MP Lab 11

Manufacturing Processes Lab
5th SEMESTER
Session: ME-14 Section: C
Name: Muhammad Bilal Kamran
CMS ID: 403281
Submitted to: Sir Khayyam Ahmad

Objectives:
• To understand the working of the CNC lathe machines.
• To familiarize yourself with the G-codes for the CNC lathe machine.
Machines used:
CNC Lathe Machine
Theory:
CNC Machines:
CNC (Computer Numerical Control) machines are automated tools controlled by programmed
instructions (G-codes and M-codes) rather than manual operation. These machines are widely used
in manufacturing to achieve high precision, repeatability, and efficiency in processes like cutting,
drilling, and shaping. CNC machines significantly reduce human error and allow for intricate and
complex geometries.
1. CNC Milling Machine:
The CNC Milling Machine removes material from a workpiece using rotary cutters, guided by
programmed paths. This machine is used to produce complex parts with flat or curved surfaces,
slots, and intricate designs. It operates by moving the workpiece or the cutting tool along multiple
axes, including X, Y, and Z.
• Working Limits:
o Bed Size: 500 mm x 400 mm (X and Y axes).
o Vertical Clearance (Z-axis): Up to 300 mm.
o Spindle Speed Range: 100 RPM to 8000 RPM.
• Control Panel Buttons (CNC Milling):
o Start/Stop: Begins or halts the machining process.
o Spindle Speed Control: Adjusts the cutter's rotation speed.
o Tool Selection: Chooses the required cutting tool.
o Emergency Stop: Instantly stops all machine operations for safety.
o Axis Movement Control: Manually moves the machine along the X, Y, and Z
axes.
2. CNC Lathe Machine:
The CNC Lathe Machine removes material from a rotating workpiece using a stationary cutting
tool, ideal for creating rotationally symmetric components like cylinders, cones, and threads. It is
widely used for making shafts, bushings, and similar parts.
• Working Limits:
o Bed Length: 750 mm.
o Chuck Diameter: 250 mm.
o Maximum Spindle Speed: 6000 RPM.
o Swing Over Bed: 400 mm.
• Control Panel Buttons (CNC Lathe):
o Start/Stop: Controls the machine’s operations.
o Chuck Control: Opens or closes the chuck for workpiece holding.
o Spindle Speed Control: Adjusts the rotational speed of the workpiece.
o Tool Post Control: Selects and positions cutting tools.
o Emergency Stop: Immediately halts operations for safety.
3. G-code for CNC Lathe machine:

The CNC lathe lab demonstrated the essential role of G-code in controlling lathe machining
operations, focusing on tool movements, spindle speed, feed rate, and overall precision.
Similar to CNC milling, the integration of CAD/CAM software was emphasized for
generating G-code efficiently, especially when handling complex geometries and optimizing
toolpaths to reduce machining time and tool wear. The setup process, including tool selection,
workpiece alignment, and zero-point calibration, was critical for ensuring accurate cuts and
proper material removal.
Observations during the lab revealed how variations in machining parameters like feed rate,
spindle speed, and depth of cut influenced surface finish, cutting efficiency, and dimensional
accuracy.
Manual G-code programming presented challenges, including syntax errors and ensuring safe
lathe operation. These issues were addressed through error detection and simulations before
actual machining. Discrepancies between the machined part and the intended design
underscored the impact of machine tolerances, material properties, and tool deflection on final
part quality.The lab emphasized the significance of CNC lathe machining in industrial
production, highlighting its ability to produce highly precise components while strengthening
programming and troubleshooting skills in the manufacturing process.
4. Lab Task:
G21
G90
G17
G0 Z5
G0 X0 Y0
G1 Z-1 F100
G1 X0 Y50 F400
G1 X20 Y50
G3 X25 Y45 I5 J0
G1 X35 Y45
G2 X45 Y35 I0 J-10

G1 X45 Y15 G2 X35 Y5 I-10 J0
G1 X25 Y5
G3 X20 Y0 I0 J-5
G1 X0 Y0
G0 Z5
M30
Drawing on NC viewer
Discussion:
Writing G-code for a CNC lathe machine—more especially, for milling a circular rod with a 10mm
diameter step reduction—was the main goal of the lab. The exercise gave participants practical
experience comprehending the precise G-code commands needed for lathe operations, such as
cutting parameters, spindle speed, and tool selection. To guarantee the best machining outcomes,
great care was taken throughout the exercise to choose the right feed rates, spindle speed, and
cutting depths. The difficulties experienced with G-code syntax, toolpath strategy, and machine
setup highlighted how crucial precision and careful planning is to CNC lathe operations. Before
beginning the real machining process, we were able to detect and fix any possible problems by
simulating the G-code and confirming tool motions and cutting patterns. This reaffirmed the need
for safety checks and debugging in CNC programming. To guarantee that the finished machined
item matched the desired dimensions and surface polish, the exercise also emphasized the need for
accurate calibration and alignment.
Conclusion:
To sum up, this lab gave hands-on experience with CNC lathe programming and machining,
emphasizing the value of accuracy in toolpath design, machine configuration, and parameter
choice. We were better able to comprehend the complexities of creating high-precision
components by developing and replicating the lathe's G-code. Future CNC lathe operations will
greatly benefit from the difficulties faced and the knowledge gained via troubleshooting,
simulation, and setup. The need of meticulous programming and machine calibration in producing
precise and secure machining outcomes was emphasized by this lab.

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Manufacturing Processes Lab

Session: ME-14 Section: C

Name: Muhammad Bilal Kamran

CMS ID: 403281

Submitted to: Sir Khayyam Ahmad

• To understand the working of the CNC lathe machines.

1. CNC Milling Machine:

o Bed Size: 500 mm x 400 mm (X and Y axes).

o Vertical Clearance (Z-axis): Up to 300 mm.

o Spindle Speed Range: 100 RPM to 8000 RPM.

• Control Panel Buttons (CNC Milling):

o Start/Stop: Begins or halts the machining process.

o Spindle Speed Control: Adjusts the cutter's rotation speed.

o Tool Selection: Chooses the required cutting tool.

o Emergency Stop: Instantly stops all machine operations for safety.

o Bed Length: 750 mm.

o Chuck Diameter: 250 mm.

o Maximum Spindle Speed: 6000 RPM.

o Swing Over Bed: 400 mm.

• Control Panel Buttons (CNC Lathe):

o Start/Stop: Controls the machine’s operations.

o Chuck Control: Opens or closes the chuck for workpiece holding.

o Spindle Speed Control: Adjusts the rotational speed of the workpiece.

o Tool Post Control: Selects and positions cutting tools.

o Emergency Stop: Immediately halts operations for safety.

3. G-code for CNC Lathe machine:

G2 X45 Y35 I0 J-10

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