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Lab 6 - Face Milling On CNC Machine

The document discusses preparing a pocket of aluminum by face milling on a CNC milling machine. It provides details on CNC milling and the machine, describes the milling process and materials that can be milled, and includes common G and M codes used for CNC programming. The student is to write a program to manufacture an aluminum pocket using face milling and attach a drawing.

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Haris Naveed
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405 views5 pages

Lab 6 - Face Milling On CNC Machine

The document discusses preparing a pocket of aluminum by face milling on a CNC milling machine. It provides details on CNC milling and the machine, describes the milling process and materials that can be milled, and includes common G and M codes used for CNC programming. The student is to write a program to manufacture an aluminum pocket using face milling and attach a drawing.

Uploaded by

Haris Naveed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Title: To prepare a Pocket of Aluminum by face Milling on CNC Milling machine

Location: CIM Center

To manufacture a Pocket of Aluminum by face Milling on CNC machine


MANUFACTURING PROCESSESS LAB – VI
Student’s Name: Registration Number/Roll No.
Max. Marks: 25

A. Introduction
THE MILLING OPERATION
CNC stands for computer numerically controlled. As a milling technique, this means that a
design can be specified on a computer using CAD tools, and that a computer can handle the
milling process. And the program is able to specify the movements that the mill and table must
make.
CNC milling is a specific form of computer numerical controlled (CNC) machining consisting of
both the drilling and cutting. Mill uses a rotating cylindrical cutting tool. However, the cutter in a
milling machine is able to move along multiple axes, and can create a variety of shapes, slots and
holes. In addition, the work-piece is often moved across the milling tool in different directions,
unlike the single axis motion of a drill.
INTRODUCTION OF THE MACHINE
In the machine, the labelled axes, X and Y designate horizontal movement of the work-piece
(forward-and-back and side-to-side on a flat plane). And Z represents vertical, or up-and-down
movement.
CNC milling machine also integrate a device for pumping cutting fluid to the cutting tool during
machining. This machine can be used to produce a wide range of components, and tooling costs
involved have continued to become more affordable day by day. It provides ideal solutions to
everything ranging from prototyping and short-run production of complex parts to the fabrication
of unique precision components.
Machining Capacity

MACHINABLE MATERIALS
Virtually every type of material that can be drilled or cut can be machined by a CNC mill,
although most of the work performed is done in metal. As with drilling and cutting, the proper
machine tools must be selected for each material in order to avert potential problems. The
hardness of the work- piece material, as well as the rotation of the cutting tool must all be
factored before beginning the machining process
G codes and M codes for CNC machine controls
G-code is a common name for the programming language that is used for NC and CNC machine
tools. It is defined in EIA RS-274-D. G-code is also the name of any word in a CNC program
that begins with the letter G, and generally is a code telling the machine tool what type of action
to perform, such as:
 Rapid move
 Controlled feed move in straight line or arc
 Series of controlled feed moves that would result in a hole being drilled.
 Change a pallet
 Set tool information such as offset.
There are other codes; the type codes can be thought of like registers in a computer
 X position
 Y position
 Z position
 M code (another "action" register)
 F feed rate
 S spindle speed
 N line number
 R Radius
 T Tool selection
 I Arc data X axis
 J Arc data Y axis
G-code files are output by CAM software such as Smartcam, Gibbscam, Featurecam, Edgecam,
Mastercam, etc. G-code is also output by specialized CAD systems used to design printed circuit
boards. Such software must be customized for each type of machine tool that it will be used to
program.
G & M-Code programming language used in the CNC Machining Industry.

CNC G Codes

G00 - Positioning at rapid speed; Mill and Lathe


G01 - Linear interpolation (machining a straight line); Mill and Lathe
G02 - Circular interpolation clockwise (machining arcs); Mill and Lathe
G03 - Circular interpolation, counter clockwise; Mill and Lathe
G04 - Mill and Lathe, Dwell
G09 - Mill and Lathe, Exact stop
G10 - Setting offsets in the program; Mill and Lathe
G12 - Circular pocket milling, clockwise; Mill
G13 - Circular pocket milling, counterclockwise; Mill
G17 - X-Y plane for arc machining; Mill and Lathe with live tooling
G18 - Z-X plane for arc machining; Mill and Lathe with live tooling
G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling
G20 - Inch units; Mill and Lathe
G21 - Metric units; Mill and Lathe
G27 - Reference return check; Mill and Lathe
G28 - Automatic return through reference point; Mill and Lathe
G29 - Move to location through reference point; Mill and Lathe (slightly different for each
machine)
G31 - Skip function; Mill and Lathe
G32 - Thread cutting; Lathe
G33 - Thread cutting; Mill
G40 - Cancel diameter offset; Mill. Cancel tool nose offset; Lathe
G41 - Cutter compensation left; Mill. Tool nose radius compensation left; Lathe
G42 - Cutter compensation right; Mill. Tool nose radius compensation right; Lathe
G43 - Tool length compensation; Mill
G44 - Tool length compensation cancel; Mill (sometimes G49)
G50 - Set coordinate system and maximum RPM; Lathe
G52 - Local coordinate system setting; Mill and Lathe
G53 - Machine coordinate system setting; Mill and Lathe
G54~G59 - Workpiece coordinate system settings #1 t0 #6; Mill and Lathe
G61 - Exact stop check; Mill and Lathe
G65 - Custom macro call; Mill and Lathe
G70 - Finish cycle; Lathe
G71 - Rough turning cycle; Lathe
G72 - Rough facing cycle; Lathe
G73 - Irregular rough turning cycle; Lathe
G73 - Chip break drilling cycle; Mill
G74 - Left hand tapping; Mill
G74 - Face grooving or chip break drilling; Lathe
G75 - OD groove pecking; Lathe
G76 - Fine boring cycle; Mill
G76 - Threading cycle; Lathe
G80 - Cancel cycles; Mill and Lathe
G81 - Drill cycle; Mill and Lathe
G82 - Drill cycle with dwell; Mill
G83 - Peck drilling cycle; Mill
G84 - Tapping cycle; Mill and Lathe
G85 - Bore in, bore out; Mill and Lathe
G86 - Bore in, rapid out; Mill and Lathe
G87 - Back boring cycle; Mill
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Mill
G92 - Thread cutting cycle; Lathe
G94 - Per minute feed; Mill
G95 - Per revolution feed; Mill
G96 - Constant surface speed control; Lathe
G97 - Constant surface speed cancel
G98 - Per minute feed; Lathe
G99 - Per revolution feed; Lathe

CNC M Codes

M00 - Program stop; Mill and Lathe


M01 - Optional program stop; Lathe and Mill
M02 - Program end; Lathe and Mill
M03 - Spindle on clockwise; Lathe and Mill
M04 - Spindle on counterclockwise; Lathe and Mill
M05 - Spindle off; Lathe and Mill
M06 - Toolchange; Mill
M08 - Coolant on; Lathe and Mill
M09 - Coolant off; Lathe and Mill
M10 - Chuck or rotary table clamp; Lathe and Mill
M11 - Chuck or rotary table clamp off; Lathe and Mill
M19 - Orient spindle; Lathe and Mill
M30 - Program end, return to start; Lathe and Mill
M97 - Local sub-routine call; Lathe and Mill
M98 - Sub-program call; Lathe and Mill
M99 - End of sub program; Lathe and Mill

B. Programming
Write the program for the manufacturing of a Pocket of Aluminum by face Milling on CNC
Milling machine and also attach the drawing also.
C. Result
A Pocket of Aluminum by face Milling on CNC machine is prepared.

C. Lab Discussion

Q1) How many types of Face milling operations are there. Describe them briefly? [5]
Q2) What is the difference between face mill and end mill cutters? [4]
Q3) In which operation do you think are more forces acting on the tool, Milling or Drilling, even if
machining is done with similar cutting parameters and materials? Why? [3]
Q4) It is said that the tool material should have a good “hot hardness”. Why this property is important
for tool material? (Explain in reference to tool wear) [3]
Q5) A face milling operation is used to machine 6.0mm from the top surface of a rectangular piece of
Aluminium 300 mm long by 125 mm wide in a single pass. The cutter follows a path that is centred
over the work piece. It has four teeth and is 150 mm in diameter. Cutting speed = 2.8 m/s, and chip
load = 0.27 mm/tooth. Determine
(a) The actual machining time (Tm) to make the pass across the surface. [8]
(b) The maximum metal removal rate (MRR) during cutting. [2]

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