STANDARD OPERATING PROCEDURE

AND
SAFETY GUIDELINES
GORATU MAKE
GBM CM 8 LAGUN CNC – Header Drilling SPM

GENERAL SAFETY GUIDELINES:

The user should ensure that anyone working with the machine follows these
regulations and refrains from working in a way that will affect the safety of the
machine:

1. Never use the machine while under the influence of drugs / medication and
/ or alcohol.

2. Keep the workstation clean and free from obstacles.

3. Respect the distances between mobile and fixed parts.

4. Make sure the work station is well lit.

5. Always memorise the location of the emergency stop buttons.

6. Protect your hands. Machined pieces and tools have sharp edges. Use
gloves when handling work pieces or tools.

7. Spindle Head should be greased after every 50 working hours. Use only
KLUBER – NBU 15 Grease for the same.

8. PERSONAL PROTECTIVE EQUIPMENTS (gloves and shoes, helmet and goggles)

should be worn at all times to prevent injury from flying objects, chips etc

9. If, during the course of normal operations, you detect any anomaly or
failure in the machine’s safety systems, the machine should be isolated and all
energy dissipated, and the system repaired and checked before work can
continue.

10. In the event of a failure in the electrical power supply, disconnect the main
switch.

11. Make sure that machine’s main switch is disconnected before carrying out
any maintenance or cleaning operation.

12. Pay special attention during work piece loading and unloading operations,
since your hands may become trapped between the work piece and the
table / chuck or between work piece and tool. Spindle should be with out tool
while loading and unloading of work piece.

13. Use the tools & pull studs in accordance with machine specifications.

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 In our case (i.e. for GBM CM 8 model) Spindle taper is ISO 50 DIN
69871 / A. Use only through hole pull studs for each tool, in case we use
spindle through coolant. If we use blind hole pull stud and spindle through
coolant is commanded, it may cease the spindle.

DON’TS:
1. Operators should NEVER stand, lie, sit or otherwise locate themselves in the
vicinity of machining zone.

2. Do not use clothes that may catch in the machine’s mobile elements.
Remove watches, rings, ties etc.

3. Never cover or remove the safety instructions plates.

4. Do not move too close to the working zone or rotating areas during
machining cycles.

5. Do not use electrical welding devices near the machine.

6. Do not operate equipment if it has been exposed to water.

7. Never attempt to clean, lubricate or adjust the machine while it is in

operation.

8. Do not lay tools, extraneous equipment or material anywhere on the

machine.

GORATU
Travelling Column with fixed table milling machine
Model: GBM CM 8
TECHNICAL DATA:

Table Surface: 9500 x 1100 mm

Travels:
X axis: 8000mm (Longitudinal)
Y axis: 1200mm (Transversal)
Z axis: 1500mm (Vertical)
A axis: 0 – 360 Degrees (Chuck rotation – 4th Axis)

Spindle:
Spindle taper: ISO 50 DIN 69871/ A
Speed range: 50 to 3000 RPM
Spindle power: 28 / 34.5 KW

Accuracy:
Positioning: 0.02/ 4000 mm
Repeatability: 0.01

Control System:
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Siemens Sinumerik 840 D

ATC (Automatic Tool Changer):

Tool Capacity: 24 tools
Max. Tool diameter: 110mm
Max. Tool length: 350mm
Max. Tool weight: 15 Kg
Tool selection: Two way random selection

Chuck:
Min ID Clamping: 150mm
Max ID Clamping: 380mm

Admissible weight on Table: 3500 Kg

UNDER NO CIRCUMSTANCES SHOULD A MACHINE BE LOADED BEYOND ITS

RATED CAPACITY.

OPERATION OF THE MACHINE:

The machine is controlled with the following parts:

- Control Panel (Siemens Sinumerik 840 D)
- 4 axis of machines (X, Y, Z, and A)

Switching the machine “ON”:

To switch the machine on, proceed as follows:
1. Check the oil levels in the different tanks and top up if
necessary.
2. Release all emergency stop buttons.
3. Activate the main switch in electrical cabinet.
4. Wait for approximately 1minute.
5. Press the general on (in our case “Green Button”) on the CNC
Control panel.
6. Press reset.
7. Press feed start and spindle rotation (in either direction )
8. The machine is now ready to be referenced.

After switching the machine on, wait at least 30 seconds before

switching it off.

Referencing:
After every switch on and in case of power failure do the
referencing as per follow:
1. Switch “ON” the machine.
2. Release emergency button if pressed.
3. Press Control On.
4. Press Reference Push Button.

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 5. Press JOG mode
6. Move the “Z” axis in upward direction to a safer distance so
that while auto referencing there will not be any fouling or
collision.
7. Reference the axis Z, Y, X by this sequence. If the work piece is
clamped, decamp the steadies manually and reference A
axis.

After referencing we can switch to operating mode.

Loading / Unloading of the work piece:

1. If the mass of tools or work pieces with which you are going to
work exceeds 10kg, use crane for transportation and
positioning.
2. Position the hydraulic chuck jaws as per header ID (inner
diameter). Stroke is 50mm.
3. According the length of header, place the manual chuck at
other end. Place the steadies from at equal distance from
both the chucks.
4. Clamp the header firmly. Press hydraulic clamp button on
operator control panel and tighten the other end manually.
5. Clamp the steadies hydraulically with help of control panel
switch before starting the work piece cutting.

Work piece setup:

If the Header is of Radial Type (Regular – Drilling at centre of
Header):
1A. Load the header into the chuck so that all the three jaws of
the chuck should be placed at an angle say 30 deg. To the
perpendicular so we can avail maximum clearance for spindle
axis (Z) for drilling two extreme co- ordinates.
If the Header is Non Radial Type (Offset Drilling):
1B. Load the header into the chuck so that one Jaw of the
chuck will be at the centre i.e. perpendicular to the header axis.
This will allow maximum clearance for spindle axis (Z axis) to do
the offset drilling.

IMPORTANT: Load only those headers which has approved by

QC for bend, twist, marking or orientation etc.

1. Load the header such that maximum holes can be drilled in

line before any indexing
2. While setting the work piece, decide the work piece zero
position for all the axis as per work piece drawing and loading

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 position orientation. We can set this “Zero” position in G54,
G55, G56 and G57 ( in settable zero offsets )
3. Take the centre of header and Preset Y axis = 0.
Once we preset Y = 0 for first header , this value will remain
unchanged for all the headers irrespective of their diameters
as long as both the chucks are not disturbed in traverse
direction. Both the chucks are placed in central “T” slot of the
machine with tennon guiding the slot for both the chucks
ensuring the firm alignment.
4. Pick up the first co – ordinate punched on the header with
the help of centre pin and preset X = 0
5. Study the drawing and load the tools into tool magazine with
ATC as per drawing configurations.
6. Measure the length of each tool on Tool presetter and input
the same in corresponding tool geometry.
7. With “J” Prep. Tool take Z offset at the top of the header and
preset Z= 0.
8. With the selected work co ordinate system, say G54, at X= 0,
Y= 0, Z= 0, set A = 0. (A = Rotary axis). In machine menu
screen, by pressing “Scratch” button and selecting G54 up to
G57 we can set above values. With this work zero is defined
for absolute positions. Remember for all work co-ordinates we
set from G54 to G59, The plane should be G17. This will ensure
that our spindle is Vertical.

9. Be careful for First and last hole drilling as the header is

clamped at both ends with internal chuck. For Hydraulic
clamping chuck, jaw length engaged in job is 35mm; while at
other end i.e. at manual clamping end jaw length is 25mm.
Considering this, the first and last hole is to be drilled. In case
of fouling on jaws, leave that hole and plan it on Radial drilling
machine.

10.Do not over tighten the manual steady supports as it may

prevent the movement of A axis.

11. Offer every job for QC Check stage wise if you have any
doubt and for final inspection of the job. Take inspection
report from QC and maintain the reports.

Programming:

Basic M codes:

M00 – Stop programme execution / stop head / cooling off

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M01 - Programme stop in the programme execution
M02 - Stop programme execution / stop head / cooling off
M03 – Spindle rotation in clockwise direction
M04 - Spindle rotation in anticlockwise direction
M05 – Stop spindle rotation
M06 – Tool Change
M07 – Coolant On (High pressure – Internal coolant)
M08 – Coolant On – External coolant
M09 - Coolant stop
M30 - Stop programme execution / stop head / cooling off
M86 – Close the steady
M87 – Open the steady

G – Codes:
G0 – Rapid Traverse
G1 – Linear interpolation (at given federate)
G2 – Circular interpolation clockwise
G3 – Circular interpolation – anticlockwise
G4 - Dwell time preset
G17 – Plane selection – XY Plane
G18 – Plane selection – ZX plane
G19 – Plane selection - YZ plane
G54 – Settable zero offset
G55 – settable zero offset
G56 – settable zero offset
G57 – settable zero offset
G500 – Deactivate all settable G54 – G57 frames if G500 does not
contain A value.
G70 – Input system inches
G71 – input system metric
G90 – Absolute dimension
G91 – Incremental dimension input
G41 – Tool radius compensation left of contour
G42 – Tool Radius compensation right of contour
G40 – Cancel tool radius compensation

Notations:
X – X axis
Y – Y axis
Z – Z axis
A – A axis
T – Tool No.
S – Spindle Speed (RPM)
F – Feed rate (mm/min)
I – Circle center point for X axis
J – Circle center point for Y axis
K - Circle center point for Z axis
P - Program repetition

How to do the programme?

1. Press Program Manager soft key
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2. Make New Work piece Directory ( WPD ) – name the directory
3. Press soft key New Program – name the programme
4. Editor window will be opened for programme
5. Edit the programme and close the window

Programme Example:
; (Dia 54 mm Drilling)
T1 Tool Change for Tool No 1 in Spindle
M6
G54 G90 G0 X0 Y0 Z100 Calling Absolute work position& rapid traverse
M3 S1500 Spindle start at 1500 rpm
G0 Z3 Rapid traverse to Z 3 position
M7 High pressure coolant start
M8 External coolant start
G1 Z-35 F115 Linear movement at 115 federate
G1 Z-45 F100 Linear movement of Z axis to reqd. Depth
G0 Z50 Z axis rapid traverse up to 50mm
N10 BLOCK INSERTION
G0 G91 X-102 Incremental shift in X axis (as per pitch on drawing)
G90 Again absolute position
G0 Z3 Z axis Rapid Traverse up to 3mm
G1 Z-35 F115 Linear movement at 115 federate
G1 Z-45 F100 Linear movement of Z axis to reqd. depth
G0 Z50
REPEAT N10 P= 34 Repeat N10 loop 34 times
G0 Z100
M30 Programme end / stop spindle/ cooling off

For Detailed Programming, please refer the programming manual.

Once the program is ready, If you have made the programme first time.
Proceed as per follow:
1. Cross check the co-ordinates entered as per drawing.
2. Verify the work co ordinate system selected.
3. Keep Z axis 50 to 100mm (in offset mode) above.
4. Select the program to be run.
5. Select the auto mode.
6. Press single block key.
7. Move feed over ride potentiometer to Zero
8. Press cycle start. See the program block to be read by system. See the
distance to be traveled by each axis and accordingly release the
federate.
9. Likewise complete the dry run cycle and make sure that the program is
100% correct.
10. Remove the lift of Z axis (50 to 100mm in offset) and start actual cutting
in auto mode.
11. Inspect the job in process and after completion for any operation
missing.
12. Once you are familiar with the control system, you can run the program
directly in auto mode, provided the program and co-ordinates are well
within reach.

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