DESIGNING AND MANUFACTURING OF PROFILE BY USING CNC TURNING

CENTER MACHINE BYPROGRAMMING BASED ON LABELS

A PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS
FOR THE AWARD OF DEGREE OF
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
OF
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY ANANTAPURAMU
BY
STUDENT NAME ROLL NUMBER
MURARI ARUNA PRATAP REDDY (17G31A0316)
BADINEHAL SANDEEP (17G31A0301)
SHAIK MUSTAQHAHMMAD (17G31A0326)
MALLEPOGU SURENDRA (17G31A0314)
U.MOHAMMAD SOHAIL (17G31A0329)
UNDER THE ESTEEMED GUIDANCE OF
MR.N. FRANCIS M.TECH,
ASSISTANT PROFESSOR
MECHANICAL ENGINEERING DEPT.

DEPARTMENT OF MECHANICAL ENGINEERING

ST. JOHNS COLLEGE OF ENGINEERING & TECHNOLOGY
(PERMANENTLYAFFILIATED TO JNTU ANANTAPURAM, ACCREDITED BY NAAC, APPROVED BY NAAC,
APPROVED BY AICTE, NEW DELHI)YERRAKOTA, YEMMIGAN UR, KURNOOL – 518 360 (A.P)
2017-2021
 St. JOHNS COLLEGE OF ENGINEERING & TECHNOLOGY
(Permanently Affiliated to JNTU Anantapuram, Accredited by NAAC Approved by
AICTE, New Delhi)
Yerrakota, Yemmiganur - 518360, Kurnool (Dist). A.P.

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the project report entitled “DESIGNING AND MANUFACTURING OF PROFILE BY USING CNC
TURNING CENTER MACHINE BY PROGRAMMING BASED ON LABELS” is being submitted by MURARI ARUNA
PRATAP REDDY (17G31A0316), BADINEHAL SANDEEP (17G31A0301), SHAIK MUSTAQHAMMAD (17G31A0326),
MALLEPOGU SURENDRA (17G31A0314), U.MOHAMMAD SOHAIL (17G31A0329) in partial fulfillment of the
requirement for the award of the Degree in Bachelor of Technology in “MECHANICAL ENGINEERING” in St. JOHN’S
COLLEGE OF ENGINEERING & TECHNOLOGY is a record of bonafide work carried out under the guidance and supervision.
Project Guide HOD
Mr.N.FRANCIS M.Tech , Mr.M.RAVI SANKAR VARAPRASAD, M.Tech,(Ph.D.)
Assistant Professor Associate Professor
Dept. of Mechanical Engineering, SJCET Dept. of Mechanical Engineering, SJCET
Place:
Date:
Certified that the candidate was examined by me in the viva-voce Examination held on ________________ at St. Johns
College of Engineering & Technology, Yemmiganur.

INTERNAL EXAMINER EXTERNAL EXAMINER

ABSTRACT
➢ The aim of the project is to manufacture the designed profile by using CNC machine.

➢ The profile designed is needed to write a CNC program based on labels, the label mode of program is selected
because the programming is too easy even for complicated shapes.

➢ CNC’s had made revolutionary changes with in the manufacturing sector in before days achieving productivity up
to the desired level was not possibilities due to lots of drawbacks like complication of shapes and sizes, lack of
skilled labours, lots of wastages and scraps due to unexpected mistakes and low quality levels and accuracy.

➢ By using CNC this all draw backs can be overcome and this was our small contribution to show the performance
of CNC.

➢ Initially we got trained about the CNC programming and operations for the period of one month during the
training decided to carry our project on CNC .

➢ we designed a profile to be manufactured which would be tough to achieve it by conventional machining process
and we designed to make use of aluminium material as a work piece of dimension.

➢ The results we got was smooth finished surface with high rate of accuracy with less machining time which directly
increases the productivity and the process would be economical when compared to the normal conventional
machining process.
INTRODUCTION:
➢ In Industry it is not efficient or profitable to
make everyday products by hand.
➢ On a CNC machine it is possible to make
hundreds or even thousands of the same items
in a day.
➢ First a design is drawn using design
software, and then it is processed by the
computer and manufactured using the CNC
machine.
➢ This is a small CNC machine and can be
used to machine woods, plastics and
aluminum. In industry, CNC machines can be
extremely large.
INTRODUCTION OF NC & CNC :

• Numerical control (NC) is a method of

automatically operating a manufacturing
machine based on a code letters, numbers and
special characters.

• The numerical data required to produce a part is

provided to a machine in the form of program,
called part program or CNC (computer numerical
control).

• The program is translated into the appropriate

electrical signals for input to motors that run the
machine.
• A CNC machine is an numerical control machine
with the added feature of an on board computer.
The computer is referred to as the machine
control unit(MCU).
ELEMENTS OF CNC
MACHINE:

A CNC machine consist of following 6

major elements:
i. Input Device
ii. Machine Control Unit
iii. Machine Tool
iv. Driving System
v. Feedback Devices
vi. Display Unit
WORKING OF CNC MACHINE:
• The program is input into the MCU, and the data is converted into motion
commands at the MCU.
• The MCU sends these motion commands to the driving system.
• The drive system follows the commands given, and manages the motion and
velocity of the machine tool.
• Some CNC machines operates with the aid of feedback devices. Others do
not.
• Without feedback, the tools may overshoot or may not reach the desired
position because of inertia, wear and tear, and friction.
• To achieve higher accuracy and repeatability, sensors measure the position
and velocity, and feed these data back to the MCU.
• These feedback signals are compared with the reference signals in the MCU.
And if there are errors, new commands are sent to the machine tool to
compensate for these errors.
• The operator can see all the commands, programs and other important data at
the display unit.
TYPES OF CNC MACHINE:
There are many different types of CNC Machines used industry, such as

➢ Mills and machining centers

➢ Lathes and turning centers

➢ Drilling machines

➢ EDM (Electron Discharge Machine) sinker

➢ Wire cut machines

➢ Flame and Laser Cutting Machines

➢ Water Jet profilers

CNC Lathe Machine CNC Milling Machine

CNC TURNING MACHINE
ADVANTAGES OF A CNC MACHINES:
➢ Higher flexibility
➢ Increased productivity
➢ Improved quality:
➢ Reduced scrap rate
➢ Reliable and Safe operation
➢ Smaller footprint
LIMITATIONS OF CNC MACHINES:
➢ CNC Machines are more expensive than manually operated machines, although cost is slowly coming down.
➢ The CNC Machine operator only needs basic training and skills, enough to supervise several machines.
➢ Fewer workers are required to operate the CNC machines compared to manual operated machines. Investment in
CNC Machine can leads to unemployment.
CNC PROGRAMMING BASICS :
❖CNC instructions are called part program commands.
❖When running, a part program is interpreted one command line at a time until all lines are completed.
❖Commands, which are also referred to as blocks, are made up of words which each begin with a letter address and
end with a numerical value.
Some of the Important Things to Know:
❖Coordinate System
❖Machine Coordinate System -Three Finger Rule
❖Coordinates: X,Y,Z, RX,RY,RZ
❖Quadrant System
❖Units, incremental or absolute positioning
❖G - Codes And M-Codes
❖Part Programming
❖Preparatory Codes in Programming
COMMON FORMAT OF A BLOCK:
PROGRAMMING KEY LETTERS:

✓ O - Program number (Used for program identification)

✓ N - Sequence number (Used for line identification)

✓ G - Preparatory function

✓ X - X axis designation
✓ Y - Y axis designation

✓ Z - Z axis designation
✓ R - Radius designation

✓ F – Feed rate designation

✓ S - Spindle speed designation

✓ H - Tool length offset designation

✓ D - Tool radius offset designation

✓ T - Tool Designation

✓ M - Miscellaneous function
LIST OF G - CODES & M – CODES:
G00 - Rapid Transverse
G01 - Linear Interpolation M00 Program stop
G02 Circular Interpolation, CW M01 Optional program stop
G03 Circular Interpolation, CCW M02 Program end
G17 XY Plane, M03 Spindle on clockwise
G18 XZ Plane, M04 Spindle on counterclockwise
G19 YZ Plane M05 Spindle stop
G20/G70 Inch units M06 Tool change
G21/G71 Metric Units M08 Coolant on
G40 Cutter compensation cancel M09 Coolant off
G41 Cutter compensation left M10 Clamps on
G42 Cutter compensation right M11 Clamps off
G43 Tool length compensation (plus) M30 Program stop, reset to start
G43 Tool length compensation (plus)
G44 Tool length compensation (minus)
G49 Tool length compensation cancel
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
CNC SOFTWARES:
There are many software used in CNC Machine, some of them are listed as below.
❑SIEMENS
❑FANUC
❑HANS
❑MITSUBHUSHI
❑HADEN HAND

Enabled for Heavy CNC Communication Duty study Optimal View Scalable operator panal

SINUMERIC 828D
TOOL MANAGEMENT:
• Tool management made easy. The SINUMERIK 828D features a
command center for all tool and magazine tasks so that the
machining process is never interrupted. If the tool is at the end of its
service life, the SINUMERIK 828D will send a text message (SMS)
as necessary – thanks to the Easy Message
technology.

CNC SIMULATION:
Maximum process stability guaranteed. TOOL MANAGEMENT

CNC SIMULATION
HISTORY OF CNC:

❖ In 1775, John Wilkinson- cannon boring machine (lathe).

❖ In 1881, Eli Whitney- milling machine.
❖ In 1947, Mr. John Parsons began experimenting for using 3-axis curvature data to control the machine tool motion
for the production for aircraft components.
❖ In 1949, parsons- first NC machine.
❖ In 1951, MIT was involved in the project.
❖ In 1955, after refinements NC became available in industry
❖ Today, modern machinery are CNC milling machines and lathes.
 ACTUAL PROJECT WORK
➢ AIM
Designing of a profile and Manufacturing the desired profile by using CNC Smart run Lathe machine.

•DESCRIPTION
The profile is designed by using SINUMERIK 828D software. In this software we gave the required dimensions
of the profile that we want to produce by using CNC Lathe machine. The design of this profile is given by the manual
or cycle program in the software. After giving the program, the program is been simulated before executing in the
CNC machine.
PROJECT PROFILE
PROGRAM FOR DESIGNED PROFILE:
Program Execution work piece dimension
2D simulation 3D simulation

Stock removal Face View

MANUFACTURING OF THE PROFILE BY USING CNC SMARTRUN LATHE
MACHINE
After designing the profile using the SINUERIK 828D Software it is simulated in the different
views as shown in the above figures. The program for this profile design is copied and pasted in
the actual CNC Lathe machine for execution.

Before manufacturing the given profile the following points should be followed:

• Measure the diameter and length of the given work piece that is to be manufactured.

Clamp the work piece within the chucks tightly.

Aluminium Workpiece
• Start the spindle by giving command in MDI mode to check whether the work piece
clamped properly or not.

• Clamp the tools in the tool holder that are used for manufacturing the given profile.

• Measure the tool offset manually through JOG mode and fixes the X and Z axis.

• Give the command to move the X axis and Z axis to the work piece with less federate. If the
tool doesn’t make any error and reaches the work piece zero point then the tool offset given
is correct. Now bring the X axis and Z axis to the reference point by using REFERENCE
mode. Tools Used
• Now the machine is ready to design the given profile.
RESULT &
CONCLUSION
• Thus we achieved desired
profile, by using CNC machines we
can complete the work with less time
and with great accuracy compare to
conventional machines. The profile
produced by this Smart run CNC lathe
machine has good finishing surface
and with accurate dimensions in 30
minutes cycle time.
CONCLUSION:
➢ Compare to conventional machine, CNC machines provide many advantages than traditional machines.

➢ CNC Machines are very accurate. The CNC machines produce high production compare to conventional machines.

➢ These CNC Machines doesn’t require a skilled operator to perform specified operations, whereas in conventional machining
the operator should have good skill and well trained.

➢ In CNC Machines we can produce complicated profiles easily with less time rather than conventional machine.

➢ Now-a-days large numbers of industries are coming forward to plant CNC Machines in their respective industries which
increase the demand of CNC Machines and their developments.

➢ CNC machines are applicable to perform any type of processing easily within short time required.

➢ Many industries would like to prefer using CNC machines for productivity as well as quality of the products.

➢ CNC machine have high storage capacity which store lot of programs and these will be used for mass production.
 REFERENCES
➢ http://www.ehow.com/about_5415088_types-cnc-machines.html
➢
➢ http://www.cncci.com/resources/articles/what%20is%20cnc.htm
➢
➢ http://www.bracingsystemsinc.com/basic-motion-types-in-a-cnc-machine
➢
➢ http://www.madehow.com/Volume-2/CNC-Machine-Tool.html
➢
➢ http://dget.nic.in/lisdapp/Trade/syllabus/pdf/TTCNC.pdf
➢
➢ http://users.isr.ist.utl.pt/~pjcro/courses/api0910/API_I_C5.pdf
➢
➢ http://www.tradekorea.com/products/cnc_machine.html
➢
➢ http://www.nd.edu/~manufact/MET%20pdf_files/MET_Ch37.pdf
➢
➢ http://huayucnc.win.mofcom.gov.cn/en/plate01/product.asp?id=24916
➢
➢ http://www.automation-drive.com/cnc-lathe-machine
➢
➢ http://www.cnc-machining-center-yida.com/cnc-turning-center-bml-420.html
➢
➢ http://cnc-machine-center.blogspot.com/2008/09/cnc-surface-grinding-machine.html
THANK YOU