(AN AUTONOMOUS INSTITUTION UNDER VISVESVARAYA TECHNOLOGICAL UNIVERSITY, BELGAUM)

APPROVED BY UGC/AICTE/GOVT. OF KARNATAKA, ACCREDITED BY NBA (Tier-1) AND NAAC (Grade ‘A+’)

Yelahanka, Bangalore 560064

INTERNSHIP REPORT

On

“CNC MACHINES”
Submitted by

Name: USN:
SUNIL KUMAR K 1NT18ME152

In partial fulfilment of the requirement for the award of the degree of Bachelor of
Engineering in Mechanical Engineering during 2021-2022

Under the guidance of

Mr. Girish Prasad (Assistant Professor)

NMIT, Bengaluru
 (AN AUTONOMOUS INSTITUTION UNDER VISVESVARAYA TECHNOLOGICAL UNIVERSITY,
BELGAUM)
YELAHANKA, BANGALORE – 560 064

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

This is to Certify that the Internship entitled “CNC MACHINES” is a bona fide work
carried out by Mr SUNIL KUMAR K, bearing USN 1NT18ME152, in partial
fulfilment for the award of the degree Bachelor of Engineering in Mechanical
Engineering of the Visvesvaraya Technological University, Belgaum during the
academic year 2021-22. It is certified that all suggestions indicated during Internal
Assessment have been incorporated in the report. The report has been approved as it
satisfies the academic requirements in respect of Internship work prescribed as per the
Autonomous scheme of Nitte Meenakshi Institute of Technology, for the said Degree.

Signature of the Guide(s)           Signature coordinator(s)

Signature of the HOD Signature of the Principal

Examiner Name Date

 DECLARATION

I hereby declare that internship report titled “CNC MACHINING TECHNOLOGY” is a record of an
original work done by me under the guidance of Mr Girish Prasad, Assistant Professor of Mechanical
department, and this report is submitted in the partial fulfilment for the award of the degree Bachelor of
Engineering in Mechanical Engineering of the Visvesvaraya Technological University, Belgaum during the
academic year 2021-22.

SUNIL KUMAR K
1NT18ME152
 ACKNOWLEDGEMENT

First and foremost, we thank Mr Girish Prasad for providing wonderful opportunity to take internship in one of
the reputed company ACE MICROMATIC GROUP.

We are grateful to our mechanical HOD Dr. J Sudheer Reddy for providing us endless opportunities and
activities that ensure the students to do productive work and thus help them gain various skills for benefitting
their career and placements.

Last but not least, we are thankful to all our teachers, trainers and friends for guiding us and successfully
complete the internship.
CERTIFICATE
 List of Figures

Figure 1 WATER JET CUTTING MACHINE.....................................................................................................................10

Figure 2 CNC PROGRAM EXAMPLE...............................................................................................................................17
Figure 3 M CODES..............................................................................................................................................................18
Figure 4 G CODES...............................................................................................................................................................19
Figure 5 AUTOMATIC AND MANUAL CMM MACHINES...........................................................................................21
Figure 6 PROBES USED FOR MEASUING DISTANCE...................................................................................................22
1.1 WEEKLY OVERVIEW OF INTERNSHIP ACTIVITIES

DATE DAY NAME OF THE COMPANY VISITED

1st WEEK

01/9/21 Wednesday Orientation at MMT

02/9/21 Thursday ACE 7&8- CMD
03/9/21 Friday ACE 7&8- CMD
04/9/21 Saturday ACE 7&8- CMD
05/9/21 Sunday HOLIDAY
06/9/21 Monday ACE 7&8- CMD

DATE DAY NAME OF THE COMPANY VISITED

07/9/21 Tuesday PRAGATHI TRANSMISSION-1

08/9/21 Wednesday PRAGATHI TRANSMISSION-1

09/9/21 Thursday PRAGATHI TRANSMISSION-1

10/9/21 Friday Holiday

11/9/21 Saturday SPHOORTI MACHINE TOOLS

12/9/21 Sunday SPHOORTI MACHINE TOOLS

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DATE DAY NAME OF THE COMPANY VISITED

13/9/21 Monday ACNC UNIT-2

14/9/21 Tuesday ACNC UNIT-2

15/9/21 Wednesday ACNC UNIT-2

16/9/21 Thursday ACNC UNIT-2

17/9/21 Friday ACNC UNIT-2

18/9/21 Saturday ACNC UNIT-1

DATE DAY NAME OF THE COMPANY VISITED

4th WEEK

20/6/21 Monday ACNC UNIT-1

21/6/21 Tuesday ACNC UNIT-1
22/6/21 Wednesday ACNC UNIT-1
23/6/21 Thursday ACNC UNIT-1
24/6/21 Friday PRAGATHI TRANSMISSION-1
25/9/21 Saturday PRAGATHI TRANSMISSION-1
27/9/21 Monday PRAGATHI TRANSMISSION-1
28/9/21 Tuesday PRAGATHI TRANSMISSION-1
PRAGATHI TRANSMISSION-1
29/9/21 Wednesday
30/9/21 Thursday PRESENTATION/ VALEDICTION AT
MICROMATIC

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1.2 COMPANIES VISITED

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1.3 OVERVIEW OF INTERNSHIP ACTIVITIES

ACE DESIGNERS  Basics of a CNC machines

 Parts of CNC machines
 Assembly of a CNC machine
 Positioning and calibration of
axis

PRAGATHI TRANSMISSIONS  Introduction to gears

 Gear hobbing
 Gear cutting tools
 Gear grinding
 Quality check
SPHOORTI MACHINE  Introduction to tools and holders
TOOLS  Manufacturing process and
calibration

AUTO CNC UNIT-1  Introduction to CNC machining

 Machining in multi axis
machines
 CMM machines and GD&T
Symbols
AUTO CNC UNIT-2  Programming/Coding in CNC
Machines
 G & M Codes
 Sand Blasting and Water jet
machines

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1.4 ABOUT THE COMPANIES

ACE DESIGNERS

Ace Designers, led by three experienced design engineers and powered by a

dynamic team of more than 500 members is one of India’s largest machine tool
manufacturing companies. With a spread of over 50000 square meters, its
manufacturing plants, located in Bangalore, India, are equipped with state-of-
the-art technology to deliver large-scale high-quality products.

Ace Designers, was founded in 1979 as a design-consulting firm. Initially, the

team developed product designs for various machine tools including special
purpose machines. Three years hence, in 1982, Ace stepped into the world of
manufacturing with a range of special purpose import substitution machines for
the I. C. Engine valve Industry.

Since then, Ace has rapidly grown to become India’s largest manufacturer of
CNC turning centers and has remained the undisputed leader for nearly two
decades. With a strategic focus on manufacturing of CNC turning centers, Ace
has developed a wide range of indigenous cost-effective products to meet the
changing needs of its customers. Ace has ensured product excellence through
quality driven manufacturing processes supported by meticulously planned world
class infrastructure.

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PRAGATI TRANSMISSION PVT LTD

A professionally managed company, Pragati Transmission is a focused organization

engaged in manufacturing, supplying, and exporting precision gears used in
automobiles, industrial gearboxes, power tools, machine tools, and aerospace
applications. The company is acclaimed in the market for the quality and performance
of its components that include - precision gears, gear shafts, worm gears, bevel gears,
and power tool components. Also, the company offers job work facilities on CNC
gear grinding, hob sharpening, CNC gear testing among others.

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AUTO CNC MACHINING LTD UNIT 1,2

It’s the one of the largest manufactures of machining centre in India. Strong R&D
facility passion to excel and a young dynamics team led by experienced professionals
has fuelled the rise of AMS to this premier position.

Auto CNC can offer a comprehensive solution to a variety of machining requirements

with a sustained programme dedicated to keeping the factories up-to-date on
capabilities through technology. We constantly ensure that best tools & practices are
available to satisfy the complex requirements of our customers.

The company has a total manufacturing area of 60,000 Sq. Ft with plans to expand its
capacity in the future.

Established 3 manufacturing plants in Bengaluru offering top quality machined parts

in high-volumes for a variety of applications and industry segments.

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Auto CNC can offer a comprehensive solution to a variety of machining requirements

with a sustained programme dedicated to keeping the factories up-to-date on
capabilities through technology.

SPHOORTI MACHINE TOOLS PVT. LTD. 

Sphoorti Machine Tools Pvt. Ltd. was incorporated in the year February 1996 and
started its manufacturing activities with two Vertical Machining Centers.

Over the years the company has undergone many stages of developments to
emerge as one of the India’s leading manufacturers of Tool Discs and Tool
Holders for CNC Turning Centers and Turn Mill Centers.

Sphoorti is one of the trusted manufacturer and supplier to many industries

(machine tool) in the whole world.

Wherein, the company is gradually growing, by providing superb quality products

and also assists in improving the latest technology.

Also, the expert team checks the production capacity, as well as tests these
products thoroughly to make it suitable to sell to the final customers.

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1.5 INTRODUCTION

CNC stands for Computerized Numerical Control. It is a computerized manufacturing

process in which pre-programmed software and code controls the movement of
production equipment. CNC machining controls a range of complex machinery, such
as grinders, lathes, and turning mills, all of which are used to cut, shape, and create
different parts and prototypes. On the day to day, CNC machinists combine elements
of mechanical design, technical drawings, mathematics, and computer programming
skills to produce a variety of metal and plastic parts. CNC operators can take a sheet
of metal and turn it into a critical airplane or automobile part.

Computer Numerical Control machines are automated machines, which are operated
by computers executing pre-programmed sequences of controlled commands. CNC
machines are essentially the opposite of “old-school” devices that are manually
controlled by hand wheels or levers, or mechanically automated by cams alone.
Today’s modern CNC machines understand and function using CNC machining
language – called G-code – which tells them precise measurements for production,
like feed rate, speed, location, and coordination.

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Today’s design and mechanical parts for CNC systems are highly automated – unlike
the old, dangerous, factory machines you’d think of back in the day. The parts’
mechanical dimensions are defined using computer-aided design (CAD) software, and
then translated into manufacturing directives by computer-aided manufacturing
(CAM) software. Therefore, it is important to have knowledgeable CNC machinists
and programmers in the industry to operate this high-tech machinery.

1.6 HISTORY

Although the idea had been around for some time, the first Numerical Control concept
wasn’t developed until 1949. John T. Parsons, an early computing pioneer, developed
it as part of an Air Force research project carried out at the Massachusetts Institute of
Technology (MIT). An experimental milling machine was built at the institute’s
Servomechanisms Laboratory, with the goal of using motorized axes to produce
helicopter blades and stiffer skins for aircraft.

Parsons Corporation in Traverse City, Michigan, got to work on the first system even
before the MIT collaboration. Parsons was able to use an IBM 602A multiplier to
calculate airfoil coordinates. The data points were fed into a Swiss jig borer by
feeding punched cards into the system. Preprogrammed information could be used to
produce parts for helicopters; this was the precursor to CNC machine programming.

The idea was further developed and, in 1952, Richard Kegg (in collaboration with
MIT) introduced the Cincinnati Hydro-Tel, a 28-inch vertical-spindle contour milling
machine. Its commercial introduction came with a patent for a “Motor Controlled
Apparatus with Positioning Machine Tool.” The initial prototype, although it was

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operated using eight-column paper tape, a tape reader, and a vacuum-tube electronic
control system, became a focus for future developments

1.7 EVOLUTION OF TODAY’S CNC FACTORY

The highly automated motion control systems manufacturers now used are still based
on the three primary components of their predecessors. They require a command
function (whether a digital or analog system, a cam follower, or a flap handle to
activate it); a drive/motion system such as a motor, cylinder, valve, or clutch; and a
system that provides feedback, such as an encoder. In early NC machines, a control
level would ride on a cam. In turn, the motor would rotate to operate the machine, but,
if the feedback cable broke, the fluid flow couldn’t be stopped.

Modern CNC machines are electronically controlled so this scenario is highly

unlikely. The end results are now more predictable. Also, they can use just about any
kind of material, including metal, wood, plastic, fiberglass, or foam.

In addition, novel forms of machining have been developed. Using the same concept
as CNC machining, they include Electron Beam Machining, Electrical Discharge
Machining, and Photochemical machining. These and others are often selected

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depending on the material used in the mass-production process. Also common are
laser, oxy-fuel, water-jet, and plasma cutting machines.

Figure 1 WATER JET CUTTING MACHINE

1.8 CNC TURNING

CNC Turning is a manufacturing process in which bars of material are held in a chuck
and rotated while a tool is fed to the piece to remove material to create the desired
shape. A turret, with tooling attached is programmed to move to the bar of raw
material and remove material to create the programmed result. This is also called
“subtraction machining” since it involves material removal. If the center has both
tuning and milling capabilities, such as the one above, the rotation can be stopped to
allow for milling out of other shapes.

 The starting material, though usual round, can be other shapes such as squares
or hexagons.
 Depending on the bar feeder, the bar length can vary. This affects how much
handling is required for volume jobs.
 CNC lathes or turning centres have tooling mounted on a turret which is
computer-controlled. The more tools that that the turret can hold, the more
options are available for complexities on the part.

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 CNCs with “live” tooling options, can stop the bar rotation and add additional
features such as drilled holes, slots and milled surfaces.
 Some CNC turning centres have one spindle, allowing work to be done all
from one side, while other turning centres, such as the one shown above, have
two spindles, a main and sub-spindle. A part can be partially machined on the
main spindle, moved to the sub-spindle and have additional work done to the
other side this configuration.
 There are many different kinds of CNC turning centres with various types of
tooling options, spindle options, outer diameter limitations as well as power
and speed capabilities that affect the types of parts that can be economically
made on it

1.9 CNC MILLING

CNC milling, or computer numerical control milling, is a machining process which

employs computerized controls and rotating multi-point cutting tools to progressively
remove material from the workpiece and produce a custom-designed part or product.
This process is suitable for machining a wide range of materials, such
as metal, plastic, glass, and wood, and producing a variety of custom-designed parts
and products.

It's is a type of machining that uses cutters to shape a workpiece, often on a moveable
tabletop, although some milling machines also feature movable cutters. Milling
started out as a manual task performed by humans, but most milling these days is
done by a CNC mill, which utilizes a computer to oversee the milling process. CNC
milling offers higher precision, accuracy, and production rates, but there are still some
situations when manual milling comes in useful. Manual milling, which requires a lot
of technical skill and experience, offers shorter turnaround times. It also has the added

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benefit that manual mills are cheaper and the user doesn’t need to worry about
programming the machine.

Like most conventional mechanical CNC machining processes, the CNC milling

process utilizes computerized controls to operate and manipulate machine tools which
cut and shape stock material. In addition, the process follows the same basic
production stages which all CNC machining processes do, including:
 Designing a CAD model
 Converting the CAD model into a CNC program
 Setting up the CNC milling machine
 Executing the milling operation

PROCESS

Once the CNC milling process is initiated, the machine begins rotating the cutting tool
at speeds reaching up to thousands of RPM. Depending on the type of milling
machine employed and the requirements of the milling application, as the tool cuts
into the workpiece, the machine will perform one of the following actions to produce
the necessary cuts on the workpiece:

1. Slowly feed the workpiece into the stationary, rotating tool

2. Move the tool across the stationary workpiece
3. Move both the tool and workpiece in relation to each other

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1.10 CNC Milling Machine Operations

CNC milling is a machining process suitable for producing high accuracy, high
tolerance parts in prototype, one-off, and small to medium production runs. While
parts are typically produced with tolerances ranging between +/- 0.001 in. to +/- 0.005
in., some milling machines can achieve tolerances of up to and greater than +/- 0.0005
in. The versatility of the milling process allows it to be used in a wide range of
industries and for a variety of part features and designs, including slots, chamfers,
threads, and pockets. The most common CNC milling operations include:
 Face milling
 Plain milling
 Angular milling
 Form milling

FACE MILLING
Face milling refers to milling operations in which the cutting tool’s axis of rotation is
perpendicular to the surface of the workpiece. The process employs face milling
cutters which have teeth both on the periphery and tool face, with the peripheral teeth
primarily being used for cutting and the face teeth being used for finishing
applications. Generally, face milling is used to create flat surfaces and contours on the
finished piece and is capable of producing higher quality finishes than other milling
processes. Both vertical and horizontal milling machines support this process.
Types of face milling include end milling and side milling, which use end milling
cutters and side milling cutters, respectively.
Plain Milling
Plain milling, also known as surface or slab milling, refers to milling operations in
which the cutting tool’s axis of rotation is parallel to the surface of the workpiece. The
process employs plain milling cutters which have teeth on the periphery that perform
the cutting operation. Depending on the specifications of the milling application, such
as the depth of the cut and the size of the workpiece, both narrow and wide cutters are
used. Narrow cutters allow for deeper cuts, while wider cutters are used for cutting
larger surface areas. If a plain milling application requires the removal of a large
amount of material from the workpiece, the operator first employs a coarse-toothed
cutter, slow cutting speeds, and fast feed rates to produce the custom-designed part’s

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approximate geometry. Then, the operator introduces a finer toothed cutter, faster
cutting speeds, and slower feed rates to produce the details of the finished part.
Angular Milling
Angular milling, also known as angle milling, refers to milling operations in which
the cutting tool’s axis of rotation is at an angle relative to the surface of the
workpiece. The process employs single-angle milling cutters—angled based on the
particular design being machined—to produce angular features, such as chamfers,
serrations, and grooves. One common application of angular milling is the production
of dovetails, which employs 45°, 50°, 55°, or 60° dovetail cutters based on the design
of the dovetail.
Form Milling
Form milling refers to milling operations involving irregular surfaces, contours, and
outlines, such as parts with curved and flat surfaces, or completely curved surfaces.
The process employs formed milling cutters or fly cutters specialized for the
particular application, such as convex, concave, and corner rounding cutters. Some of
the common applications of form milling include producing hemispherical and semi-
circular cavities, beads, and contours, as well as intricate designs and complex parts
with a single machine setup.

1.11 Other Milling Machine Operations

Besides the aforementioned operations, milling machines can be used to accomplish

other specialized milling and machining operations. Examples of the other types of
milling machine operations available include:

 Straddle milling: Straddle milling refers to milling operations in which the

machine tool machines two or more parallel workpiece surfaces with a single
cut. This process employs two cutters on the same machine arbor, arranged
such that the cutters are at either side of the workpiece and can mill both sides
at the same time.  
 Gang milling: What is gang milling? Gang milling refers to milling
operations which employ two or more cutters—typically of varying size,
shape, or width—on the same machine arbor. Each cutter can perform the
same cutting operation, or a different one, simultaneously, which produces
more intricate designs and complex parts in shorter production times.

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Profile milling: Profile milling refers to milling operations in which the machine tool
creates a cut path along a vertical or angled surface on the workpiece. This process
employs profile milling equipment and cutting tools which can be either parallel or
perpendicular to the workpiece’s surface.
 Gear cutting: Gear cutting is a milling operation which employs involute gear
cutters to produce gear teeth. These cutters, a type of formed milling cutters,
are available in various shapes and pitch sizes depending on the number of
teeth necessary for the particular gear design. A specialized lathe cutter bit can
also be employed by this process to produce gear teeth.
 Other machining processes: Since milling machines support the use of other
machine tools besides milling tools, they can be used for machining processes
other than milling, such as drilling, boring, reaming, and tapping.

1.12 CODING IN CNC MACHINES

In CNC machining, G codes and M codes serve a critical role and function. A G code
in CNC programming controls the movements of a machine, dictating how and where
a machine should move to fabricate a part.

An M code in CNC programming controls miscellaneous machine functions,

including starting and stopping specific actions or programs. These two codes work
together to manufacture parts and components, making them essential in the
manufacturing and industrial sectors.

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The original program language used by NC machines was G code. G stands for
geometry, and it's the alphanumeric format the system uses to tell the parts what to do.
It indicates where to start, how to move and when to stop.

Figure 2 CNC PROGRAM EXAMPLE

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Figure 3 M CODES

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Figure 4 G CODES

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1.13 CMM MACHINES

A coordinate measuring machine (CMM) is a device that measures the
geometry of physical objects by sensing discrete points on the surface of the
object with a probe. Various types of probes are used in CMMs, including
mechanical, optical, laser, and white light. Depending on the machine, the
probe position may be manually controlled by an operator or it may be
computer controlled. CMMs typically specify a probe's position in terms of its
displacement from a reference position in a three-dimensional Cartesian
coordinate system (i.e., with XYZ axes). In addition to moving the probe
along the X, Y, and Z axes, many machines also allow the probe angle to be
controlled to allow measurement of surfaces that would otherwise be
unreachable.

Parts
Coordinate-measuring machines include three main components:

 The main structure which includes three axes of motion. The material used to
construct the moving frame has varied over the years. Granite and steel were used
in the early CMM's. Today all the major CMM manufacturers build frames from
aluminium alloy or some derivative and also use ceramic to increase the stiffness
of the Z axis for scanning applications. Few CMM builders today still
manufacture granite frame CMM due to market requirement for improved
metrology dynamics and increasing trend to install CMM outside of the quality
lab. Typically, only low volume CMM builders and domestic manufacturers in
China and India are still manufacturing granite CMM due to low technology
approach and easy entry to become a CMM frame builder. The increasing trend
towards scanning also requires the CMM Z axis to be stiffer and new materials
have been introduced such as ceramic and silicon carbide.
 Probing system
 Data collection and reduction system — typically includes a machine
controller, desktop computer and application software.

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Figure 5 AUTOMATIC AND MANUAL CMM MACHINES

1.14 DIFFERENT TYPES OF CMM

 BRIDGE TYPE CMM

The first type of CMM is also the most common. Bridge-style CMMs are further
divided into moveable-tables and moveable-bridges. Bridge style designs provide
very stable anchors for the measuring apparatus. They are available as both fixed
machines and as portable units. Unlike laboratory machines, these are usually
hardened to stand-up to the rigors of the machine shop floor. However, bridge style
CMMs are often limited to measuring small and medium-sized parts which can be
lifted and placed on the table. 

 GANTRY TYPE CMM

Gantry-style CMMs are used for large products such are automobiles where the floor
itself can serve as a datum. These designs eliminate the need to lift an article onto a
table, so they are useful for heavy machine parts. Their enormous size makes them
much more expensive than the other styles, but their utility makes them critical for
machine shops that churn out large and hefty parts. 
 

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 CANTILEVER TYPE CMM

Next are cantilever machines. These are interesting because they are supported at only
one point, which makes them less rigid than styles that use two-point support. These
are generally limited to measuring small parts: they have the advantage of allowing
the part to be accessed from three sides, rather than just one or two. 

 HORIZONTAL ARM
The first three types mount their probes vertically; horizontal arm CMMs, though,
mount theirs’ horizontally. These machines are used to measure long, slender parts
that would otherwise be out of the range of the typical CMM. While they are useful
for this application, these machines are not as accurate as the other types.  

Figure 6 PROBES USED FOR MEASUING DISTANCE

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1.15 CONCLUSION

It’s been an overwhelming experience interning at India’s largest CNC manufacturing

company, we learnt how different parts of a CNC machines are manufactured and
what are the process that are to be undertaken for manufacturing them.

We were looking at the different types of manufacturing process in awe and

astonishment. We would like to thank the management of Ace Micromatic Group for
providing us with this wonderful opportunity.

1.16 REFERENCES
https://winnmachine.com

https://www.acemicromatic.net

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