fastmoving spares is done.

The rolls in circula on are placed in iden fied areas of

the roll storage area for their easy retrieval. Roll shop-II comprises roll turning shop,
bearing shop and guide shop catering to the requirement of MMSM. Roll turning
shop is equipped with six CNC lathes for grooving new rolls, as well as redressing.
The grooved rolls are assembled with bearings in the bearing shop. Chocks with
bearings serviced periodically. Assembly and service and repair of guides,
prepara on of strippers used in rolling of angles, channels and beams.
Area repair shop is a machine shop with general purpose machine tools like lathes,
shapes, milling, slo ng, drilling and grinding machines, ver cal press fabrica on
etc... Repair and manufacture of spares for the mills as well as Roll shop spares is
done here. The planning and procurement of mill guides chocks, with bearings and
other spares required for the guides is done by the planning sec on. The quality of
spares and service of roll shop and repair shop has a very important role in the mills
produc on and produc vity.

Grooved Rollers RolingRolling Stands

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Different Guides used in Rolling Stands:

Entry Guide Structural Delivery Guide Neutral Guide

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3. OPERATION AND MAINTENANCE OF CNC LATHE
 A CNC (Computer Numerical Control) lathe operates by rota ng the
workpiece while a cu ng tool moves in various axes to remove material. The
lathe can perform various opera ons like facing, turning, drilling grooving
and threading.
 It is highly precise and can produce complex parts with consistent quality.
They offer advantages like increased produc vity, reduced setup mes, and
minimized human error.
 Programming for CNC lathes involves wri ng code that specifies tool
movements and cu ng parameters.
 Modern CNC lathes o en feature automa c tool changers and mul axis
capabili es for enhanced versa lity.

In Rolling shops CNC Lathe machine is used for two main processes:
[Link]: Turning is a machining opera on that involves cu ng Workpiece while
it rotates on a lathe. The cu ng tool is moved Parallel to the axis of rota on,
removing material from the workpiece to create a cylindrical or tapered shape.

[Link]: Turning process takes place for the rolls which already used in
rolling process

New Rolls Roll Turning

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PARTS OF CNC LATHE:

PROCESSING OF CNC MACHINE:

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3.2 TYPES OF PROGRAMMING
• ABSOLUTE PROGRAMMING:
In absolute programming, coordinates are given with respect to a fixed reference
point, typically the origin (0, 0, 0) of the machine's coordinate system.
For example, if you want to move the tool to a specific posi on (X, Y, Z), you specify
the exact coordinates from the origin.
Absolute programming is straigh orward and easy to understand but can be less
flexible when dealing with complex machining opera ons or when there are
changes in the workpiece setup.

• RELATIVE PROGRAMMING:
In rela ve programming (also known as incremental programming), coordinates are
specified rela ve to the current posi on of the tool. Instead of specifying an
absolute posi on, you specify the distance and direc on the tool should move from
its current posi on.
For example, if the tool is currently at posi on (X1, Y1, Z1) and you want to move it
10 units in the X direc on and 5 units in the Y direc on, you would specify (X1 + 10,
Y1 + 5, Z1).
Rela ve programming is o en used for making incremental adjustments or
performing opera ons rela ve to the current setup, which can be more efficient for
certain types of machining tasks.

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3.3 SPECIFICATIONS OF CNC LATHE
3.3.1 SPECIFACTIONS OF HERCULES CNC LATHE

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3.4 MAIN TYPES OF CODES
• G CODES:
G-codes are a set of programming instruc ons used in Computer Numerical Control
(CNC) machines to control various aspects of the machine's opera ons. Here are
some key points about G-codes.

Defini on: G-codes are alphanumeric codes (le ers and numbers) that define
specific func ons or opera ons for the CNC machine. Each G-code performs a
par cular task or opera on, such as rapid movement, cu ng speed, tool changes,
etc.

Types of G-codes:
Mo on G-codes (G0-G3):
Control the movement of the machine tool along different axes (X, Y, Z).

Canned Cycle G-codes (G81-G89):

These are predefined sequences of opera ons for common machining processes
like drilling, tapping, boring, etc.

Miscellaneous G-codes (G4, G10, G17-G20, G40-G49, etc.):

Control other aspects such as dwell me, tool and workpiece offsets, plane
selec on, and more.

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• M CODES:
M codes are a set of machine codes that control machine func ons beyond basic
mo on commands.

Machine Func ons: M-codes primarily control machine-specific func ons such
as:

Tool changes: M06 is commonly used to command a tool change. It specifies

which tool to load into the spindle.

Coolant control: M08 turns on coolant or flood coolant, while M09 turns it off.
Spindle control: M03 starts the spindle clockwise, M04 starts it
counterclockwise, and M05 stops the spindle.

Feed rate override: M48 sets the feed rate override to a certain percentage, and
M49 cancels it.

Safety and Opera ons: M-codes also manage safety features and opera onal
modes:

Machine warm-up: M17 ensures that the machine is warmed up and ready to
operate.

Automa c mode: M60 ensures that the machine operates in automa c mode.
Program Flow Control: Some M-codes help in controlling the flow of the CNC
program.

Program stop: M00 stops the program temporarily, allowing for manual
interven on or inspec on.

Program end: M30 ends the program en rely.

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3.5 Opera onal Features of CNC Machine:
By using CNC Machine, we can do Turning, Drilling, Taper Turning, Boring, Notch
Milling, Branding, etc.
 In Roll Shop –II, CNC lathe Machine is Primarily used for Turning & Dressing
Opera on of Rolls in Strands which supplies to MMSM

3.5.1 Turning Process in CNC Lathe Machine:

The following steps are followed in Roll turning and redressing process:
1. Roll Pass design:
According to the specifica ons of the customer roll passes are designed. A series of
roll passes are designed to achieve the required product by rolling. These roll pass
profiles are sent to the programming sec on.
2. Developing Profile Tracing:
A er the roll pass design is finalized and is received standard drawings are prepared
using AutoCAD for the respec ve profiles. A er finishing these drawings in
AutoCAD, 1:1 tracing is taken as the standard drawings.
3. Part Programming for Templates:
Part programming is done for the profile and is fed into the CNC milling machine for
cu ng the template. This programming is done manually or using Gibbs CAM
so ware according to the convenience. R - parameter programming is also used for
developing programs for the profile of the same shape.
4. Cu ng template and standardizing:
Template is cut using programs and compared with master tracing and template is
standardized. Using fi ng techniques, bench-vice file and hacksaw, templates were
prepared. But this is very cumbersome and requires high workman skill.
5. Part programming for roll turning:
For roll turning also part programs are developed. They are used for roll turning on

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CNC lathes. This is also accomplished using Gibbs CAM or R parameter
programming or by using coordinates of various points from CAD drawing.
6. Roll turning beginning:
Roll turning is performed by using these programs and master templates are used
for checking the correctness of groove pass. New rolls are turned using canned
cycles and a er that prepared programs are used for ge ng the required profile.
Redressing is also done using these programs.

3.5.2 Opera on:

Staring Procedure:
A certain order must be followed to switch the machine and the control on and off.
• Set the selec on switch NC ON-OFF at Service sta on to ON resp. OFF.
• Switch on main switch control at the control sta on.
• Switch on main switch drive at the control sta on.
• Switch on Key-operated switch Machine Off on the main control sta on.
• Press bu on 1 at the main control sta on.
The machine is ac vated. The lamp in the illuminated push bu on HOLD ALL
MOTIONS flashes.
A er this bu on has been pressed, the lamp goes out the machine is now ready for
opera ons.
• Set the Selector switch NC-MAN at the main control sta on to MAN or NC.
• Observe the indica on lamp FAULT.
The lamp FAULT must not be lit up. If, however, it is flashing or con nuously lit up,
there is a fault.
• Switch on Chip conveyor.
• Switch on machine Ligh ng.
RE-SWITCH ON AFTER EMERGENCY STOP, Unlock the EMERGENCY STOP bu on

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3.5.3 Main Opera ons and Control Elements:
The opera ng and control elements for the machine func ons are located in the
control sta on on carriage.
Addi onal opera ng panels for the respec ve par al func ons are situated at the
control cabinet, headstock and tailstock.

1. HEADSTOCK CONTROL SYSTEM:

MAIN DRIVE: The main spindle rotates in the resp. direc on at low speed for as
long as the bu on is held depressed.
SPINDLE 0: When this bu on is pressed, any running drives are stopped
immediately. The main drive however is stopped a er a brief delay so that the tool
can cut itself free.
EMERGEMCY STOP: Press in case of danger: all running drives are stopped at once.

2. TAILSTOCK CONTROL STATION:

TAILSTOCK ADJUSTMENT: By pressing the bu on, the tailstock travels in the resp.
direc on for as long as the bu on is pressed.
CLAMP-UNCLAMP: The selector switch is used for clamping and
unclamping of the tailstock on the bed.
LUBRICATION: The bu on lights up during an automa c
lubrica on pulse. By pressing the bu on, addi onal lubrica on
pulses can be given.
EMERGENCY STOP: Press only in case of danger: all running
drives are stopped at once.

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3. MAIN CONTROL STATION AT THE CARRIAGE:
 AXIS PRESELCTION:
X+, X-, Z+, Z- to Pre-select the feed axes and direc ons.
X- to the turning center
X+ outwards
Z- to the headstock
Z+ to the tailstock
The resp. bu on lights up to show the selected direc on.
For taper turning purposes, both axes can be selected at the same me.
 MACHINE: It directs to the Home page. If you are in any page just press this
bu on to go to Home page as shown in fig.
 PROGRAM: In this Page, we have opera on to choose like Turning, Drilling,
Taper Turning, etc. Also, we have simula on in the page so that we can get
the output of the program in the HMI. Then if all correct, we can press
EXÈCUTE.
 OFFSET: Here we will have all details of Tool names, Working area limita ons,
Axis data and Spindle data.
 PROGRAM MANAGER: In this page, we can create New Program, New
Backup. It contains Sub-program and Part program op ons to see. It contains
op ons like New, Open, Mark, Copy, cut to use.
 ALARM: In this page, all the alarm logs will be noted and the machine stops
immediately if any problem noted in alarm log. It also notes all the opera ons
we are doing in messages and if any log in noted in messages the machine
will not stop. We can monitor all the NC/PLC variables like Inputs and outputs
in alarm page.
 AXIS Diagram: In ALARM Page, We have axis diagram in which we can select
which axes to be run.
 MENU SELECT: In this page, we have all opera ng modes displayed and we
can select which to be Run.

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 3.5.4 Operating modes:

• MDA : In this MDI (manual data input) we can create your own Program check it.
• JOG: If we select this then we have to operate the machine manually.
• REPOS: Using this we can reposition the axes.
• [Link]: If you ON the machine and the axis is somewhere and to bring to
initial position, you can use this mode.
• AUTO: Using this mode, the machine runs automatically according to the Program
code,

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