G50
on factors to
1.0
Turn on
Compensati
G51 scale
on
factors
Local
workshift for
all
G52 Coordinate coordinate
systems:
add XYZ
offsets
G53 Coordinate Machine
coordinate
system
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(cancel
work
offsets)
Work
coordinate
G54 Coordinate
system (1st
Workpiece)
Work
coordinate
G55 Coordinate
system (2nd
Workpiece)
Work
coordinate
G56 Coordinate
system (3rd
Workpiece)
Work
coordinate
G57 Coordinate
system (4th
Workpiece)
Work
coordinate
G58 Coordinate
system (5th
Workpiece)
Work
coordinate
G59 Coordinate
system (6th
Workpiece)
Exact stop
G61 Other
check mode
Automatic
G62 Other corner
override
Tapping
G63 Other
mode
Best speed
G64 Other
path
Custom
G65 Other macro
simple call
G68 Coordinate Coordinate
System
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Rotation
Cancel
Coordinate
G69 Coordinate
System
Rotation
High speed
drilling cycle
G73 Canned
(small
retract)
Left hand
G74 Canned tapping
cycle
Fine boring
G76 Canned
cycle
Cancel
G80 Canned canned
cycle
Simple
G81 Canned
drilling cycle
Drilling
cycle with
G82 Canned dwell
(counter-
boring)
Peck drilling
G83 Canned cycle (full
retract)
Tapping
G84 Canned
cycle
Boring
canned
G85 Canned cycle, no
dwell, feed
out
Boring
canned
cycle,
G86 Canned
spindle
stop, rapid
out
G87 Canned Back boring
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canned
cycle
Boring
canned
cycle,
G88 Canned
spindle
stop,
manual out
Boring
canned
G89 Canned
cycle, dwell,
feed out
Absolute
programmin
G90 Coordinate g of XYZ
(type B and
C systems)
Absolute
programmin
G90.1 Coordinate g IJK (type
B and C
systems)
Incremental
programmin
G91 Coordinate g of XYZ
(type B and
C systems)
Incremental
programmin
G91.1 Coordinate g IJK (type
B and C
systems)
Offset
coordinate
G92 Coordinate system and
save
parameters
Clamp of
G92
maximum
(alternat Motion S
spindle
e)
speed
G92.1 Coordinate Cancel
offset and
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zero
parameters
Cancel
offset and
G92.2 Coordinate
retain
parameters
Offset
coordinate
G92.3 Coordinate system with
saved
parameters
Units per
minute feed
G94 Motion mode. Units
in inches or
mm.
Units per
revolution
feed mode.
G95 Motion
Units in
inches or
mm.
Constant
G96 Motion surface
speed
Cancel
constant
G97 Motion
surface
speed
Return to
initial Z
G98 Canned plane after
canned
cycle
Return to
initial R
G99 Canned plane after
canned
cycle
M-Codes
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Functio
Code Category Notes
n
Program
M00 M-Code Stop (non-
optional)
Optional
Stop:
M01 M-Code Operator
Selected to
Enable
End of
M02 M-Code
Program
Spindle ON
M03 M-Code (CW
Rotation)
Spindle ON
M04 M-Code (CCW
Rotation)
Spindle
M05 M-Code
Stop
Tool
M06 M-Code
Change
Mist
M07 M-Code
Coolant ON
Flood
M08 M-Code
Coolant ON
Coolant
M09 M-Code
OFF
FADAL
M17 M-Code subroutine
return
Rigid
Tapping
M29 M-Code Mode on
Fanuc
Controls
M30 M-Code End of
Program,
Rewind and
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Reset
Modes
Haas-Style
M97 M-Code Subprogram
Call
Subprogram
M98 M-Code
Call
2.8.3
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2.8.4
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2.9 Tools
The accessories and cutting tools used on machine tools (including
milling machines) are referred to in aggregate by the mass noun "tooling".
There is a high degree of standardization of the tooling used with CNC milling
machines, and a lesser degree with manual milling machines. To ease up the
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High speed steels and cobalt end mills are used for cutting operations in milling
machines.
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In this approach, the tool travels along a gradually evolving spiral path.
The spiral starts at the center of the pocket to be machined and the tool
gradually moves towards the pocket boundary. The direction of the tool path
changes progressively and local acceleration and deceleration of the tool are
minimized. This reduces tool wear.
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Chapter 3
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3.1 CNC
CNC means Computer Numerical Control. This means a computer
converts the design produced by Computer Aided Design software (CAD), into
numbers. The numbers can be considered to be the coordinates of a graph and
they control the movement of the cutter.
3.2 Axis
An axis is a direction of motion controlled by the CNC machine control.
It can be linear (motion along a straight line) or circular (a rotary motion).
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3.3.2 Frame 1
Base: 330mm×2、360mm×3
Angle Support×6、M5*10×12
Spacer×12
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3.3.3 Frame 2
Base 220mm×2、360mm×2
Angle Suport×4、M5*10×8
Specer×8
3.3.4 Frame 3
Angle Support×6、M5*10×16
Spacer×12
Connecting pieces×2
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3.3.7 Y-Axis
M6*10×10
Sliding Block×5
Worktable×1
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SPINDLE OF CNC:
CNC Spindle
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Arduino
GRBL-Shield
Stepper Driver
Power Supply
Stepper Motors
Milling Spindle
Inverter
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Linear bearings
Linear rails
Ball circulating spindles
Fix spindle bearing and stepper holder
Lose spindle bearings
Spindle stepper coupling
Frame
Gantry
Linear X- bearing
Y-Profile
Z-Profile
Z-Sliding plate for spindle mounting
3.6 Working
Computer numerical control (CNC) has been incorporated into a variety
of new technologies and machinery. Perhaps the most common type of machine
that is used in this realm is known as a CNC mill.
CNC milling is a certain type of CNC machining. Milling is a process
that is quite similar to drilling or cutting, and milling can perform these
processes for a variety of production needs. Milling utilizes a cylindrical cutting
tool that can rotate in various directions. Unlike traditional drilling, a milling
cutter can move along multiple axes. It also has the capability to create a wide
array of shapes, slots, holes, and other necessary impressions. Plus, the work
piece of a CNC mill can be moved across the milling tool in specific directions.
A drill is only able to achieve a single axis motion, which limits its overall
production capability.
CNC mills are often grouped by the number of axes on which they can
operate. Each axis is labeled using a specific letter. For example, the X and Y
axes represent the horizontal movement of the mill’s work piece. The Z axis
designates vertical movement. The W axis represents the diagonal movement
across the vertical plane.
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Plain milling
Gear cutting
Form milling
Straddle milling
Gang milling
Slot milling
T-slot milling
Angular milling
Flat milling
Drilling
Reaming
Boring
References
Brown & Sharpe 1914, p. 7.
Currently the term "miller" refers to machines built when that term
was current, as with "phonograph" and "horseless carriage."
Baida 1987
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Pease 1952
Bibliography
Usher, John T. (1896). The Modern Machinist (2nd ed.). N. W. Henley.
Retrieved 2013-02-01.
Roe, Joseph Wickham (1916), English and American Tool Builders, New
Haven, Connecticut: Yale University Press, LCCN 16011753. Reprinted
by McGraw-Hill, New York and London, 1926 (LCCN 27-24075); and
by Lindsay Publications, Inc., Bradley, Illinois,(ISBN 978-0-9179-73-7)
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Roe, Joseph Wickham (1916), English and American Tool Builders, New
Haven, Connecticut: Yale University Press, LCCN 16011753. Reprinted
by McGraw-Hill, New York and London, 1926 (LCCN 27-24075); and
by Lindsay Publications, Inc., Bradley, Illinois, (ISBN 978-0-914-73-7).
Internet
www.wikipedia.org
www.szmillingmachine.com
www.warco.com
www.axminster.com
www.indiamart.com
www.toolco
www.engineeringtools.com
www.engineeredge.com
www.machinex.com
www.skyfirecnc.com
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