1

MANUFACTURING PROCESS
ARTICLE
2018
By: Rino Andias Anugraha and Assistant Team
Telkom University

2
 Manufacturing Process Laboratory Assistants 2018/2019

Audrey Rahmanti Unadi Aldyan Nurfaizi B. Tau

Aufa Rinaldo Alia Agistina
Dimas Fathurrahman Anak Agung Sri Nandini
Evita Rengganis Anggit Pratama
Fahreza Fadhil Hakeki Bagas Arganto P
Fildzah Fajrina Bela Pitria Hakim
FM Anggra Mandala Putra Damario Haznam
Husein Bimantoro Farras Burhanuddin
Lailatul Fitri Gitanjali Widayu Diatri
Nurul Farhana Mario Adiprana Muki
Maulidan Khoir Nafisha Herma Hanifha
Muhammad Ichsan Nurliyan Pangestu Rizky Purnama
Patricia Amelia Sabrina Diana Pratiwi
Putu Ayu Anggrasari Wirawardani Satria Rahmadani Putra
Raihan Muhammad Faizal Sri Yuzarnimar
Sarah Wahyuni Tri Maisyah Nugrah Samudro
Silmi Aprilia Andari Zakaria Gunada

3
 Document
MANUFACTURING PROCESS LABORATORY
Number
Form
MODULE 2
Number
Valid 2018
Module Machining Process
Labwork NC Code Milling
Student Outcomes SO2. Able to apply mathematics, science and engineering principles to solve
complex engineering problems in integrated systems (including human,
material, equipment, energy, and information)
Learning Outcomes LO14. Students are able to make a process plan for a given product

4
A. Tools and Requirements
Tools & Software Requirements
1. Personal Computer 1. Labwork of Module 2.1
2. CNC Simulator Pro 2. Guideline of Module 2.1
3. Stationary

B. References
Black, J. T. (2008). De Garmo's Material and Processes in Manufacturing Tenth Edition.
United States of America: John Wiley and Sons Inc.
Equipment/CNC Model Mill. (2016, April 24). Retrieved from Wiki Makespace:
http://wiki.makespace.org/Equipment/CNC_Model_Mill
Groover, M. P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and
Systems Fourth Edition. United States of America: John Wiley and Sons Inc.

5
C. Labwork Steps
Flow Process Charts Process Description
1. Read the study case well. Because the study
START case contained information that will be
carried out.
2. Pay attention to the specifications of each
Read The Study process (facing dan profiling).
Case 3. Create A New CNC Program on CNC
Simulator Pro in accordance with the tutorial
on Labwork.
Pay Attention To 4. Setting Tools and Zero Point on CNC
The
Simulator Pro in accordance with the tutorial
Specifications Of
Each Process on Labwork.
(Facing And 5. Create NC Code for facing sub program and
Profiling) input it on CNC Simulator Pro.
6. Create NC Code for profiling sub program
and input it on CNC Simulator Pro.
Create A New 7. Create NC Code for main program and input
CNC Program it on CNC Simulator Pro.
8. Simulate NC Code that has been created on
CNC Simulator Pro in accordance with the
Setting Tools And tutorial on Labwork.
Zero Point

Create NC Code
For Facing Sub
Program

Create NC Code
For Profiling Sub
Program

Create NC Code
For Main
Program

Simulate NC
Code

END

6
 MODULE 2.1
MACHINING PROCESS: NC CODE MILLING

1. OBJECTIVES

1.1 Students are able to understand about NC Code Milling.

1.2 Students are able to create NC Code Milling.

2. OUTLINE

2.1 Milling Process

2.2 Main Classification of Milling Processes
2.3 Types of Milling Machines
2.4 CNC Milling Machine
2.5 Structure of Program Milling
2.6 Numerical Control
2.7 NC Code for Milling

7
 3. BASIC THEORY

3.1 Milling Process

The milling process is one of the basic machinery processes where the reduction of
workpiece material is done by cutting tools that rotate on the workpiece. Sometimes the
workpiece remains stationary, and the cutter feeds the workpiece. In nearly all cases, a multiple-
tooth cutter is used so that the material removal rate is high (Black, 2008).
In milling process, a rotating tool with multiple cutting edges is fed slowly across the
work material to generate a plane or straight surface. The direction of the feed motion is
perpendicular to the tool’s axis of rotation. The speed motion is provided by the rotating milling
cutter. A cutting tool has one or more sharp cutting edges and is made of a material that is
harder than the work material (Groover, 2010).

Figure 2.1. 1 Milling Process (Groover, 2010)

3.2 Main Classification of Milling

Processes
Two main classifications of milling processes are peripheral milling and face milling.
Here are some differences between those two milling processes.
1. Peripheral Milling
In peripheral milling the surface is generated by teeth located on the periphery
of the cutter body. Both flat and formed surfaces can be produced by this method.
a. Cutter axis is parallel to surface being machined.
b. Cutting is accomplished by the peripheral teeth of the milling cutter.
c. Mostly performed on a horizontal milling machine.

8
 Figure 2.1. 2 Types of Peripheral Milling; (a) Slab Milling, (b) Slot Milling, (c) Side Milling, (d)
Straddle Milling, (e) Form Milling. (Groover, 2010)

2. Face Milling
In face milling, the generated surface is at right angles to the cutter axis.
a. Cutter axis is perpendicular to surface being milled.
b. Cutting is accomplished by both the flat face of the cutter and the peripheral
teeth of the milling cutter.
c. Mostly performed on a vertical milling machine (Black, 2008).

Figure 2.1.3 Face milling: (a) Conventional Face Milling, (b) Partial Face Milling, (c) End Milling, (d)
Profile Milling, (e) Pocket Milling, and (f) Surface Contouring (Groover, 2010)

9
 3.3 Types of Milling

There are types of milling machines based on the direction of cutter :

a. Up (Conventional) Milling
The direction of motion of the cutter teeth is opposite the feed direction when the
teeth cut into the work. It is milling “against the feed”.
b. Down (Climb) Milling
The direction of cutter motion is the same as the feed direction when the teeth cut
the work. It is milling “with the feed”.

Figure 2.1. 4 Two types of milling machine : (a) up milling and (b) down milling.
(Groover, 2010)

3.4 Numerical Control

The first numerically controlled (NC) machine tool was developed in 1952 at the
Massachusetts Institute of Technology (MIT). Numerical control is used to control the work
part motions during cutting (Groover, 2010). It had three-axis positional feedback control and
is generally recognized as the first NC machine tool (X, Y, Z) (Black, 2008).

Figure 2.1. 5 Axis on the milling machine (3 Axis): X, Y, and Z (http://wiki.makespace.org)

10
3.5 Structure Program

1. Title of Program
OXXXXX
Example: O12345
2. Homing Tool
G28 X0. Y0.
3. Select Tool
TX M06
TX: Number Tool (X means tool number)
M06: Tool Change
4. Rapid Move to Start Point
G00 G54 X… Y…
The tool will move to the X-axis and Y-axis.
5. Spindle On
G90 S2000 M03
M03: Spindle Clockwise
M04: Spindle Counterclockwise
6. Program
G43 H0X Z50.
G90 G01 X10. Y15. F500
7. Safety Movement
G00 G28 Z0.
Select the Z-axis safe.
8. Spindle Off
M05
9. Homing Tool
G28 X0. Y0
10. End Program
M30: Program end, it also stops the spindle and turns off the coolant. The
program pointer will be reset to the first block.
M02: Program end but does not advance the program pointer to the next block.

11
 3.6 Nc Code for Milling

A. Example of NC Code for Milling

Perum Peruri will make parts for coin printing machines with a milling process on CNC
machines. The following figure will help the NC-Code programmer to Y
determine the
cutting tool movement so that it will form the part as desired

DESCRIPTION
S :Speed of Spindle (rpm)
F :Feed Rate (mm/minute)
R : Radius (mm)

Figure 2.1. 6 Example for Milling Process

Based on the picture above the cutting tool movement is determined and made in the
form of NC-Code as follows.
O01234; Program Title
G28 X0. Y0.; Homing Tool
T1 M06; Selection Tool no. 1 (T1)
Rapid Move to Start Point and
G00 G90 G54 X0. Y0. S3000 M03;
Spindle on
G43 H01 Z5. M08; Tool Height Offset and Coolant On
Program, Use Z-0.5 to Safety Point
G01 Z-0.5 F20;
from Workpiece
X0. Y0.; Start point
G01 X80.; Start point to A

12
 Y40.; A to B
X50. Y70.; B to C
X10.; C to D
G03 X0. Y60. R10.; D to E
G01 Y40.; E to F
G02 Y10. R15.; F to G
G01 Y0.; Back to State Point
G00 G28 Z0.; Safety Movement
M09; Coolant Off
G28 X0. Y0.; Homing Tool
M05; Spindle Off
M30; End Program

Notes:
[1] Black font is used as the standard form of code structure
[2] Blue font is used as the movement of tool that follows the shape of the geometry
[3] Red font is used as the tool movement in G code

13
B. Create NC Code for Milling Operation
In this case you are asked to create NC Code to do facing on a part with known
data as follows.
Depth of cut : 1 mm
Feed rate (F) : 100 mm/minute
R plane : 5 mm
Spindle Speed (S) : 800 rpm
Tool diameter : 63 mm
Tool number :1
Stepover : 100%
Material : Dural
Allowance : 1 mm

Figure 2.1. 7 Example to Create NC Code Milling

14
• Facing Sub Program
O22009;
G90 G01 Z-1. F100;
G91 G01 X225.;
G00 Y63.;
G01 X-225.;
G00 Y63.;
M99;

• Facing Main Program

O11009;
T1 M06;
G00 G90 G54 X0. Y0. F100;
S800 M03;
G43 H01 Z5.;
G90 G01 Z0.;
M98 P22009 L2;
G28 Z0.;
M05.;
M30.;

15
SCAN HERE TO UNDERSTAND MORE

Vertical Milling Machine

https://www.youtube.com/watch?v=WuGKnL0q1ps&t=1s

Horizontal Milling Machine

https://www.youtube.com/watch?v=kGws9QKhYbI&t=923s

Coordinate System of Milling Machine

https://www.youtube.com/watch?v=AKwlzIJG5lo

16
 4. REFERENCES

Black, J. T. (2008). De Garmo's Material and Processes in Manufacturing Tenth Edition.

United States of America: John Wiley and Sons Inc.
Equipment/CNC Model Mill. (2016, April 24). Retrieved from Wiki Makespace:
http://wiki.makespace.org/Equipment/CNC_Model_Mill
Groover, M. P. (2010). Fundamentals of Modern Manufacturing: Materials, Processes, and
Systems Fourth Edition. United States of America: John Wiley and Sons Inc.

17