Visvesvaraya Technological University

BELAGAVI, KARNATAKA - 590 014.

Internship report carried out at

SHIMOGA JOB WORKS
Submitted By
 
ULLAS MOHAN NAIK [4PM17ME084]

Submitted in partial fulfillment for the award of Bachelor of Engineering

in
MECHANICAL ENGINEERING
Of Visvesvaraya Technological University, Belagavi during the year 2020-21
Under the guidance of
H. THARANATH.BE, M. Tech
Dept. of Mechanical Engineering,
PESITM, Shivamogga
1. Introduction to CNC machines

CO:- Develop part program for CNC Turning, Milling

and verify on simulation software.

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 Contents
• Introduction to CNC
• Operations in CNC
• Advantages and Disadvantages of CNC
• Axis selection
• 5 Axis CNC
• Advantages and application of 5 axis
• Types of machine configurations for 5-axis machining
• Specification of a 5 axis CNC machine

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 Introduction to CNC
 Numerical control (NC) is the automation of machine
tools that are operated by precisely programmed
commands encoded on a storage medium, as opposed to
controlled manually.

 Most NC today is computer numerical control (CNC), in

which computers play an integral part of the control.

 In modern CNC systems, end-to-end component design

is highly automated using computer-aided design (CAD)
and computer-aided manufacturing (CAM) programs.

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 Operations in CNC

CNC Milling

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CNC Plasma Cutter CNC Electric Discharge Machining
 Other CNC Operations are:-

 CNC Water Jet Cutter

 Drilling

 Sheet metal works (Turret punch)

 Wire bending machines

 Surface grinders

 Cylindrical grinders

 submerged welding

 Glass cutting

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 Advantages of CNC
CNC machines can be used continuously
Batch production with high accuracy
can be updated by improving the software
Training in the use of CNCs is available through the
use of ‘virtual software’.
Intricate detail machining
no need to make a prototype or a model
One person can supervise many CNC machines
simultaneously
saves time

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 Disadvantages
more expensive than manually operated machines

The CNC machine operator only needs basic training

and skills, enough to supervise several machines. In
years gone by, engineers needed years of training to
operate centre lathes, milling machines and other
manually operated machines. This means many of the
old skills are been lost.

Investment in CNC machines can lead to unemployment

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 Axes of CNC Machine Tool

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 From 3-axis to 5-axis machining

• dozens of views need to be defined

• more tool movements
• not sufficient for the complete • programming is quite difficult
finishing process for very • sum of all views does not cover the
deep part and having narrow whole geometry
cavities • overlapping views lead to surface
• results in a bad surface quality quality problems
and long machining times in • More number of lead-in and out
Case of harder material movements

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 Five Axis CNC

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 ADVANTAGES OF 5 AXIS CNC
to machine complex shapes in a single setup
reduces the machinist setup time and increases production rates
By eliminating multiple set-ups, time and errors are reduced
the feature-to-features accuracy is improved because the same
zero or datum reference frame is used throughout the
manufacturing process
since simultaneous movement is allowed along the X and Y axis,
shorter and more rigid tools may be used
 higher spindle/cutting tool speeds may be achieved while
reducing the load on the cutting tool
Shorter and thicker cutters also reduce vibration when machining
deep pockets or contoured features with three-axis machines.

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 Application
complex three dimensional profiles
for impellers, turbine blades, and plastic mold tools

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 Types of machine configurations for 5-axis
machining

Swivel Head with Rotary Traveling Column

Table Integrated Trunnion Table
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 Specification of a 5 axis CNC Machine
Manufacturers
HURCO
TARUS
CMS north America
OKUMA
CNC TAKANG Taiwan
maximart corporation
YCM (YEONG CHIN MACHINERY INDUSTRIES CO., LTD )

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 Specification cont…
TARUS TPGM5X1083 SPECIFICATIONS
Parameters
X Axis Travel 3048 mm
Y Axis Travel 2540 mm
Z Axis Travel 1117 mm
Space between columns 3886 mm
Workable size,L*W 3568 mm*2235 mm
X , Y and Z axis maximum feed rate 30m/min
A axes tip +/-100 degrees
C axis tip Continuous
A and C axis positioning peak torque 4073 NM
A and C axis positioning Feed 30 degrees per second
Milling Spindle HSK 63A, 0-20,000 RPM
(3 axis and 5 axis milling)
4,000 RPM base speed
70 NM constant torque,160 NM peak torque
29 KW rated power
Linear Accuracy (X,Yand Z) ± .013 mm , ± 0.006 mm, ± 0.005 mm

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 CONTENTS
1. History
2. CNC Introduction
3. how they look like?
4. Elements of CNC
5. Block diagram of CNC
6. How CNC Works?
7. Features of CNC Machines
8. CNC Programming Basics
9. Common Format of a Block
10. Programming Key Letters
11. Table of important G-codes
12. Table of important M-codes
13. Advantages
14. Challenges
15. Conclusion
16. References
 History

The first NC machines were built in the

1940s and 1950s by Prof. John T Parson.
CNC machine came into existence after
evolution of computer around 1980.
Modern CNC Machine are improving
further as the technology is changing with a
variety of functions according to
applications.
 CNC Introduction

A numerical control
system in which the data
handling, control
sequences, and response
to input is determined by
an on-board computer
system at the machine
tool.
 CNC Machines- How do they look like?

Servo Motors

Display Console Coolant

control
Slides Automated
Tool changer

Controller
Controller

Chip collection and

removal
 Elements of CNC Machine

A CNC machine consist of following 6

major elements:
i. Input Device
ii. Machine Control Unit
iii. Machine Tool
iv. Driving System
v. Feedback Devices
vi. Display Unit
Block diagram of CNC Machine
 Open loop and Closed loop controls

In open loop systems the slide may overshoot or may not reach desired
position because of inertia, wear and tear and friction, hence inaccurate
machining.
In closed loop systems the position sensors are used to correct slide
movements and achieve higher accuracy and repeatability
 How CNC Works
Controlled by G and M codes.
These are number values and co-ordinates.
Each number or code is assigned to a particular operation.
Typed in manually to CAD by machine operators.
G & M codes are automatically generated by the computer
software.
 Features of CNC Machinery

The tool or material moves automatically.

Tools can operate in 1-5 axes.
Larger machines have a machine control unit (MCU)
which manages operations.
Movement is controlled by motors (actuators).
Feedback is provided by sensors (transducers)
Tool magazines are used to change tools automatically.
 CNC Programming Basics

 CNC instructions are called part program commands.

 When running, a part program is interpreted one command line

at a time until all lines are completed.

 Commands, which are also referred to as blocks, are made up

of words which each begin with a letter address and end with a
numerical value.
 CNC programming
Important things to know: Programming consists of a series
of instructions in form of letter codes
 Coordinate System
•Preparatory Codes:
G codes- Initial machining setup and
 Units, incremental or absolute establishing operating conditions
positioning N codes- specify program line number
to executed by the MCU
 Coordinates: X,Y,Z, RX,RY,RZ
•Axis Codes: X,Y,Z
 Feed rate and spindle speed Used to specify motion of the slide along
X, Y, Z direction
 Coolant Control: On/Off,
•Feed and Speed Codes: F and S
Flood, Mist
Specify feed and spindle speed

 Tool Control: Tool and tool •Tool codes: T – specify tool number
parameters
•Miscellaneous codes – M codes
For coolant control and other activities
 Common Format of a Block

Sequence # Preparatory Dimension Feed Spindle Tool Misc.

Function Words Rate Function Function Function

N50 G90 G01 X1.40Y2.25 F10 S1500 T01 M03

Individual Words
Programming Key Letters
 O - Program number (Used for program identification) 
 N - Sequence number (Used for line identification) 
 G - Preparatory function 
 X - X axis designation 
 Y - Y axis designation 
 Z - Z axis designation 
 R - Radius designation 
 F – Feed rate designation 
 S - Spindle speed designation 
 H - Tool length offset designation 
 D - Tool radius offset designation 
 T - Tool Designation 
 M - Miscellaneous function
 Table of Important G codes
G00 Rapid Transverse
G01 Linear Interpolation
G02 Circular Interpolation, CW
G03 Circular Interpolation, CCW
G17 XY Plane,G18 XZ Plane,G19 YZ Plane
G20/G70 Inch units
G21/G71 Metric Units
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation (plus)
G43 Tool length compensation (plus)
G44 Tool length compensation (minus)
G49 Tool length compensation cancel
G80 Cancel canned cycles
G81 Drilling cycle
G82 Counter boring cycle
G83 Deep hole drilling cycle
G90 Absolute positioning
G91 Incremental positioning
 Table of Important M codes
 M00 Program stop
 M01 Optional program stop
 M02 Program end
 M03 Spindle on clockwise
 M04 Spindle on counterclockwise
 M05 Spindle stop
 M06 Tool change
 M08 Coolant on
 M09 Coolant off
 M10 Clamps on
 M11 Clamps off
 M30 Program stop, reset to start
 Advantages of CNC

i. - Easier to program;

ii. - Easy storage of existing programs;

iii. - Easy to change a program

iv. - Avoids human errors

v. - CNC machines are safe to operate

vi. - Complex geometry is produced as cheaply as simple ones

vii. - Usually generates closer tolerances than manual machines

 Challenges

i. Costly setup, skilled operators

ii. Computers, programming knowledge
required
iii. Maintenance is difficult
 Conclusion
The advantage of a CNC system are that the
operation of a conventional machine is removed
and the part production is made automatic.
It reduces the labor work and hence highly
efficient in the manufacturing process.
BHEL generally uses CNC machines to achieve
its manufacturing targets. For manufacturing
works of large scale it is very difficult to work
with manual machines as they are time
consuming. CNC machines have their wide scope
because they are easy to handle, the work
becomes easier and jobs are done with perfection.
Thank You

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