EXPERIMENT 1

Aim: To understand desktop CNC lathe configuration, make a program and perform the turning
operation.

Apparatus: CNC Lathe Machine

Photo and the imp parts to be labeled.

A CNC lathe is an assembly of intricate components, each playing a crucial role in its
operation. Understanding these components gives you a deeper insight into how these
machines achieve such high levels of precision and efficiency. Here’s a breakdown of the
key parts:

● Main Spindle: The heart of the lathe, where the workpiece is mounted and rotated.
● Chuck: A device that holds the workpiece in place on the spindle.
● Tailstock: Provides additional support for longer workpieces, ensuring stability during
machining.
● Tool Turret: Holds various cutting tools and rotates to bring the desired tool into position.
● Control Panel (CNC Controller): The interface where you input the G-code and control
the machine’s operations.
● Bed: The base that supports all major components of the lathe.
● Carriage: Moves along the bed, carrying the cutting tool and guiding it along the
workpiece.
● Headstock: Houses the main spindle and often includes the gear mechanism for
controlling spindle speed.
● Coolant System: Delivers coolant to the cutting area to manage temperature and
prolong tool life.
● Chip Conveyor: Removes the metal chips produced during machining, keeping the work
area clean.
G code and final image of the part:
EXPERIMENT 2

Aim: To understand desktop CNC milling configuration, make a program and perform the
milling operation.

Apparatus : CNC Milling Machine

Photo and the imp parts to be labeled.

● Column: The column in case of the CNC Machine is to provide the support and structure
to the other machine components. Column acts as a support structure for the milling
machine.
● Machine Interface : We already know the CNC machines are computer numeric control
machines. The operators are needed to load, initiate and execute the programs in the
CNC milling machines. The machine interface enables the operator to do the same.
● Knee : The knee is kind of adjustable component fixed to the column. Knee provides the
required support to the saddle and the worktable on which the work holding device is
mounted. The knee can be adjusted in Z-axis it can be lowered or raised according to
the requirements.
● Saddle : The saddle is mounted over the knee. Just like the knee supports the saddle
the saddle supports the worktable. Also, the saddle can be moved parallel to the axis of
spindle. It can help workpiece to adjusted horizontally.
 ● Worktable : It is located at the top of saddle. It consists of work holding device on which
the workpiece is mounted. Work holding devices like the chuck or vice is used. The
worktable can be adjusted horizontally, vertically both or fixed at one direction according
to the work requirements.
● Spindle : The spindle is rotating device which holds the machine tool. The spindle is
driven by the electric motor.
● Arbor : It is a kind of shaft that is inserted into the spindle in horizontal milling machines.
Multiple machines can be easily mounted on this shaft. They are available in various
sizes, lengths, and diameters according to the specifications.
● Ram : The Ram is generally found in the vertical milling machines. These are located on
the top and affixed to the column. It can be adjusted for the different position of milling
operations.
● Machine Tool : This is the major part which accommodates the milling operation. The
tool is held by the spindle and it performs the material removing operations. There are
various types of cutters are available like multi-point cutting tools, single point cutting
tool. Depending upon the requirements needed in the workpiece the cutter is selected.
Milling machine are also used for drilling, boring, reaming tools for other operations.

G code for milling machine operation and the final object:

EXPERIMENT 3

Aim: To generate G-codes using a CAD software for a given job.

Step 1: Coordinate System

Step 2 : Define coordinates

Step 3: Define Machine

Step 4: Click “Select” and then click “Ok”

Step 5: Click on “Extract Machinable Operation”

Step 6: Click on “Generate Operation Plan”

Step 7: Click on “Generate Toolpath”

Step 8: Click on “Simulate Toolpath”

Step 9: Click on “Post Process” to generate the Gcode.

Gcode for the operation:

EXPERIMENT 4

Aim: To understand the configuration and important functions of CNC Vertical milling machine.

Apparatus Required: CNC Vertical Milling Machine

Parts:

● Column: The column in case of the CNC Machine is to provide the support and structure
to the other machine components. Column acts as a support structure for the milling
machine.
● Machine Interface : We already know the CNC machines are computer numeric control
machines. The operators are needed to load, initiate and execute the programs in the
CNC milling machines. The machine interface enables the operator to do the same.
● Knee : The knee is kind of adjustable component fixed to the column. Knee provides the
required support to the saddle and the worktable on which the work holding device is
mounted. The knee can be adjusted in Z-axis it can be lowered or raised according to
the requirements.
● Saddle : The saddle is mounted over the knee. Just like the knee supports the saddle
the saddle supports the worktable. Also, the saddle can be moved parallel to the axis of
spindle. It can help workpiece to adjusted horizontally.
● Worktable : It is located at the top of saddle. It consists of work holding device on which
the workpiece is mounted. Work holding devices like the chuck or vice is used. The
worktable can be adjusted horizontally, vertically both or fixed at one direction according
to the work requirements.
● Spindle : The spindle is rotating device which holds the machine tool. The spindle is
driven by the electric motor.
 ● Arbor : It is a kind of shaft that is inserted into the spindle in horizontal milling machines.
Multiple machines can be easily mounted on this shaft. They are available in various
sizes, lengths, and diameters according to the specifications.
● Ram : The Ram is generally found in the vertical milling machines. These are located on
the top and affixed to the column. It can be adjusted for the different position of milling
operations.
● Machine Tool : This is the major part which accommodates the milling operation. The
tool is held by the spindle and it performs the material removing operations. There are
various types of cutters are available like multi-point cutting tools, single point cutting
tool. Depending upon the requirements needed in the workpiece the cutter is selected.
Milling machine are also used for drilling, boring, reaming tools for other operations.

Accessories Used With CNC Milling Machines:

● Coolant System: A coolant system is crucial in a CNC milling machine. It ensures a
continuous flow of coolant to the workpiece and the tool so that they do not heat up
excessively during the milling operation, thereby preventing tool or workpiece damage.
The coolant or cutting fluid can be water or oil-based, where water-based coolants are
suitable for minimizing heat, and oil-based coolants are ideal to maximize lubrication.
Generally, a coolant system consists of a pump, piping, and nozzles.
● Powered Drawbar: Powered drawbars are iron or steel couplings that use a pneumatic
system to tighten or loosen the drawbar automatically for tool change. It is generally
used in CNC milling machines integrated with an automatic tool changer.
● Enclosure: An enclosure is an acrylic or metallic guard that encloses the workspace of
the milling machine so that the chips produced during milling do not fly off. This adds to
the safety of the operation, preventing any injury to the CNC operator.
● 4th Axis or Rotary Kit: A rotary kit adds a 4th axis to the milling system and provides
the ability to mill curved or cylindrical workpieces. It generally consists of rotary rollers
that can hold cylindrical workpieces and rotate them to access the workpiece from all
sides.
● Automatic Tool Changer (ATC): An automatic tool changer enables easy and fast tool
change, especially when you require different milling operations on a workpiece. These
tool changers are available in different types, such as chain type, drum type, disk type,
turret type, etc., and each type provides a different tool holding capacity. Generally,
chain-type ATC can hold around 100 tools at a time, while a drum type is suitable for
holding around 32 tools, while the turret type can hold 8 tools. An ATC can either be
mounted on the column or separately from the machine and the G-code from the CNC
program activates the CNC tool changer to automatically replace the tool for further
machining. However, CNC tool changers or ATCs can be expensive and are only
suitable for industrial applications where high productivity is of utmost importance.
● Chip Tray: A chip tray collects all the chips generated during the milling operations. The
high-pressure coolant flushes the chips from the cutting area and collects them in the
chip tray, where the cutting fluid is filtered out and collected in a separate tank while the
 chips are accumulated in the chip tray. This minimizes the need for cleaning and
enhances the productivity of the process by reducing maintenance time.
● Machine Guards: According to ISO 13849, machining safety is crucial and demands
machine guards be installed against moving parts of the machine. Unlike enclosures,
machine guards only cover the cutting area and prevent the chips from flying off and
injuring the operator. Machine guards are generally made of metal or thick plastic
covering the milling tool’s cutting area. Although they do not affect the performance of
the machine, they can minimize the risk of any serious accidents.

GUI: The graphical user interface (GUI) of a CNC (Computer Numerical Control) vertical milling
machine provides operators with an intuitive way to interact with the machine and control its
operations. Here's an explanation of the typical elements:
● Main Screen: The main screen of the GUI displays essential information such as current
machine status, program being executed, tooling information, and any alarms or alerts.
● Control Panel: This section of the GUI contains buttons and switches for basic machine
control functions like power on/off, emergency stop, spindle speed control, feed rate
control, and axis movement (jogging).
● Program Management: This area allows operators to manage CNC programs. They can
load, save, edit, and run programs from here. Some advanced systems might support
USB or Ethernet connections for program transfer.
● Tool Management: Operators can manage tooling information in this section, including
tool length offsets, tool wear compensation, and tool library management. This ensures
accurate machining and reduces setup time.
● Axis Control: Here, operators can control individual axes (X, Y, Z) either by jogging them
manually or inputting specific positions. This feature is crucial for setting workpiece zero
points and tool offsets.
 ● Simulation and Visualization: Many modern CNC milling machine interfaces include
simulation and visualization tools. These allow operators to simulate toolpaths, verify
machining operations, and detect potential collisions before running the actual program.
● Diagnostic and Maintenance Tools: This section provides access to diagnostic tools for
troubleshooting machine issues and performing routine maintenance tasks. It might
include features like spindle load monitoring, tool life monitoring, and lubrication system
status.
● Settings and Configuration: Operators can adjust machine settings and parameters in
this section to optimize performance and tailor the machine to specific machining tasks.
This includes parameters related to feed rates, spindle speeds,
acceleration/deceleration, and coolant usage.
● Help and Documentation: A built-in help system provides operators with information on
machine operation, programming syntax, troubleshooting tips, and safety guidelines. It
may include manuals, tutorials, and FAQs accessible directly from the GUI.
● Safety Features: The GUI also incorporates safety features such as interlocks, door
locks, and safety warnings to prevent accidents and ensure operator safety during
machine operation.

EXPERIMENT 5

Aim: To prepare bill of material, material requirement planning sheet, purchase order for a given
part/product.
(The tables given below are just for your reference. Take a product of your choosing and make
similar tables for your product.)
EXPERIMENT 6
Aim: To understand the basics and functions of OPENCIM software.

Basics: OpenCIM Offline is the simulation version of OpenCIM. Users can design and run an
unlimited variety of CIM or FMS cells in simulation mode, but cannot operate or control actual
CIM cells.
OpenCIM Intro is a basic version of OpenCIM Offline. Users can run all the demo CIM systems
included in the software and can perform manufacturing management (such as part definition,
storage management, MRP, reports), but cannot design or modify CIM cell configurations.

Various tasks performed by the software:

● Storage Station: The ASRS storage station is a floor-mounted or a table top automated
storage and retrieval (ASRS) system designed for educational use. The system’s
dedicated Cartesian robot transfers parts between storage cells and conveyor pallets
stopped at the ASRS station. The robot is controlled by Controller-USB and by a
dedicated ASRS software module in the OpenCIM software. An optional hand-held
teach pendant can also be used for direct control of the ASRS.
● Machine Tending Station: This package can be used as a stand-alone workcell, or
integrated within a CIM system. The robot tends the CNC machine and performs other
part manipulation and/or assembly tasks. When used in a CIM system, the robot loads
and unloads parts to and from the CIM conveyor. The robot is mounted on a linear
slidebase for mobility and larger work area. Any of the MTS stations can be provided as
a standalone FMS.
● Assembly & Quality Control Station: The assembly and QC station is equipped with a
variety of assembly and quality control devices as well as with local storage devices.
This turnkey station gives students training and skills in assembly, quality control, robotic
programming and automated manufacturing systems.
● Welding Station: This automated welding station can be used as a stand-alone
workcell, or integrated within a CIM system. When used in a CIM system, the robot loads
and unloads parts to and from the CIM conveyor in addition to performing arc welding
and part manipulation tasks.
● Conveyors: The conveyor frame is constructed of extruded, black anodized aluminum,
and its moving belt is a double flexible-chain rail.
● PLC Station: The PLC (Programmable Logic Controller) can control and monitor the
flow of pallets on the conveyor with the help of sensors and actuators that are built into
the stop stations.
● Pallet Tracking Station: The stop station allows the PLC to control and monitor the flow
of pallets on the conveyor with the help of sensors and actuators that are built into the
stop stations.
● Management Station: The OpenCIM software is a computer-integrated systems
management solution that contains all the elements found in fully-automated facilities.
Shop floor management controls the operation of all the elements of automated factory.
Administrative software connects the shop floor management to the production facility’s
Enterprise Resource Planning (ERP). The OpenCIM software contains an ERP package
which breaks down customer orders to analyze bill of materials, check availability of raw
materials, produce vendor’s purchase order and schedule production based on expected
lead times.