MEL 527: CNC Milling

TITLE: CNC MILLING

AIM: To know the principle of operation of a CNC milling machine

OBJECTIVES:

 Writing the first milling program according to a drawing

 Running the program on simulation
 Executing the program on the Milling Machine

EQUIPMENTS REQUIRED:

 PC computer
 S-MILL software
 C-501 CNC Milling Machine
 3 mm milling cutter
 90x80x20 mm plastic material

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MEL 527: CNC Milling

DIAGRAM:

Rotating cutting tool

Workpiece

Figure 1.0 Illustration of CNC Mill

Figure 1.1 Example of CNC Milling

Figure 1.2 Coordinate system

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MEL 527: CNC Milling

DESCRIPTION OF APPARATUS:

Features of C-501 CNC Milling Machine

 General dimensions; 650 x 590 x 590 mm

 X axis - 90 mm
 Y axis - 95 mm
 Z axis - 40 mm
 Spindle speed; 0-3000 RPM
 Table surface;150 X 230 mm
 Mechanical resolution ± 0.01 mm
 Spindle motor 24V DC
 X, Y and Z axis motors servo type; 12 V DC
 Spindle bore 10mm,
 Morse taper ISO No. 1.
 Emergency stop button
 Low voltage lighting
 Vacuum cleaner unit
 Computer - machine connection RS-232 or USB port
 2 cutting tools (3 mm, 6 mm)
 Tool kit
 Cleaning brush

The system's description

The C-501 is a computerized system for sliver processing of plastic, hard wood and soft metal
products. The system includes a rotating mill cutting operated by a spindle DC motor. The mill
motor is located above a table, which is operated by a DC motor, which raises and lowers it.

The processed material is installed on a table, which moves on two axes (X and Y). In this way,
the processed material moves on the X-Y plane and the miller moves up and down (goes into
and out of the material) on axis Z.

The movement of each axis is done by a DC motor, which includes a magnetic encoder with
Hall Effect sensors. The encoder outputs pulses according to the motor's rotation.

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The system is located in a metal structure with a transparent door in the front. The door operates
a magnetic switch when it is closed.

The system includes a computerized control unit. The control unit operates the motors, receives
the pulses from the encoders and operates the spindle DC motor of the miller. The system stops
each time the front door is opened.

A computerized system for sliver processing is called CNC (Computerized Numeric Control).
The system's controller receives data, which determine the processed material movement and
the mill cutter (location and speed) and moves them accordingly in a controlled manner.

A special language was created for CNC machines called G&M-Code. This language is a
universal language and despite this, each machine has its own unique commands. This material
describes the C-501 command set and the system's programming method.

The programming language enables us to create programming files, where each file is
designated to manufacture a certain product (or part). The files are saved in the computer's disk.
In this way, we can manufacture a certain part in the same level of accuracy and unity at each
manufacturing, even if the first manufacturing was a long time ago.

The CNC system enables us to manufacture the exact amount of products we need. All it takes
is to load the computer with the appropriate file and run the program. This process turned the
manufacturing significantly flexible. Flexibility means an easy transfer from one product to
another. These machines are called FMS (Flexible Manufacturing Systems).

The C-501 system is accompanied with the S-MILL software. This software enables us to
create and edit a G&M-Code file and run it.

Running the file can be done in two ways – by simulation or by operating the machine.

In the simulation method, the software draws the mill's movement on the screen and drags lines
accordingly. Each line receives a color according to the milling depth.

In the machine operation method, the computer sends a movement commands to the system's
control unit and the control unit executes the processing.

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MEL 527: CNC Milling

INTRODUCTION:

CNC Milling Machine

A CNC Milling machine is a computer controlled machine that can be used to make very
precise parts. The machine works by removing material from the workpiece with a rotating
cutting tool. The machine does this by guiding the tool in all three directions of the Cartesian
coordinate system, that meaning along the X, Y and Z axis.

Introductory Concepts of Machining

Machining is basically removal of material, most often metal, from the workpiece, using one
or more cutting tools to achieve the desired dimensions. There are different machining
processes, such as, turning, milling, boring etc. In all these cases metal is removed by a shearing
process, which occurs due to the relative motion between the workpiece and the tool. Generally,
one of the two rotates at designated and generally high speed, causing the shearing of material
(known as chips), from the workpiece. The other moves relatively slowly to effect removal of
metal throughout the workpiece. For example, as seen above in a turning operation of lathes,
the “job” or the workpiece rotates in a chuck, while the tool moves in two dimensions
translationally. On the other hand, in milling, it is the cutter which rotates on a spindle, while
the workpiece, which is fastened to a table, moves in X-Y dimensions. While, a precise and
high speed rotational motion is needed for good finish of the machined surface, for dimensional
accuracy, precise position and velocity control of the table drive are essential.

For all metal-cutting processes, the cutting speed, feed, and depth of cut are important
parameters. The figure below shows the important geometry for the turning process. The
cutting speed, which is a measure of the part cut surface speed relative to the tool. Speed is a
velocity unit for the translational motion, which is may be stated in or meters/min. The depth
of cut, DOC is the depth that the tool is plunged into the surface. Feed defines the relative
lateral movement between the cutting tool and the workpiece. Thus, together with depth of cut,
feed decides the cross section of the material removed for every rotation of the job or the tool,
as the case may be.

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THEORY:

Computer Numerical Control

Modern precision manufacturing demands extreme dimensional accuracy and surface finish.
Such performance is very difficult to achieve manually, if not impossible, even with expert
operators. In cases where it is possible, it takes much higher time due to the need for frequent
dimensional measurement to prevent overcutting. It is thus obvious that automated motion
control would replace manual “hand wheel” control in modern manufacturing. Development
of computer numerically controlled (CNC) machines has also made possible the automation of
the machining processes with flexibility to handle production of small to medium batch of
parts.

In the 1940s when the U.S. Air Force perceived the need to manufacture complex parts for
high-speed aircraft. This led to the development of computer-based automatic machine tool
controls also known as the Numerical Control (NC) systems. Commercial production of NC
machine tools started around the fifties and sixties around the world. Note that at this time the
microprocessor has not yet been invented.

Initially, the CNC technology was applied on lathes, milling machines, etc. which could
perform a single type of metal cutting operation. Later, attempt was made to handle a variety
of workpieces that may require several different types machining operations and to finish them
in a single set-up. Thus CNC machining Centers capable of performing multiple operations
were developed. To start with, CNC machining centers were developed for machining
prismatic components combining operations like milling, drilling, boring and tapping.
Gradually machines for manufacturing cylindrical components, called turning centers were
developed.

Basics of CNC Programming

There are two ways to program modern CNC machine tools.

(a) Conversational Programming.

This is the simpler of the two methods. In effect, this is a macro programming language used
to instruct the machine to perform pre-programmed cycles (i.e. facing, drilling holes in arrays,
etc.). When writing a conversational program, you simply enter the appropriate parameters
associated with each machining cycle. This is analogous to using the polar array function in

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SolidWorks or Pro/E; you don’t have to do the layout or trig to find the location of the features;
you just specify the essential parameters and the software does the rest for you.

(b) CAM Programming.

This is the more powerful of the two methods. Using this method, you import your part model
into a CAM (computer aided manufacturing) program and define the parameters associated
with each and every machined feature on the part. These parameters include tool diameter and
length, depth of cut, tool path geometry, etc.

Numerical Control
Automatically controlling a machine tool based on a set of pre-programmed machining and
movement instructions is known as numerical control, or NC. In a typical NC system, the
motion and machining instructions and the related numerical data, together called a part
program, used to be written on a punched tape. The part program is arranged in the form of
blocks of information, each related to a particular operation in a sequence of operations needed
for producing a mechanical component. The punched tape used to be read one block at a time.
Each block contained, in a particular syntax, information needed for processing a particular
machining instruction such as, the segment length, its cutting speed, feed, etc. These pieces of
information were related to the final dimensions of the workpiece (length, width, and radii of
circles) and the contour forms (linear, circular, or other) as per the drawing.

Based on these dimensions, motion commands were given separately for each axis of motion.
Other instructions and related machining parameters, such as cutting speed, feed rate, as well
as auxiliary functions related to coolant flow, spindle speed, part clamping, are also provided
in part programs depending on manufacturing specifications such as tolerance and surface
finish. Punched tapes are mostly obsolete now, being replaced by magnetic disks and optical
disks.

Computer Numerically Controlled (CNC) machine tools, the modern versions of NC machines
have an embedded system involving several microprocessors and related electronics as the
Machine Control Unit (MCU). Initially, these were developed in the seventies in the US and
Japan. However, they became much more popular in Japan than in the US. In CNC systems
multiple microprocessors and programmable logic controllers work in parallel for simultaneous
servo position and velocity control of several axes of a machine for contour cutting as well as
monitoring of the cutting process and the machine tool. Thus, milling and boring machines can
be fused into versatile machining centers.

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Similarly, turning centers can realize a fusion of various types of lathes. Over a period of time,
several additional features were introduced, leading to increased machine utilization and
reduced operator intervention. Some of these are:

(a) Tool/work monitoring: For enhanced quality, avoidance of breakdowns.

(b) Automated tool magazine and palette management: For increased versatility and reduced
operator intervention over long hours of operation

(c) Direct numerical control (DNC): Uses a computer interface to upload and download part
programs in to the machine automatically.

Advantages of a CNC Machine

CNC machines offer the following advantages in manufacturing.

 Higher flexibility: This is essentially because of programmability, programmed control and

facilities for multiple operations in one machining centre.
 Increased productivity: Due to low cycle time achieved through higher material removal
rates and low set up times achieved by faster tool positioning, changing, automated material
handling etc.
 Improved quality: Due to accurate part dimensions and excellent surface finish that can be
achieved due to precision motion control and improved thermal control by automatic
control of coolant flow.
 Reduced scrap rate: Use of Part programs that are developed using optimization
procedures.
 Reliable and Safe operation: Advanced engineering practices for design and
manufacturing, automated monitoring, improved maintenance and low human interaction.
 Smaller footprint: Due to the fact that several machines are fused into one.

On the other hand, the main disadvantages of NC systems are:

 Relatively higher cost compared to manual versions

 More complicated maintenance due to the complex nature of the technologies
 Need for skilled part programmers.

The above disadvantages indicate that CNC machines can be gainfully deployed only when the
required product quality and average volume of production demand it.

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Parts suitable for CNC machines

The following parts are usually made in practice on the CNC Machines:

(a) Aerospace equipment.

(b) Automobile Parts.

(c) Complex shapes.

(d) Electronic industry uses CNC e.g. Printed circuit board.

(e) Electrical industry uses CNC e.g. Coil winding.

Figure 1.3 Example of CNC Milled parts

Classification of NC Systems

CNC machine tool systems can be classified in various ways such as:

1. Point-to-point or contouring: depending on whether the machine cuts metal while the
workpiece moves relative to the tool.

2. Incremental or absolute: depending on the type of coordinate system adopted to

parameterize the motion commands.

3. Open-loop or closed-loop: depending on the control system adopted for axis motion control.

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G&M-Code language
The G&M-Code language is a very simple programming language and this is the secret of its
popularity. The programming file is a text file written by a text editor (a simple word
processing). The programming rules are as follows:
 Every instruction to the machine should start with the letter G or M (this is the reason for
the name G&M-Code).
 The software ignores lines that do not start with the letter G or M.
For example, G1 X10 Y30 Z-15 F125 meaning: Move in straight line to point X,Y,Z =
10,30,15 from the home position at feed of 125 millimeters per minute. The movement
is done in 3D dimensions.
 All the parameters should be given in millimeters.
 S-MILL software allows using a decimal point. i.e.: G1 X10.5 Y20.7
 The parameters are optional. It means that the current value of a parameter that is not
indicated in an instruction remains without change.
 We use the '/' sign to indicate relative values. i.e.: G1 X/20.3 Y/-5, which means: Move
20.3 millimeters forward on X and 5 millimeters backward on Y from the current location
at previous feed and without changing Z height.

The S-MILL G-Code instruction set:

1) G0 Xxx Yyy Zzz:
Idle movement on straight line (in a Cartesic axes system) to point xx,yy,zz at maximum
speed. Examples:
G0 X10 Y25 Z-3
G0 Y15.2
2) G1 Xxx Yyy Zzz Fff:
Milling movement on straight line (in a Cartesic axes system) to point xx,yy,zz at ff
speed.
Examples:
G1 X10 Y25 Z-3 F200
G1 Y15.2
3) G10 Rrr Ccc Iii Jjj:
Idle movement on straight line (in a Polar axes system) to point on a circle's perimeter
at maximum speed.

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R is the circle radius.

C is the angle (in degrees) of the point.
I and J are the X,Y coordinates of the center of the circle.

Examples:
G10 R10 C30 I25 J20 R
G10 C180 0o
I,J

4) G11 Rrr Ccc Iii Jjj Fff:

Milling movement on straight line (in a Polar axes system) to point on a circle's
perimeter at ff speed.
R is the circle radius.
C is the angle of the point.
I and J are the X,Y coordinates of the center of the circle.

Examples:
R
G11 R10 C30 I25 J20 F200 Co
0o
G11 C180 I,J

5) G02 Iii Jjj Rrr Ccc Eee Fff:

Clockwise milling circular movement (arch) at ff feed.
R is the circle radius.
C is the angle (in degrees) of the starting point.
E is the angle (in degrees) of the ending point.

Example:

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MEL 527: CNC Milling

G02 I25 J20 R10 C30 E60 F200

6) G03 Iii Jjj Rrr Ccc Eee Fff:

Counter clockwise milling circular movement (arch) at ff feed.

7) G81 Zzz:
Z axis movement for drilling.
8) G4:
"Wait" instruction, usually applied for stopping in order to replace the milling cutter
or the processed material.
A message appears on the screen and the PC waits for clicking OK to continue.

M-Code instruction set:

1) M4 Sss - Command to start the spindle Motor CCW at ss speed in RPM.

2) M5 - Command to stop the spindle Motor.

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PROCEDURE:

Step 1: The power red wire was checked to be connected to the + (red) terminal of the
power supply and the red and black wire was connected to the – (black) terminal
of the power supply.
Step 2: The serial communication cable (CBL-1) is a 3 wire cable with a D-connector on
one side and an earphone plug on the other side.
The D-connector was connected to the serial communication outlet of the PC
(COM1 or COM2) and the earphone plugged to the earphone inlet.
Step 3: The power supply of the C-501 was connected to the Mains.
Step 4: C-501 has an emergency pushbutton on the front panel.
The pushbutton was turned ON by turning it to the right.
Step 5: The power supply Main switch was turned ON.
Step 6: The mouse was clicked over the S-MILL icon on your desktop.
Step 7: The FILE function and the NEW sub-function were selected.
Step 8: The G&M-Code was typed into the milling program:
Step 9: The program was compared with the drawing.
Step 10: The function FILE and the SAVE AS sub-function were selected.
Step 11: The slot name was typed and OK was clicked.
Step 12: The OPTIONS function was selected again. Then SIMULATION sub-function
was selected.

In simulation mode, the software simulates the machine behavior on the screen,
without processing the material. This option enabled us to check our program
before milling the material.

Step 13: The function RUN and the RUN sub-function were selected. A graph window
appeared. The program was executed step by step graphically on the window.
Observe the drawing, the colors of the lines describe the Z-dimension of the
lines.

Step 14: The material (90x80x20 mm) on the table of the C-501 was located and tightened
with the handy screws.
Step 15: The OPTIONS function and the MACHINE sub-function were selected in order to
operate the system.
Step 16: The function MONITOR and the sub-function CNC MONITOR were selected.

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Step 17: The cutter center was moved to the relative project home with the STEPS (mm)
and the MOVE buttons.
Step 18: The milling motor was turned ON by clicking over the "Start Spindle Motor"
button.
Step 19: The cutter was lowered slowly until the cutter almost touched the material surface.
Step 20: The "DEFINE PROJECT HOME" button was pressed.
Step 21: The RUN function and the RUN sub-function were selected.

RESULTS:

G&M-CODE for the design

M4 S2000
G0 X0 Y0 Z4
G0 X-22 Y20
G1 Z-2 F125
G1 Y30
G1 X-18
G1 Y20
G1 X-20 Y10
G1 X-24
G1 X-26 Y20
G1 Y50
G1 X-24 Y60
G1 X-20
G1 X-18 Y50
G0 X-16 Y10 Z4
G1 Z-2 F125
G1 Y50
G1 X-14 Y60
G1 X-12
G1 X-10 Y50
G1 Y40
G1 X-12 Y30
G1 X-16
G1 X-12
G1 Y30
G1 X-10 Y10
G0 X-6 Y10 Z4
G1 Z-2 F125
G1 X-8 Y20
G1 Y50
G1 X-6 Y60
G1 X-2
G1 X0 Y50
G1 Y20
G1 X-2 Y10
G1 X-6
G0 X2 Y60 Z4

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MEL 527: CNC Milling

G1 Z-2 F125
G1 Y20
G1 X4 Y10
G1 X8
G1 X10 Y20
G1 Y60
G0 X12 Y10 Z4
G1 Z-2 F125
G1 Y50
G1 X12 Y60
G1 X18
G1 X20 Y50
G1 Y40
G1 X18 Y30
G1 X12
G0 X34 Y50 Z4
G1 Z-2 F125
G1 X32 Y60
G1 X28
G1 X26 Y50
G1 Y20
G1 X28 Y10
G1 X32
G1 X34 Y20
G1 Y30
G1 X32 Y40
G1 X26
M5

Figure 1.4(a) Simulation

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Figure 1.4(b) G&M Code

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DISCUSSION OF RESULTS:

After running the G & M code written, the simulation gave an output as shown in Figure 1.4
(a) which is a representation of the expected result.

SOURCES OF ERROR:

1. Error due to inaccurate design.

2. Error due to imperfect G&M-Code.

PRECAUTION:

1) It was ensured that the G&M-Code was written to avoid any error in execution of
the code.
2) It was ensured that all dimensions do not exceed the maximum dimension that
can be accommodated by the machine.
3) It was ensured that according to the design, not more than 1mm of workpiece is
removed at a time.
4) It was ensured that milling step resolution not over 1mm was used and the
feeding speed to the processed material was adapted.

APPLICATION:

(a) Aerospace equipment.

(b) Automobile Parts.

(c) Complex shapes.

(d) Electronic industry uses CNC e.g. Printed circuit board.

(e) Electrical industry uses CNC e.g. Coil winding.

CONCLUSION:

The G&M code was successfully written according to the drawing. The program was run and
simulation produced gave satisfactory result. CNC programming was understood. Thus, the
experiment was successful.

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MEL 527: CNC Milling

REFERENCE:

Department of Mechanical and Production Engineering. 2018. MEL 527: CNC Milling
Laboratory Manual. Abubakar Tafawa Balewa University.

Version 2 EE IIT, Kharagpur. Module 5, CNC Machine: Lesson 23 Introduction to Computer

Numerically Controlled (CNC) Machines. Retrieved September 18, 2018 from:
http://nptel.ac.in/courses/108105063/pdf/L-23(SM)%20(IA&C)%20((EE)NPTEL).pdf

Viktor Stenberg, Student CNC Guide, KTH Royal Institute of Technology. Stockholm,
Sweden, 2015

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