CNC Machine Lab Report and Process Plann

1.
INTRODUCTION:
This report based on two subjects. First one is related to the CNC lab visit and second part
comprises of the process plan for the given part.
A. CNC Lab Report

A1. Introduction to CNC
a.
b.
c.
d.
e.
Machine Specifications
Setting up the machine
The CNC keypad
Entering the program
Computer Interface & CNC machine
A2. Simulation of a program

B. The Process Selection & Programming Of A Given Part
A1. Introduction to CNC

a. Machine Specifications
Parameter
Max Travel Range of x/y/z axis
Max Loading Capacity
Spindle Taper
Max Taverse of X/Y/Z
Magazine Tool Capacity
Max Adjacent Tool Diameter * Length
Max Tool gauge
Max Spindle speed
Automatic Tool Change System
Specification
1060/630/630
1000Kg
ISO 40
30M/Min
Std: 24Pcs
Dia 80 * 250 Length
6kg
Std 8000rpm
Hydraulic System
Detailed Specifications of machine from manufacturers resources:
Table
Travel Range
Spindle
Feedrate
ITEM
Dimension
Working Area
T-Slot
Max. Loading
Capacity
Max. Travel Range Of
X / Y / Z - Axis
Distance From
Spindle Nose To Table
Surface
Distance From
Spindle Center To
Column
Spindle Taper
Spindle Nose Outer
Dia.
Spindle Speed
Feedrate Of
X / Y / Z - Axis
MV-1060
1180 x 560 (46.5 x 22.0)
1060 x 620 (41.7 x 24.4)
CD125 x 18 x 4 (CD4.9 x 0.7 x 4)
1000 kg ( 2200 lbs )
1060 / 620 / 620 (41.7 x 24.4 x 24.4)
150 - 770 (5.9 - 30.3)
680 (26.8)
ISO No.40
70 (2.8)
STD: 10000 rpm; OPT: 6000, 12000 rpm
1 ~ 12000 mm / min (0.04 - 472.4 ipm)
Slideways Of
X / Y / Z - Axis
Rapid Traverse Of
X / Y / Z - Axis
Tool Capacity
Tool Selection
Max. Adjacent Tool
Tool Magazine
Dia. x L
Max. Tool Weight
Tool Shank
Spindle Drive Motor
Servo Motors Of
X / Y / Z - Axis
Coolant Motor
Chip Conveyor Motor
Positioning
Accuracy
Repeatability
Power Requirement
Packing Dimension
Miscellaneous (L x W x H)
Net Weight
Gross Weight
Drive Motor
Linear Guideway
Type: 30 m / min (1181 ipm)
Type: 20 m / min (787 ipm)
STD: 24 pcs; OPT: 30 pcs
Bi - Direction & The Shortest Selection
80 250 (3.15 9.84)
6 kg (13.2 lbs)
BT40 or V40 CT or V40 ANSI
STD: 11 / 15 kW (15 / 20 HP)
OPT: 15 / 18.5 kW (20 / 25 HP)
Motor: 3.0 kW (4 HP)
Motor: 2.5 kW (3.4 HP)
960 W (1.2 HP)
215 W (1 / 4 HP)
0.004
0.003
208 - 220V / 75 Amps / 3 Phase
3010 x 2310 x 2550 (118.5 x 90.9 x 100.4)
6130 kgs (13486 lbs)
6980 kgs (15356 lbs)
b. Setting up the machine

To setup the machine for a given job, 1st we have to set the job into the machines fixture located
on the moveable bed of the machine. Then we have to set the machines zero for all the axis by
locating a job beneath the machine spindle and using G54-G58 codes for coordinate axis. We
have two methods for this purpose, one with conventional method of setting the job below the
spindle and the other of using the laser tool for more precision.
c. The CNC keypad
The keypad of CNC machine indicates a number of functions related to machine. Lets discuss a
few of them.
A. Power: The green colored power on button is used to turn the machine on.
B. Axis Direction Section: Setting up the coordinates and axis. Reset it to machine zero after
selecting ZRN button in mode selection. Care is to be taken that while resetting the machine, we
need to 1st reset the Z axis and after wards other for making it as safe as possible.
C. Chip Conveyor section: To control the chip conveyor section,
D. Mode Selection: The selection of mode for what we want to do. i.e edit a program, enter a
short program or using the tape function.
E. Spindle: Control on the movements of spindle.
F. Override buttons: To reduce or increase the rotations as compared to machine
G. Coolant Control: Control the coolant flow.
H. Status lights: Show the status of machine.
I. Emergency Stop: To stop the machine in case of emergency.
K. Rapid over ride & Handle: In mode selection, if we select handle, the spindle movement in
three axis would be controlled by the handle, it would be controlled by rapid over-ride buttons if
in the mode we have selected for JOG button.
d. Entering the program
A program can be entered into the machine by following three methods: \
i.
Using the Card
ii.
Using the machine keypad and setting up by mode selection.
iii.
Using the RS-232 machine interface ( In computer use care is to be taken regarding the
power supply)
e. Computer Interface & CNC machine
In computers many software packages are available for operating CNC machines. Examples
include
A2. Simulation of a program
It is a good practice to simulate the program before practically running it on the CNC, it helps debug
errors, increased improvement possibilities and in some cases decrease the chance of sever mistakes.
In the lab visit, the simulation of milling operation on a flat part was shown using pro-e software. A
datum plane was created and the material was removed giving the physical animation features on
display. The tool path of CNC can also be simulated on the software named CIMCO Edit.
B. The Process Selection & Programming Of A Given Part

While completing the process for writing a program we have to determine and analyze the
conditions in which the programming is being done. Based upon the given drawing only, we
have to choose the option in,
i.
Part material
(Usually on the basis of application and other machining parameters)
ii.
Machine & tool selection
(On the basis of machine & tool availability & part geometry)
iii.
Process plan
(Choose the appropriate machining conditions for rough & finish machining)
iv.
Tool Path generation
v.
Program transfer & Machining
The Given Part Drawing:
i.
Part Material: When a specific material is not given, we will select the material on the basis
of which material is easier to machine and would also suite the available tools. In this regard
Aluminum is a soft material that can be easily machined. Sometimes, its softness can counterreact the machinability by chips sticking to the tool making a built edge reducing tool life. In
case we need improved machinability with stiff alloy, we can use an Aluminum alloy 2011 or
6020.
ii.
iii.
iv.
v.
Machine & tool selection

Based upon the part geometry, we have to cut the material in a straight periphery and the best
suited is end milling (profile). On the basis of typical speeds mentioned in lecture slide 71, the
speed should be 1000 with HSS tool
Process plan
On the basis of selected tools and material, the given part would be machined by giving 1mm
increase in depth towards the table for getting a complete profile of the object.
Tool Path generation
Program transfer & Machining

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1.

A. CNC Lab Report

A2. Simulation of a program

A1. Introduction to CNC

Detailed Specifications of machine from manufacturers resources:

b. Setting up the machine

B. The Process Selection & Programming Of A Given Part

The Given Part Drawing:

Machine & tool selection

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