1.0 TITLE: CNC Milling (Non Traditional Machining) 2.0 OBJECTIVE: 1.

To develop more understanding about development and principle of CNC machine. 2. To learn various type of modern CNC machines and CNC modes of operations. 3. To understand the fundamentals of part programming in terms of t he various steps needed to be taken for completing a successful CNC program. 4. To understand the different preparatory (G codes) and miscellaneous functions (M codes) as used in CNC part program. 5. To understand the advantages and disadva ntages of CNC machines and their applications. 1

3.0 INTRODUCTION Numerical control (NC) refers to the automation of machine tool s that are operated by abstractly programmed commands encoded on a storage mediu m, as opposed to manually controlled or mechanically automated via cams alone. T he first NC machines were built in the 1940s and '50s, based on existing tools t hat were modified with motors that moved the controls to follow points fed into the system on paper tape. These early servomechanisms were rapidly augmented wit h analog and digital computers, creating the modern computer numerical controlle d (CNC) machine tools that have revolutionized the design process. In modern CNC systems, end-to-end component design is highly automated using CAD/CAM programs . The programs produce a computer file that is interpreted to extract the comman ds needed to operate a particular machine, and then loaded into the CNC machines for production. Since any particular component might require the use of a numbe r of different tools, modern machines often combine multiple tools into a single "cell". Diagram 1.1: CNC milling machine Modern CNC mills differ little in concept from the original model built at MIT i n 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 motor s through a series of step-down gears in order to provide highly accurate moveme nts, or in modern designs, direct-drive stepper motors. As the controller hardwa re evolved, the mills themselves also evolved. One change has been to enclose th e entire mechanism in a large box as a safety measure, often with additional saf ety interlocks to ensure the operator is far enough from the working piece 2

for safe operation. Mechanical manual controls disappeared long ago. CNC-like sy stems are now used for any process that can be described as a series of movement s and operations. These include laser cutting, welding, friction stir welding, u ltrasonic welding, flame and plasma cutting, bending, spinning, pinning, gluing, fabric cutting, sewing, tape and fiber placement, routing, picking and placing (PnP), and sawing. Diagram 1.2: the Data Processing in a CNC Machine Tool Features of CNC CNC systems include additional features beyond what is feasible with conventional hardwired NC. These features, many of which are standard of mo st CNC machine control units (MCU) where others are optional, include the follow ing: 1. Storages of more than one part. With improvements in computer storage te chnology, newer CNC controllers have sufficient capacity to store multiple progr ams. 2. Various forms of program input. Hard-wired MCUs are limited to punched t ape as the input medium for entering part programs, whereas CNC controllers poss ess multiple data entry capabilities. 3. Program editing at the machine tool. CN C permits a part program to be edited while it resides in the MCU computer memor y. Hence, the process of testing and correcting a program can be done entirely a t the machine site rather than returning to the programming office to edit the t ape. 3

4. Fixed cycles and programming subroutines. The increased memory capacity and t he ability to program the control computer provide the opportunity to store freq uently used machining cycles as macros that can be called by the part program. I nstead of writing the full instructions for the particular cycle into every prog ram, a call statement is included in the part program to indicate that the macro cycle should be executed. 5. Interpolation. Linear and circular interpolation i s sometimes hard-wired into the control unit, but helical, parabolic and cubic i nterpolations are usually executed in a stored program algorithm. 6. Positioning features for set up. Setting up the machine tool for a given workpart involves installing and aligning a fixture on the machine tool table. The alignment task can be facilitated using certain features made possible by software option in CN C system. Position set is one of these features. With position set, the operator is not required to locate the fixture on the machine table with extreme accurac y. 7. Cutter length and size compensation. In older style controls, cutter dimen sions had to be set very precisely to agree with the tool path defined in the pa rt program. 8. Acceleration and deceleration calculation. This feature is applic able when the cutter moves at high feed rates. It is designed to avoid tool mark s on the work surface that would be generated due to machine tool dynamics when the cutter path changes abruptly. 9. Communication interface. Most modern CNC co ntrollers are equipped with RS-232 or other communication interface to allow mac hine to be linked to other computers and computer driven devices. 10. Diagnostic . Many CNC systems possess an online diagnostics capability that monitors certai n aspects of the machine tool to detect malfunctions or sign of impending malfun ctions or to diagnose system breakdowns. Advantages of CNC machine CNC machine h as several advantages with emphasis on machine tool applications. When the produ ction application satisfies the characteristics needed, CNC yields many benefits over manual production methods. The benefits translate into economic saving for the user company. Some of the advantages are: i. ii. Nonproductive time is redu ced through fewer setup, less setup time, less workpiece handling time, and auto matic tool changes. Greater accurancy and repeatability. 4

iii. iv. v. vi. vii. viii. ix. x. xi. Lower scrap rates. Inspections requirements are reduced. More complex part geome tries are possible Enginnering changes can be accommodated more gracefully. Simp le fixture are needed. Shorter manufacturung lead times. Reduced parts inventory . Less floorspace required Operator skill level requirements are reduced. Machine Control Unit (MCU) CNC machine is fitted with MCU which is performs the various controlling functions under the program control. The MCU may be generall y housed in a seperated cabinet like cabinet body or may be mounted on the machi ne itself. Apperance wise it looks like a computer with a display panel generall y of small size and a number of button to control the machine tool along with a keyboard. This control unit control the motion of cutting tool, spindle speeds, feed rate, tool changes, cutting fluids application and several other functions of the mahine tool. The MCU consists of the following components and subsystems: (1) central processing unit, (2) memory, (3) input and output interface, (4) co ntrol for machine tool axes and spindle speed, and (5) sequence control for othe r machine tools. This subsystem interconneted by means of a system bus. Numerica l Control Mode The controller have number of modes in which the can operate. The re could be four possible modes in which the controller can function in relation to a machine centre. 1. Termed as point to point mode. In this, the control has the capability to operate all the three axes, but not necessarily simultaneousl y. It would be possible to move the tool to any point (in X and Y axes) and carr y out the machining operation in one axis (Z axis) at that point. 2. Improvement over point to point mode. The machine tool has the capability to carry out a co ntinuous motion in each of the axis direction. 3. A control system, which has si multaneous motion capability in any two axes. 5

4. The highest form of control that gives the capability of simultaneous three o r more axes motion. Part Program Part program is a very important software eleme nt in the NC manufacturing system. It is a detailed plan of manufacturing instru ctions required for machining the part as per drawing. The format standardized b y ISO. For example, N30 G00 X120 N40 G90 N50 G03 X200 ISO Standards for coding C HARACTER ADDRESS FOR A B C D E F G H I J K L M Angular dimension around X axis Angular dimension arou nd Y axis Angular dimension around Z axis Angular dimension around 3rd feed func tion Angular dimension around 2nd feed function Feed function Preparatory functi on Unassigned Distance to arc centre to X Distance to arc centre to Y Distance t o arc centre to Z Do not use Miscellaneous function Y45 Z 85 I-100 J0 F200 CHARACTER ADDRESS FOR N O P Q R S T U V W X Y Z Sequence number References rewind stop Third rapid tra verse dimension Second rapid traverse dimension First rapid traverse dimension S pindle speed function Tool function Secondary motion dimension parallel to X* Se condary motion dimension parallel to Y* Secondary motion dimension parallel to Z * Primary X motion dimension Primary Y motion dimension Primary Z motion dimensi on Preparatory functions This is denoted by G . It is a pre-set function associated with he movement of machine axes and the associated geometry. It has two digits as pe r ISO specifications. Some examples are shown: 6

CODE G00 G01 G02 G03 G04 G05 G06 G33 G53 G64 G80 FUNCTION rapid traverse line interpolation ciccular interpolation, clockwise circular int erpolation, anti-clockwise dwell hold/delay parabolic interpolation thread cutti ng, constant lead deletion of zero offset change in feed rate or speed canned cy cle cancelled Miscellaneous functions These functions operate some controls on the machine too l and affect the running of the machine. Generally, only one M-code is supposed to be given in a single block. The ISO standard examples are: CODE M00 M01 M02 M03 M04 M09 M10 M31 M68 FUNCTION program stop, spindle and coolant off optional programmable stop end of program spindle on, clockwise spindle on, anticlockwise coolant off clamp interlock by-p ass unclamp piece art 4.0 APPARATUS 1. CNC centroid milling machine 7

2. Machine control unit (MCU) 3. Plastic workpiece (100x100x15) 5.0 EXPERIMENTAL PROCEDURE A demonstration was carried on by our lecturer on: 8

1. At first, we have to check the programs to ensure that the machinery will fun ction properly and that the output will meet specifications. We downloaded the N C program to the controller by key in the data, cabling RS232 or APT after the p rogramming work is completed. 2. Tool layout. Before the machining was started, the tool layout must be check so that we got the desired shape of workpiece. 3. Workpiece setting. In this step, operator loaded the proper cutting tools into t he tool holder and positions the workpiece that is piece of metal or plastic tha t is being shaped on the CNC machine tool. 4. In machining process, after operat or load workpieces and cutting tools into a machine, after that the start button was pressed. Operator monitored the machine for problems, and measure the parts produced to check that they match specifications. 6.0 DATA AND RESULT 9

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ADDRESS X 14 14 30 70 86 86 70 30 Y 14 86 86 86 86 14 14 14 A B C D E F G H N01 N02 N03 N04 N05 N06 N07 N08 N09 N10 G00 G01 G01 G01 G03 G01 G01 G01 G03 G01 X X14 X14 X14 X30 X70 X86 X86 X30 X30 X14 Y Y14 Y14 Y86 Y86 Y86 Y86 Y14 Y14 Y14 Y14 Z Z5 Z2 Z2 Z2 Z2 Z2 Z2 Z2 Z2 Z2 Fix Rate(F) F0.5 Radius(R) F0.2 F0.5 R27 R27 11

7.0 DISCUSSSION From this experiment we can see the result of the work piece whe n using non-traditional machine CNC milling machine. This CNC milling are contro l by Centroid control, is a powerful PC based CNC that eliminates many typical l imitations of other controls. This Centroid control is so easy to use. These con trols are perfect for proto-typing, mold working, short or long run production. The Centroid control can be ordered in 3, and 4 axis configurations. The package provides automatic control of the spindle motor, the flood pump; the mister and lube pump (with auto low-lube detection with most models). Below is the result that we get with using this machine:

For the above product, we use the polymer material called Perspex . As we got the resu t, we could determine that the final shape of the product is very fine cutting; no burrs and the dimensional is precise and accuracy. Before we can get this result we need to program the code using NC programming. In order to ensure CNC machine do all the required operation, there are commands that must be included in the CNC programs in proper order. The command that bei ng used in CNC programs are in form of G and M codes, which each codes have thei r own function. So the codes that have been use to make this product we can see below:G00-rapid traverse G01-linear G02-circular counter clockwise G03- circular counter clockwise CD-G03 X70 Y86 R27 DE-G01 X86 F0.5 EF-G01 X86 Y14 FG-X30 12

GH-G03 X70 Y14 R27 HA-G01 X14 Before we do this operation zero set-up for the wo rk piece and machine tool must carried out. Generally, there are two types of me thod that can be used in zero set-ups for work piece and machine tool. The first method is to assign program zero in the program. This is the old method. By usi ng this method, the programmer will tells the control how far the distance of th e starting position of the machine from the program zero point. Usually this met hod is done by using G50 command. The second method to assign program zero is th rough some form of offset. This is the latest method. In this method, the cuttin g tool is pointed to the work piece and zero position is set at the computer con trol or input data. Between these two methods, the second one is the better way to assign program zero. The important of these zero set up before running the op eration is in order to get a positive value for the coordinates. It also allowed for a fixing a number of positions on the machine table whose coordinates can b e entered into the controller as a permanent memory. This zero set-ups helps to avoid errors from occur. On the run-test graphic screen, the present status such as the position of the machine slide, the spindle RPM, the feed rate and the pa rt programs will be displayed when the machine is running. We can also see the g raphic simulation of the tool path. Much other important information about CNC s ystem can also be seen on the screen. It is important for maintenance and instal lation work such as machine parameter, logic diagram of the programmer controlle r, error message and diagnostic data. So these machine much better than conventi onal machine because the flexibility of operation is improved, as well as the ab ility to produce complex shapes with good dimensional accuracy, good repeatabili ty, reduced scrap loss, high production rates and high product quality. We also can reduce tooling cost, because templates and other fixtures are not required. With CNC machine more operation can be performed with each setup, and the lead t ime for setup and machining required is less. Furthermore, design changes are fa cilitated, and inventory is reduced. Programs also can be prepared rapidly, and they can be recalled at any time, by utilizing microprocessors. Less paperwork i s involved. 13

8.0 CONCLUSION 1. The objective to acquaint students with NC programming and CNC Milling Machine has been achieved. 2. From this experiment, we can see that NC programming and CNC Milling Machine help a lot especially in milling process. 3. Milling machines are being replaced rapidly by this CNC Machines (computer numerical-control machines), which are more versatile and have capable of millin g, drilling, boring and also tapping with repetitive accuracy. 4. Milling proces s will be more easily and less time has been taken to complete the process. 5. O ther than that, this machine has the ability to produce complex shapes with high dimensional accuracy besides it can reduce the scrap loss. 14

9.0 REFERENCES i. ii. iii. Mikell P. Groover, Automation, Production Systems and Computer Integrated Manufa cturing, 2nd edition, Prentice Hall, 2001 P. N. Rao, CAD/CAM Principles and Appl ications, 2nd edition, Mc Graw Hill, 2004, Serope Kalpakjian, W.R. Schmid, Manuf acturing Technology and Fundamental, 5th edition, Prentice Hall, 2004 15