MEB4106 CNC MACHINE TOOLS LAB

LAB MANUAL AND RECORD

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 INTRODUCTION TO CNC

Numerical control (NC) is a method employed for controlling the

motions of a machine tool slide and its auxiliary functions with input
in the form of numerical data. A computer numerical control (CNC)
is a microprocessor-based system to store and process the data for
the control of slide motions and auxiliary functions of the machine
tools. The CNC system is the heart and brain of a CNC machine which
enables the operation of various machine members such as slides,
spindles, etc. as per the sequence programmed into it, depending on
the machining operations.
The main advantage of a CNC system lies in the fact that the skills
of the operator hitherto required in the operation of a conventional
machine is removed and the part production is made automatic.
The CNC systems are constructed with a NC unit integrated with a
programmable logic controller (PLC) and sometimes with an
additional external PLC (non-integrated). The NC controls the
spindle movement and the speeds and feeds in machining. It
calculates the traversing path of the axes as defined by the inputs.
The PLC controls the peripheral actuating elements of the machine
such as solenoids, relay coils, etc. Working together, the NC and PLC
enable the machine tool to operate automatically. Positioning and
part accuracy depend on the CNC system's computer control
algorithms, the system resolution and the basic mechanical machine
accuracy. Control algorithm may cause errors while computing,
which will reflect during contouring, but they are very negligible.
Though this does not cause point to point positioning error, but
when mechanical machine inaccuracy is present, it will result in
poorer part accuracy.
Computer Numerical Control (CNC) is a specialized and versatile
form of Soft Automation and its applications cover many kinds,
although it was initially developed to control the motion and
operation of machine tools.
Computer Numerical Control may be considered to be a means of
operating a machine through the use of discrete numerical values
fed into the machine, where the required 'input' technical
information is stored on a kind of input media such as floppy disk,
hard disk, CD ROM, DVD, USB flash drive, or RAM card etc. The
machine follows a predetermined sequence of machining
operations at the predetermined speeds necessary to produce a
work piece of the right shape and size and thus according to
completely predictable results. A different product can be produced
through reprogramming and a low-quantity production run of
different products is justified.
ADVANTAGE OF CNC MACHINES
 Higher flexibility
 Increased productivity
 Consistent quality
 Reduced scrap rate
 Reliable operation
 Reduced non-productive time
 Reduced manpower
 Shorter cycle time
 High accuracy
 Reduced lead time
 Just in time (JIT) manufacture
 Automatic material handling
 Lesser floor space
 Increased operation safety
 Machining of advanced material
Preparatory Functions
 G00 – Rapid Traverse
 G01 – Linear Interpolation (Cutting feed)
 G02 – Circular Interpolation (Clockwise)
 G03 – Circular Interpolation (Counter Clockwise)
 G04 – Dwell
 G20 – Inch Data Input
 G21 – Metric Data Input
 G28 – Return to Machine reference position
 G40 – Tool nose radius compensation cancel
 G41 – Tool nose radius compensation left
 G42 – Tool nose radius compensation right
 G50 – Maximum spindle speed setting / Coordinate system setting
 G70 – Finishing cycle
 G71 – Turning cycle (Rough)
 G72 – Facing cycle
 G73 – Pattern repeating cycle
 G74 – End face peck drilling
 G75 – Outer diameter / Internal diameter drilling
 G76 – Multiple thread cutting
 G81– Drilling Cycle
 G82– Drilling Cycle with Dwell
 G83– Peck drilling cycle.
 G84– Tapping Cycle.
 G85– Boring Cycle.
 G92 – Thread Cutting Cycle
 G96 – Constant surface speed
 G97 – Constant surface speed cancel (constant rpm)
 G98 – Feed per minute
 G99 – Feed per revolution.

Miscellaneous functions
 M00 – Program stop
 M01 – Optional stop
 M02 – End of Program
 M03 – Spindle clockwise
 M04 – Spindle counter clockwise
 M05 – Spindle stop
 M08 – Coolant on
 M09 – Coolant off
 M10 – Chuck open
 M11 – Chuck close
 M30 – Program Stop and reset
 M40 – Parts Catcher Extend
 M41 – Parts Catcher Retract
 M98 – Subprogram Call
 M98 – Subprogram end and Return.
 INTRODUCTION TO CAM
The modern manufacturing environment can be characterized by the
paradigm of delivering products of increasing variety, smaller batches
and higher quality in the context of increasing global competition.
Industries cannot survive worldwide competition unless they introduce
new products with better quality, at lower costs and with shorter lead-
time. There is intense international competition and decreased
availability of skilled labor. With dramatic changes in computing power
and wider availability of software tools for design and production,
engineers are now using Computer Aided Design (CAD), Computer
Aided Manufacturing (CAM) and Computer Aided Engineering (CAE)
systems to automate their design and production processes. These
technologies are now used every day for sorts of different engineering
tasks. Below is a brief description of how CAD, CAM, and CAE
technologies are being used during the product realization process. 1.1
PRODUCT REALIZATION PROCESS The product realization process can
be roughly divided into two phases; design and manufacturing. The
design process starts with identification of new customer needs and
design variables to be improved, which are identified by the marketing
personnel after getting feedback from the customers. Once the
relevant design information is gathered, design specifications are
formulated. A feasibility study is conducted with relevant design
information and detailed design and analyses are performed. The
detailed design includes design conceptualization, prospective product
drawings, sketches and geometric modeling. Analysis includes stress
analysis, interference checking, kinematics analysis, mass property
calculations and tolerance analysis, and design optimization. The
quality of the results obtained from these activities is directly related to
the quality of the analysis and the tools used for conducting the
analysis. The manufacturing process starts with the shop-floor activities
beginning from production planning, which uses the design process
drawings and ends with the actual product. Process planning includes
activities like production planning, material procurement, and machine
selection. There are varied tasks like procurement of new tools, NC
programming and quality checks at various stages during the
production process. Process planning includes planning for all the
processes used in manufacturing of the product. Parts that pass the
quality control inspections are assembled functionally tested,
packaged, labeled, and shipped to customers. A diagram representing
the Product Realization Process (Mastering CAD/CAM, by Ibrahim Zeid,
McGraw Hill, 2005) is shown below.

BRIEF HISTORY OF CAD/CAM DEVELOPMENT

The roots of current CAD/CAM technologies go back to the beginning of

civilization when engineers in ancient Egypt recognized graphics
communication. Orthographic projection practiced today was invented
around the 1800’s. The real development of CAD/CAM systems started
in the 1950s. CAD/CAM went through four major phases of
development in the last century. The 1950’s was known as the era of
interactive computer graphics. MIT’s Servo Mechanisms Laboratory
demonstrated the concept of numerical control (NC) on a three-axis
milling machine. Development in this era was slowed down by the
shortcomings of computers at the time. During the late 1950’s the
development of Automatically Programmed Tools (APT) began and
General Motors explored the potential of interactive graphics. The
1960s was the most critical research period for interactive computer
graphics. Ivan Sutherland developed a sketchpad system, which
demonstrated the possibility of creating drawings and altercations of
objects interactively on a cathode ray tube (CRT). The term CAD started
to appear with the word ‘design’ extending beyond basic drafting
concepts. General Motors announced their DAC-1 system and Bell
Technologies introduced the GRAPHIC 1 remote display system.

During the 1970’s, the research efforts of the previous decade in

computer graphics had begun to be fruitful, and potential of interactive
computer graphics in improving productivity was realized by industry,
government and academia. The 1970’s is characterized as the golden
era for computer drafting and the beginning of ad hoc instrumental
design applications. National Computer Graphics Association (NCGA)
was formed and Initial Graphics Exchange Specification (IGES) was
initiated. In the 1980’s, new theories and algorithms evolved and
integration of various elements of design and manufacturing was
developed. The major research and development focus was to expand
CAD/CAM systems beyond three-dimensional geometric designs and
provide more engineering applications. The present day CAD/CAM
development focuses on efficient and fast integration and automation
of various elements of design and manufacturing along with the
development of new algorithms. There are many commercial CAD/CAM
packages available for direct usages that are user-friendly and very
proficient. Below are some of the commercial packages in the present
market.

 AutoCAD and Mechanical Desktop are some low-end CAD software

systems, which are mainly used for 2D modeling and drawing.

 NX, Pro-E, CATIA and I-DEAS are high-end modeling and designing
software systems that are costlier but more powerful. These software
systems also have computer aided manufacturing and engineering
analysis capabilities.

 ANSYS, ABAQUS, NASTRAN, Fluent and CFX are packages mainly used
for analysis of structures and fluids. Different software are used for
different proposes. For example, Fluent is used for fluids and ANSYS is
used for structures.

 Geomagic and CollabCAD are some of the latest CAD systems that
focus on collaborative design, enabling multiple users of the software
to collaborate on computeraided design over the Internet.

Computer Aided Manufacturing – CAM CAM

Technology involves computer systems that plan, manage, and control

the manufacturing operations through computer interface with the
plant’s production resources. One of the most important areas of CAM
is numerical control (NC). This is the technique of using programmed
instructions to control a machine tool, which cuts, mills, grinds,
punches or turns raw stock into a finished part. Another significant
CAM function is in the programming of robots. Process planning is also
a target of computer automation.
Ex No. 1 DATE:

AIM:
To write, simulate and execute a CNC Lathe program for the job of given
dimensions.
MACHINE REQUIRED:
CNC Lathe Machine: BATLIBOI Sprint 16TC
Controller: Siemens 828D
Language: Sinumeric
PROCEDURE:

1. Identify the required coordinates of the profile based on profile origin.

2. Select appropriate tool, speed, feed rate for the operations
3. Write the CNC program using appropriate Preparatory and
miscellaneous codes.
4. Enter the program..
5. Ensure the program should be free from errors using check syntax and
dry run
6. Simulate the program.
7. Do manual setting, Take Work Offset and Tool Offset.
8. Carryout machining.
9. Inspect the Job.
PART MODEL:
PROGRAM:

RESULT:
Thus manual part programming was written to the given dimensions,
simulated and executed in CNC Lathe.
Ex No. 2 DATE:

AIM:
To write, simulate and execute a CNC Lathe program for the job of given
dimensions.
MACHINE REQUIRED:
CNC Lathe Machine: BATLIBOI Sprint 16TC
Controller: Siemens 828D
Language: Sinumeric
PROCEDURE:

1. Identify the required coordinates of the profile based on profile origin.

2. Select appropriate tool, speed, feed rate for the operations
3. Write the CNC program using appropriate Preparatory and
miscellaneous codes.
4. Enter the program.
5. Ensure the program should be free from errors using check syntax and
dry run
6. Simulate the program.
7. Do manual setting, Take Work Offset and Tool Offset.
8. Carryout machining.
9. Inspect the Job.
PART MODEL:
PROGRAM:

RESULT:
Thus manual part programming was written to the given dimensions,
simulated and executed in CNC Lathe.
Ex No. 3 DATE:

AIM:
To write, simulate and execute a CNC Lathe program for the job of given
dimensions.
MACHINE REQUIRED:
CNC Lathe Machine: BATLIBOI Sprint 16TC
Controller: Siemens 828D
Language: Sinumeric
PROCEDURE:

1. Identify the required coordinates of the profile based on profile origin.

2. Select appropriate tool, speed, feed rate for the operations
3. Write the CNC program using appropriate Preparatory and
miscellaneous codes.
4. Enter the program.
5. Ensure the program should be free from errors using check syntax and
dry run
6. Simulate the program.
7. Do manual setting, Take Work Offset and Tool Offset.
8. Carryout machining.
9. Inspect the Job.
PART MODEL:
PROGRAM:

RESULT:
Thus manual part programming was written to the given dimensions,
simulated and executed in CNC Lathe.
Ex No. 4 DATE:

AIM:
To write, simulate and execute a CNC Mill program for the job of given
dimensions.
MACHINE REQUIRED:
CNC Mill Machine: BMV 35 TC20
Controller: Fanuc series oi Mate
Language: Fanuc
PROCEDURE:

1. Identify the required coordinates of the profile based on profile origin.

2. Select appropriate tool, speed, feed rate for the operations
3. Write the CNC program using appropriate Preparatory and
miscellaneous codes.
4. Enter the program.
5. Ensure the program should be free from errors using check syntax and
dry run
6. Simulate the program.
7. Do manual setting, Take Work Offset and Tool Offset.
8. Carryout machining.
9. Inspect the Job.
PART MODEL:
Depth of Cut: 0.5mm
Diameter of the tool: 6 mm
PROGRAM:

RESULT:
Thus manual part programming was written to the given dimensions,
simulated and executed in CNC Mill.
Ex No. 5 DATE:

AIM:
To write, simulate and execute a CNC Mill program for the job of given
dimensions.
MACHINE REQUIRED:
CNC Mill Machine: BMV 35 TC20
Controller: Fanuc series oi Mate
Language: Fanuc
PROCEDURE:

1. Identify the required coordinates of the profile based on profile origin.

2. Select appropriate tool, speed, feed rate for the operations
3. Write the CNC program using appropriate Preparatory and
miscellaneous codes.
4. Enter the program.
5. Ensure the program should be free from errors using check syntax and
dry run
6. Simulate the program.
7. Do manual setting, Take Work Offset and Tool Offset.
8. Carryout machining.
9. Inspect the Job.
PART MODEL:
Depth of Cut: 0.5mm
Diameter of the tool: 6 mm
PROGRAM:

RESULT:
Thus manual part programming was written to the given dimensions,
simulated and executed in CNC Mill.
Ex No. 6 DATE:

AIM:
To write, simulate and execute a CNC Mill program for the job of given
dimensions.
MACHINE REQUIRED:
CNC Mill Machine: BMV 35 TC20
Controller: Fanuc series oi Mate
Language: Fanuc
PROCEDURE:

1. Identify the required coordinates of the profile based on profile origin.

2. Select appropriate tool, speed, feed rate for the operations
3. Write the CNC program using appropriate Preparatory and
miscellaneous codes.
4. Enter the program.
5. Ensure the program should be free from errors using check syntax and
dry run
6. Simulate the program.
7. Do manual setting, Take Work Offset and Tool Offset.
8. Carryout machining.
9. Inspect the Job.
PART MODEL:
Depth of Cut: 0.5mm
Diameter of the tool: 6 mm
PROGRAM:

RESULT:
Thus manual part programming was written to the given dimensions,
simulated and executed in CNC Mill.
Ex No. 7 DATE:

AIM:
To generate tool path and CNC program for the given component using
the CAD/CAM software (NX 11)
SOFTWARE REQUIRED:
NX 11
MACHINE REQUIRED:
3 axis Milling Machine
PROCEDURE:
• Starting the NX 11 software:
• Go to start -> All programs -> Siemens NX 11.0.
• Start a New File -> Go to Model Tab.
• In Model Tab -> click Model.
• Change the working Directory and Title of the model -> click OK.
• To Model the Part file that needs to Manufacture using CNC machine:
• Start EXTRUDE command -> Click Sketch -> Select Plane -> click
OK.
• Sketch the profile of the Model -> Finish Sketch.
• Feed the Depth of extrude -> Click OK.
• Save the Model.
• To start the Computer Aided Manufacturing Process:
• Start a New File -> Go to Manufacturing Tab.
• In Manufacturing Tab -> Go to General Setup -> Click OK.
• Setting up the Model.
• Click Geometric View Icon (to show MCS-MILL).
• Click MCS-MILL -> Double click Work piece.
 • Select Part icon -> Specify the Part.
• Select Blank icon -> Select Type -> Bounding Block -> Click OK.
• Select Check icon -> Specify the Check.
• Setting up the operations:
• Face Milling
• Click Create operation -> Select Type -> Mill Planar -> in
operation Subtype select Floor and wall.
• In Mill planar dialogue box -> Click Geometry -> Select Work
piece in the popup.
• Click the Cut area Icon -> Specify the Cut Region.
• Pocket Milling
• Click Create operation -> Select Type -> Mill Contour -> in
operation Subtype select Contour Mill.
• In Mill Contour dialogue box -> Click Geometry -> Select
Work piece in the popup.
• Click the Cut area Icon -> Specify the Cut Region.
• Setting up the Tool(Create tool separately for each operation):
• Click Tool Icon -> Mill Tool (in tool subtype).
• Change the dimension of the tool according to the requirement ->
OK.
• In Feed and Speeds Section -> specify Spindle Speed -> Press
Enter.
• Click the Calculate Icon -> Click OK.
• Stimulating and generating Operation:
• Go to Actions sections -> Click Generate.
• Click Verify -> Go to 3D Dynamic.
• Play the Simulation of the Process and check for errors -> Click
OK.
 • Generating CNC Code:
• Click Post Process Icon.
• Select the MILL 3 AXIS -> Click OK and the code is generated.
PART MODEL:

RESULT:
Thus the tool path and CNC Code is Generated for the Model using NX11
Software.
Ex No. 8 DATE:

AIM:
To generate tool path and CNC program for the given component using
the CAD/CAM software (NX 11)
SOFTWARE REQUIRED:
NX 11
MACHINE REQUIRED:
3 axis Milling Machine
PROCEDURE:
• Starting the NX 11 software:
• Go to start -> All programs -> Siemens NX 11.0.
• Start a New File -> Go to Model Tab.
• In Model Tab -> click Model.
• Change the working Directory and Title of the model -> click OK.
• To Model the Part file that needs to Manufacture using CNC machine:
• Start EXTRUDE command -> Click Sketch -> Select Plane -> click
OK.
• Sketch the profile of the Model -> Finish Sketch.
• Feed the Depth of extrude -> Click OK.
• Save the Model.
• To start the Computer Aided Manufacturing Process:
• Start a New File -> Go to Manufacturing Tab.
• In Manufacturing Tab -> Go to General Setup -> Click OK.
• Setting up the Model.
• Click Geometric View Icon (to show MCS-MILL).
• Click MCS-MILL -> Double click Work piece.
 • Select Part icon -> Specify the Part.
• Select Blank icon -> Select Type -> Bounding Block -> Click OK.
• Select Check icon -> Specify the Check.
• Setting up the operations:
• Island Milling
• Click Create operation -> Select Type -> Mill Contour -> in
operation Subtype select Contour Mill.
• In Mill Contour dialogue box -> Click Geometry -> Select
Work piece in the popup.
• Click the Cut area Icon -> Specify the Cut Region.
• Setting up the Tool(Create tool separately for each operation):
• Click Tool Icon -> Mill Tool (in tool subtype).
• Change the dimension of the tool according to the requirement ->
OK.
• In Feed and Speeds Section -> specify Spindle Speed -> Press
Enter.
• Click the Calculate Icon -> Click OK.
• Stimulating and generating Operation:
• Go to Actions sections -> Click Generate.
• Click Verify -> Go to 3D Dynamic.
• Drilling
• Click Create operation -> Select Type -> Hole Making -> in
operation Subtype select Drilling.
• In Hole Making dialogue box -> Click Geometry -> Select
Work piece in the popup.
• Click specify feature geometry Icon -> Specify the holes.
• Setting up the Tool:
• Drilling Operation:
 • Click Tool Icon -> Drill Tool (in tool subtype).
• Change the dimension of the tool according to the
requirement -> OK.
• Stimulating and generating Operation:
• Go to Actions sections -> Click Generate.
• Click Verify -> Go to 3D Dynamic.
• Play the Simulation of the Process and check for errors -> Click
OK.
• Generating CNC Code:
• Click Post Process Icon.
• Select the MILL 3 AXIS -> Click OK and the code is generated.
PART MODEL:

RESULT:
Thus the tool path and CNC Code is Generated for the Model using NX11
Software.
Ex No. 9 DATE:

AIM:
To generate tool path and CNC program for the given component using
the CAD/CAM software (NX 11)
SOFTWARE REQUIRED:
NX 11
MACHINE REQUIRED: 2 axis Lathe.
PROCEDURE:
 Starting the NX 11 software:
o Go to start -> All programs -> Siemens NX 11.0.
o Start a New File -> Go to Model Tab.
o In Model Tab -> click Model.
o Change the working Directory and Title of the model -> click OK.
 To Model the Part file that needs to Manufacture using CNC machine:
o Start SKETCH command -> -> Select Plane -> click OK.
o Sketch the profile of the Model -> Finish Sketch.
o Start SKETCH command -> -> Select Plane -> click OK.
o Sketch the profile of the Blank -> Finish Sketch.
o Save the Model.
 To start the Computer Aided Manufacturing Process:
o Start a New File -> Go to Manufacturing Tab.
o In Manufacturing Tab -> Go to Turning Express -> Click OK.
 Setting up the Model.
o Click Geometric View Icon (to show MCS-MILL).
o Click MCS-MILL - Work piece > Double click
TURNING_WORKPIECE.
o Select SPECIFY PART BOUNDARIES icon -> Select the Curves ->
Select the Profile of part.
o Select SPECIFY BLANCK BOUNDARIES icon -> Select the Curves ->
Select the Profile of Blank > Click OK.

 Setting up the operations:

o Face Milling
 Click Create operation -> Select Type -> turning exp-> in
operation Subtype select Rough turn OD
  In Mill planar dialogue box -> Click Geometry -> Select
Turning work piece in the popup.

 Setting up the Tool:
o Click Tool Icon -> Tool (in tool subtype).

 Stimulating and generating Operation:

o Go to Actions sections -> Click Generate.
o Click Verify -> Go to 3D Dynamic.
o Play the Simulation of the Process and check for errors -> Click
OK.

 Generating CNC Code:

o Click Post Process Icon.
o Select the Lathe -> Click OK and the code is generated.

PART MODEL:

RESULT:
Thus the tool path and CNC Code is Generated for the Model using NX11
Software.
Ex No. 10 DATE:

AIM:
To generate tool path and CNC program for the given component using
the CAD/CAM software (NX 11)
SOFTWARE REQUIRED:
NX 11
MACHINE REQUIRED: 2 axis Lathe.
PROCEDURE:
 Starting the NX 11 software:
o Go to start -> All programs -> Siemens NX 11.0.
o Start a New File -> Go to Model Tab.
o In Model Tab -> click Model.
o Change the working Directory and Title of the model -> click OK.
 To Model the Part file that needs to Manufacture using CNC machine:
o Start SKETCH command -> -> Select Plane -> click OK.
o Sketch the profile of the Model -> Finish Sketch.
o Start SKETCH command -> -> Select Plane -> click OK.
o Sketch the profile of the Blank -> Finish Sketch.
o Save the Model.
 To start the Computer Aided Manufacturing Process:
o Start a New File -> Go to Manufacturing Tab.
o In Manufacturing Tab -> Go to Turning Express -> Click OK.
 Setting up the Model.
o Click Geometric View Icon (to show MCS-MILL).
o Click MCS-MILL - Work piece > Double click
TURNING_WORKPIECE.
o Select SPECIFY PART BOUNDARIES icon -> Select the Curves ->
Select the Profile of part.
o Select SPECIFY BLANCK BOUNDARIES icon -> Select the Curves ->
Select the Profile of Blank > Click OK.

 Setting up the operations:

o Face Milling
 Click Create operation -> Select Type -> turning_exp-> in
operation Subtype select Rough turn OD
  In Mill planar dialogue box -> Click Geometry -> Select
Turning work piece in the popup.

 Setting up the Tool:
 Click Tool Icon -> Tool (in tool subtype).

 Stimulating and generating Operation:

o Go to Actions sections -> Click Generate.
o Click Verify -> Go to 3D Dynamic.
o Play the Simulation of the Process and check for errors -> Click
OK.

 Generating CNC Code:

o Click Post Process Icon.
o Select the Lathe -> Click OK and the code is generated.

PART MODEL:

RESULT:
Thus the tool path and CNC Code is Generated for the Model using NX11
Software.